Editorial

Banbury-based Powerline Electric Motors has completed the refurbishment of its latest batch of Landia slurry pumps, including one unit that has been in operation for almost 25 years.

With its ongoing investment in new equipment and growing number of apprentices, Powerline has seen a significant increase in demand for its repair services, which not only help prolong the lifetime of pumps, but also improve efficiencies.

Landia’s Paul Davies, commented:” Although we have our own nationwide service team, Powerline’s skill in overhauling pumps is first-class. We are pleased to see our equipment continue to provide excellent, long-term service.”

Richard Thompson of Powerline added: “We’re not in the habit of disappointing our customers. Landia make very robust pumps and they always have a good stock of spares on hand for us, so that we can offer the best possible turnaround.”

Landia and Powerline also both work closely with Shipston-on-Stour-based Midland Slurry Systems, who specialise in the supply and maintenance of industrial and agricultural wastewater treatment installations and animal slurry management.

Giles Russell for Midland Slurry Systems, said: “We have total confidence in the Landia pumps and mixers that we’ve used for many years. In slurry pits, equipment has to be tough, but it must be maintained properly too. After our pumps have been in for service with Powerline, they’re like new!”

In addition to the farming sector, Powerline also provides high-quality repairs, rewinding and refurbishment of electric motors, pumps, fans, and gearboxes to a wide variety of industries, such as manufacturers of foods, plastics, and automotive, as well as servicing customers working in chemicals, utilities, healthcare, construction, and Oxfordshire-based F1.

www.landiaworld.com

www.PowerlineElectricMotors.co.uk

www.midlandslurrysystems.co.uk

this article can also be found in the latest issue of  EMS

Successful assembly tasks rely on several key aspects:the equipment, automation expertisethe knowledge about adhesives and their application as well as on available professional support. Based on its longstanding expertise and its range of leading high-performance products and services under the well-known Loctite brand Henkel offers total assembly solutions that help customers to increase productivity, improve reliability and simplify design.

The Henkel portfolio includes comprehensive equipment for dispensing, light curing and robotics as well as a broad range of adhesive solutions focusing on bonding, sealing and coating. The company also offers extensive global support, technical expertise, on-site or remote training, and a full range of services. These services extend from integration and start-up support, through to calibration, field service, spare parts and consumables (needles, tips and nozzles), warranty support and a rebuild exchange program. Based on this holistic approachHenkel enables its customers to unlock new potentials in the global assembly market.

Over the past 30 years, the company has designed, built, and integrated advanced equipment solutions for uncountable customers. Regardless of the challenge – from water-thin liquids to high-viscosity pastes – Loctite equipment is capable of dispensing and curing a wide variety of adhesives, sealants and other industrial fluids, including acrylics, anaerobics, cyanoacrylates, epoxies, hot-melts, greases, inks, solvents and more. 

Available dispensing systems include anaerobic, bottle, cartridge, syringe and volumetric types, alongside dispense valves, and controllers and dispense reservoirs. The latest-generation reservoirs, for example, provide the effective dispensing of single-component Loctite adhesives at workstations, laboratories, and industrial installations. These units typically feature a dispensing valve for manual and benchtop applications, and a Loctite controller for semi- and fully automated processes. The compact design provides two independent digital timing channels that allow for the control of two pneumatic outputs to control dispense valves or any other pneumatic device. Loctite integrated dispensers also offer enhanced digital connectivity and precision pressure control for low viscosity dispensing applications. 

Loctite LED light-curing equipment includes flood-curing systems, spot-curing and handheld systems, as well as process control and monitoring systems. New-generation solutions provide high power, portability, continuous duty, and long life. These light sources offer optimal curing for the extensive Loctite line of UV/visible light-curing adhesive products, providing customers with a best-practice solution for their process needs.

Another important element of Henkel’s total assembly solutions proposition is the Loctite range of automated robotic dispensing systems. These innovative systems simplify the dispensing of adhesives and sealants on to complex surface configurations, improving process efficiency, minimizing material waste and reducing manufacturing costs.

Based on the holistic approach Henkel offers the know-how and expertise for total assembly solutions that create value for its global customer base.

www.Henkel.com

EXAIR's Super Air Knife™ is the latest generation of our engineered air knife. It dramatically reduces compressed air usage and noise when compared to other blowoffs. The Super Air Knife offers a more efficient way to clean, dry or cool parts, webs or conveyors. It delivers a uniform sheet of laminar airflow across the entire length with hard-hitting force.

Advantages

Noisy blowoffs become a whisper when replaced with the compact Super Air Knife. Even at high pressures of 80 PSIG (5.5 BAR), the sound level is surprisingly quiet at 69 dBA for most applications! Air amplification ratios (entrained air to compressed air) of 40:1 are produced. Meets OSHA maximum dead-ended pressure and noise requirements. https://exair.co/190_523

Heating and combustion equipment manufacturer Riello continues to develop products to meet andexceed NOx emission regulations, and in 2023 is launching a new burner series in the UK which incorporatesinnovative and patented Ultra-Low NOx combustion head technology.

Legislation continues to drive down permissible NOx emission levels from combustion equipment, and there is increasing monitoring of appliance emissions to ensure compliance with multiple environmental and regulatory requirements.

Previously therehave been two principal means by which combustion NOx emission levels have been mitigated;either Flue Gas Recirculation (FGR) technology, or the application of premix burner technology.  Each of these technologies is effective in reducing appliance NOx emission levels, but bothhave some limitations on their application.

FGR technology requires a higher degree of burner technology and the installation of extra ducting from the appliance flue to the burner.  This adds to installation complexity and maintenance costs, and has some limits on operation with regard to minimum permitted recirculating flue gas temperature.

Premix technology has a relatively low maximum capacity limit of approximately 3,000 kW, and the configuration of the required long combustion head adds to installation and servicing costs.

The NEW Riello ULX Series of Ultra-Low NOx emission gas burners removes theseapplication barriers which prevent utilisation of the FGR and premix technologies andprovides a solution that can be applied on all boiler types* and at all operating temperatures.

(*The only current exception to this being appliances which incorporate a reverse flame combustion chamber configuration, as testing of the burners on these types of boilers is yet to be completed.  It is well known however, that to permit ultra-low NOx emission combustion and deliver minimum emission levels,appliances with through-pass [3-pass] combustion chamber design enable substantially better performance than reverse flame designs.)

Essentially the NEW series burners are based on the tried and tested Riello RS pressure jet burner design principles, maintaining the reliability and robustness of those models.  On first appearance they look very much likethose burner models that have been available for many years, but it is the innovative and patented combustion head technology of the Riello ULX series which ‘breaks new ground’ with regard to minimising NOx emissions.

Riello RS 510/E ULX Burner

The combustion head design of the Riello ULX series burnersincorporates both ‘staged air’introduction control in the ‘core’ of the flameand ‘internal flue gas recirculation’control in the external region,or periphery,of the flame.

The resultant reduction in NOx emission with this combustion head technology allows compliance with the requirements of the most stringent requirements worldwide, on multiple appliance types, including steam and high temperature hot water boilers.

Tests performed in the Riello Combustion Research Centre in Italy, and on appliances installed in multipleinternational locations have shown that with the right conditions, NOx emission levels of 30 mg/kWh (net CV),i.e. 30 mg/Nm3 @ 3% O2 flue gas reference, are readily achievable.  This NOx emission level is significantly below the current Greater London Authority (GLA) requirements of 40 mg/kWh (gross CV).

All models of the NEW Riello ULX series of gas burners incorporate electronic cam, or direct digital control, of the air fuel ratio by means of independent servomotor driven regulation, maximising efficiency and simplifying commissioning and servicing.

Burner specification options for Variable Speed control of the combustion air fan and O2 combustion trim, are also available for further improvement in efficiency and reduction in electrical consumption and noise reduction.

The NEW Riello ULX series of gas burners is available for an operating capacity range from 350 kW to 4,600 kW, with further models extending the range to greater than 7,000 kW to be introduced following completion of field and approval testing. Additionally, dual fuel firing versions of the burner series, able to operate with gas or light oil, are being developed for future introduction to the market, so watch this space!

For details of the NEW Riello ULX series of gas burners please contact the Riello Limited Sales Team on 01480 432144.

Bernard Dawson – Technical Director, Riello Limited

This article can also be found in the issue below.

Certified hazardous area-safe portable lights are essential tools for workers in explosive hazardous environments. Hence, it is crucial to ensure they are fully certified to the latest ATEX and IECEx standards by reputable certification bodies such as UL or Intertek. Nightstick designs and engineers’ products that eliminate potential sparks or heat that could ignite flammable gases, dust, or fibers present in the atmosphere.  

Usually, suppliers promote inexpensive, uncertified lights, falling short of the required standards for working in explosive atmospheres. Selecting correctly certified products should always come before costs. Certified lights may be more expensive, but they are worth the investment to ensure the safety of workers and the facilities where they work.

The Nightstick XPR-5584GMX dual-light lantern is an excellent example of a quality, ATEX/IECEx Zone 0 certified light that helps prevent slips, trips, and falls. Dual-light torches typically have two beams of light, one for close-up work and one for distance. This eliminates the need to switch between different types of lights and reduces the risk of tripping or slipping, as workers can see obstacles in their path.

In conclusion, investing in a correctly certified, intrinsically safe portable light is crucial to ensure the safety of workers in explosive environments. Quality and certification should always be prioritized over cost.

By prioritizing safety, workers can perform their duties knowing they are truly protected. When Life Depends on LightTM, choose Nightstick! Visit nightstick.com for more information or call us at 1-469-326-9400.

This article can also be found in the issue below.

Introduction

Refractory linings are insulating and minimize heat loss, making them essential to retaining the high-temperature environment. However, when subjected to high temperatures, refractory can deteriorate and potentially lead to failure if remedial work is not carried out. 

If refractory failure results in an unplanned shutdown, it can cost plants more than $1m/day in lost production.

This article will discuss the most common causes of refractory failure, and the method of repairing refractory online without the need to disrupt normal operation. 

3Common Causes of Refractory Failure

As refractory linings age, their physical properties change. The high-temperature environment causes microstructural changes to the binders within the materials, leading to a loss of surface or internal strength. If the refractory material carries a compressive load, such as bricks, or castable linings, this can lead to local, or widespread failure. 

If the refractory is subject to flame impingement, which is common in many radiant wall applications, the useful life will be shorter. 

In oil-fired heaters, refractory deterioration is accelerated by corrosive agents in the combustion products. Fortunately, there are few cases where oil-firing is used now.

A combination of refractory materials is a common feature in fired heaters. Openings such as doors often use fiber and brick material, and peep sights may use IFB, castable, or fibermodules.

A standardized design using different materials can be challenging as each material has varying properties at high temperatures. Therefore, refractory linings can become damaged, leaving the shell exposed to hot flue gases and causing hot spots. 

To lower the risk of mismatched refractory materials, it is a good idea to work closely with the refractory supplier to ensure comparable materials are used around openings. 

There are several factors that can cause mechanical stress to lead to refractory failure. This includes:

Vibration or interference from other equipment can cause refractory to become displaced and break down over time.

This occurs when refractory linings expand and contract at different rates due to thermal conditions. This often leads to cracking and spalling which can cause failure if not repaired.

Mechanical impact from falling objects or components can also damage refractory.

Methods to Repair Refractory

Once the damage has been identified, there are several options. Production can be interrupted to take the asset offline and carry out conventional repairs, or the furnace can continue to run at reduced performance until the next planned turnaround. 

Alternatively, an online refractory repair service is offered byHot-tek™, where there is no need to bring the heater off-line and production will not be interrupted or capacity limited.This is a good option to temporarily fix damage until the next planned turnaround.

A team of refractory technicians can be mobilized at short notice and the repair involves creating minimal access point openings to insert specially designed components and repair material, delivering a semi-permanent repair lasting at least until the next turnaround.

Conclusion

There are many more causes of refractory failure such as loss of support and poor installation or maintenance, but shutting down the furnace should always be a last resort as this has a huge impact on production and revenue. The operating environment is responsible for most refractory failures and a common oversight is to increase the furnace temperature without assessing the impact that this will have on the design parameters of the refractory. Planning for over-capacity can help to mitigate the risk of refractory failure if specifications change after installation. 

If unexpected performance losses are impacting your operations, Integrated Global Services (IGS) can mobilize quickly to help you identify, fix, and prevent future damage.   

This article can also be found in the issue below.

As well as offering a spares and repair service for all makes and types of heat transfer equipment including fuel-fired and electric steam boilers, Fulton’s aftercare portfolio also includes numerous training solutions such as City & Guilds accredited boiler operator training to INDG436 and BG01-R2 and water treatment training to BG04 and EN12953. But what are the benefits of having competent steam boilers operators?

Safety: Boilers can be dangerous if not operated correctly, and a competent operator can help ensure that steam boilers are operated safely and in compliance with relevant regulations.
 
Efficiency: Competent operators can help optimise the operation of the boiler, ensuring that it runs efficiently and therefore consumes the least amount of fuel possible, which will lower the overall running costs.
 
Maintenance: A competent operator can help to identify potential problems with the boiler and take appropriate action to prevent them from turning into major issues. This can prolong the life of the boiler, maintain its operating efficiencies and reduce the need for costly repairs.
 
Record Keeping: Keeping accurate records of the boiler’s operation, including fuel consumption, maintenance records, and safety inspection records can be useful in identifying trends and making decisions about how to operate the boiler more efficiently.
 
Compliance: Operators can help facilities ensure compliance with local and national regulations regarding the operation of boilers, preventing penalties and fines.
 
Reliability: Skilled operators can assure continuity of operation, avoiding downtime and ensuring that the best quality and correct amount of steam is produced as required.

With regard to operator competence however, the boiler manufacturer should be considered the first point of contact and best suited to provide training for specific boiler operation. Additionally, being the manufacturer, they will have sufficient industry experience to ensure the information is delivered at the correct level and in the right context.Alternatively, per the HSE's INDG436 (Safe Management of Industrial Steam & Hot Water Boilers), training should at the very least be delivered by those with the appropriate knowledge, training and assessment skills on their own equipment.To help them become competent operators, Fulton has created affordable training courses aimed at boiler operation, boiler maintenance and water treatment.

For further information on its courses click http://bit.ly/2UrgRRh, email This email address is being protected from spambots. You need JavaScript enabled to view it. or call the office on +44 (0)117 972 3322.

This article can also be found in this issue below.

Despite the soaring prices brought on by an energy crisis that shows no signs of diminishing, ask pump and blower operators about the efficiency of their equipment, and the truth is that most don’t know – according to a leading monitoring technology provider.

The pumps, for example, might often be described as ‘working fine’ and ‘doing their job’, but is that, now more than ever, a strategy? How about saving money now, and in the future?

“The opportunity to truly maintain, protect and optimise assets is here and now, with a Return on Investment (ROI) that is shorter than ever”, says Julian Lowe from Riventa. “The cost of solving asset management challenges is on a much smaller scale than most companies imagine”.

So, just how can you make hidden costs more visible?

At minimum, put some testing in place. By obtaining accurate, quality data, this first proactive step will give you a snapshot of performance, as well as health and efficiency. Even this entry-level testing will help identify poor assets and inefficient pumps.

Riventa’s Julian Lowe added: “All we hear about at the moment, understandably, is the giant hike in energy prices, so best test your pumps (and/or blowers and turbines) to reduce energy consumption and maximise savings. This will almost immediately help identify actions to improve performance. In addition to pump efficiency, measuring key parameters such as flow rate, head and electrical power - current pump performance characteristics can be compared to ‘as new’ and ‘post-refurbishment’ conditions. This provides the same accuracy as a pump manufacturer’s test facility – but with the distinct advantage of real operating conditions”.

Across numerous industries, where for some, running pumps ‘til destruction is the modus operandi, Lowe has a point. He claims that for larger pumps, blowers and turbines, the ROI can be as little as 18 months.

A level up from pump testing is to look at an Optimisation Service, utilising secure on-site pump monitoring equipment to provide real-time data. This enables you to start seeing what’s happening across your system by capturing data over 14-days or longer. This doesn’t have to involve tons of ‘spaghetti’. Systems can now be cable-free; up and running in around 1 hour per pump, at low risk and with minimal disruption to existing operations.

‘Realistic payback calculations’

Dr Tom Clifford from Riventa, continued: “Once in place, real-time data for each asset can be evaluated, with information-driven insights highlighting performance issues and supporting decisions. This can establish best practice recommendations, realistic payback calculations and a business case for moving forward – all backed by precision measurement and innovative analytics”.

Clifford explained how Riventa had recently worked with a food manufacturer; testing the company’s cooling system, which is split into two pumping sub-systems: factory pumps 1-5 for sending chilled water from heat-exchangers to the factory; and evaporator pumps that send chilled water from the factory to refrigeration heat exchangers.

“To test the pumps, we used the thermodynamic measurement technique (with our specialist software) to measure suction and discharge pressures either side of the pump, differential temperature, and motor input power. These measurements enabled us to calculate differential head across the pump, hydraulic efficiency and volumetric flow. Pumps were altered gradually. After each change, a test point was taken, while allowing enough time to obtain the best statistical average. Tests also involved a routine of testing performance at an incumbent set point, followed by throttling the pump to reduce its flow rate. The latter action allowed other pumps running in parallel to increase in speed to compensate, with a final test point taken at this moment”.

He continued: “Throttling meant we could observe the maximum possible flow through each pump under test, without altering the overall flow to the plant. At times this was challenging, because conditions downstream in production would change, altering the cooling load and in-turn the flow set point. Nevertheless, good quality performance information was obtained.

‘Strong case for robust savings’

“We found that all pumps were showing signs of wear. Moreover, manufacturer performance levels were not being achieved. None of the pumps we tested reached the manufacturer’s BEP (81%). In fact, the maximum pump efficiency possible was found to be 75% (achieved by pumps 1 & 2 only). Our findings enabled us to put pumps into a descending order of repair: 1, 2, 3, 4 & 5. While pumps 1-3 achieved a good relationship between power and flow, pumps 4 & 5 were not performing when at lower flows. This indicated a high likelihood of internal recirculation – from high to low pressure parts of the impeller – being caused by high wear. We were able build a strong case for robust savings through the pump refurbishment. Broadly, two options were made available:

• Basic Refurbishment: Internal coating plus replacement of wear-rings, bearings and seals.

• Comprehensive Refurbishment: As per the Basic Refurbishment, plus a new tailored impeller.

“We calculated that pump refurbishment would bring potential

savings of £19,200 per year, with possibilities to refurbish 2, 3

or 5 pumps”.

This is just one example of what Riventa say they are helping companies achieve across industries that also include water, power, mining, petrochemical, to name but a few.

Advanced pump monitoring and optimisation are available too, continuously focusing efforts by evaluating and understanding performance gains across priority pumps and sites. And for some organisations, full optimisation of networks is available.

‘Change in Mindset’

“Nobody wanted an energy crisis”, concluded Clifford, “but as prices soar, we are beginning to see a change in mindset about just how important it is to know how your assets such as pumps, blowers and turbines are really performing.  Initially, some basic testing might reveal some not altogether pleasing facts (!), but you can soon put yourself on a very positive course to make some seriously good, ongoing savings”.

www.riventa.com

New software implementation enables precision handling of KPIs and budgets, plus autonomous support functions

IFS Ultimo’sEnterprise Asset Management (EAM) platform has been selected by Orkla to manage activities for projectsatits site inFilipstad, Sweden. The facilitycurrently uses the cloud-based software solutionto ensure that administrative assignments and maintenance tasksat the site are carried out efficiently and effectively.Further functions of the software will be rolled out to other departments within the organisationat a later date.

As one of the leading operators of brands and concept solutions for supermarkets, pharmacies, bakeries and catering, Orkla has 15 production facilities in Sweden. These are mainly focused onfood and hygiene products.The company has set the objective of contributing towards resolving global health andenvironmental challenges, through developing healthier food products, reducing food waste, curbing greenhouse gas emissions and launching products that contribute to a circular economy.Itneeded a new software solution to match suchambitions, having relied on the same computerised maintenance management system (CMMS) for 25 years.

“Our old CMMS system was unable to keep up with the organisation's evolving requirements, as we looked to achieve full-scale digital transformation at ourFilipstadsite,” explained Jack Delang, Process Improvement Manager at Orkla.“We were experiencing unexpected system breakdowns,which led to costly disruption.We needed a user-friendly platform to help us streamline maintenance projectsand help us grow as a company.”

Orkla first heard about IFS Ultimo through jointpartner Good Solutions. Since partnering with Good Solutions, IFS Ultimo has been expanding further in the Nordic region, gaining greaterlocal knowledge of customers’ requirements there andproviding them with a local point of contact.

“IFS Ultimo has powerful features to manage preventive maintenance and maintenance plans andcan play a huge role in becoming a part ofManufacturing Operations Management. Alongside this, in comparison to competitors, IFS Ultimo is better developed as a company, with great responsiveness, personal contact and reliable support. The potential with IFS Ultimo solution and their overall professional organisational approach werethe main reasons for our choice,” Orkla’sDelang added.

Featuring innovative technologies and functionalities, the software helps optimise maintenance management allowing the customer to have more control and structure over their assets, to gain greater understanding to empower decision-making and deliver results and to improve cost control.

Delang concluded: “We are up and running with Ultimo forone month now, almost effortlessly. We are impressed with the structure and responsiveness and all the flexible possibilities of changing the fundamental structure. This way, it can be applied in the best way to suit the organisation’s needs. Customer satisfaction from the project team hasbeen very high since thefirst discussions which is a big compliment to the IFS Ultimo team. I’m looking forward tothe upcoming period when we can start to apply new functions of IFS Ultimo to the maintenance department, and later on to the larger organisation that hasn’t had the possibility to use the software yet.”

“We are thrilled that Orkla has chosen IFS Ultimo’s EAM platform for use in itsFilipstad site.By working with us, Orkla is laying the foundation for achieving increased efficiency in project tasks, while alsolowering maintenance costs,” saidMarco Parnela, Business Development Manager at IFS Ultimo.“This is just the start for Orkla.Implementing the software across other departments in the near future will lead toimproved cooperation between the operators and the maintenance department.”

To find out more, visit www.ultimo.com.

Surprisingly, many companies still use a system of Planned PeriodicMaintenancein an attempt to avoid costly downtime arising from the failure of their equipmentand machinery. In other words, they replace parts that tend to wear out(e.g. motor bearings) on a routine basis whether they need replacing or not.Not only is this needlessly costly, but can make matters worse by introducing faults during the process of stripping down and rebuilding a perfectly good machine. Even more of a problem is deciding the PPM time intervals. Too frequent,means more wasted time and cost (and morepotential for introducing faults) but not frequent enough, means more unexpected breakdowns.

Condition Based Maintenancerelies on the fact that a machine’s condition (degree of wear) can be monitored, by measuring the vibration levels in motor bearingsfor example. This way,the machine only needs to be maintainedwhen its condition deteriorates beyond an acceptable level. This decision isbased on recording and tracking changes in the machine’s condition over time (trending).Put simply, CBMphilosophy isif it’s not broken, don’t try to fix it!

This approach obviously saves time and money since machineparts are only changed when they need to be. However,CBM can potentially save a lot of money by spotting a machinethat is about to fail prematurelybefore it fails and hence avoid an unexpected and costly shutdown.

Clearly, CBM is a superior technique but until now,its cost of implementation has put off some companies from using it. Traditionally, both CBMequipment and the expertise required to use it has been prohibitively expensive.

Test Products International (TPI) has however completely revolutionised this concept with the introduction ofits low cost, portable vibration analysers and free to use trending software. Both the analysers and software arevery easy to use,stemming from the fact that they are very intuitive and based on internationally agreed (ISO) alarm levels for rotating machinery.

TPI’s free to use VibTrend machine management and trending software stores machine condition readings and displays their trends in a clearand easily understood graphical format. In addition, various ‘expert system’ features are incorporated into the software, such as bearing quality assessment, which is achieved by analysing the frequency components of the vibration data and automatically identifying the classic ‘signatures’ associated with bearing wear. That way,it is very easy to monitor the health of a bearing simply by observing the level ofbearing quality displayedon the trend plots.

A complete CBM system can cost from as little as £1,450 with the TPI 9080, whichuses industry standard accelerometers and offers on-meter analysis for the detection of machine faults such as unbalance, misalignment, looseness and bearing wear. Theequivalent intrinsically safe version (IEC Ex, ATEX and North American)TPI 9080Exoffers a complete Zone 1 CBM solution for £3,500. Both versions include a full VibTrendfree to use unlimited software license.

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.