Editorial

Condition Based Maintenance (CBM), using tools such as vibration analysis, thermal and ultrasonic imaging, and oil analysis, is now clearly recognised as being the key to running an effective maintenance program. By comparison, planned periodic maintenance, or worse still breakdown maintenance, are not only unnecessarily expensive and unreliable, but potentially fraught with danger!

But why is CBM the answer? Firstly, when using CBM tools, service and maintenance personnel bring another very valuable asset to the job – they use their eyes and ears!  For example, by spotting things like oil leaks or worn drive belts, breakdowns can be avoided through timely intervention.

To assist with this process, software tools are now available to lead even a novice user through the process of making inspections to produce clear and fully documented reports, which can automatically generate alerts and workflow tasks. 

Additionally, CBM brings with it the ability to implement Proactive Maintenance. This is essentially the process of “closing the loop” by identifying the root cause of a fault and correcting it. For example, vibration analysis might indicate a badly worn bearing that has failed after only a few months, well within the manufacturer’s specified MTBF.  Without identifying the root cause of the premature failure, the bearing might simply be changed only to soon wear out again. 

It is generally accepted that the three main causes of premature bearing failure in rotating equipment are:

• Out of balance
• Misalignment
• Lack of lubrication

Fortunately, thanks to modern technology, all of these conditions can be detected very easily using extremely affordable, simple to use handheld vibration analysers.

Out of balance for example, shows up as a large amplitude vibration at the running speed (1X) of the machine.

Misalignment on the other hand generally shows up as an additional large vibration at twice the running speed (2X).

Lack of lubrication will result in high frequency vibration (bearing noise) that is not necessarily audible to the human ear but can easily be detected by a vibration analyser.

These days, once diagnosed, all these faults can easily be remedied in-house using affordable easy-to-use tools such as in-situ rotor balancers, laser alignment systems or even a simple grease gun!

Not so long ago CBM tools used to be considered expensive and difficult to use. But thanks to modern technology, these tools are now not only extremely affordable; they are also simple to use.

The TPI 9070 (pictured) is a simple to use, incredibly low-cost vibration analyser that records, analyses and displays vibration at the push of a button. The unit displays colour coded alarm levels based on internationally agreed (ISO) vibration values and bearing condition. It also incorporates a fully zoomable vibration frequency spectrum (FFT) display with cursor, and diagnoses out of balance, misalignment, looseness and bearing faults.

TPI manufactures a complete range of low cost, high performance, easy to use vibration analysis tools for maintenance engineers. All are incredibly easy to use, from the simple one-button-to-press, TPI 9070 to top-of-the-range CBM units that include machine balancing. 

The TPI 9085 (with the ATEX/IECEx/USA/Canada Zone 0 certified TPI 9085-Ex version also available) is the latest in the line of easy-to-use high specification maintenance products. The TPI 9085 offers high level functionality and capability, including instantaneous bearing temperature measurement, at extremely low cost. The TPI 9085 can automatically download machine routes (as simple lists) that can be followed by even the lowest skilled operative to collect and store vibration and temperature readings for automatic upload to the included, free-to-use, C-Trend II trending software. This powerful but highly intuitive windows-based software, with its ability to automatically generate reports and email alerts, allows faults to be identified well ahead of when they start to become a problem that could result in unexpected breakdowns.

For more information, please contact TPI Europe on +44 1293 530196 or www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

In this article, Fulton managing director Carl Knight delves into the importance of BG13 and the insights it provides into how to ensure the safe operation of electric powered steam boilers.

Guidance for the Safe Operation of Electrically Powered Steam Boilers (Ref: BG13) is a guidance document intended to assist the managers, designers, operators, maintenance personnel and Competent Persons (CP) of new and existing steam boiler systems. Developed and written by the Combustion Engineering Association (CEA) and in consultation with other stakeholders – like Fulton – within the steam boiler industry. It serves as a vital resource to those named and addresses key issues including design, installation, safe operation, maintenance requirements, and compliance with legal standards.

The document covers various dangers and challenges including loss of feed water, over-pressure, overheating, electrical safety, and water treatment. Electric boilers – classified as small, medium, or large – encompass two main types: electric boilers and electrode boilers. Electric boilers utilise fully immersed heating elements, while electrode boilers employ conducting probes or electrodes to directly heat the water.

BG13 applies to industrial and commercial electrically powered steam boiler plants with a working pressure up to 32 bar gauge. It excludes steam boilers exceeding 37 MW nett rated thermal input or above 32 bar gauge working pressure, as well as coffee boilers, jet type electrode boilers, and hot water boilers. Nevertheless, the principles outlined in BG13 can still be applied where suitable and applicable, even to excluded boiler types.

DESIGN & INSTALLATION

Proper design and installation are fundamental to the safe operation of electric steam boilers. BG13 outlines design considerations such as sizing the boiler to meet the specific requirements of the application, ensuring adequate ventilation, and implementing appropriate safety features such as pressure relief valves and automatic shutdown systems.

To guarantee compliance with BG13 standards, installation should be undertaken by qualified professionals and follow manufacturer guidelines and relevant regulations.

BOILER OPERATION

This section outlines operational requirements and routine checks for electric boiler systems. Employers must conduct site-specific risk assessments to determine appropriate controls, supervision levels, and maintenance. Before use, boilers must be examined by a competent person and subsequently tested according to a Written Scheme of Examination (WSE).

Boiler instructions should cover safe operation, daily checks, start-up procedures, safe work practices, and notification of significant operational changes. System re-starts following lock-out require a suitably experienced operator to avoid potential risks.

Routine testing of controls, limiters, and water quality is crucial for safe and efficient operation. Testing frequency should be based on risk assessment, manufacturer's instructions, and operational requirements. Records of tests and maintenance activities must be maintained for audit purposes.

Water level controls need specific testing, with results logged and corrective actions taken as necessary. Feed water and boiler water checks, including chemical dosing and quality assessments, should be conducted regularly.

Special consideration must be given to water treatment for standby and unused boilers to prevent scale build-up and ensure system integrity.

PERSONNEL & RESPONSIBILITIES

The user/owner must appoint competent individuals responsible for daily boiler operation, with competence entailing relevant education, training, and experience.

Operators must be capable of recognising the limits of their expertise and seeking assistance when necessary and their duties are determined by site-specific risk assessments. Employers have general duties to provide safe workplaces and adequate staff training under the Health & Safety at Work Act 1974, MHSWR, and PUWER. These responsibilities cannot be delegated to employees or third parties.

Qualified electricians or electrical engineers must manage electrical issues associated with boilers, ensuring electrical safety, compliance with regulations, and implementing safety measures. Individuals monitoring boiler alarms must be adequately trained to respond appropriately to alarm conditions, ensuring safety before seeking assistance. Access during emergencies should be restricted to trained personnel.

Maintenance personnel require sufficient knowledge and training to carry out their duties safely, performing tasks only for which they are trained and competent. User/owners hiring subcontractors for specialised tasks must ensure their competency, oversee their work, and ensure compliance with legal requirements and safety standards.

Manning and supervision levels are determined by detailed risk assessments, considering factors like automation, location, water quality, and operational scenarios. Electric boilers require a competent operator present during start-up and lockout. Advanced automation may still necessitate full-time supervision for steam security or other reasons.

MAINTENANCE, REPAIR & MODIFICATION

Boiler systems must be properly maintained to prevent danger, adhering to PSSR Regulation 12 and PUWER Regulation 5. Responsibility for maintenance should be clearly defined, with the user/owner ensuring all personnel are competent, boiler operators handing over safely, and maintenance checked before the boiler is back in operation.

Steam leaks should be promptly repaired, and maintenance activities should be documented, including maintenance frequency, and logs kept up to date.

Before any modifications or repairs, a risk assessment must be conducted and the CP should assess the effects on pressure equipment, reviewing the WSE as required.

Significant repairs must address causal factors and comply with PSSR Regulation 13, documenting alterations and ensuring equivalent standards.

OPERATOR TRAINING

Employers must ensure all personnel possess adequate knowledge of boiler systems and receive training under PUWER Reg 9. Training should be ongoing, structured, and updated to reflect technological advancements and legislative changes, and should cover boiler operation, controls, emergency procedures, legal aspects, and site-specific elements.

Competence levels and training requirements must be reviewed, especially with system modifications, and employers must maintain training and assessment records securely for audit purposes.

Personnel, including managers and operators, must undergo regular work audits and periodic reassessment of training. Training validation must include written and/or oral assessments with recorded results.

Essential elements of boiler house training should include understanding Steam Boiler Water Treatment (SBWT) principles to maintain water quality. Recommended courses include CertIBO for operators, DipBOM for managers, and SBWT training as part of the CEA suite.

PERIODIC INSPECTION

A boiler must be examined according to a WSE that details parts, examination types, and intervals, and may be written and certified by an independent or in-house CP.

The examination includes two phases: "out of service" and "in service.", with the latter involving verifying protective devices such as pressure gauge, controller, safety relief valve, and water level controls.

Post-examination, the CP should issue a report with recommendations, while other devices such as control system power failure and critical alarms should also be checked and tested.

ENERGY & THE ENVIRONMENT

Efficient boiler energy management is crucial for cost reduction, safety, and plant longevity, so seeking expert advice before altering operating parameters ensures safety, environmental compliance, and efficiency.

Options such as metering for efficiency monitoring, water treatment, energy improvement devices (e.g., variable speed drives), and plant scheduling for optimisation should all be considered. It is worth noting that simply reducing steam pressure may not always enhance efficiency, so measurement is therefore recommended to demonstrate efficiency.

Electric boilers are not subject to emissions regulations, but environmental considerations such as noise and waste streams require attention. Water discharged must meet utility restrictions, and resources on legislation and guidance are available from government and industry websites.

Large organisations may need to comply with the Energy Saving Opportunities Scheme (ESOS).

CONCLUSION

The CEA’s BG13 stands as a comprehensive guide for the management of electric steam boilers, addressing design, installation, operation, and maintenance best practices. It serves as a vital resource for professionals involved in boiler systems, covering essential aspects such as safety and compliance with legal standards.

By adhering to BG13 guidelines, organisations can ensure the safe and efficient operation of boiler systems, mitigating risks and maximising longevity. Furthermore, considerations for energy management and environmental impact underscore the document's relevance in promoting sustainable practices within industrial settings.

Overall, BG13 provides a comprehensive framework for ensuring the optimal performance and safety of electric steam boilers, contributing to the overall efficiency and sustainability of industrial operations.

www.fulton.co.uk

Within the oil and gas industry, pipeline integrity and corrosion control are top concerns. Transporting untreated wet gas poses significant risks, as the presence of corrosive contaminants like hydrogen sulfide (H₂S) and carbon dioxide (CO₂) can severely damage critical pipeline assets. This damage results in leaks, loss of containment, and costly unplanned shutdowns.

Integrated Global Services (IGS) understands the urgency of effective corrosion control to maintain pipeline integrity and operational efficiency. As a result, IGS has developed a cutting-edge Metalspray® Pipe ID Rover system, representing a major leap forward in internal corrosion protection strategies for oil and gas pipelines.

The Challenges of Internal Corrosion

Corrosion in wet gas pipelines develops from various mechanisms, including CO₂ corrosion (sweet corrosion) and H₂S corrosion. CO₂ dissolves in water, forming carbonic acid that attacks the pipe wall, while H₂S dissociates to form sulfuric acid, leading to pitting. Additionally, the oxygen content, corrosive by-products, and contaminants introduced during production operations further contribute to internal corrosion.

Existing prevention methods, such as chemical inhibitors and coatings, have limitations in addressing the complexities of internal corrosion in hazardous environments like wet gas pipelines.

The Metalspray® Pipe ID Rover: A Breakthrough Solution

IGS's Metalspray® Pipe ID Rover system represents a breakthrough solution for pipeline corrosion protection. By offering a field-applied alloy upgrade for pipelines, slug catchers, and flare lines, this cutting-edge technology addresses the challenges of wet CO₂ corrosion and internal corrosion with unparalleled precision.

The self-propelled rover navigates through pipelines, applying a durable alloy coating to interior surfaces without the need for direct human intervention. This approach ensures comprehensive surface preparation, alloy application, and quality control in environments previously considered challenging or impossible to treat effectively.

Key Benefits of the Metalspray® Pipe ID Rover

• Targeted Protection: 360-degree access to critical areas ensures comprehensive coverage, protecting bottom sections, low spots, and weld seams.
• Pipe ID Corrosion Mitigation: Alloy upgrades restore and reinforce affected areas, significantly extending the asset's life.
• Laser Integrity Scans and Visual Documentation: Real-time scans provide essential documentation, ensuring quality and accountability.
• Safe Operation in Hazardous Environments: Designed for operation in hazardous wet gas environments, eliminating the need for confined space entry.
• Cost-Effectiveness: Maximizes capital efficiency, avoiding expensive replacements and providing a financially viable corrosion prevention solution.

A Comprehensive Corrosion Control Strategy

By stopping further damage and mitigating pipeline corrosion, the Metalspray® Pipe ID Rover becomes more than a technology; it becomes a comprehensive strategy to tackle CO₂ and H₂S corrosion. The solution supports operators in strengthening offshore infrastructure, ensuring uninterrupted production, and protecting their investment in pipeline systems.

Whether addressing finger slug catcher corrosion, enhancing flare line durability, or controlling corrosion in wet gas systems, IGS's Metalspray® Pipe ID Rover system is at the forefront of internal corrosion control technology.

With a track record of success and a team of experts dedicated to excellence, IGS is pushing the boundaries of innovation to safeguard operations against the threats of corrosion.

www.integratedglobal.com

Food processing plants typically run their equipment for 16 to 20 hours a day, yet a Forbes report claims that manufacturers face an average of 15 hours downtime per week. This translates into increased operation costs and disruptions in the supply chain, causing delays in deliveries. Here Tom Cash, director of Siemens parts supplier, Foxmere, explains how the role of condition-based maintenance (CBM) helps maintenance engineers recognise gross defects before catastrophe strikes.

CBM is a strategy that monitors the actual condition of an asset to decide what maintenance needs to be done. Using sensors, this strategy dictates that maintenance should only be performed when specific indicators show decreasing performance or upcoming failure.

Checking a machine for these indicators include non-invasive measurements, visual inspection, performance data and scheduled tests. Condition data can then be gathered at specific intervals or continuously, as is done when a machine has internal sensors.

Simply put, the primary goal of CBM is to optimise equipment maintenance practices by monitoring real-time data and responding to the actual condition of assets. It aims to prevent unplanned downtime, reduce maintenance costs and extend equipment lifespan by conducting maintenance activities only when necessary.

Better than predictive maintenance?

Although similar, CBM differs from predictive maintenance in its approach. Yes, both strategies involve real-time data and analytics, but CBM is a broader concept that covers various maintenance strategies driven by equipment condition.

Predictive maintenance, on the other hand, specifically relies on data analysis and machine learning to predict when equipment failures are likely to occur. As the name suggests, this method focuses on predicting when equipment failures might occur, with the aim to pre-emptively address issues.

That’s not to say that CBM can’t include predictive maintenance as one of its components. However, it encompasses other techniques, such as preventive and corrective maintenance, based on observed conditions.

Therefore, the question food maintenance engineers should ask is, what strategy best suits your requirements? For instance, CBM is suitable for equipment impacted by variations in operating conditions, like temperature, pressure or flow rates, as continuous monitoring ensures consistent product quality.

Whereas predictive maintenance is valuable for predicting failures in equipment critical to maintaining specific processing conditions, like heat exchangers or refrigeration systems.

CBM for food safety

Food safety problems can have many root causes. A significant number of incidents reported to the Rapid Alert System for Food and Feed (RASFF), which is established by the European Union to ensure a high level of food safety and protect public health, are caused by contaminations with extraneous material.

Such material includes metal pieces coming from broken equipment, grease or detergent remnants. In fact, heavy metals represented the fourth most often notified hazard category in the RASFF from 1980 to 2016.

Contamination is arguably the biggest risk to any food and beverage manufacturing firm. As a result, these companies should be looking at new technologies, like IoT sensors, to ensure food safety as well as improving overall equipment effectiveness.

Monitoring the condition of bearings and metal detection equipment that impact food safety eliminates the risk of metal parts ending up in the food. As mentioned above, an advanced and very welcome development is the use of sensors, which trigger timely cleaning to avoid contamination risks.

Calling upon the support of parts suppliers, like Foxmere, food manufacturers can source these sensors in their journey in making CBM, or predictive maintenance for that matter, a reality.

These tools allow you to identify where the choke points are in your food and beverage production lines proactively, rather than reactively. As, after all, these efforts are geared towards helping maintenance engineers recognise gross defects before a catastrophe, like contamination, strikes.

To ensure that your business is amongst those thriving, contact Foxmere today for a no-obligation quote on automation equipment ranging from replacement or obsolete parts to complete robotic systems.

IFS Cloud specialist Arcwide and Enterprise Asset Management (EAM) platform provider IFS Ultimo have signed an implementation partnership. By adding IFS Ultimo as a best-of-breed EAM platform to its portfolio as part of this partnership, Arcwide empowers customers to get more value out of its IFS Cloud platform solution. Arcwide will be managing the partnership on a global scale, following the formation of its EAM center of expertise in Benelux.

Olivier Baudry, Director, Arcwide comments, “We are thrilled to announce our joined efforts through our newly founded EAM center of expertise in which IFS Ultimo will play a key role. With IFS Ultimo, we will enable our industrial customers to improve their asset management operations, with an emphasis on maintenance and safety.”

Pierre Robino, Director, Arcwide adds, “Through this partnership, Arcwide is reinforcing its commitment to the IFS best-of-breed solutions. The partnership between IFS Ultimo and Arcwide will support customers in managing their assets, adding further value to their businesses.”

Maarten Meijer, Manager Channel Services, IFS Ultimo says, “We strengthen each other on our joint growth opportunities in this partnership, including our mutual growth ambitions in the USA and Europe. Arcwide is well-known in the industry with years of experience in the IFS ecosystem. Its core business is IFS Cloud ERP implementations, which often also include EAM services. Now, Arcwide can expand its portfolio by offering its customers the best of both worlds: A best-of-breed EAM solution like IFS Ultimo and an integrated best-of-suite solution, such as IFS Cloud.”

www.ultimo.com

www.arcwide.com