Editorial

By releasing the new MGF X Line range of oil-free compressors into the UK market, FPS Air Compressors is providing dental labs running CAD/CAM-driven milling machines and 3D printers with a proven way to utilise a continuous and highly reliable source of clean, dry compressed air without risk of contamination.

Computer-Aided Design/Computer-Aided Manufacturing (CAD/CAM) systems are finding growing use in the creation of dental restorations such as crowns, bridges and veneers. The new X Line can supply clean and dry compressed air continuously and reliably to CAD/CAM-driven milling processes, ensuring the precise, reliable and high-integrity production of dental prosthetics.

A further benefit of using innovative MGF X Line compressor technology at dental labs is increased air capacity and, subsequently, lower energy bills. This advantage arrives courtesy of a patented MGF system that reduces the air requirements of the membrane dryer, which in turn increases the available flow of air from the compressor by 20-25% to help optimise dental lab processes such as milling.

The X Line is also ideal for serving 3D printers, which although an additive rather than a subtractive process like milling, still need a compressor that provides continuous, high air quality and low vibration to support the precision and stability demanded by the 3D Printers industry. Notably, as 3D printing technology becomes more widespread, the importance of air quality in the printing process is gaining more and more attention in the process.

                                                                                                                                                                        Continued ……

Producing consistent air quality is a primary capability of X Line compressors, which house a 0.01 µm filtration system and a high-quality, high-efficiency membrane dryer. The provision of clean, dry, continuous air allows dental labs everywhere to take advantage of uninterrupted workflows. X Line compressors run at a maximum pressure of 10 bar, producing constant air flow at the capacity stated from a broad range of models suitable for multi applications.

Offering yet another advantage, the low vibration of the cabinet-housed X Line air compressors contributes to quiet operation. In addition to the four ‘Base’ models, a trio of ‘Silent’ versions are available providing low noise levels that do not exceed 53-56 dB(A). Furthermore, with the robust build quality, X Line compressors offer highly durable operation and a long service life, helping to minimise total cost of ownership (TCO) for dental labs.

Ultimately, the MGF X Line combines efficiency, performance and reliability with extremely quiet operation, providing genuine added value to dental labs running CAD/CAM-driven milling and 3D printing processes.

In addition, FPS extensive range of oil-free and SCROLL compressors are suitable for a myriad of applications in other sectors that demand high air quality. These include: product handling and packaging at food and beverage plants; aseptic processes and cleanrooms in pharmaceutical facilities; circuit board manufacturing and chip production in the electronics market; jet looms and air splicing at textile factories; testing and analytical instruments at research laboratories; and sampling and analysis devices in environmental monitoring processes.

For further information on the X Line range oil-free compressors please visit:
https://www.fps-compressors.co.uk/oil_free_compressors-cadcam_applications.html

Introduction

Improving fired heater performance is crucial for optimizing energy consumption, reducing emissions, and enhancing overall process performance. In large-scale process facilities, energy typically accounts for at least 50% of operating costs. An energy use reduction of 10% will often improve margins by 5% and reduce CO₂ emissions by 10%.

This article will discuss symptoms and causes of fired heater performance issues, and the solutions available to fix them and improve efficiency.

What are the Symptoms of Underperforming Fired Heaters?

Inefficient fired heaters can lead to increased energy consumption, decreased production rates, and potentially unsafe operating conditions. There are several symptoms of fired heater underperformance:

• Elevated Bridgewall Temperature
• Tube Overheating
• High Stack Temperature
• Production Bottleneck
• Excessive CO2 and NOx Emissions
• Insufficient Process Pre-heat/Steam Production
• Excessive Ammonia Slip

What are the Causes and Solutions of Underperforming Fired Heaters?

Cause 1: Fouled Convection Section Tubes

Fouling, which is the accumulation of deposits on the inner surfaces of the heater tubes in the convection section, can reduce heat transfer efficiency. Common fouling agents include carbon deposits, coke, ash, and other particulates. Fouled tubes can reduce heat transfer rates, increase fuel consumption, and decrease overall efficiency.

Solution 1: Robotic Convection Section Cleaning

To restore heat transfer efficiency, convection section tubes should be cleaned regularly. Robotic methods to remove fouling are now favoured as they offer several benefits compared to traditional manual cleaning methods, including:

Increased efficiency and speed: Robotic systems are more precise and can navigate complex geometries and hard-to-access areas with greater speed. This results in faster cleaning cycles and reduced downtime during maintenance.

Remote Operation: Robotic cleaning systems are often operated remotely, allowing technicians to control and monitor the cleaning process from a safe distance. This is particularly advantageous in situations where the convection section poses safety challenges.

Cost Saving: The initial investment in robotic cleaning services can often be higher than manual labor costs, however, the long-term benefits often outweigh this. Improved efficiency, reduced downtime, enhanced performance, and decreased maintenance needs can lead to significant cost savings over the equipment's lifespan.

Environmental Benefits: Efficient convection section cleaning helps maintain optimal heat transfer efficiency, leading to reduced energy consumption and lower CO2 and NOx emissions. This aligns with sustainability goals and environmental regulations.

Conducting a technical evaluation before cleaning the convection section is advisable. This will indicate the expected performance gains in terms of increase in capacity, % reduction in emissions, and fuel consumption benefits.

Watch: Robotic Convection Cleaning

Cause 2: Radiant Tube Scaling

Radiant tubes are designed to transfer heat from the combustion of fuel to the process fluid or material being heated. However, they are susceptible to scaling, which is the deposition of solid materials on the external surfaces of the tubes. Scaling can have several negative effects on the performance and efficiency of radiant tubes including reduced heat transfer efficiency, tube overheating, emissions increase, and higher bridgewall temperatures.

Solution 2: High Emissivity Coatings

High emissivity coatings, such as Cetek coatings, are materials that besides improving radiant heat transfer, also prevent oxidation and scale formation on the radiant tubes. These coatings are applied to the external surfaces of the tubes and significantly enhance heat transfer to the process and protect tubes from scaling. They are designed to withstand high temperatures and harsh operating conditions.

Some of the benefits of high emissivity coatings include:

Extended Tube Lifespan: By preventing oxidation and associated tube wall thinning, the life of the radiant tubes can be extended, if oxidation is the limiting factor.

Reduced Fuel Consumption: High emissivity coatings can help achieve the desired process temperatures with less energy input by improving heat transfer efficiency. This can lead to reduced fuel consumption and lower operating costs.

Watch: Catalytic Reformer Heater Process Tube Coating

Cause 3: Refractory Deterioration

Refractory deterioration can lead to hot spots on refractory material. It is an area of localized high temperature within a furnace, kiln, or other high-temperature process equipment where the refractory material is exposed to more intense heat than the surrounding areas. Hot spots can occur for various reasons and can have negative implications for the performance, efficiency, and lifespan of the refractory lining.

In these cases, the operator must decide whether to interrupt production by bringing the heater off-line to make a conventional repair or continue at reduced capacity until the next scheduled shutdown.

Solution 3: Online Heater Repairs

To avoid costly shutdowns or operating at a reduced capacity, it is possible to conduct online refractory repairs until further maintenance can take place during a planned shutdown.

Online refractory repair can be a valuable strategy to extend the lifespan of refractory linings and minimize downtime. However, it should only be performed by qualified and experienced personnel following proper safety guidelines and in accordance with industry best practices. Consulting with Hot-tek refractory experts and conducting thorough assessments are essential to ensure a successful outcome.

See How It Works: Online Refractory Repair

Conclusion

There are many causes of fired heater underperformance. It is important to identify warning signs early as even a 1-2% decrease in efficiency in fired heaters can consume an additional $1m in fuel across a 12-month period.  

To address this issue, it's crucial to conduct regular inspections, implement proper maintenance practices, monitor operating parameters, and address any issues promptly. Engaging with experienced process engineers and fired heater experts can help diagnose and resolve underperformance issues effectively.

Contact Integrated Global Services (IGS) for a free technical evaluation.

IGS fired heater experts will perform a comprehensive technical evaluation that will determine your efficiency improvement (%) and the payback period as well as projected (%) improvement based on your objectives (fuel/emission reduction, capacity increase or a combination of both).

To Claim Your Free Technical Evaluation, Visit: www.integratedglobal.com

This article can also be found in the issue below.

Compressed air and fluid power specialist Thorite have added hydraulic power pack maintenance and repairs to their vast portfolio of service solutions. This comes as a response to the demands of the numerous Energy from Waste sites choosing Thorite as their trusted service partner.

The company’s dedicated Energy Recovery Facility (ERF) Team will exhibit at the Resource and Waste Management (RWM) Expo at the Birmingham NEC from 13^th -14^th September where they will showcase a range of products and services designed to help ERF and EfW sites to improve efficiency, reduce energy consumption and achieve cost savings.

These include:

• The new comprehensive hydraulics service, which includes hydraulic power pack and hydraulic cylinder overhaul, repairs and post inspection reporting.

• A display of Norgren and SMC impact rapping cylinders, which are ideally suited to the removal of slag in ERF / EfW conversion facilities, optimising pneumatic power to deliver improved reliability and low maintenance costs.

• Next generation Gardner Denver compressors, with unparalleled efficiency and featuring ICON monitoring software to support predictive maintenance programmes.

• Energy saving services such as leak detection surveys and energy audits.

• Air and fluid power support, from install and start up to workshop overhaul.

Thorite’s ERF Team Manager, Josh Davis, said: “Our new hydraulic repair service is a unique offering and is a valuable addition to our range of bespoke services and products developed specifically for energy recovery sites.

This is Thorite’s first visit to the RWM Expo and we’re looking forward to sharing our expertise, built on more than a century of experience in hydraulics and pneumatics, at the UK’s leading event for the sector.”

Visit Thoite at stand stand R-K251 at the RWM Expo on 13^th & 14^th September at the NEC

or contact the ERF team on This email address is being protected from spambots. You need JavaScript enabled to view it.

This article can also be found in the issue below.

In the context of Condition Based Maintenance (CBM) it is generally accepted that measuring the vibration of a rotating machine (motor, pump, fan etc.) will tell us something about the condition of the machine. But what exactly are we measuring and what does it tell us about the machine?

Basically, it boils down to two numbers. One is the average (RMS) value of the low frequency vibration that tells us something about how well the machine is running. The other is the average value of the high frequency vibration that tells us something about the condition of its bearings.

The low frequency vibration is the typical “hum” you hear from a rotating machine. This vibration is due to the centrifugal force resulting from any out-of-balance in the machine. Since it is virtually impossible to exactly align a machine’s centre of gravity with its centre of rotation, even a well-balanced machine will still vibrate or “hum”. But what is an acceptable level? This is where the International Standards Organisation (ISO) comes to our aid. ISO have produced a set of guidelines that define suitable levels of machine vibration in the frequency range 2Hz to 1kHz (120 RPM to 60,000 RPM). That frequency range being chosen because it covers the vast majority of machine running speeds normally encountered.

The high frequency vibration is the typical “whine” you hear from a badly worn bearing. In practice, it is there all the time but is inaudible until the bearing becomes so bad it is probably about to fail. Fortunately, a vibration analyser can detect the inaudible bearing noise well before it gets to that point. This means bearing wear can then be displayed, for example, in Bearing Damage Units (BDU) that can very roughly be thought of as a “percentage” of bearing wear.

Vibration analysers employ sensors to capture a vibration waveform from a machine and then analyse it to automatically generate the ISO reading and the bearing condition. It is largely this ability that distinguishes them from simple vibration meters. The readings below, taken from a typical VibTrend report, show vibration levels measured on a motor. The ISO readings appear in green as they are below the recommended 4.5mm/s ISO warning level for a medium size motor. However, the drive end bearing noise is displayed in red as it is above the specified 100 BDU critical alarm level. The high BDU reading was in fact due to an outer race defect on the drive end bearing.

Test Products International manufactures a complete range of low-cost, high-performance vibration analysers from the £575, one-button-to-press TPI 9070, to devices that include advanced diagnostic and machine balancing capability. The TPI 9070 features colour coded alarm levels and zoomable on-screen vibration frequency plots together with on-meter analysis for the detection of machine faults such as unbalance, misalignment, looseness and bearing wear.

The TPI 9080 from £1,100 comes complete with VibTrend PC based trending and reporting software that includes automatic report generation and email notification of alarms, implementing a full CBM solution. The TPI 9080 can store lists (routes) of machines (up to 1000), each with up to 10 measurement points, all with full vibration waveform and frequency spectrum (FFT) capture.

Routes and readings can be transferred between the TPI 9080 and the included, license free, VibTrend in a variety of different ways.  Via the included USB docking cradle, wirelessly via Bluetooth or remotely via a Bluetooth link with a smart phone or tablet running the free TPI Bridge App. This allows service personnel to receive and return routes and readings, no matter where they are in the world.  

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.

Compressed air and fluid power specialist Thorite will introduce its new hydraulic repairs service at the Resource and Waste Management (RWM) Expo, at the NEC, Birmingham, from September 13^th -14^th.

The company’s dedicated Energy Recovery Facility (ERF) Team will be on stand R-K251 at the Expo to showcase a range of services and products designed to help ERFs and energy from waste (EfW) sites to improve efficiency, reduce energy consumption and achieve cost savings.

These include:

• The new comprehensive hydraulics service, which includes hydraulic power pack and hydraulic cylinder overhaul, repairs and post inspection report.
• A working demonstration of a Norgren impact rapping cylinder, which is ideally suited to the removal of slag in EfW conversion facilities, optimising pneumatic power to deliver improved reliability and low maintenance costs.
• Compressor/blower services and products, such as the new Gardner Denver compressor, featuring an Icon monitoring system to support predictive maintenance programmes.
• Energy saving services such as energy audits and system optimisation.
• Air and fluid power support, from install and start up to workshop overhaul and air leak surveys.

Thorite’s ERF Team Manager, Josh Davis, said: “Our new hydraulics repair service is a unique offering and is a valuable addition to our range of bespoke services and products developed for energy recovery sites.

“This is Thorite’s first visit to the RWM Expo and we’re looking forward to sharing our expertise, built on more than a century of experience in hydraulics and pneumatics, at the UK’s leading event for the sector.”

www.thorite.co.uk

IFS Ultimo EAM and SAP S/4HANA also have a certified integration in 2023/2024. This certified integration allows users of "best-of-breed" EAM system IFS Ultimo to seamlessly exchange data with this ERP system. A great opportunity to further increase efficiency within your maintenance and purchasing organization.

Maintenance and asset information is recorded in IFS Ultimo, and all related order requests can be submitted through SAP. The certification covers 25 scenarios, starting incrementally with importing and synchronizing various master data, such as suppliers and articles, and then focusing on purchasing processes, including purchase requisitions, purchase orders, receipts and invoicing.

Read more:

https://www.ultimo.com/en-uk/blog/recertification-ifs-ultimo-eam-sap-s-4hana-cloud/

The Bristol Port Company approached IFS Ultimo in 2021 with the goal of increasing safety, reducing complexity, and enabling standardization across the port. As a key national asset and a major economic driver for the South-West region of the United Kingdom, Bristol Port along with the businesses on the Port Estate, reach a contribution of more than £1 billion to UK GDP. Each year, Bristol Port handles over 3 million tons of dry bulk goods, 550,000 motor vehicles, 27% of all UK aviation fuel imports, and 25% of all animal feed imports. Aiming to coordinate and simplify all its processes, Bristol Port started the implementation of IFS Ultimo’s Enterprise Management (EAM) solution. This involved replacing its existing maintenance management system as well as over 50 databases and spreadsheets.

Implementation with the support of DNASTREAM and IFS Ultimo

The implementation of IFS Ultimo was done by subcontractor and support partner DNASTREAM. The important Permit to Work (PTW) implementation, handling permits leading to better visibility of hazardous and non-hazardous jobs, was done by IFS Ultimo, while DNASTREAM took care of all other customizations and configurations requested by Bristol Port. “After the implementation, IFS Ultimo EAM was easy to use and made our whole asset management approach much simpler than before,” states Richard Ashley-Smith, Asset Manager at The Bristol Port Company.

One system to work for everyone

Bristol Port now uses a wide range of IFS Ultimo EAM modules like Asset Management, Stock Management, several HSE modules, Work Order Management, Periodical Maintenance, Project Management, and Reports. In addition to this, IFS Ultimo is fully integrated with Microsoft Power BI. This unified solution enables Bristol Port to currently use 150 full licenses for operations, maintenance, and business roles and over 200 self-service licenses for other staff functions and contractors working for Bristol Port.

Making the best business decisions based on better data, now and in the future

The implementation of IFS Ultimo has also evolved the Port’s business processes, granting the management team complete control over the collected data. With the ability to capture improved data, The Bristol Port Company can make well-informed business decisions based on accurate and reliable information. “We are very content with the overall performance of IFS Ultimo’s EAM solution as well as the system’s usability and the futureproofing it offers us going forward,” said Richard Ashley-Smith.

The LOCTITE Xplore e-learning platform brings together over 65 years of combined product, industry, application, and engineering expertise. By leveraging the collective learning of Henkel's 650 global assembly and maintenance experts, it delivers an unparalleled resource accessible anytime, anywhere - and best of all, it is completely free to use.

Comprising five modules LOCTITE Xplore offers professionals essential knowledge to excel in their fields. The platform offers a dynamic and interactive learning experience hosted by two endearing and funny cartoon characters called LOC and ROSON. It features a variety of quizzes, engaging content and a ligh-hearted approach to make learning enjoyable.

The latest module, ‘An Introduction to Bonding’, provides a good grounding on the science behind the subject through it’s practical application. It compares the use of adhesives with mechanical joining alternatives such as riveting, bolting and welding and takes the viewer into the lab to show each joining method being tested to destruction.

Paul Marshall, Head of Marketing at Henkel UK, Ireland & Nordics, said: "We are thrilled to introduce LOCTITE Xplore, our innovative e-learning platform that brings together decades of expertise in assembly and maintenance. Professionals can now access valuable insights and practical knowledge that will revolutionise their work. We believe that by sharing our expertise freely, we can contribute to the advancement of industries worldwide."

Henkel's commitment to providing exceptional value extends beyond the e-learning platform. In line with this, LOCTITE Xplore offers a unique Call to Action feature, allowing users to request a free consultation from one of Henkel's LOCTITE Experts. This initiative presents an excellent opportunity for professionals to seek expert advice and forge valuable connections.

sign up for the platform click  here

www.henkel.com

This article can also be found in the issue below.

IGS today published its first Environmental, Social, and Governance (ESG) report. The report outlines the company’s ESG commitments and the environmental and social impact created by its global operations and innovative products and services.

Rich Crawford, President and CEO at IGS, commented:

“Releasing our first ESG report is a significant milestone for IGS and demonstrates how our operations allow us to not only deliver on our mission to provide innovative and reliable surface solutions for mission-critical equipment but also further our vision to create positive environmental and social impact within our communities around the world.

“In addition to our leading technologies, the IGS Way—our cultural distinctions that have fueled our growth as the global leaders in our industry—resonate well with our ESG vision and will continue to provide a strong foundation to guide our growth and development.”

Highlights from the ESG report includes:

• IGS products and services reduce customers’ emissions of NOx by as much as 30% and CO₂ by as much as 15%
• 54% of our global workforce are People of Color (POC)
• 49% of our employees are located outside of the United States
• 27% of IGS employees are located in developing countries
• 75% of career advancement is done from promotions within IGS
• Field technicians globally receive an average of 1,000 hours of training in their first year
• Maintain ISO 45001:2018 certification and Four-Star safety rating with NOSA

For more information on IGS’ ESG efforts and to read the full report, visit: https://integratedglobal.com/esg/

Integrated Global Services (IGS) has recently launched a SMARTGard® CFB Boiler Inspection Drone Service which introduces a blend of advanced drone technology complete with expert boiler inspection knowledge. It offers a comprehensive view of the condition of a boiler, promising enhanced efficiency, reduced costs, and early issue detection.

The service is transforming the landscape of boiler inspections. By leveraging progressive drone technology, the service provides access to every location of the boiler during the cooling-down phase.

A skilled team comprising a certified pilot and a CFB inspection specialist collaborate to operate the drone. Together, they manoeuvre the drone to critical areas of the boiler, offering a detailed examination. Each notable point of interest is meticulously documented with precise location coordinates, along with high-definition images and video footage.

All inspection data and reports are stored in a protected cloud-based portal. This streamlined approach enables easy access, allowing users to review and analyze information at their convenience. Such accessibility facilitates well-informed decisions regarding maintenance, repairs, and overall boiler management.

The SMARTGard® Inspection service provides several advantages, including improved CFB boiler availability. By promptly identifying potential issues and continuously monitoring the boiler's condition, proactive measures can be implemented, minimizing downtime, and maximizing productivity. Additionally, the service significantly reduces costs associated with extensive scaffolding, making SMARTGard® a cost-effective solution for boiler inspections.

Al Geraskin, who developed the SMARTGard® drone program, said: "There are several drone inspection services available on the market, however IGS is currently the only company that has combined its 40-year expertise in boiler reliability with drone technology to not simply fly the drone around the boiler but to focus on critical areas and advise on the best course of action.”