Editorial

MiB is a product/service that builds in diagnostic support for multiple assets via machine learning and Artificial Intelligence.

Where it would be difficult for non-experts to diagnose complex data or where there are multiple assets with multiple data feeds, human decision making can be limited and error prone.. 

Conventional AI systems base advice upon the identification and verification of outliers. They do not then normally offer a diagnosis of cause, but instead point the user to carry out further investigations and analysis and then update the system with the outcomes, such that if similar events are witnessed then the system can then respond with suggested outcomes. The problem with this is that the system is born naive and requires many learning events to become truly useful.

MiB incorporates the diagnostic knowledge of expert diagnosticians in the conventions of mature condition monitoring techniques and aligns this with AI functionality to identify true outliers and then offer meaningful diagnostic advice.

As more assets are managed remotely and fewer onsite personnel are sufficiently experienced to deal with all scenarios, it is becoming clear that a marriage of technology and experience is needed to balance the equation.

MiB have this as our objective, this is why we exist. 

We have the tools to deliver it in a simple software platform that we can place within your existing workflow for maintenance planners in any industry, world-wide.

Be sure to come visit us at the Autonomous Ship Expo, we will be at stand number AS252.

The conference program is available here:
https://www.autonomousshipexpo.com/conference-program.php

Condition monitoring is a crucial aspect of equipment maintenance that involves tracking the health of machines in real-time to prevent potential breakdowns and unplanned downtime. Traditionally, condition monitoring has been carried out through manual inspections and routine maintenance checks. However, with the advancements in technology, artificial intelligence (AI) is being increasingly used in condition monitoring to automate the process and improve the accuracy of the results.

AI can be used in several ways to perform condition monitoring, including:

1. Predictive maintenance: Predictive maintenance involves analysing data from sensors installed on equipment to predict when maintenance will be required. AI can be used to analyse large amounts of data in real-time and detect patterns that may indicate a potential problem. This helps to identify potential equipment failures before they occur, minimizing downtime and maintenance costs.
2. Fault diagnosis: AI can be used to diagnose faults in equipment by analysing sensor data and comparing it to a database of known fault signatures. This helps to identify the root cause of a problem quickly and accurately, allowing for timely repairs and maintenance.
3. Anomaly detection: AI can be used to identify anomalies in equipment behaviour that may indicate a potential problem. This involves analysing sensor data and comparing it to historical data to detect any deviations from the norm. This helps to identify potential problems early on and prevent equipment failures.
4. Asset optimization: AI can be used to optimize the performance of equipment by analysing data from sensors and other sources to identify opportunities for improvement. This can include optimizing energy usage, reducing waste, and improving production efficiency.

Overall, AI can significantly improve the accuracy and efficiency of condition monitoring, leading to reduced maintenance costs, increased equipment uptime, and improved safety. However, it’s essential to ensure that the AI algorithms used in condition monitoring are properly trained and validated to ensure that they provide accurate results. Additionally, human experts must be involved in the process to provide oversight and interpret the results.

In conclusion, AI is an increasingly important tool in condition monitoring that can help to improve the reliability and performance of equipment. As technology continues to evolve, we can expect to see even more advanced AI applications in this field, providing greater insights and value to businesses

www.cmservicesglobal.com

this article can also be found in issue below.

 

 

Manufacturers face a £20,000 fine and, at worst, imprisonment, for failing to comply with regulations which cover the disposal of compressed air condensate. Yet many companies are unaware of the regulations and their responsibilities under it, warns Steve Boults, of compressed air and fluid power specialist Thorite. Here he explains how you can avoid putting both your finances and reputation at risk.

Almost all manufacturing processes use compressed air in their operations and condensate is a by-product of the compression process.

It is caused when the compressed air temperature decreases and turns back into a liquid, which contains contaminants such as lubricants, solid particles and airborne micro-organisms which were present in the compressed air.

Compressed air condensate is classified as hazardous waste and the legislation relating to its disposal is stringent. Companies which fail to comply can face fines of £20,000 and, in worse case scenarios, directors can face a prison sentence.

The solution to safely disposing of condensate – an oil/water separator - is simple and relatively low cost. Yet the number of compressed air users who do not employ one is surprisingly high.

We estimate that as many as 40% of compressed air plants fail to employ an oil/water separator, and a further 5% to 10% have one but fail to maintain it properly. This can apply to SMEs and multinationals alike.

The result is that toxic waste from their processes is draining to the ground and potentially making its way into waterways.

The legal ramifications and environmental implications alone should give companies pause for thought. But additionally, a compressor without an oil/water separator is also a compressor which is very likely to be performing inefficiently, as the build-up of oily condensate will eventually cause damage, leading to downtime and repair costs.

With the penalties for breaching the legislation so high it is essential that both company managers and operatives on the factory floor understand the regulations that govern condensate treatment and the steps they must take to meet them.

Safe disposal of condensate

Companies must handle all condensate and associated materials, from filters to spillage mats, in compliance with the Hazardous Waste (England and Wales) Regulations 2005.

This is as simple as installing an oil/water separator to separate the emulsified oil and waste water. Separators can cost as little as £100 and even at the larger end of the scale will only cost a few thousand pounds. They can also be retrofitted.

With relevant permissions, the waste water can then be drained to the foul sewer, while the oil collected must be removed by a registered Hazardous Waste Producer or Licensed Waste Carrier, usually on an annual basis.

If an oil/water separator is not fitted, this mix of pollutants is discharged into the compressor house drain and eventually makes its way into the nearest waste water system or, worse still, directly onto the compressor house floor where it drains to the ground outside. This activity is illegal.

The cost of failing to comply

If you have a compressed air system producing condensate, you are governed by a further two key pieces of legislation.

Water Resources Act 1991

This states that it is an offence to knowingly permit entry of toxic waste to surface or ground water. The penalty is a fine of £20,000 or more in a Crown Court.

Water Industry Act 1991

This sets out the administrative requirements relating to the discharge of the treated condensate water, such as gaining consent from the local sewerage service provider and provision of analysis data and records if requested.

It also states that under no circumstances can treated condensate water be discharged to open water such as rivers and streams, ground water or storm/rain water drains and that penalties for breaching the Act can result in fines of up to £20,000 and potential imprisonment for company directors.

The solution is straightforward - so why is the number of companies failing to fit an oil/water separator so high?

The main reason appears to be a genuine lack of awareness of the legislation, at all levels.

Management are unfamiliar with the law and consider oversight of the compressor house as belonging to the engineering or maintenance teams, while operatives might have inherited legacy equipment which never had a separator fitted, and have no cause to question the status quo. Therefore, responsibility falls between two stones.

Failing to comply with the regulations around condensate disposal presents a very real cost in terms of equipment efficiency, potential fines and professional reputation, not to mention the ethical implications of polluting the local environment.

Is that risk really worth the price of an oil/water separator?

www.thorite.co.uk

• Schaeffler supplies Zentis with ProLink condition monitoring system to monitor stacker crane trolley bearings in cold and frozen storage areas. 
• Zentis required a solution that could reliably take measurements despite inconsistent measuring conditions and ultra-low temperatures. 
• ProLink provides early warning of any change in bearing condition, which has improved the planning of maintenance tasks and safety. 

Birmingham, UK | June 07, 2023 | Global automotive and industrial supplier Schaeffler has supplied a fruit processing company with its ProLink condition monitoring system to monitor the condition of trolley bearings on stacker cranes, which operate in cold and frozen storage areas. 

Zentis GmbH & Co. KG, with its headquarters in Aachen, Germany, is one of Europe’s leading fruit processing companies, producing jams and fruit preparations for the baking, confectionery and dairy industries.  

The Aachen site uses large stacker cranes for storage, transfer and retrieval. In order to monitor the large and difficult-to-access moving components in the cold and frozen storage areas and to avoid unplanned downtime, the logistics team at Zentis was looking for a predictive maintenance solution. 

Previous CM success 

Zentis had previously implemented Schaeffler’s SmartCheck condition monitoring devices on gearboxes and cable reels to monitor the health of a critical pallet lifter. The devices have helped to prevent unplanned downtime and optimise production. If the pallet lifter fails, the first production stoppages occur around two hours later. The SmartCheck devices measure the vibration, speed, temperature and imbalance of various rolling bearings in the gearbox, as well as the gear teeth/mesh. The CM solution has enabled an early warning period of several weeks which allows Zentis to carry out repairs and remedial action as part of planned maintenance work, thereby avoiding costly unplanned downtime.

A cold challenge 

In the cold and frozen storage areas at Aachen, a different kind of CM solution was required. The stacker cranes constantly move around the 30-metre tall racks in different directions. The trolley bearings, in particular the non-driven bearings, are highly stressed. The fact that constant measuring conditions do not exist during regular operation posed an even greater challenge. In addition, temperatures in the frozen storage area are as low as -20°C, which presented yet another challenge for the new measuring system, for example, how to attach the sensors to the measuring points.  

Michael de Ben, Head of Internal Logistics at the Aachen site, comments: “We were looking for a monitoring solution for our stacker cranes that could reliably take measurements despite inconsistent measuring conditions and ultra-low temperatures in order to protect us from unplanned downtimes.” 

A smart solution 

After approaching one of Schaeffler’s local authorised sales partners the Schaeffler ProLink condition monitoring system (CMS) was chosen. This intelligent measuring concept was adapted to suit Zentis’ unique requirements.  

To monitor the stacker cranes, a Schaeffler ProLink CMS and five sensors (bearing guards) were installed on each stacker crane unit. In order to perform meaningful vibration monitoring, the original measurement concept had to be changed in the multi-channel CMS. Schaeffler achieved this by breaking down the short, slow travel times into many short measurements. Any extreme impacts could then be determined from these measurements. 

To solve the temperature challenge in the cold storage area, the ProLink CMS was installed in the switch cabinet. In the frozen storage area, the ProLink system was placed in heated control cabinets that escort each stacker crane run. The sensors were attached to the measuring points using a special, cold-resistant adhesive compound. 

Permanent benefits 

The implementation of the ProLink CMS, has benefitted Zentis in several ways. With early warnings of any change in the condition of the stacker crane trolley bearings, the site has also seen an improvement in the planning of maintenance activities, as well as improved safety and transparency. The ProLink CMS is also fully integrated into the sites own control system. 

As Michael de Ben states: “The ProLink CMS monitors heavily strained moving components on the stacker cranes that, due to their size or mounting position, cannot be repaired promptly in the event of an unplanned malfunction. By using bearing guards, the vibration pattern of this equipment can be permanently observed and any deviation can be detected at an early stage. In this way, the ProLink CMS makes a crucial contribution to safeguarding the production supply at Zentis KG Aachen.” 

ProLink is part of the Schaeffler Lifetime Solutions portfolio, which offers a comprehensive range of products, services and solutions for industrial maintenance. It is designed to support maintenance engineers over the entire lifetime of a machine.

www.schaeffler.com

This article can also be found an issue below.

 

 

IFS Ultimo and InfoConsulting, one of the fastest growing consulting companies specialized in digital transformation have signed a reseller agreement designed to support customers in the implementation of the IFS Ultimo Enterprise Asset Management (EAM) platform. In the first stage, sales will be developed in Europe and Australia where InfoConsulting has a well developed customer maintenance and sales network.

Global growth strategy

This partnership allows InfoConsulting to add the IFS Ultimo EAM solution to its portfolio, and offer customers a better solution for the evolving needs of their business  through rapidly improving cross-team collaboration, boosting productivity, maximising asset availability, controlling costs and securing health and safety requirements.

InfoConsulting serves its customers globally in industrial and asset-intensive verticals like manufacturing, construction and mining but also in many others. IFS Ultimo provides a SaaS EAM solution, focused on maintenance & safety with an unparalleled time to value.

InfoConsulting had noticed an increased demand for EAM solutions, advancements in technology and changes in the business landscape, alongside the need to meet customer requirements, such as reducing costs and improving efficiency. This partnership provides them with a comprehensive EAM solution and addresses the evolving needs of businesses. IFS Ultimo’s EAM portfolio enables customers to have the tools needed to harness real value and achieve business goals faster and with more efficiency.

Integrated solutions

Mirosław Kamiński, Head of InfoConsulting commented: “We are enthusiastic about the Introduction of IFS Ultimo to our offerings, as it is a complementary solution to the IFS ERP System. Above all, we see a number of benefits for our customers. By improving maintenance, safety and cross-team collaboration, they can increase their efficiency. One of the benefits of the product is also the rate and speed at which customers obtain value and an ROI.

Freddy Vos, Vice President International Sales & Channel at IFS Ultimo said: “With the years of experience that InfoConsulting has in industrial markets, this is a perfect partnership for us to explore the European and Australian markets. I’m convinced that we can offer value for the customers of InfoConsulting, supporting them with their maintenance and safety challenges. InfoConsulting’s experience in solutions that are connected to EAM, like ERP, also offers an opportunity for us to provide solutions in a more integrated way together.”

www.ultimo.com

This article can also be found in the issue below.

 

Fourteen Rotary Lobe Pumps made by Borger have been installed for a membrane filtration application at a water treatment plant.

Achieving a total output of up to 10,000 m³/h, the Borger pumps extract water so that it can be purified through the membranes.

In addition to being extremely stable and practically wear-resistant, the pumps were chosen to suit the cleaning of the membranes by back-flushing with filtered water. This made it essential for the operator of the plant to have pumps that could be operated in reverse. The rotary lobe pumps from Borger also have a high suction capacity that allows the treatment plant to vary the quantity of water during the back-flushing phase.

Regulated by a frequency converter, the Borger Rotary Lobe Pumps (which have a rated capacity of 450 - 720 m³/h),

are designed with maintenance-in-place for easy servicing, requiring only basic tools to keep downtime and costs to a minimum.

 

Borger UK

01902 798 977

www.boerger.com

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

Facilities maintenance operations can face different circumstantial challenges which require modern solutions. Particularly for hazardous environments such as the oil & gas and petrochemical industries, cold-curing polymeric repair and protection materials can provide a novel means of bypassing these challenges.

This application demonstrates a Customer’s use of Belzona’s cold-curing epoxy two-part structural adhesive, Belzona 7311, to navigate these challenges in the petrochemical industry to fulfil their maintenance needs.

This metal tank needed maintenance to both the base and the roof           

         

The structural epoxy adhesive, Belzona 7311, provided a cold bonding solution for the metal substrate

What was the Problem?

A metal storage tank in a Chemical Plant containing concentrated sulfuric acid required maintenance to both the base and the roof. The Customer needed to bond pipe supports to the top of the tank to reinforce the pipes directly above. However, the tank was installed with a rubber lining, ruling out hot work such as welding as a means of attaching the pipe supports.

Meanwhile, the existing tank base coating had been exposed to chemical attack and needed to be replaced with a suitable chemical-resistant coating to protect the tank from future chemical spills.

The tank base had been exposed to chemical attack       

The internal rubber linning made welding inappropriate to bond the metal pipe supports

                                                                                                      

Belzona 7311: A New Cold Bonding Solution

Belzona’s first ever structural adhesive, Belzona 7311, proved to be the optimal cold bonding solution for the Customer’s requirements due to its high mechanical strength, cleavage and shear resistance. By using this technology, the supports could be cold bonded to the top of the metal tank without the associated risks of welding such as damage to the rubber lining and metal distortion known as Heat Affected Zones (HAZ). HAZ can be the result of the intense process of heating and cooling the substrate, leading to weaknesses in the metal and compromising the integrity of the weld joint.

Bonding of the Pipe Supports

The Contractor specified that the best way of attaching pipe supports was to cold bond six 254 mm by 254 mm (10 inch by 10 inch) metal plates to the top of the tank, which could then be cold bonded to the pipe supports. The chosen areas were marked with tape, before being prepared using handheld surface preparation tools. The application areas were prepared to SSPC-SP11 standard, producing a bare metal surface and a minimum 25 μm (1 mil) profile for a high level of adhesion.

The two-part epoxy adhesive, Belzona 7311, was then mixed and applied to both the substrate and the underside of the metal plates, before being held in place with no additional weight or pressure

while the product was allowed to cure. Once the plates had been cold bonded to the metal tank, the pipe supports were subsequently attached to reinforce the pipes in operation above the tank.

 

 The metal surface was prepared to allow the plates to adhere

The epoxy 2-part adhesive, Belzona 7311, was applied to both the tank surface and the plates

  

The cold bonding solution was allowed to cure with no extra weight or pressure

 

Application of the Chemical Resistant Coating

Belzona 4311 (Magma CR1) was specified to protect the tank base due to its chemical resistant qualities, having encountered no significant deterioration after a year of immersion in up to 98% sulfuric acid at 40°C (104°F), when tested in accordance with ISO 2812-1.

The previous tank base coating was removed and the concrete surface was prepared with an ATEX-rated power tool and conditioned using Belzona 4911 (Cleaner/Degreaser) to ensure maximum adhesion for the new coating.

Two coats of Belzona 4311 (Magma CR1) were applied to provide long-term protection to the tank base, avoiding the harmful financial, safety and environmental consequences of a future leak.

Belzona 4311 (Magma CR1) was applied to the tank base

The chemical resistant coating will provide protection in the case of chemical spills

Results of the Repair

The sulfuric acid tank base will be protected against chemical attack for the long term due to the chemical resistant properties of Belzona 4311 (Magma CR1). Meanwhile, the Customer was impressed by the ability of Belzona 7311 to solve the challenges caused by the tank’s rubber lining, cold bonding the metal pipe supports securely without the need for welding. The Customer was also very satisfied by the high mechanical strength, cleavage and shear resistance demonstrated by the cold bonding solution during the application.

The strength of the cold bonding solution allowed the pipe supports to be seamlessly attached to the top of the tank

Cold Bonding Solution in Action

This application presented an example of the opportunities provided by the epoxy two-part structural adhesive, Belzona 7311 as a cold bonding solution, offering an effective and safe alternative to welding. The solution can be used for structural bonding applications requiring high mechanical strength, cleavage and shear resistance, including ladders, handrails and plate bonding, and is suitable for harsh service environments.

www.belzona.com

 

 

 

Introduction

Inefficient heat transfer in the convection section of a process heater is readily witnessed by an increase in stack temperature beyond design parameters. The timing and urgency for addressing this situation are related to not only the degree of overheating in the stack but also product demand, economics, and fuel costs.

This article will discuss Tube Tech’s, an Integrated Global Services (IGS) solution, approach to restoring heat transfer efficiency of fired heater furnaces and the results achieved at an Egyptian oil refinery. 

Part One: Inspection and Technical Evaluation 

For many IGS Tube Tech projects, a site visit is made to complete an inspection of the convection section and to collect current operating data so that an evaluation can be conducted. The evaluation determines the baseline operating conditions and estimates the potential project scope and expected benefits.

The evaluation is based on calculating the external fouling resistance factor for each bundle in the convection section based on the process data. The factors will be relieved by cleaning and a further evaluation would determine the post-cleaning performance, based on a constant processing duty, for example. The IGS Tube Tech cleaning technology allows for more than 90% of all the tube and fin surface area to be treated, unlike other more conventional methods which reach only 20% to 40% of the tube surfaces, depending on configuration.

Part Two: Project Planning & Execution Approach

To perform an effective clean using a unique Remotely Operated Vehicle (ROV) and protect the existing equipment from water exposure, the following five steps are considered for each project (figure 1):

Figure 1. The Tube Tech Solution

 

The ROV is designed to fully clean convection bank coils by penetrating its lance deep between tube rows. The technology removes more than 90% of fouling from all convection bundles. No refractory is damaged since the ROVs are programmed to direct a high-pressure medium to the tubes only. All activities typically can be completed in 72-120 hours (three to five twelve-hour shifts).

Figures 2&3. The external casing in this instance is cut to create 350 mm openings

Figures 4&5. Plastic tarpaulin at the bottom of the convection section and the ROV on the top of the bundle.

Part Three: Post-Project Benefit Analysis.

In many cases, the stack temperature is determined to be a key performance indicator to identify and quantify the benefit after cleaning. To illustrate the benefits, we will review a recent project, referred to as project x. On completion of project x a sizeable benefit of 40°C in stack temperature reduction was achieved. The plant also reported an average increase in overall fuel efficiency from 89.5% to 91.5%,leading to 2 MW less heat loss to the stack under the same operating capacity. The customer reported a payback period of less than four months.

Figure 6. Stack Temperature Before and After Cleaning

Figures 7&8. Before and After Cleaning -Part One

Part Four: Acknowledgements and New Data Two Years After Cleaning

A balanced heat distribution between sections is crucial in coking-sensitive services. Keeping the convection section surface clean not only helps to save fuel and increase steam generation but also positively influences the steam cracking process. The achieved benefit on project x was 16,000 MWh/year fuel savings and 2500 tons annual CO2 reduction (fuel is CH4/H2 mixture). 

After almost two years, the client reported a slight elevation in stack temperature of 10 °C and a stable efficiency increase of 1.5%. The next clean is anticipated to take place after sixyears to reinstate the efficiency. To ensure the obtained benefit is long-lasting, IGS also recommends a combination of the Tube Tech ROV cleaning with Cetek’s proprietary ceramic refractory coatings to protect and encapsulate the ceramic fiber and stop refractory deterioration and new fouling formation on the outside surface of the convection tubes.

Part Five: Example of Tube Tech ROV Cleaning – Ethylene Furnace  

IGS was provided with furnace configuration and process parameters for each bank of the convection section of this ethylene furnace. The objective was to keep the process duty and thus, the coil outlet temperature the same and compare scenarios before and after. 

It is worth mentioning that these furnaces were designed to have 68.3% to 71.0% process duty of total absorbed duty (depending on whether it is SOR or EOR), and if, for example, steam superheating coils are fouled, cleaning may reduce this ratio process/total duty. An additional indicator of this potential fouling consequence is the fact that almost no BFW is being used for attemperation (desuperheating). For this scenario, constant flow rates for process streams are assumed, but it is also possible to consider all the factors and heat balance changes for the entire system.

Table 1. Convection Section Cleaning Results for Ethylene Cracker.

Parameter	UOM	Before	After
Fuel Firing	nm3/hr	5565	5655
Fuel Firing**	Gcal/hr (LHV)	32.04	32.64
Total Absorbed Duty	Gcal/hr	29.37	30.56
Radiant Duty	Gcal/hr	14.86	15.02
BWT	°C	1033	1037
Stack Temperature	°C	180	134
Radiant Inlet	°C	590	582
CSS Outlet	°C	376	454
HSS Outlet*	°C	446	541
BFW Outlet	°C	269	254
Overall Efficiency	%	91.67	93.61
Process Duty	Gcal/hr	21.21	21.21
Steam Duty	Gcal/hr	8.16	9.35

*HSS coil has been evaluated assuming no BFW for desuperheating

** 1.5% of Heat Losses have been assumed, and 11% of Excess Air is calculated using the flue gas oxygen content. 

Part Six: Example of Tube Tech ROV Cleaning - CCR Platforming Heater

In configurations where a steam generator is only located in the convection section, such as platforming heaters, it is crucial to adjust flow rates and reflect changes in absorbed duty for each bundle that may result from cleaning. Specifically, a steam drum should be included in the model to respond accurately to all changes in temperatures/pressures of inlet/outlet streams. 

The following convection section reflects the most widespread design with the following bundles (from top to bottom): Economizer, Upper Steam Generation, Steam Superheating and Lower Steam Generation. (Example under the same firing rate).

Table 2. Convection Section Cleaning Evaluation Results for CCR Platformer Heater

Parameter	UOM	Before	After
Stack Temperature	°C	208	168
Fuel Efficiency	%	88.32	90.38
Absorbed Duty	Gcal/hr	13.8	14.8
BFW Inlet Temperature	°C	122	122
BFW Mass Flow	kg/hr	22203	23886
Mass Circulation Through Steam Generator	tonne/hr	150	150
Steam Drum Pressure	kg/cm2_g	36.2	36.2
Blowdown Amount	%	5	5
Total Amount of Produced Superheated Steam	kg/hr	21146	22748
Superheated Steam Temperature	°C	360	362

Part Seven: Case Study - Revitalizing the Performance of a Refinery's Hydrogen Generation Unit

An Egyptian oil refinery, in operation since 1999, has faced challenges with its Hydrogen Generation Unit (HGU) since 2005. Issues such as hot spots on catalyst tubes, ageingreformer tubes and outlet systems, and reduced hydrogen demand have led to the unit operating at a reduced capacity. To address these bottlenecks and evaluate the unit's current status, a comprehensive assessment and debottleneck study was conducted by the OEM.

Key Study Findings

One significant finding of the study revealed the underperformance of the convection coils, which hindered the unit from achieving its desired efficiency. Over more than 20 years of operation, the convection coils, primarily consisting of finned tubes, suffered from increased fouling due to inadequate inspection and cleaning practices. The study recommended a potential solution of inspecting and robotically cleaning the external surface of the finned tubes to overcome this issue.

Project Overview

On the advice of the OEM, Integrated Global Services (IGS) was contracted to perform Tube Tech’s convection section performance recovery service at a hydrogen production unit at the refinery. The project involved increasing the size of six existing access doors in the convection section and the robotic de-fouling of convection coils.

The project commenced on March 29, 2023, and was completed on April 3, 2023. The original planned scope of work, which included de-fouling and door installation, remained unchanged throughout the project.

Case Study Image 1

Safety

Safety is a primary concern for IGS, and a robust safety program was implemented to ensure a safe working environment for all personnel involved. The company maintains a zero-incident safety philosophy and actively promotes a culture of safety among its employees. Daily toolbox talks, safety observations, unit walk-downs, and job safety audits were conducted to mitigate potential hazards and maintain safety standards throughout the project.

IGS has a strong safety track record, with a Total Recordable Incident Rate (TRIR) of 0.0 in 2022, well below the industry average. The company adheres to OSHA best practices and local safety regulations to ensure compliance and maintain a safe work environment.

Quality

IGS follows stringent quality control standards to meet customer requirements. The project was executed in accordance with the IGS quality control standards, and a Quality Control Package (QCP) was agreed upon before the start of work.

Achieved Results

A performance test run was then conducted to evaluate the unit's condition after the cleaning process. The unit's capacity was successfully raised to 100% on April 16 and maintained for 24 hours. The test procedure for evaluating the unit's performance after cleaning was based on the HPU's latest probation test, ensuring consistency and comparability. Data from various sources, including DCS data, laboratory analysis results, outside field/local data, and electrical data, were collected during the test to accurately assess the unit's performance.

Case Study Image 2&3

Test Parameters

The performance test for the HGU was conducted from April 16 at 11:00 to April 17 at 11:00, lasting 24 hours. The main feedstock for the unit was natural gas, supplemented by a small portion of recycled hydrogen. The composition of the natural gas feed, as well as mass flow rates for different streams, was recorded. The laboratory analysis results showed changes in the feed composition and products during the probation test.

Unit Operating Parameters

Various operating parameters of the unit, such as temperatures, pressures, steam-to-carbon ratio, and steam drum pressure, were monitored during the probation test. The unit's performance was compared to previous tests, revealing improved performance in terms of duty recovered by the convection section and a reduction in stack temperature.

Probation Test Evaluation

The evaluation of the probation test results indicated that the cleaning of the convection section had led to a 14% increase in duty recovered from flue gases compared to the previous test in December 2021. The reformer inlet temperature also increased from 437°C to 501°C, contributing to improved thermal efficiency. The lower stack temperature and increased efficiency resulted in cost savings of approximately $220,000 annually.

Case Study Image 4

Case Study Conclusions

The successful cleaning of the convection section in the refinery's HGU unit marked a significant step towards restoring the unit's performance. The removal of fouling from the finned tubes facilitated enhanced heat absorption and a reduction in stack temperature, thereby improving overall thermal efficiency. This achievement represents a noteworthy milestone in the refinery's ongoing expansion project and contributes to its long-term operational success.

IGS also provided technical recommendations for future maintenance and improvement, including the application of Cetek Refractory Coating to prevent refractory fouling. The conclusion of the project underscores the collaborative efforts between the oil refinery and IGS, as well as the positive working relationship among all team members.

Part Eight: Conclusion

Project execution excellence (as well as certainty in terms of % clean surface) and the ability to rigorously evaluate the future performance of the heater system provides IGS andTube Tech with an opportunity to offer unique services to clients. This combined approach reflects the increased demand for thoroughly conducted feasibility studies, even for small projects. Moreover, it is essential to quantify the influence (if any) of all IGS products on fired heater performance.

Convection Section Fouling Removal - Tube Tech | An IGS Solution (integratedglobal.com)

this article can also be found in issue below.

 

Abstract

When identifying solutions that can offer assurance and longevity, the maintenance and reliability of assets repairs can be challenging, this white paper will look into the use of structural adhesives as the first-choice solution.

Structural adhesives can be used for affixing metal substratesor components as they provide high modulus and high strength. However, they are not currently internationally recognised like the traditional methodseven though adhesives are already used in a wide range of industries, such as aerospace, rail, and construction.

Traditional practice such as welding, riveting, nuts and bolts and mechanical fixing are perceived as the go to method.However, they all have their inherent inadequacies. Welding can be hazardous to health, riveting,nuts and bolts concentratethe stress locally while mechanical fasteners can concentrate stress.

This paper introduces a novel, two-component, solvent-free toughened epoxy adhesive material that provides high adhesion to metallic substrates while also being able to withstand high movement or cyclic fatigue in comparison to general epoxy materials.

As well as potential application areas, the article also discussesa number of benefits, including ease of use, load bearing andimpact resistanceproperties.

Introduction

Most industrial maintenance or repair procedures can eitherinvolve welding or use of mechanical fasteners as these can be perceived as easy andquicker, however, these procedures might initially seem to correct the issue but may cause more harm than good.Depending on the repair situation for instance welding or drilling to connect mechanical fasteners on a storage tank containing flammable liquid is not recommended for obvious reasons this is where a structural adhesive can really offer a solution for that maintenance repair.

There are many structural fixings used across a whole range of industries that may be part of any maintenance or repairthese include support brackets such as cable trays, antennas, heating coils filter pans or any other internal fixtures in vessels that’s suffer from corrosion, impact orvibration damage. Within construction there are fire water deluge systems, nozzles connections, facades panels and signs which can require maintenance overtime or adverse weather conditions.

Processequipment or piping can suffer from thinning or the steel or even through wall defects which will need either monitoring or repairing depending on whether the integrity of the equipment has been lost.

Structural fittings are generally for fixing of static members but maybe subjected to forces unbeknown at time of installation this could include thermal cycling of the joints, cyclic loading or vibration due to fatigue of a component.

If there are repairs due to the above, the contractor maybe in asituation where a choice of solution can be made, then the strengths and weaknesses need identifying.

Welding is regularly used for repairs as it is widely available while being well regulated with high customer confidence and high strength of the repair it does come with its inherent risks both the use, the material by heat stressingand the user as welding can cause both acute and chronic health risks.Application of welding repairs onto live piping sections, storage tanks or process systems and equipment should not be undertakendue to the high temperatures involved and not forgetting the combustible nature of the process fluid or gasrunning through or being stored in these components.

Bolted joints are seen as simple and low cost due to the ease ofdisassembly and reassembly and these can be dissimilar metals,but the use of dissimilar metals will contribute to galvanic corrosion, add weight to the joint, requiring routine inspection and tensioning while the drilled holes in the support material, stress distribution is not uniform and concentrated at the holes.

Structural adhesives have high bond strength whilst being lightweight, adhesive applied to cover the entire joint, resulting in uniform stress distribution, reducing metal distortion under strain.

Importance of a Strong Bond

Adhesive bonding is the joining of similar or dissimilar members together while creatingpermanent high strength bonds which can transfer structural stress without loss of structural integrity.

Regardless of the joint type used, it is important to understand the different stresses that are imparted onto a bonded assembly. Adhesives perform the best when the stress is two-dimensional to the adhesive, allowing the force to be applied over the entire bond area.

Joints that are well designed for adhesives place most of the stress into compression or shear modes, adhesives perform the worst when stress is one-dimensional to the adhesive, concentrating the load onto the leading edge of the bond line. Joints placing stress into cleavage or peel concentrate the stress onto the leading edge, which may lead to premature bond failures, especially if subjected to vibration, impact or fatigue

Bonds of high strength are obtained after cleaning of the substrate by removal of any contaminants followed by the roughening of the substrate generally in the form of grit blasting to international recognised standards, this is why surface preparation is critical to success regardless of what type of adhesive is used.

There are three types of bonding that are important to achieve to ensure good adhesion. These are:adhesive, chemical, and mechanical. 

Adhesive relies on surface energy to generate adhesion to the substrate. While chemical relies on chemical bond formation and electronic bonding to produce adhesion. Mechanical adhesion is due to the creation of an irregular profile that allows a deeper profile to be produced.

Thetypes of structural adhesivesavailable have been summarised in Table 1

Table 1 - Types of Structural Adhesives

 

 

 

 

There are two types of failure mechanisms associated with structural adhesives:

1. Cohesive failure occurs in the bulk layer of the adhesive material. This failure mode is limited by the strength of the adhesive material and can be caused by insufficient curing of the adhesive and applications at a greater thickness than that recommended among others.

2. Adhesive failure occurs when the mechanical adhesion between the adhesive and the parts being joined is overcome by the loading. This failure mode is associated with inadequate surface preparation, presence of contaminants, or insufficient curing of the adhesive among others. 

Background 

Design considerations for Belzona 7311 were based on both technical target requirements and a practicality approach, as summarised in Table 2.

 

 

 

 

 

 

 

 

 

Table 2 - Design Considerations

Belzona 7311 was subjected to at least the following tests and evaluation protocols in to ensure that it met the design criteria previously discussed. Where possible, internationally recognised standards were used.

 

Experimental Procedure

1. Cleavage Adhesion – ASTM D1062

Cleavage adhesion is used to assess the strength of an adhesive bond between two substrates when exposed to cleavage stress.

Belzona 7311 wasapplied between two identical grit blasted metallic cleavage test pieces to create a fixed bond area of 125mm² of minimal bondline thickness.

The specimen was allowed to cure then attached to a 25kN tensometer using suitable grips. The tensometer then applies a load at a fixed rate of 1.3mm/min exerting a cleavage force on the specimen until bond failure. This test is repeated five times so an average force can be calculated.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 1 - Cleavage adhesion test

2. Tensile Shear Adhesion – ASTM – D1002

Tensile Shear Adhesion or lap shear adhesion is used to determinethe adhesive strength of a material when bonded between two ridged metallic substrates.

Samples are 100 x 25.4 x 2mm and are overlapped lengthwise by approximately 12.7mm and bonded toa minimalbondlinethickness with Belzona 7311.

The specimen was allowed to cure then attached to a 25kN tensometer using suitable grips. The tensometer then applies a load at a fixed rate of 1.3mm/min exerting a cleavage force on the specimen until bond failure.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 2- Tensile force

3. Fatigue Resistance – ISO 9664

Fatigue resistance is the highest stress that a material can withstand for a given number of cycles without breaking.

A standard static Tensile shear adhesion test was conducted to determine the mean breaking stress – 24.17 MPa following this 35% of the mean breaking stress value is used as the mean stress in fatigue testing - 35% mean shear stress = 8.461 MPa (24.17 MPa x 35%)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 3- Tensile shear adhesion test

At four different alternating stresses, fatigue testing was conducted at 30Hz until failure:

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Impact tests can be used to assess the toughness of a material, a material’s toughness is a factor of its ability to absorb energy during plastic deformation. Brittle adhesives have low toughness as a result of the small amount of plastic deformation that they can endure. Tougher materials on the other hand can absorb greater energy during fracture and thus, have improved impact resistance.

The Izodimpact test allows for samples to be tested in two forms: either ‘notched’ or ‘un-notched’ in our case the testing will be notched which has a V-shaped notch of approx. 2.5mm in depth with a total defect angle of 45°in the centre of a specimen sample with dimensions of 12.7 x12.7 x 65mm. The notch concentrates stress and allows measurement of crack propagation.

Non-standard testing:

5. 3-Point Load Test

This comparative technique is used to assess the relative flexibility of adhesives when applied to a metallic substrate. In this test a mild steel panel of dissimilar dimensions

Plate 1 550 x 50 x 10 mm thick

Plate 2 225 x 50 x 10 mm thick

are stressed to the point the adhesive fails. The panel is held in position at two points, one at either end of the sample and is gradually stressed at a single point in the centre of the specimen via a hydraulic press as seen in figure 3. The greater the displacement i.e., the further the press travels until failure the more flexible the adhesive. The thickness of the adhesive will influence the degree of flexibility so analysis should be duplicated for repeatability purposes. In the case of this testing at the manufacturing stage the specimens were compressed by hand pressure only, to try and replicate ‘in field’ applications of achieving below the maximum bondlinethickness of 2mm.

 

 

 

 

 

Figure 5– 3-Point Load Testing

Testing Results and Discussion

1. Cleavage Adhesion – ASTM D1062

Table 3 - Cleavage Adhesion Results - ASTM D1062

 

 

 

2. Tensile Shear Adhesion – ASTM – D1002

Table 4 - Tensile Shear Adhesion Results– ASTM D1002

 

 

3. Tensile Fatigue Resistance – ISO 9664

Table 5 - Cyclic Fatigue Testing Results

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 6 - Belzona 7311 SN Curve

From a mean breaking stress of 35% (8.461 Mpa), Belzona 7311 will survive 106 cycles at 56.6%, with an alternating stress amplitude of ± 4.791 Mpa = 13mpa to 3.67 Mpa

4. Impact Resistance – ASTM D256

Table 6 - Impact Resistance Results – ASTM D256

 

 

 

 

5. 3-Point Load Test

Table 7– 3-Point Load Test Results

 

 

 

 

 

 

Figure 7–3-point load Specimen Testing

Conclusions

Several conclusions can be drawn from the use of Belzona 7311 as a solution for the repair or maintenance of assets:

 

 

 

Figure 8 - Structural adhesive, Belzona 7311, used to bond bracket

Please click here for more information about Belzona 7311. 

Recent developments to IFS Ultimo’s EAM software spotlight improving collaboration. IFS Ultimo's ambition is to deliver the world's highest customer-rated EAM solution, empowering maintenance, operations, and safety teams to perform their jobs confidently and proactively. Alongside this, IFS Ultimo has recently launched a comprehensive Operations Suite and is working on further enhancements to simplify mobile inspections. Visitors to Maintec 2023 can visit the IFS Ultimo booth (A58) at the National Exhibition Centre (NEC) in Birmingham, UK on 7th and 8th June 2023 to discover more about these latest updates through in-person demonstrations.

Better collaboration through the Operations Suite
In the development towards becoming an optimally profitable organisation, it is crucial that departments work cooperatively from a single source of truth. Companies can bridge the gap between production and maintenance with the IFS Ultimo Operations Suite. Through the Operations Suite, users of the EAM software can use the available capacity more effectively, increase the involvement of various employees and respond quickly to information needs with accessible input from first-hand sources. The Operations Suite features sections on shift handover, autonomous maintenance, and downtime analysis.

Autonomous Maintenance by Operators
The autonomous maintenance section has an accessible solution available for asset operators to perform first-line maintenance.

Kris Sage, Sales Director UK at IFS Ultimo commented: “Often actions, such as cleaning, inspections, lubricants or simple repairs, are carried out in practice by operators, but are not registered on IFS Ultimo’s EAM software. Actions that can easily be shifted from mechanics to operators are also often not registered. Through the autonomous maintenance section of the Operations Suite, knowledgeable operators can now complete tasks without lead times and the scarce capacity of technicians can be deployed primarily on preventive and improving maintenance.”

The functionality is designed so that through accessible checklists and visual elements (for example photos) operators can work quickly, using IFS Ultimo’s EAM software, on a tablet or smartphone.

Easily accessible mobile inspection
In further developments of the functionality for mobile inspections, accessibility, and user-friendliness are key. It needs to be easy for operators to do inspections quickly and intuitively. In the latest developments, IFS Ultimo is focused on further developing an intuitive mobile experience on the Ultimo Go app, where data can be entered with minimal actions. The app recognises when data has previously been entered, helping to prevent repetition. Updates to the app are also improving the follow-up of findings and measurements.

Visit IFS Ultimo at Maintec
As in recent years, IFS Ultimo will be exhibiting at Maintec (Manufacturing + Engineering Week) at the National Exhibition Centre (NEC) in Birmingham, UK on 7th and 8th June 2023. Visit the IFS Ultimo booth (A58) to experience demonstrations which will showcase how the latest developments of the EAM software can help users to work more efficiently on the shop floor, allowing for better shape collaboration. This results in lower costs and better information to make the right decisions.

www.Ultimo.com