Editorial

SPIE Nederland partners with IFS Ultimo to improve asset management and maintenance for customers

spie.jpeg

SPIE Nederland, the Dutch subsidiary of SPIE, the independent European leader in multi-technical services in the areas of energy and communications, and Enterprise Asset Management (EAM) Software leader, IFS Ultimo, have joined forces to enhance asset management and maintenance for customers. As of now, SPIE Nederland’s Business Unit Maintenance Solutions will act as an implementation partner for IFS Ultimo in the Netherlands.

The mission of SPIE’s Business Unit Maintenance Solutions is to help customers improve their key maintenance performance. SPIE adds true value for its customers by supporting them in developing, coordinating, and executing maintenance in line with asset management. EAM plays a key role in supporting maintenance processes nowadays. Using an EAM system ensures the best outcomes in relation to a company’s targets and objectives. It supports companies in their sustainable development approach, helping to reduce resources needed for maintenance, as well as energy consumption by improving the performance of assets. IFS Ultimo makes it easy to set up and track asset performance and facilitates organizations in maintaining their assets in an efficient and effective way. The user-friendly interface can be made fit for purpose by SPIE engineers and is compatible with many partner ERP systems and Industry 4.0 tooling.

SPIE has used IFS Ultimo’s EAM software to manage the assets of maintenance contracts of several customers, including some large Dutch governmental organizations, for many years. SPIE’s Business Unit Maintenance Solutions, in particular, uses the software on a daily basis since a large percentage of its customers use it to manage and optimize their maintenance activities. By partnering with IFS Ultimo, SPIE will be able to provide and implement the EAM software across the Netherlands.

Lesley Fraats, Business Development Manager, SPIE Nederland comments: “By partnering with IFS Ultimo, we build an even broader portfolio of expertise around EAM software. We combine our strengths so that our customers benefit from the best of both worlds: IFS Ultimo’s EAM tool, which adapts to the needs and requirements of their business, implemented by SPIE’s consultants, who have the best understanding of the environment in which the software will be deployed and used.

Maarten Meijer, Manager Channel Services, IFS Ultimo adds: “We see companies struggle with both opportunities and challenges that arise due to the fast-changing business landscape and digitalization. IFS Ultimo and SPIE customers will benefit from this partnership by experiencing the joint expertise of both companies from both a maintenance perspective on the work floor and a digitalization perspective. Our EAM software fits extremely well in this landscape and the specialists at SPIE will ensure that the IFS Ultimo software is implemented, used, and adopted in the most effective way.”

About SPIE Nederland

SPIE Nederland is a subsidiary of the SPIE group, the independent European leader in multi-technical services in the areas of energy and communications. SPIE Nederland provides advice and technical solutions in design, installation and maintenance of network systems and energy, infrastructure, industrial and building installations. 

Employing almost 6,000 people at 41 locations, SPIE Nederland holds the number one position as technical service provider in the Netherlands. 

With around 48,000 employees and a strong local presence, SPIE achieved in 2022 consolidated revenues of €8.09 billion and consolidated EBITA of €511 million.

About IFS Ultimo  

IFS Ultimo is a SaaS EAM / CMMS solution from IFS, focused on maintenance & safety and well known for a rapid deployment, ease of use and an unparalleled time to value. IFS Ultimo is part of IFS.

IFS develops and delivers cloud enterprise software for companies around the world who manufacture and distribute goods, build and maintain assets, and manage service-focused operations. Within our single platform, our industry specific products are innately connected to a single data model and use embedded digital innovation so that our customers can be their best when it really matters to their customers—at the Moment of Service™️. The industry expertise of our people and of our growing ecosystem, together with a commitment to deliver value at every single step, has made IFS a recognized leader and the most recommended supplier in our sector. Our team of 5,000 employees every day live our values of agility, trustworthiness and collaboration in how we support our 10,000+ customers.

www.ultimo.com

IET and WISE join forces to significantly move the dial on gender diversity in STEM

The Institution of Engineering and Technology (IET) has officially taken ownership of the Women into Science and Engineering (WISE) Campaign.

 IET Head of EDI and WISE Managing Director, Dr Laura Norton wants 35% of core UK STEM roles filled by women by 2030.

Engineering and science organisations, the Institution of Engineering and Technology (IET) and the Women into Science and Engineering (WISE) Campaign have joined forces to accelerate the pursuit of gender equality in the UK STEM sector, with the goal of 35% of roles to be filled by women by 2030.

According to recent government statistics*, women make up 29% of the current STEM workforce – this remains the biggest and largest untapped talent pool for engineering, science and technology, and as the engineering skills deficit widens, the IET and WISE want to increase the pace of change.

Dr Laura Norton, IET Head of Equality, Diversity and Inclusion and new WISE Managing Director, said: “The number of women in STEM occupations has doubled to 1.4 million in the past decade thanks to the hard work of organisations like WISE and the IET – it’s fair to say progress has been made but there’s a long way to go to reach gender parity.

“Together we can increase our impact and drive forward a stronger platform which builds on the leading products and services we both deliver including WISE’s Ten Steps Programme and the IET’s role in championing women in the sector through its Young Woman Engineer of the Year Awards.”

Trudy Norris-Grey BA (Hons) FCCA Chair, WISE Board, said: “This integration represents a huge opportunity for all the individuals, communities and organisations that we both serve. By coming together, we are better equipped with the ambition and the tools to significantly make a difference to the gender balance in the sector to achieve our united goal for 35% of women in STEM roles by 2030. Jointly, we have an incredible track-record, heritage, and drive to truly move the dial on gender diversity and to advancing EDI excellence for the benefit of all.”

The IET has an experienced EDI team and has been promoting and celebrating women working in the sector through various campaigns and initiatives such as its Young Woman Engineer of the Year Awards for over 45 years. WISE’s products include its trademarked ‘Ten Steps Programme’ and ‘My Life My Skills Programme’, as well as the WISE Conference and WISE Awards.

Dr Norton added: “WISE will continue to operate under its current model, in parallel to the IET, to ensure the two organisations can deliver the biggest impact and value to our members and customers.

“We want to hit at least 35% of UK STEM roles filled by women by 2030 and together I believe we can make this happen.”

 

Condition Monitoring with a FLIR Si-Series Acoustic Imager

Practically all production, manufacturing and assembly processes use compressed air or vacuum systems at some point in their process. Compressed air and vacuum systems are reasonably inexpensive to install, fairly easy to maintain, and usually very reliable.

While these systems are installed and used with very good reason, they can have inefficiencies that can impact their performance, costing businesses a significant amount of money.

Leaks develop over time and subsequently compressors and pumps run at higher rates to compensate; processes are rarely interrupted. If leaks become severe then its often easier to add additional compressors and pumps then it is to fault-find and repair leaks, especially in loud and noisy operational factories.

Enter the FLIR Si-series of acoustic cameras. These cameras see sound, overlaying leak information onto a digital camera screen, adding quantifiable metrics about the leak severity and likely cost to the business for each individual leak identified.

FLIR acoustic cameras work at distances well beyond 50 meters, filtering out irrelevant noise from operating production lines to isolate leak information and clearly pinpoint their location.

After surveying a facility, all images, along with their leak metrics can be viewed on-camera, or uploaded onto cloud-based reporting software, or transferred to FLIR Thermal Studio reporting software.

Leak images will clarify and improve repair work orders, every leak repaired will reduce the electricity consumption of the compressors and pumps used, which in-turn reduces their associated emissions.

Acoustic imaging works beyond air leaks, also locating leaks in CO2, Nitrogen, Hydrogen, Helium, Argon and other industrial gas systems too, associated savings are significantly higher for industrial gasses due to their increased production and purchase costs.

Contact FLIR or one of our partners and request a telephone consultation, or even an in-person demo to see how much money we can help your business save too.

Click the link below for more information.

https://bit.ly/3SVefGZ

VKK Group joins Babcock Wanson Group

bw.jpeg

Getec and Babcock Wanson Group are pleased to announce that they have agreed to the sale of the VKK Group, a prominent German company renowned for its expertise in industrial boiler technology.

 VKK Group, comprising VKK Standardkessel Köthen GmbH, VKK Standardkessel Service Köthen GmbH, VKK Standardkessel Verwaltung Köthen GmbH, Dampferzeuger-Rohrleitungsbau GmbH and PCE GmbH was originally acquired by Getec Group in 2018. Under Getec’s ownership, the boiler manufacturer, with physical presence in Kothen, Duisbourg and Lichtentanne, has undergone significant reorganisation, restructuring, and strategic positioning over the past five years, positioning VKK Group as a leading and innovative player in the German industrial boiler market.

 

Coming from the still famous story of Standardkessel boilers, the group of companies nowadays known as VKK Group, is a specialist in the design and manufacture of industrial boilers for the energy, food, chemical and other diverse industries. VKK Group also offers a wide range of services including engineering, installation of turnkey projects, monitoring and maintenance of equipment. The company has developed an expertise in high power boilers that gives it a strong competitive advantage in the industrial boiler market in Germany.

 

“With the takeover by Babcock Wanson Group, VKK Group will benefit from a strong and highly respected European specialist to pursue its growth trajectory” states Volker Schulz, chairman of the advisory board. “VKK Group can look ahead with optimism and confidence to its next step of development.”

 Babcock Wanson Group is pleased to make this strategic move and lay the foundation for its expansion into Germany, being one of the largest markets for industrial boilers, leveraging the production site in Kothen and the service site in Duisbourg.

 

“We are thrilled to welcome VKK Group to our journey of growth,” remarks Cyril Fournier-Montgieux, Chairman of Babcock Wanson Group. “VKK’s stellar reputation and expertise in industrial boilers make it the perfect gateway for our entry into Germany, enabling us to continue supporting our industrial clients in their energy transition and decarbonisation efforts.”

 

The Babcock Wanson Group intends to leverage the expertise of the VKK Group’s management and existing teams to bring to local customers the most energy and cost efficient solutions for their boiler room needs. This acquisition thereof represents a mutually beneficial arrangement, facilitating the integration of VKK’s expertise in high power boilers across all of Babcock Wanson’s European subsidiaries while harnessing its production capabilities. In parallel, VKK will benefit from Babcock Wanson Group’s advanced portfolio of technologies, including Parat’s high-voltage electric boilers, thereby contributing to the decarbonisation efforts within the industrial sector.

 

Supported by its main shareholder, Kartesia, Babcock Wanson Group remains committed to expansion and aims to cement its position as the European leader in decarbonisation solutions for industrial processes.

 

For information on Babcock Wanson, go to www.babcock-wanson.com

Strategise to Optimise: Your CMMS Selection Roadmap

maintmaster_iage.jpeg

 

Faced with an ever-evolving technology landscape, maintenance professionals are faced with a dizzying array of Computerised Maintenance Management Software (CMMS) choices. The challenge is not finding a CMMS, but finding one that truly meets the unique needs of your operation. The key? Start with a solid strategy.

Plan your CMMS journey: Essential first steps

Before diving into the sea of CMMS options, it's important for maintenance managers to lay the groundwork. This means taking a step back to assess your team's specific needs, workflows and long-term goals. What pain points do you want to address? What processes can be streamlined? How can a CMMS align with your company's growth trajectory? Answering these questions will provide a clear direction and avoid the common pitfall of being swayed by flashy features that don't necessarily solve your core problems.

 The MaintMaster advantage: Simplicity, flexibility and expertise

Once you have defined your selection criteria, MaintMaster offers remarkable qualities such as ease of use and the ability to adapt to changing requirements. It excels in areas often overlooked by others. The ease of reporting jobs via QR codes and mobile phones is not just a feature - it is the gateway to ensuring accuracy and comprehensive data collection, and importantly, promoting HSE compliance. By making incident and near-miss reporting accessible on the shop floor, hazards can be addressed promptly, driving continuous improvement in your safety culture.

Theis ease of use extends to all aspects of the system, making it accessible to all team members. As your needs evolve, the flexibility of the system ensures it evolves with you, providing a sustainable, long-term solution. Plus, with zero-coding customisation, you can easily adapt MaintMaster to your unique workflows and processes without relying on expensive developers or IT resources. This is in line with the PAS 55 guidelines on asset management, which emphasise the importance of tailoring tools to optimise organisational performance.

So, features are cool, but remember what we said before: they're not the whole story, right? Well, let us tell you that MaintMaster has even more to offer. It's not just a system, it's a partnership with experienced experts who have a deep understanding of maintenance workflows. This expertise is invaluable in ensuring that MaintMaster not only manages maintenance tasks efficiently, but also improves them through best practice and industry knowledge. As your operational needs change, MaintMaster's scalability means that your CMMS is dynamically, ready to support your growth and adapt to new challenges to ensure a sustainable and future-proof maintenance strategy.

Discover MaintMaster: Your partner for maintenance excellence

Your journey to the perfect CMMS starts with understanding your needs and ends with a system that meets them. When you're ready to explore how MaintMaster can fit into your well-researched plan and improve your maintenance operations, get in touch. Let your search for the ideal CMMS end with a solution that not only meets, but exceeds your expectations.

https://maintmaster.com/

Contact:

MaintMaster Systems Ltd

Plexal, 14 East Bay Lane

Here East, Queen Elizabeth Olympic Park,

E15 2GW London, United Kingdom

Phone: +44 749 332 8466   E-Mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

ICML expands Associate Membership with exam discounts and exclusive eLibrary access, opens it up to non-certified practitioners

icml.jpeg

Membership options will continue to evolve through 2024 as ICML restructures its individual and organizational benefits to take advantage of new content and partnership opportunities.

 The International Council for Machinery Lubrication (ICML) announces a major expansion of its Associate Membership package for individual practitioners. Effective immediately, Associate Members can now enjoy discounts on their ICML certification exams, retakes, and recertifications. Each member will also receive a one-year subscription to ICML’s eLibrary that houses a growing catalog of essential lubrication-related books and media resources. And, lastly, Associate Membership is now open to non-certified professionals who want to be a part of ICML’s worldwide initiatives.

“This exciting expansion of our Associate Membership package is in keeping with ICML’s mission that supports hard-working lubrication and oil analysis practitioners with opportunities for educational and professional development,” said Executive Director Leslie Fish. “Individual membership will continue enabling practitioners everywhere to have a personal stake in ICML’s mission, now even more so with these new enhancements.”

First-time Associates will also receive a free digital download of ICML 55.0, "Optimized Lubrication of Mechanical Physical Assets Overview," which serves as the executive summary of the seminal ICML 55® global standard for lubricated asset management.

The Associate Member package price has been revised to reflect these new initiatives. At $160/year (certified) or $195/year (non-certified)—plus a one-time processing fee for first year—the revised pricing is in line with those of other nonprofit organizations in the M&R space. A three-year option remains available for ICML-certified practitioners, conveniently aligning with recertification cycles.

“Overall, these changes for individual members are aimed at improving our ability to offer the kinds of quality benefits, resources, and experiences that practitioners have come to expect from ICML,” said Marketing Manager Paul Hiller. “These changes will make it possible for us to sustain significant, useful offerings for all, while at the same time positioning ICML for future plans.”

ICML’s Associate Member application process itself remains unchanged for now. Individual applicants will still complete a PDF form and submit it for confirmation. Each new Associate will be assigned a unique membership number that will enable access to the exam discounts and to the eLibrary portal.

Corporate memberships—currently the Full, Supporting, and Affiliate packages—will be retooled in the coming months to utilize the expanded Associate offerings. A full description of membership packages, complete with application links, can be found on ICML’s Membership web page.

Current Associate Members will not be automatically grandfathered into the new plan. These individuals will have the option to complete their current terms on the previous plan or to upgrade to the new, enhanced plan.

The Membership Role of ICML’s eLibrary

ICML’s new eLibrary, hosted by River Publishers, is expected to be a massive draw for Associate Members. Accessible anytime and anywhere, the eLibrary is a centralized, vendor-neutral, education portal for members and non-members. It comprises a growing catalog of digital content specifically designed and curated for career advancement, from emerging topics to principles and fundamentals that will help practitioners further their knowledge.

Members will be able to submit their own works to be considered for publication in the eLibrary.

The eLibrary interface allows subscribers to read, highlight, take notes, and search over 10,000 pages of content. Furthermore, subscribers can make downloadable purchases of any eLibrary book.

Titles already include the complete ICML 55 Standard series. Books, journal articles, guides, podcasts, and other content introduced to the eLibrary during the membership term are added to existing subscriptions at no extra cost.

Valued at $250/year for non-members, ICML Associates will find eLibrary subscription already built into their $160 or $195 membership fee, which is considerably less than the non-member subscription rate.

“Members will have access to the entire ICML 55 series plus everything else that will constantly be added to the eLibrary—all for an annual Associate Membership fee that is less than a single ICML 55.2 book alone,” notes Hiller. “We really, really want lubrication professionals to have access to this digital library that will become a massive resource of published media content.”

What do you expect from a screw compressor?

aeren.jpeg

For decades, leading packagers and industrial users have insisted upon AERZEN compressor stages and packaged units. Why? Because with their exceptional versatility these machines are the ideal solution for every application. Originally designed for compressing air, nitrogen and neutral gases, these all-round geniuses are also developing their strengths in use with special gases, in vacuum operation and in inlet pressure applications. Direct and belt-driven, dry running and classified oil-free to class 0 or with oil injection, with or without pre-inlet. Let’s put it this way: AERZEN has the right compressor for every application.

Screw compressors are perforce twin-shaft rotating lobe machines. They work on the positive displacement principle with internal compression and are so-called compulsive conveyors. This applies for all screw compressors. However, what makes AERZEN screw compressors special is that we have made reliability, ease of maintenance, user-friendliness, flexibility and energy efficiency a matter of principle. The result is a range of unique design features.

Compared to standard compressors they save a considerable amount of energy. And what is the ultimate in compressor technology? It is AERZEN's new E-compressors. With an increase in efficiency of around 6% they free up even more valuable potential.”

Case Study: Solving Waste Heat Boiler Corrosion in the Copper Smelting Industry

Overview

In a collaborative effort with a prominent global copper smelting operation, IGS (Integrated Global Services) successfully executed a groundbreaking project aimed at enhancing the reliability and longevity of a waste heat boiler.

The project not only showcased the technical capabilities of IGS but also delivered substantial commercial benefits to the plant.

Commercial Benefit Analysis

Avoided Downtime and Replacement Costs

Traditionally, the copper smelter plant faced significant challenges with the waste heat boiler, experiencing only 11 to 13 months of service life for critical panels. This led to extensive downtime, high replacement costs, and logistical challenges, particularly exacerbated by supply chain disruptions due to the COVID-19 situation.

IGS intervened with a high velocity thermal spray (HVTS) cladding solution, aiming to extend the intervals between turnarounds. The successful application resulted in a remarkable avoidance of downtime and replacement costs, contributing significantly to the project’s return on investment.

Identification of Issues and Initial Contact

The copper smelter plant in Chile, facing corrosion and erosion issues in their waste heat boiler, had historically resorted to panel replacements, single tube replacement and weld build-up strategies.

The turning point occurred when a representative came across another waste heat boiler reliability project delivered by IGS and approached the company seeking alternative solutions. This led to a comprehensive technical presentation to the plant’s maintenance and commercial teams.

Contract Award and Application

Following successful presentations and discussions, IGS secured a contract for a 70-square-meter application of their proprietary HVTS high-nobility alloy. The application took place in a laydown yard in October 2022, targeting critical areas of the waste heat boiler was applied.

igs_feb1.jpeg

igs_feb_2.jpeg

Post-Application Inspection

igs_febb_3.jpeg

igs_feb_4.jpeg

The waste heat boiler ran continuously until the end of September 2023. In August, anticipating an outage, IGS mobilized an inspection crew, including local representatives from Chile. Despite a tight five-hour window, the team conducted a thorough inspection using magnetic lift-off (MLO) gauge testing. The results were overwhelmingly positive, with the cladding exhibiting no degradation after 11.5 months of service. Kevin Phillips, who has overseen both the project and inspection, described the cladding as in-applied condition.

“In all my years as a technical solutions partner, I have never had a client hug me. They were so pleased with the outcome!”, said Kevin.

Future Collaborations and Market Expansion

The success of the waste heat boiler project paved the way for potential collaborations on other critical components within the copper smelter. Converter hoods, copper cooling plates, and other identified assets are now under consideration for IGS solutions. The client’s satisfaction has positioned IGS as a trusted partner.

Conclusion

The IGS project on the waste heat boiler at the copper smelter stands as a testament to the company’s innovative solutions, delivering both commercial benefits and engineering excellence. This case study exemplifies how IGS’s proactive approach and proven solutions can transform operational challenges into opportunities for extended asset life and enhanced productivity.

Integrated Global Services, IGS - Your Efficiency & Reliability Partner

THORDON BEARINGS APPOINTS BRUNTONS PROPELLERS AS AUTHORIZED DISTRIBUTOR IN UK AND IRELAND

THORDON.jpeg

Leading water-lubricated and grease-free seals and bearings pioneer Thordon Bearings has appointed one of world’s most well-known propeller manufacturers as its new distributor for the UK and Ireland region.

Bruntons Propellers will represent Thordon Bearings across the countries from the 1st of January, 2024.

The propeller manufacturer will market, supply and service Thordon’s entire marine portfolio of propeller shaft bearings and seals. There is also provision for Bruntons to promote and service Thordon’s products in other market segments.

Neil McDonald, Thordon Bearings’ Regional Manager, Northern Europe & Africa, said: “We are delighted Bruntons has agreed to represent Thordon Bearings in this important geographical market. Bruntons is a well-known and established brand, with a prestigious heritage spanning more than 100 years. The company, part of the Langham Group, which includes Stone Marine and Tridan Engineering, also has the capability to machine and service bearings and seals on-site.”

A unique arrangement among Thordon’s global network of authorized distributors, it is anticipated that Bruntons will provide greater exposure across a number of market sectors in the UK and Ireland, leveraging Thordon products with major system integrators, systems suppliers, ship owners and shipyards.

Bruntons’ Director, Jonathan Shaw, explained that “the merchant maritime and defence sectors will be the main focus areas, but the agreement allows us to diversify into new industrial and pump markets. With our technical know-how and CNC machining technology, we can offer a wide range of professional sales and engineering services. We plan to have the Thordon inventory in place soon for quick turn-around delivery.”

While the UK’s defence sector has for decades been a significant proponent of water-lubricated bearings and seals due to their low noise and vibration signature, Thordon Bearings is seeing more and more UK-flagged merchant vessels look to the technology to meet existing and future environmental regulations.

“We hope soon to be in a position to announce the first order under this new agreement in coming weeks,” said McDonald. “There are a number of opportunities with new and existing customers throughout the region, since Bruntons can now offer complete propeller shaft lines with a Thordon seal and bearing package.”

A pioneer in the development of elastomer technology, Canada-headquartered Thordon has more 35 years’ experience designing, manufacturing, and installing robust, long-lasting marine bearings and seals that operate without the need for oil or grease.

The company’s marine portfolio includes the award-winning COMPAC seawater-lubricated propeller shaft bearing (the industry leader in zero environmental impact bearings); the award-winning TG100 shaft seal; the award-winning grease free deck and rudder bearing system ThorPlas-Blue; and the new and revolutionary sterntube-less propeller shaft system design, T-BOSS.

www.thordonbearings.com

A PATTERN EMERGES AS VSRT INSTALLATION SHOWS SIGNIFICANT SAVINGS IN EMISSIONS AND GAS CONSUMPTION

fulton_feb.jpeg

Established in 1974, Truck Trye Specialists has a reputation for providing premium bead-to-bead (hot cure) and procure (cold cure) remould tyres with over 100 tread patterns to suit all relevant commercial vehicle operations. Its products are manufactured using the highest-grade rubber compounds available and have a proven track record of improving mileage, traction and fuel efficiency, equalling and even outperforming tyres from established brands.

With a five-yearly NDT inspection due on its ageing horizontal steam boiler within 18 months, and given past experiences, there was a very real prospect of it requiring major coded pressure vessel repairs again. Truck Tyre therefore needed to find a replacement solution that could cope with current and future demands, while ensuring its Net Zero commitments – already established thanks to existing recycling procedures, upgrades to facility insulation and the installation of roof-mounted PV panels – weren’t compromised.

So having discussed the requirements and researched the options with its existing steam solutions specialist, the tyre manufacturer was presented with just one realistic option, VSRT vertical steam boilers from Fulton!

 

Steam is used throughout Truck Tyre’s facility – including steam and waste steam via heat exchangers for domestic hot water and space heating for the facility’s offices and factory – but plays a crucial role in the vulcanisation process when moulded rubber that is extruded onto the tyre structure is placed in high-pressure curing presses or autoclaves, with steam introduced at a controlled temperature and pressure, and serving several critical functions during the process.

Firstly, steam is an excellent heat transfer medium. It transfers heat efficiently to the rubber components, causing the necessary chemical reactions for vulcanisation to occur. The heat and pressure help the sulphur atoms in the rubber chains form crosslinks, which strengthen the material. Secondly, many vulcanisation accelerators work more effectively at elevated temperatures, with heat from the steam therefore accelerating the chemical reactions between the rubber and curing agents, reducing the curing time and improving the overall process efficiency. Finally, steam ensures uniform heating throughout the company’s curing chambers and autoclaves, preventing hotspots or temperature variations that could lead to uneven vulcanisation.

In a typical five-day work week, the boiler is operational for 12 hours per day, giving Truck Tyre the ability to produce over 30,000 tyres annually using its 28 commercial presses and autoclaves. Its maximum requirement for steam peaks at approximately 1,800kg/h and the original horizontal boiler would achieve this. However, during breakdowns, regular servicing, five-yearly NDT inspections and maintenance periods, the boiler and processes using steam were all shut down. It was therefore recommended that the new system should allow for duty assist within the specification.

Two VSRT-60 steam boilers were subsequently specified, each with a rated output of 960kg/h, easily coping with demand and affording the company the ability to reduce, not completely stop, throughput during planned shutdowns.

Commenting for Truck Tyre Specialists, director Daniel Collins says: “In the 12 months prior to the installation of the two VSRT steam boilers, we were using up to 213,000kWh of gas per month during high throughput periods. However, in the six months since Fulton’s VSRTs were commissioned, we’re now using around 155,000kWh.”.

As Carl Knight, Fulton’s managing director explains, a VSRT installation has once again resulted in significant savings for the end user. “With turndown increasing from 2.5:1 to 20:1 for the installation, Truck Tyre has reported a reduction in gas consumption of nearly 30% and over 140 tonnes per year of CO2 emissions reduced, savings that can be credited towards its Net Zero goals. Additionally, based on historical data, there has been a reduction in NOx emissions in excess of 75%.

“These alone are truly impressive, but let’s not forget savings achieved from the reduction in water usage, chemical dosing, annual inspection, five-yearly NDTs and of course process downtime haven’t been factored in, making overall financial savings compared to the original horizontal boiler installation even more impressive!”.

Applications using steam, like those at Truck Tyre, have revolutionised over the years, yet the same cannot be said for steam boilers themselves. That was until, in 2018, Fulton launched the VSRT vertical steam boiler.

Claimed to be the most radical change to vertical steam boiler design since it first pioneered the vertical tubeless boiler in 1949, Fulton’s VSRT has rocked the steam boiler market since its launch to become class-leading and a symbol of efficiency, with many users benefitting from excellent savings in gas and water consumption and reductions in CO2 and NOX emissions.

At launch, the seven-model VSRT range was available with outputs from 160 to 960 kg/h, but with demand increasing for an energy efficient boiler with larger outputs, Fulton has now expanded the range and introduced two new, re-designed VSRTs with outputs of 1,565 and 1,956 kg/h.

Thanks to its unique design, the VSRT’s patented spiral-rib heat exchanger virtually eliminates thermal stress, so Fulton has therefore created a longer-lasting boiler that not only improves boiler efficiency but one that the company believes will beat the competition in every category of durability. This is why all VSRTs come with the assurance of a 10-year ‘unparalleled’ warranty on the pressure vessel, double that of the industry standard.

Additionally, with features including a vertical tubeless design with no refractory whatsoever, and thanks to its industrial control platform and easy access to the pressure vessel, the VSRT is also extremely easy to maintain. As the design is tubeless, there is no requirement for five-yearly, NDTs, which contributes to reduced lifecycle costs when compared to standard horizontal boilers.

In summary, as Carl Knight explains, Fulton’s VSRT can deliver steam (at up to two tonnes per hour from single boiler) while helping with both the financial and environmental challenges that are at the forefront of mind for many decision makers.

www.fulton.co.uk

 

This website is owned and operated by: MSL Media Limited

msl logo
www.mslmedialtd.com

Co. Number: 05359182

© 2022 MSL Media Ltd. All rights reserved. E&OE

ems logo mobile