The C581 is the first model in an exciting new lineup of powerful and versatile Flow & Energy Computers. It combines our extensive expertise in instrumentation, a deep understanding of international requirements, and a commitment to user-friendly design. The result? The most robust, accurate and versatile field mount Flow & Energy Computer available today. The C581 sets a new standard for performance and reliability, leading the way in a promising range of Flow & Energy Computers!

Accurate

The C581 single stream flow and energy computer is a powerhouse for precision measurement. It accurately measures flow, temperature, and pressure of water or steam, and uses IAPWS density and enthalpy determinations to precisely calculate energy, mass, and volumetric flow. Thanks to 11 linearization points for all input signals, you'll experience enhanced accuracy across all flow ranges.

Flow measurement
The C581 can handle all ISO5167 flow elements and more; either with signals form a single dP sensor up to 3 stacked or averaged dP sensors.  As such range and accuracy at the lower end of the flow spectrum is significantly improved. For other applications the flow calculation can be based at the design conditions of the flow element.  Pulse inputs are soon available for the measurement of rotating flow meters. The C581 is able to determine the energy transfer in heat exchangers.

Robust and weatherproof
Built to endure the toughest environments, our robust IP66/67, Type 4X aluminum field enclosure withstands extreme weather and harsh industrial conditions. It’s engineered to perform flawlessly in temperatures ranging from a -40°C/-40°F to +70°C/+158°F. With this rugged enclosure, the C581 stays protected, no matter what nature or the job throws at it!

More information: https://www.fluidwell.com/c581

Acoustic imaging technology is redefining industrial maintenance with precise, non-invasive detection of hidden leaks, mechanical faults, and hazardous gases. The FLIR Si-Series offers cutting-edge solutions that enhance safety, reduce costs, and improve operational efficiency across various industries, including the likes of manufacturing, automotive, food and beverage, and pharmaceuticals.

Acoustic imaging allows inspections to be carried out without interrupting operations using a safe, easily operated device that requires minimal training. The advanced technology converts sound into visual data, allowing users to easily pinpoint issues and assess their severity. By identifying early-stage problems before they escalate, companies can maintain safer environments and avoid costly downtime. The FLIR Si-Series offers versatile models to meet diverse industrial needs, ensuring the right tool is available for any specific application.

Simply Effective Air Leak Detection with FLIR Si124-LD Plus

The FLIR Si124-LD Plus is an easy-to-use, lightweight acoustic camera designed for precise air leak detection, capable of identifying leaks as small as 0.004 liters per minute.  Equipped with AI-driven features, the Si124-LD Plus filters out background noise and measures the distance to leaks accurately.

Users benefit from real-time analysis of leak size and cost estimates that provide clear, actionable insights for informed maintenance decisions, helping to ensure operational efficiency and minimizing costs. The user-friendly interface allows maintenance teams to quickly locate and fix issues, enabling reliable system performance and reducing the time and resources spent on repairs.

Find the Right Si-Series Acoustic Imager for Your Needs

The FLIR Si-Series offers a range of acoustic imagers to tackle various industrial challenges, from detecting concealed air leaks and uncovering mechanical faults to identifying hazardous industrial gases. Choose the perfect Si-Series model from our Comparison Chart, and elevate your predictive maintenance strategy to a new level!

Learn more: https://www.flir.com/promotions/si124-ld-plus-price-promotion/

Disruption to manufacturing and production lines damages more than just delivery times. The impact of unexpected failure can damage a businesses reputation as well the risk of spiralling costs to repair, especially if replacement parts are not readily available.

Being informed about the condition of equipment along a production line, along with componentry in an electrical cabinet can make the difference between avoiding downtime, and panicking when something goes wrong.

Thermal cameras can be used to inspect critical componentry to see their safe and reliable operating temperature, which can then be recorded and referenced against in the future to alert the maintenance manager when the operating conditions vary outside of reliable operating parameters.

Whether inspecting each component once a month to build a thermal trend, or viewing similar equipment through a thermal camera to compare operating temperatures, insights can be gained into the condition of components and critical assets.

Often equipment failure can be caused by simple issues, such as a loose electrical connection that simply needs re-crimping or tightening, or blocked air-ducts reducing cooling on electric motors or similar equipment. Identifying where temperatures are increasing allows maintenance managers to take action, often simple action, before these small issues develop into larger faults which are more expensive to repair.

This is a simple process and a core pillar of condition based monitoring which can make the difference between identifying a fault and intervening before a production line becomes disrupted; or being surprised when something stops a production process and needing to fault-find before undertaking repairs.

FLIR have a wide range of thermal cameras to suit every budget, along with a selection of analysis, trending and reporting tools to support maintenance managers as their predictive maintenance processes. Read more by visting the link https://bit.ly/3AOQafB

www.flir.com

Thordon Bearings is supplying multiple sets of grease-free bearings to completely replace old technology at the Otto Holden Generating Station on the Ottawa River in Ontario, Canada.

Andritz Hydro was contracted to undertake the mid-life refurbishment of the station’s turbines on behalf of Ontario Power Generation (OPG). Two of the 243MW station’s eight units have now been fitted with Thordon’s ThorPlas-Blue and Thorseal products, via its local distributors RMH Industries in Quebec and Millstream Engineering in Ontario.

Unit 7 was refurbished in 2022, unit 5 in 2023, and unit 8 is next with installation expected in Q4 2024. By 2029, all eight of the station’s units will have been refurbished.

Each retrofit involved 262 bearings per turbine including wicket gate bearings and seals, Thorseal linkage bearings, Thordon SXL operating ring wear pads, and servo motor bearings and seals. The bearings being installed have high-end edge loading performance and range from about 100 to 300mm (4-12in) outside diameter.

The servomotors are being made entirely by Thordon distributor RMH Industries, one of the company’s specialties honed over the last 50 years. Gaétan Dionne, RMH Industries’ General Manager, cites, for example, that the company can install Thordon’s bearings on the servomotors using liquid nitrogen in less than a minute.

Thordon’s bearing and sealing solutions were chosen for their reputation for being the highest-performance materials available on the market. A key on-going benefit is that they eliminate the need for regular greasing, thus reducing maintenance costs and avoiding contamination of rivers.

Thordon’s wicket gate, operating mechanism and linkage bearings operate wet or dry and are self-lubricating to ensure performance in limited-motion applications. There is no galling from edge loading caused by minor misalignments or gate deflections. The bearing material is ThorPlas-Blue which is a homogeneous, self-lubricating engineered thermoplastic capable of withstanding operating pressures up to 45MPa (6,527 psi).

Thordon’s Thorseals are made of a proprietary elastomer with no shelf life or degradation of properties over time. Thorseals are available in a wide range of standard sizes or can be quickly machined to custom size requirements up to 1.5m (60in) in diameter.

Greg Auger, Commercial Director at Millstream Engineering, explains that installing the wicket gate bearings requires careful attention to detail.

“It is critical to get accurate measurements of the shaft and housing dimensions before final machining of the ThorPlas-Blue bearings so that they can be sized correctly for proper fit and clearance. During installation, care must be taken to press-fit the bearings to prevent damage, and then they must be protected from risk of damage while other overhaul work continues. Careful measuring of the installed dimensions will help verify that all the large components will assemble correctly.”  

Millstream Engineering will continue to provide local support to OPG for all their facilities across Ontario. Auger says there is a big push underway for overhauling and modernizing hydropower facilities across Canada, and the Otto Holden station is one of many to be rehabilitated over the next decade.

Additionally, demand for electricity is constantly increasing, and OPG has identified significant untapped hydroelectric generation opportunities. In the northern rivers of Ontario alone, there are about 4,000MW of potential power, or enough electricity to power about 3.5 million homes.

Business Development Manager for Hydro & Industrial at Thordon Bearings, Ryan Edmonds, said: “The hydropower market is growing globally due in part to the increasing demand for renewable energy. Hydropower is a clean, secure, domestic source of electricity, and Thordon’s high-performance solutions are a perfect fit for these durable assets.”

www.thordonbearings.com

It is estimated that unplanned downtime costs oil and gas companies an average of $42 million per year, and up to $88 million per year in worst-case scenarios. In response to this substantial financial impact, advancements in automation and material science are revolutionising refinery inspection and maintenance, offering promising solutions to enhance efficiency, reliability, and cost-effectiveness.

Such technologies are being adopted by the industry and the trend is set to grow phenomenally in the next five years. In fact, according to a recent GlobalData article, sales of industrial robots are predicted to be worth $352 billion by 2030, growing at a compound annual growth rate (CAGR) of 38%. This article explores three key reasons why automation and material science are defining the future of refinery operations.

1. Enhanced Safety through Robotic Solutions

Safety is crucial in refinery operations, and automation is key in enhancing safety and efficiency. Most importantly, it reduces the risk of human intervention during hazardous inspection and maintenance processes. Robotic crawlers and rovers now perform critical tasks in environments too hazardous for human entry. These next-generation robots provide essential services such as inspection, cleaning, and alloy upgrades, all while ensuring the safety of personnel.

Integrated Global Services (IGS) is an example of a company that are at the forefront of this technological revolution, developing robotics for inspection and maintenance that identify and solve asset integrity issues early on, increasing safety standards and minimising unplanned downtime. As Eric Hellström, a Mechanical Engineer from Borealis, Sweden, attests: "IGS Tube Tech's expertise and commitment to quality ensures projects run smoothly, and on-site personnel are always a pleasure to work with. We have full confidence in their ability to deliver excellent results."

2. Advanced Materials for Extreme Conditions

The harsh environments within refineries demand materials that can withstand extreme conditions. Developments in material science are solving this challenge, with researchers and engineers creating solutions, such as:

• Unique superalloys, such as High Velocity Thermal Spray (HVTS), designed to combat specific corrosion and erosion challenges
• NASA-approved high-emissivity Cetek ceramic coatings for use in high-temperature rocket nozzles, control surfaces, industrial furnaces, and transfer lines.
• Proprietary claddings that address thermal efficiency and erosion-corrosion issues

These advancements are being used in the field, with proven results. A NASA Tech Brief, comments:

"The high emissivity coating was instrumental in advancing the radiation-cooled metallic nozzle extension for the J-2X Upper Stage Engine. It exceeded our thermal performance expectations and brought significant design efficiency and weight reduction to the table."

3. Cost Reduction and Sustainability

Automation reduces labour costs and minimises human error, leading to more accurate and consistent inspections. At the same time, material science innovations lead to the creation of more durable materials and coatings that can withstand harsh refinery environments, reducing the frequency of maintenance and replacement.

Case Study Example:

A refinery had been suffering from reduced performance due to fouling on the convection bank tubes within a steam methane reformer, a problem that had persisted since the unit came online in 1993. The refinery faced increased fuel consumption, higher flue gas temperatures, and reduced heat transfer efficiency. Integrated Global Services (IGS) applied a Cetek high-emissivity ceramic coating to address these issues, followed by Tube Tech’s robotic convection section cleaning service. This combination restored the heat transfer efficiency and resulted in a 20% increase in steam production and a 3% improvement in the furnace’s thermal efficiency. Additionally, the project delivered a rapid return on investment, with the cost of hydrogen production decreasing by $24.6 per ton, and the payback period being less than 60 days. This case exemplifies how material science and automation advancements can lead to significant cost reductions and sustainability improvements in refinery operations.

Conclusion

According to industry reports, implementing predictive maintenance strategies can reduce maintenance costs by 10% to 40% and increase equipment uptime by 5% to 20%. This highlights the significant financial advantages that refineries can achieve through the integration of automation and material science, ultimately leading to improved operational efficiency and cost-effectiveness in refinery operations.

To find out how automated solutions and material science advancements could benefit your plant, www.integratedglobal.com

A new international survey¹, published at the end of 2023, by the Institution of Engineering and Technology (IET) confirms what the engineering sector has been saying for years: that a considerable skills gap exists which impacts productivity.  What’s particularly interesting to note from this latest survey is that, in the face of climate change, that gap feels more like a chasm.

According to the survey, two thirds of UK employers are concerned about climate change and most have made a technological or organisational change to lower their environmental impact in the last three years, primarily focussed on emissions reductions.  However, around three-quarters think their organisation does not have the full skillset to be resilient against climate change, and 29% feel their organisation is not agile enough to adapt.  Furthermore, they cite increased costs in their supply chain because of climate change which, ironically, is seen as a widespread barrier to becoming net zero.

The findings of this survey is supported by the government’s November 2023 research briefing, ‘The UK's Plans and Progress to Reach Net Zero by 2050’.  It states that the industrial sector was responsible for 14% of UK emissions in 2022, with the Climate Change Committee 2023 Progress Report considering there to be higher risks to decarbonisation than in 2022, with insufficient plans for the majority of the Carbon Delivery Budget Plan targets for the fifth and sixth carbon budgets due to a continuing lack of progress.

UK Engineering employers surveyed by the IET largely put the blame for the skills gap on the education system.  63% think the UK education system does not prepare young people to work in their industry.  However, the engineering sector also has a role to play here by providing appropriate training and quality apprenticeship schemes. 

To make these changes will take political willpower, time and investment.  But time is one thing we are running short of when it comes to climate change and the UK’s 2050 Net Zero goal.  We need to act now to decarbonise industry. 

With process heating being a major consumption of energy and source of emissions within industry, it’s an area that manufacturers and engineering firms across the UK – and the world – are focussing their decarbonisation efforts and resources on.  Inefficient boilers and burners are being replaced with modern energy efficient heat raising equipment and systems that incorporate heat recovery, and we are seeing a big move towards electric powered systems, away from fossil fuel.

But as we make these changes, the skills to operate and manage much of this equipment is in short supply as we have clearly seen.  So, if the skills aren’t readily available, what options does industry have?  The answer has to be to reduce or remove the skills required, which is where manufacturers such as Babcock Wanson have a role to play.  We can’t solve the skills gap but we can engineer some of the skill out of day to day operation.  Here we suggest four ways to help bridge the skills gap:

1 Thermal fluid heaters

Increasingly popular, thermal fluid heaters work at high temperatures in a simple closed loop.  When compared to a steam system this means no change of state of the fluid so no condensate and therefore no flash steam losses, no blow down losses or make up water required, no effluent discharge and completely corrosion free without the need for expensive chemical treatment.  Not only are they more energy and cost-effective but in the context of the skills gap they are much easier to operate daily.  Furthermore, they operate outside the Pressure Systems Safety Regulations as the fluid is not maintained in the liquid phase by pressure, so are safer. 

Across Europe and now in the UK there is a move towards electric thermal fluid heaters, such as own newly launched EPC EL which, being modular, can be configured in series and parallel to meet different applications and site requirements. 

2. Unattended boiler operation

Where thermal fluid heaters are not an option, steam generators remain, but these require a far higher level of skill to operate.  Some of this can be mitigated by introducing unattended boiler operating systems.  Traditionally these were used by organisations whose operational hours extend beyond the standard.  However, recent years have seen a considerable acceleration in both the popularity of these systems (our customers now ask for it as standard) and the length of time they are able to safely operate unattended, from three to seven days.  Systems, such as our own BW7DAYS, make for easier operation requiring less skill.  Once set up for unattended operation, all the user needs to do is monitor for any operational alarms and undertake a very simple 15 minute test every three or seven days, which is completed without interfering with boiler operation and is acknowledged to the boiler control system, thereby ensuring the tests are completed to the operating schedule.  Improved safety and conformance with current and future UK & EU legislation is also a key benefit and one that even 24/7 operational sites that are fully staffed are increasingly attracted to. 

3. Water treatment services

All steam raising equipment requires the feed water to be treated to prevent corrosion.  Both the quality of the steam and the longevity of the boiler producing it are completely dependent upon the condition of that water feed.  Poorly prepared water can cause rapid and costly damage to the heating surface and can lead to the end of a boiler’s working life in a short period of time.  Water treatment is a skilled task, so consider outsourcing this.  At Babcock Wanson we have a partnership with water treatment specialists Deep Water Blue to conduct this service and, in between scheduled consultancy visits, our vSteam web portal allows customers to simply enter daily readings on-line and receive real-time feedback support.

4. Outsource maintenance

Regular service and maintenance are essential for steam plant to ensure smooth operation and safety, but even thermal fluid heating systems benefit from regular servicing.  Being able to operate such a system does not mean you have the skills to maintain it. Outsourcing this to a specialist, or the manufacturer itself, ensures the work is conducted to a professional level by experienced, trained service engineers. 

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs. 

020 89537111

This email address is being protected from spambots. You need JavaScript enabled to view it.

www.babcock-wanson.com

Efficient cold storage container from ICS Cool Energy ensures smooth beer service for Camerons Brewery.

Camerons Brewery Ltd., the largest independent brewer in the North East of England, partnered with ICS Cool Energy to secure a reliable cold storage solution for a recent music festival, ensuring a smooth experience for both customers and the service team.

Challenge

For four consecutive years, Camerons Brewery has played an important role in a prominent festival, setting up the main bar and keeping beer and drinks chilled for attendees. Previously, Camerons relied on cold storage vans from a different provider, which ceased operations. As Camerons Brewery sought new options, they encountered difficulties with other suppliers due to restrictive hire terms and limited service areas.

“We were in a tight spot when our previous cold storage provider shut down. We quickly needed a solution that could meet our specific requirements without the complications we faced with other companies,” said Simon Ritson, brand ambassador for Camerons Brewery Ltd.

Solution

ICS Cool Energy stepped in to fill this gap by offering a Cold Store container tailored to Camerons Brewery’s needs. Following a prompt discussion over the phone, ICS Cool Energy arranged for a unit to be delivered, positioned on-site, and ready for immediate use.

“ICS Cool Energy’s responsiveness was impressive. They confirmed our needs over the phone and had their unit delivered and set up without any hassle, right on time” noted Simon Ritson. ”The cold store container turned out to be more spacious than we anticipated, which gave us additional flexibility and storage capacity."

ICS Cool Energy temperature-controlled containers are available in 10ft, 20ft and 40ft length and feature tried and tested refrigeration technology from Thermo King, a leader in transport temperature control solutions. The units can be plugged in the 360-500 Volt 50 or 60 Hz power supply to ensure cold or frozen temperatures in the container.

Designed originally for global, seagoing reefer applications, ICS Cool Energy containers are equipped with features that make them suitable as static cold stores. They are washable with wash down drains, have man trapped person alarms, lighting inside emergency escape release and conform to B.R.C. audit standards.

Results

ICS Cool Energy’s cold store container provided ample space and maintained the desired temperature control, ensuring the beer was stored at the right temperature throughout the festival, with no dispensing issues. The unit's capability to handle high ambient temperatures and frequent door openings proved essential for the festival environment.

“ICS Cool Energy made the entire process easy, from delivery to collection. Everything went smoothly, and we plan to use them for future events. Their reliability was crucial for us, and it ensured our customers enjoyed their experience at the festival,” concluded Simon Ritson

 For more information on ICS Cool Energy complete process temperature control solutions, please visit www.icscoolenergy.com/.

SONOTEC GmbH looks back on a highly successful participation at the World Conference on Non-Destructive Testing (WCNDT 2024) in Incheon, South Korea. As a leading provider of innovative ultrasonic solutions for non-destructive testing (NDT), SONOTEC presented its diverse developments and products, which were very well received by the numerous international experts. In addition to exhibiting on the trade fair floor, SONOTEC’s experts impressed with two presentations and a poster presentation.

Focus on Innovation and Expertise

At WCNDT 2024, SONOTEC showcased its advanced ultrasonic solutions for various applications in NDT. Visitors to the trade fair had the opportunity to learn about SONOTEC’s latest devices and technologies, which significantly enhance the efficiency and reliability of non-destructive testing.

Two Presentations by SONOTEC Experts

As part of the conference, SONOTEC experts delivered two high-profile presentations that captivated the professional audience:

1. New Possibilities in Air-Coupled Ultrasonic Testing with Phased-Array Technology
   For optimal results in air-coupled ultrasonic testing, a compromise between material attenuation and resolution is necessary. Phased-array technology improves sound fields through phase shift analysis and demonstrates clear advantages over conventional methods.

2. Robust Ultrasonic Transducers for Pipeline Inspection
   Inspecting pipelines is crucial to detect damages such as corrosion and cracks and to prevent accidents. Ultrasonic testing allows for precise assessment and requires robust transducers that can withstand extreme conditions. The development involves careful material selection and rigorous testing, with the stability of the transducers being critical.

Poster Presentation: New Approaches in Material Testing

In addition to the presentations, SONOTEC showcased a scientific poster focusing on new approaches in material testing. The poster presentation attracted great interest and facilitated intensive exchange with other professionals and scientists.

An Inspiring Experience

Participation in WCNDT 2024 was not only an opportunity for SONOTEC to present the latest technologies but also an inspiring experience. The exchange with international experts and the positive response to its developments reinforce SONOTEC’s commitment to continue developing innovative solutions for non-destructive testing and advancing progress in this important field.

With great enthusiasm, SONOTEC looks forward to incorporating the gained insights and contacts into future projects and developments. WCNDT 2024 was a complete success and another milestone on the path to excellent solutions in NDT.

www.sonotec.de

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.