Latest Case Studies & White Papers

To ensure the safe, effective and efficient transfer of plant equipment into the basement energy room of a new residential tower block in London, a major construction project leveraged the advantages of appointing Hoist & Winch Ltd as its supplier of turnkey lifting equipment. Tasked with meeting the requirements of a technically challenging brief, Hoist & Winch demonstrated why it has become the nation’s go-to solution provider of high-quality lifting systems.

Many new tower block development projects face a common challenge: how to install large, heavy pieces of equipment into the building’s energy centre, typically located in the basement. Specifying the optimal hoists is paramount to project success. Fortunately, the subcontractor supplying and installing the energy room’s plant for this particular project knew where to turn for a turnkey lifting solution: Hoist & Winch Ltd.

Hoist & Winch has extensive experience in all kinds of construction and industrial lifting applications. The company offers sales, installation, service, inspection, repair and hire services, with a special emphasis on project work. Supplying the optimal solution, with safety as the number one priority, is always the objective.

During the design phase, after formal tender and contract award, Hoist & Winch set about identifying the optimal solution by carefully assessing the specific lifting requirements. The project required the installation of hoists on both the upper and lower ground floor levels to ensure the successful lifting and transfer of large energy plant. It was clear from the outset that the solution would need to overcome the issue of very tight headroom clearances due to the size of the equipment.

After thoroughly considering all aspects of the project, Hoist & Winch Ltd was able to put forward its proposal, recommending two William Hacket low-headroom manual hoists, both with a hand-geared trolley. Offering a safe working load (SWL) of 2.5t each, the hoists provide 8m of lifting height and run on beam lengths of 8.5m and 7.0m.

Hoist & Winch duly submitted its design proposal, including drawings and structural calculations, for approval by engineers at the main contractor. Following approval, the company commenced manufacture before delivery to site.

During the installation phase, Hoist & Winch tested the installation anchor points to 1t before raising each beam into position using hand chain blocks. Elevating the beams to full height and clamping them hard against the concrete ceiling ready for drilling required the use of special lifting rigs. Once in position, the company proceeded with drilling operations and resin anchor installation for all ceiling anchor points after meticulously cleaning each hole with a special heavy-duty internal brush and suction pump. Following the specified resin curing time, Hoist & Winch tightened each anchor bolt to the required torque levels.

LOLER (Lifting Operations and Lifting Equipment Regulations) inspection of the lifting beams and manual chain hoist units was the final operation. This activity included dynamic load testing of both beam lengths with a 2.5t skid-mounted test load followed by 125% static proof load test in accordance with BS 2853 2011. As a point of note, following customer handover, the hoists were to remain in place for use by the on-site maintenance team.

“We provided the client with a comprehensive project records and documentation package upon completion of works, which is standard practice,” says Hoist & Winch Director Andy Allen. “We then went through the handover process to ensure total peace of mind for our client. At Hoist & Winch, our focus is on ensuring customers benefit from our exceptionally knowledgeable team who never fail to deliver on their promise of providing a detailed and proficient approach to every project.”


Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

by Steven Sandler, founder and CEO of Picotest

Modern electronic systems require precise and reliable power delivery, yet designing effective Power Distribution Networks (PDNs) presents significant challenges. Issues such as noise, instability, and inappropriate capacitor selection can compromise performance and lead to device failures. How can engineers address these challenges? The key lies in leveraging advanced analysis tools like Vector Network Analyzers (VNAs) from the early stages of design and throughout the development process. These tools are essential for identifying potential issues and preventing instability or other faults in the power distribution system. Whether resolving existing problems or designing advanced systems, using a state-of-the-art analyzer provides the precision and insights needed to optimize designs and ensure robust performance.

PDNs are a critical but often overlooked component of modern electronics. These networks, comprising printed circuit board (PCB) power planes, bulk capacitors, and decoupling capacitors, deliver electrical power from Voltage Regulator Modules (VRMs) to Application-Specific Integrated Circuits (ASICs) and other components that require precise power. Proper PDN design is essential for maintaining device stability and performance, ensuring power delivery is both reliable and free from noise or instability.

A common misconception in PDN design is the oversimplified belief that "lower impedance is always better." While low impedance is generally beneficial, achieving a "flat impedance" profile across the operating frequency range is far more critical. Another frequent error involves assuming that a diverse selection of capacitors automatically leads to optimal performance. Effective PDN design requires meticulous analysis and strategic component placement to meet specific impedance and stability criteria, rather than relying on arbitrary component choices.

Challenges in PDN Design

PDN design for modern devices, particularly those with compact, high-speed circuits, poses numerous challenges. A primary concern is minimizing the distance between VRMs and ASICs to reduce noise and improve power delivery efficiency. Capacitor selection and placement are vital for achieving a flat impedance profile, which mitigates noise and enhances stability. However, insufficient validation during the design phase often results in performance issues, such as excessive noise or instability, especially in circuits with narrow voltage margins.

The interrelation of noise, impedance, and stability further complicates PDN design. Noise is generated by dynamic current changes within the ASIC, and the PDN must counteract these variations effectively. Poorly designed capacitors can destabilize the control loop, leading to uneven impedance and increased noise. Given the tight operating margins of modern ASICs, effective noise mitigation is critical to ensuring device functionality.

Avoiding Common Pitfalls

One of the most frequent mistakes in PDN design is relying on inaccurate capacitor models for simulations. Many engineers also mistakenly assume that the same models can be used interchangeably in SPICE and electromagnetic (EM) simulators, leading to flawed designs. Tools like the Bode 500 Vector Network Analyzer address this issue by providing de-embedded capacitor models tailored for both SPICE and EM simulation environments. Picotest offers both component mounts and component test fixtures that allow accurate micro-Ohm measurements with the Bode 100 and Bode 500 Vektor Network Analyzers, as well as other instruments up to 2GHz and higher.

Another common error is underestimating the importance of thorough validation. Advanced tools, such as the Bode 500 Vector Network Analyzer and Picotest probes, simplify the validation process, allowing engineers to detect and resolve issues early in the design phase. By emphasizing accurate modeling and validation, these tools significantly reduce the risk of noise and instability in PDNs.

The Right Tools for the Job

Advanced tools like OMICRON Lab's Bode 500 Vector Network Analyzer are indispensable for tackling PDN design challenges. This device enables precise impedance measurements across a wide frequency range using the 2-port shunt-through method, a widely recognized standard in PDN analysis. It supports capacitor characterization and the creation of simulation models, facilitating the selection and placement of components. This capability is particularly valuable since vendor-provided capacitor models often lack the precision required for PDN design. The Bode 500 Vector Network Analyzer compensates for this shortfall by generating more accurate models.

The instrument also offers features such as Non-Invasive Stability Measurement (NISM), support for Touchstone file formats, and compatibility with various measurement configurations. These capabilities ensure PDN stability and help minimize noise. By incorporating PDN probes, such as the P2102A and P2105A models, PDN analysis can be further enhanced. Designed for examining PDNs, these probes enable accurate measurements of individual power rails within complex systems. Their advanced shielding and interchangeable heads support diverse use cases, including near-field analysis and step load testing, while minimizing interference.

Conclusion

Excelling in PDN design requires a methodical approach, employing advanced tools for precise measurement and analysis. By focusing on accurate capacitor modeling, achieving flat impedance profiles, and rigorous validation, engineers can overcome the challenges of modern PDN design and ensure the stability and performance of electronic systems. For those new to the field, committing to continuous learning and engaging with expert resources will pave the way for success.

These networks, comprising printed circuit board (PCB) power planes, bulk capacitors, and decoupling capacitors, deliver electrical power from Voltage Regulator Modules (VRMs) to Application-Specific Integrated Circuits (ASICs) and other components that require precise power.

Modern electronic systems require precise and reliable power delivery, yet designing effective Power Distribution Networks (PDNs) presents significant challenges.

A primary concern is minimizing the distance between VRMs and ASICs to reduce noise and improve power delivery efficiency.

Advanced tools like OMICRON Lab's Bode 500 Vector Network Analyzer and Picotest’s PDN probes are indispensable for tackling PDN design challenges.

Smart Measurement Solutions | OMICRON Lab

www.picotest.com

Deep cleaning in continuous operation: new Sword Brush® with microfilament technology thoroughly removes even fine dust particles

Compact design allows easy integration into various processing lines

Dust particles are a constant challenge in furniture production, as they can damage surfaces and, if not removed efficiently before each individual processing step, result in rejects. Chips and particles are basically removed by hand or by using compressed air. However, these cleaning methods are not sufficient as particles are merely carried away and do not provide a consistently high cleaning quality. Wandres has therefore developed the new Combi Sword Brush Una U, which exploits efficient microfilament technology. The microfilaments create a particularly large contact area with the dust particles. The particles adhere to the filaments and are reliably removed from the surface without the need for cleaning agents. Cleaning with the Combi Sword Brush Una U eliminates the need for cleaning and anti-static agents, which reduces both operating costs and environmental impact. The filaments can also penetrate fine surface structures due to the very thin filament diameter, achieving a deep-cleaning effect. The integrated pressure buffer, which allows individual filaments to adapt to the surface shape, provides for a consistent cleaning quality. The Sword Brush® was specially developed to be integrated into existing production lines, and its compact design makes it easy to retrofit.

“Mass production of furniture boards and panels generates a considerable amount of dust and particles through drilling, sawing and milling. These may damage the surfaces during stacking and transport or impair subsequent production steps. The result can be production downtime and loss of quality

if particles are pressed into the surface, for example,” says Martin Tritschler, Head of Sales at Wandres GmbH micro-cleaning. Industrial environments where high production speeds and flawless results are required, need efficient cleaning solutions to thoroughly remove various types of particles and chips. A range of methods are available, such as compressed air cleaning or manual dust removal. However, manual procedures are time-consuming and generate high labour costs. Compressed air processes are expensive to operate and are unable to remove very fine dust that adheres strongly to the surface. “Manual cleaning effectiveness varies depending on the daily performance of the particular employee in question, while compressed air cleaning can result in particles being carried over into the production environment,” Tritschler adds.

On the other hand, it takes just a few steps to integrate the various types of Combi Sword Brushes into industrial processing lines. They are specially designed to react appropriately to the changing particle load in continuous operation and ensureonsistently high cleaning effectiveness. 

Large contact area and constant cleaning result 24/7

At the heart of the new Una U product range are special microfilaments. Due to their fine structure compared to conventional brushes from other manufacturers, they can reliably pick up even tiny dust particles and feed them into the extraction system. The pressure buffer is a crucial element here, as it ensures that the filaments stand vertically on the surface without bending, meaning they are in the best position to remove the particles from the surface. This mechanism enables the system to adapt to different surfaces: “Because the brush is pressed onto the panel with a constant pressure, a consistent cleaning performance is ensured over the entire contact surface,” explains Tritschler.

The brush regenerates itself automatically thanks to a continuous self-cleaning function, which enables consistent results around the clock. Particles are removed from the brush mechanically via a roto rack and pneumatically via a self-cleaning nozzle. Afterwards, they are driven towards the suction unit. With particularly high particle volumes, the cleaning result can also be improved by combining air and wiping technology. By installing an air pre-cleaning stage at the infeed of the brush, large quantities of particles are sucked up directly instead of falling to the floor. This always keeps the working environment clean.

Compact design for easy integration

However, Wandres has not only been focussing on cleaning efficiency during the development of its products. “Low resource consumption and short maintenance and assembly times are key factors in an industrial environment,” explains Tritschler. This is the reason why the Combi Sword Brush Una U does not need any additional cleaning agents. However, it may still make sense to equip the brushes with the Ingromat system for some surfaces or applications, for example before applying the topcoat. In this case, instead of microfilaments, brush filaments with a slightly larger filament diameter are used. These are permanently coated with a microfilm of the cleaning and antistatic agent Ingromat. Micro-moistening ensures the necessary adhesion between the dust particles and the filaments and minimises the use of cleaning agents, while the subject surface remains dry. The brush system does not take up much space in existing production lines because of its small footprint. The machine is also available in different nominal widths so that it can be adapted to the roller conveyor width on site. “Production of furniture panels always creates chips and dust. We therefore felt it was important to provide customers with a solution for many cleaning applications that can be easily and reliably integrated into production processes without impairing them or slowing down the process flow. At the same time, a reliable cleaning result is guaranteed in continuous operation – irrespective of the design and surface quality of the panels or the production speed of the systems,” summarises Tritschler.

Further information is available online at www.wandres.com

At its dairy operation in the Yorkshire Dales, the introduction of new separators has given Metcalfe Farms the opportunity to futureproof the pumps it uses to transfer large volumes of slurry from its 2,000 (1,300 dairy) cows.

Separating slurry has undoubted benefits, but putting together a streamlined slurry transfer system covering three tanks, has presented plenty of challenges, especially with the need to feed the site’s 200kWh biogas plant.

Aside from the separators, one of first issues was to address the final pump in sequence that ultimately sends slurry (about 6% to 8% dry matter) about 120 meters (and 10 meters of lift) up to the 3,500m3 anaerobic digester.

Annoying bits and pieces inevitably find their way into slurry, which was enough to make the pump block quite regularly.

“I used to dread coming down here to sort it out,” said Robert Metcalfe, who oversees all things engineering on the dairy side of the business.

“The pump did an okay job when working but wasn’t the best with solids. It wasn’t a pleasant job spending over an hour unblocking it each time; a two-man job, so all very time-consuming, especially having to retrieve it with a pipe because there was no clutch at the bottom.”

That’s all changed now with the old unit replaced by a Chopper Pump made by Landia, who also supplied an integrated guide rail and a bespoke pipework system for easy access and lifting.

‘It is much a better design’

“Everything flows through so much smoother now,” added Robert. “It is much a better design. You don’t have to worry about any sort of pipe bending or extra weight of the added pipe. Generally speaking, the new pump doesn’t block, although just recently a large chunk of rope stopped it! But unlike before, it’s now a job for one person, and on this occasion, only took 20 minutes before simply lowering it back in again.”

‘Digestate from the AD plant

provides significant benefits’

At the biogas plant, which is run by Iona Management Services, a second CHP (combined heat and power) engine has

recently been added, which will help increase the amount of clean energy that is exported to the grid. Metcalfe supplies a slurry-only feedstock to the AD plant, and then buys power back at a discounted rate for its own use. In the winter this is around 300 kilowatt hours, rising to 360 kilowatt hours in the summer. In addition to providing power for the dairy and the sell-on to the grid, the digestate from the AD plant also provides significant benefits, as Robert Metcalfe explains:

“The digestate does wonders for our grassland. We spread a little bit on the crops, but it’s mainly focused on the grass. This year we did five cuts over 1,000 acres. We hardly spend anything on chemical fertilizer now.”

Working closely with Landia to look at how best to integrate the new separators, a 22kW pump was chosen to manage the slurry feeding task, with an existing long-shaft Landia pump moved up from its existing task on another tank.

“We’ve had this pump since 2004,” added Robert Metcalfe, “which has understandably endured plenty of wear, but when tested by Landia engineers during a service, the 20-year-old unit was still happily pumping full pipe, which I have to admit, I was pleasantly surprised by. Now that we have separators, we can remove solid material to reduce our environmental impact.”

To replace the old long shaft unit, a new 7.5kW Landia Chopper Pump has now been installed so that slurry levels don’t rise. Meanwhile, the existing Landia long shaft chopper pumps, which have already been in service for 20 years, since Metcalfe had its first shed, continue to work away.

Very strongly built’

Robert Metcalfe continued: “The pump at the front of the loop system that has been created gets plenty of pain, so no surprise it’s had some repairs over the years, but steadily pumping away, it, with the others, has ensured that the dairy’s channels never fill up. We’ve found that by keeping our channels narrow, the pumps keep them flushed out completely, whereas with wider channels, the whole thing would still need flushing out. Now that we have it all set up on timers, it’s seamless, so far less hassle.

“The Landia pumps are very strongly built things, and I like the fact that they are electric and quite modular, so we don’t have to hook up to a tractor. This very much fits in with what we constantly work towards with fewer engines turning and less burning of diesel. One Landia pump we’ve had now for three years, and it’s never given us a bit of trouble.”

Over in the Metcalfe milking parlour, Robert has been glad to see the back of having to replace small vortex pumps that

blocked or blew completely, even though the liquids are very watery.

He explained: “As soon as any foreign debris or plastics came into play, straining the pump, we were having to buy a new one almost every six months due to burnout or component failure, so as they clearly weren’t up to the job, I called Landia for help. Also, the pump(s) had been installed on winches and over time, blockages and sediment buildup forced us to keep raising the pumps closer to the top of the tank, which in turn meant we ended up with sediment right up to the mouth of the tank.

‘Since we’ve had it installed, we haven’t had to touch it’

“We now have a new 5.5kW Landia pump that just flies through any debris or solids, which are an inevitable part of dairy wastewater/slurry. Nothing settles out with this new, much faster pump. It’s absolutely spot-on, and what’s great is that it is completely automatic. Since we’ve had it installed, we haven’t had to touch it. You can configure it so that in this case it knows we want to keep this tank pumped out and empty. The sensor knows the tank’s dimensions and capacity. It is so much better than what we're doing before.”

Synching the pump operation, together with the investment in separators is just part of how Robert Metcalfe is helping focus

on improvements to help take the diary part of the business forward, but without expanding too quickly. The dairy provides around 45 tonnes of milk per day to Paynes Dairies at Boroughbridge. Exceptionally high animal welfare standards for the Metcalfe cows continue to see a rise in yields.

“Going forward,” said Robert, “everything matters, even the little things. For all its benefits, we’d possibly consider sand bedding, but I don’t think our slurry channels would take it, and there’ such a big wear factor on pumps and machines. The sawdust we use is perfect, apart from the price!

“We’ve also been improving the lighting for our cows, again with some help from an automatic, dimmable system. Previously in hot summer spells, you could see that our cows were uncomfortable, which we don’t want. The milk output would drop. As well as the lighting, we’ve also put up new roof sheets to block out any intensive heat, which has made a big, positive difference.”

He concluded: “In time here we will probably phase out other brands of pumps as they come to the end of their life or cause problems, and just stick with Landia. I think it helps that they focus on pumps, rather than some who try to provide everything, plus we always get very good backup and no problems with the supply of spare parts.”

www.landia.co.uk

The operational challenges of biomass-fuelled Circulating Fluidized Bed (CFB) boilers present complex materials engineering problems, particularly in managing simultaneous corrosion and erosion mechanisms. This case study examines a targeted tube protection strategy implemented at a waste to energy power generation facility.

Initial Diagnostic Assessment

Commissioned in 2008, the CFB boiler rapidly experienced critical tube metal degradation. Preliminary investigations identified two primary degradation pathways: erosive wear from particulate matter in waste-derived fuel streams and chemical corrosion induced by high-temperature gaseous elements.

The initial protective cladding quickly revealed limitations, with accelerated tube wall thickness reduction threatening the infrastructure's long-term operational integrity.

Critical observations included:

• Rapid material loss rates
• Non-uniform wear patterns
• Potential for premature structural compromise

Materials Engineering Solution

The solution chosen was SMARTGard^TM; a maintenance philosophy that includes HVTS® (High Velocity Thermal Spray) cladding, engineered to protect CFB boilers from fly ash erosion, fireside corrosion, and fouling.

Integrated Global Services (IGS) applied the cladding system, customised to the process to mitigate the wastage and extend the life of the boiler tubes. To maximise budget utilisation during past outages, a thinner specification cladding was installed in 2015, focusing on the critical areas and ensuring boiler reliability until the 2017 outage.

Performance Validation Methodology: Inspection in 2017

The inspection was carried out together with the third party CFB boiler expert and the plant manager. The cladding was observed to be in excellent condition. This mini outage verified the reliability of the IGS HVTS® cladding. An extensive inspection was completed throughout the entirety of the cladding scope. With the topcoat completely intact, the cladding system was confirmed to be in ‘as-applied’ condition.

Fouling was virtually eliminated in the cladded locations and any adhered fouling was no longer tenacious and was easily brushed away.

Maintenance Implementation Timeline

• 2008 – 3^rd party commodity thermal spray coating installed to mitigate expected corrosion within the CFB Boiler.
• 2015 – Aggressive corrosion-erosion mechanism analysed and customised IGS SMARTGard^TM HVTS® cladding solution installed
• 2018 – 5-year maintenance plan created, prioritising locations based on wastage rates and tube condition.

Technical Considerations

The HVTS® cladding solution demanded a multifaceted engineering approach. Critical design parameters included:

• Maximising protective layer adhesion
• Eliminating thermal stress
• Developing a long-term protective system and ensuring boiler reliability
• Ensuring compatibility with existing boiler infrastructure

Quantitative Outcome Analysis

The implemented cladding protection strategy demonstrated significant operational advantages including the prevention of large-scale tube panel replacement, reduced maintenance frequency, and optimised outage duration, preventing any unplanned production interruptions.

Operational Economic Considerations

The plant manager commented: "We needed to protect a large area and prevent extensive panel replacements. With outage costs running into tens or hundreds of thousands of dollars daily, the maintenance expenses were minimal compared to potential production losses. Our goal was to reduce annual outage time to under 10 days, which meant we had to be incredibly strategic about addressing critical areas efficiently."

Methodological Insights

The successful intervention underscored several critical engineering principles:

• Comprehensive initial diagnostic capabilities
• Customised material engineering solutions
• Data-driven maintenance approach
• Predictive wear modelling strategies

Conclusion

Advanced cladding technologies provide a sophisticated intervention for mitigating material degradation in boilers, particularly in challenging combustion environments with complex fuel streams.

The research suggests continued development of predictive wear modelling and adaptive cladding technologies could further enhance long-term infrastructure reliability in waste-to-energy and biomass boiler applications. The case study demonstrates the critical role of innovative materials engineering in extending operational infrastructure lifespans and optimising industrial maintenance strategies.

By integrating comprehensive diagnostic approaches, precise engineering interventions, and systematic performance monitoring, plants can transform potential operational vulnerabilities into sustainable, reliable infrastructure solutions.

To find out more, visit: integratedglobal.com

The design and installation by Hoist & Winch Ltd of replacement end carriages for two overhead cranes reached its conclusion recently with the end user expressing complete satisfaction in the outcome. Previously, the 2-ton swl (safe working load) manual overhead cranes were suffering from potentially dangerous crabbing problems due to the original design of the end carriages. Hoist & Winch thus had a responsibility to work expediently and professionally, with the aim of bringing this concerning issue to a safe resolution.

Alongside the supply, installation, hire and load testing of hoist units/cranes for all types of industries, Hoist & Winch also offers lifting equipment refurbishment and rectification services. With each project of this type presenting its own set of challenges, the company comes to the fore in tackling work that competitors often prefer to avoid.

For this project, the relatively high-temperature working conditions and access requirements were a factor due to the basement location of the manual cranes in a large, ageing building in central London. The cranes work over two large gas-fired piston engines that provide heat to neighbouring buildings.

The core objective was to design and install replacement end carriages for the cranes that in the first instance would eliminate the potentially dangerous crabbing issues. Due to this problem, the cranes had not performed correctly since initial installation.

                                                                                                                                                            Continued ……

Crabbing occurred because the original end carriage wheelbase was insufficient for the crane span, exacerbated by insufficient tread depth on the crane wheels. During long travel motion, the end carriage wheels would try and ride up (crab) on to the crane rails, a situation that can potentially lead to crane derailment.

With a solution required urgently, Hoist & Winch performed a detailed site dimensional survey to gather important design information and check the alignment of the existing crane rails. The company then set about designing replacement end carriages with a longer wheelbase and new crane wheels featuring deeper tread. Side-acting crane rail guide rollers at each extent of the end carriages were a further important part of the new design.

Working closely with the customer’s on-site scaffold team, Hoist & Winch carried out a comprehensive installation survey. For the rectification work, the scaffolders agreed to build a temporary tube and board scaffold below each crane, providing both general access and jacking positions to raise and lower the cranes when replacing the end carriages.

Hoist & Winch submitted a Risk Assessment Method Statement (RAMS) for approval by the customer. The RAMS detailed the installation procedure, the required equipment, and the hazards and risks associated with the various tasks and how appropriate actions would mitigate accordingly.

Following a five-week period to manufacture the replacement end carriages, installation took place over four days for both cranes. The work included dynamic load and 125% proof load testing with a certified roller test load for each crane. A series of lifting beams helped to move the test load into the basement area via the use of temporary manual hoist units.

Hoist & Winch issued a Thorough Examination report in accordance with LOLER (Lifting Operations and Lifting Equipment) regulations.

                                                                                                                                                            Continued ……

“The new replacement end carriages served to eliminate the crabbing issues exhibited by the original crane design,” confirms Hoist & Winch Director Andy Allen. “Our customer was very satisfied as they could carry out essential maintenance work on the gas-fired piston engines that was previously delayed. The successful conclusion of this task is yet another example of how Hoist & Winch works with its customers in a professional way to overcome challenging issues and bring genuine added-value to lifting projects.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Figure 1. Leading edge protection of wind turbine blade using polymeric technology

                                                                                                                                                                                               
In order to achieve net-zero by 2050, according to a 2023 Report from the world-leading authority on climate science, Climate Action Tracker: ‘wind and solar sources in electricity generation will need to reach 57 - 78 percent by 2030, and 79 - 96 percent by 2050.’ In 2022, this figure sat at 12 percent. Needless to say, a colossal scale-up of these industries is anticipated over the upcoming decades.

Figure 2. Historical progress toward 2030, 2040 and 2050 targets for share of wind and solar sources in electricity generation (Source: State of Climate Action 2023)

Polymeric Technology Supports Transition to 79 – 96% Renewable Energy by 2050

Given the important role wind power plays in the transition to net zero, it is absolutely critical that windfarms are maintained to an excellent standard. Otherwise, damaged wind power assets may needlessly be decommissioned and replaced; the process of which comes with a hefty carbon footprint as well as considerable financial expenditure.

As such, asset owners are investing in a simple yet extremely beneficial (both from a cost and environmental perspective) solution to extend the lifespan of wind turbines. This solution involves the use of polymeric repair composites and high-performance protective coatings to repair and protect key assets in the wind industry. This includes: turbine blades, nacelles and generating components, turbine bases, towers, transformers, amongst other assets.

The use of this technology is based on a circular economic business model: repairing damaged assets rather than replacing them. In turn, not only does this mitigate the carbon footprint incurred during the replacement process, but it is also enables the asset owner to make significant financial savings as well.

Case Study: 42 Wind Turbine Blades Repaired and Protected

At an onshore Windfarm in Denmark, 42 wind turbine blades were exhibiting signs of severe erosion on the leading edges. Previously, the Customer had used pre-formed shells that were bonded onto the substrate to provide leading edge protection. However, this process proved to be extremely time-consuming and expensive. Therefore, the Customer was seeking an alternative solution which would be financially viable and also ensure optimal operation for many years to come.

Figure 3. Damaged wind turbine leading edge

Specification of Polymeric Leading Edge Protection System

Based on test results, the ease of application as well as the high-quality finish that can be achieved, the Customer decided to repair and protect the leading edges with a combination of Belzona 5711 and Belzona 5721.

The thixotropic paste, Belzona 5711 is specially designed to be applied in conjunction with the Belzona 5721 protective coating. This solvent-free LEP system is formulated for the in-situ repair and rebuilding of leading edge erosion and impact damage on wind turbine blades.

Simple Application Method

Commenting on the application process, Morten Sivertsen, General Manager at AESSEAL Danmark A/S said: “Surface preparation was carried out on each of the 42 blades, followed by the direct application of 90 kg (198.4 lbs) of Belzona 5711 from self-mixing cartridges onto the blade. The repair area was then contoured using a piece of Belzona mixing board. Once cured, a visual inspection was conducted to ensure the application’s readiness for overcoating with 144 kg (317.5 lbs) of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure for 30 – 60 minutes. With three rope access technicians carrying out the applications, on average, six – nine turbine blades were completed each day.”

Figure 5. Morten Sivertsen, General Manager at AESSEAL Danmark A/S

In-Situ Repair Ensured Minimum Downtime Was Incurred

As the polymeric systems were applied in situ without the need for specialist tools or equipment, this ensured that a fast and seamless application was carried out. Thus, this enabled the Customer to make considerable financial savings as it mitigated the profit loss that can be incurred through lengthy periods of downtime.

 Figure 6. Leading edge repaired and protected with Belzona 5711 and Belzona 5721

Safeguarding Key Wind Power Assets for the Long Term  

The scaling up of the wind power industry is absolutely critical in order to support the transition to renewable energy, in keeping with the net zero by 2050 pathway. By safeguarding key assets within this industry through the use of polymeric technology, asset owners can successfully bypass the environmental and financial costs associated with asset replacement. Therefore, it could be argued that polymeric technology plays an intrinsic role in supporting this energy transition. 

About AESSEAL DANMARK A/S:

AESSEAL DANMARK A/S is a subsidiary owned by AESSEAL Plc and is the authorised Belzona Distributor for the Denmark territory. Established in 1999, AESSEAL DANMARK A/S provide industrial repair composites and protective coatings to a variety of industries including petrochemical, mining, power, sugar, pulp and paper, amongst others.  

Please click on the following link for more information about AESSEAL DANMARK A/S.

The world’s largest producer of spirits is now benefiting from a turnkey package of three Italkrane ATEX-rated electric chain hoists supplied by Hoist & Winch Ltd. Operational within a new extension of the Scotland-based distillery, the 2-ton swl (safe working load) hoists raise and lower sealed vessel lids and baskets containing raw materials used in the production of gin.

Among the challenges of this demanding project was a restriction in the overall height of the new building due to local planning laws. In turn, only limited headroom is available for lifting operations over the vessels. Critical for the application, therefore, was the specification by Hoist & Winch of Italkrane YY series electric chain hoists featuring a low-headroom design. The ATEX specification of the hoists is necessary due to the vapours and fumes produced in the manufacture of alcohol-based products.

Italkrane YY series electric chain hoists feature an Ex d electrical enclosure design to contain any explosions and stop flames, sparks and hot gases from escaping. Full anti-spark features are in place for all components subject to sliding friction, including the brass trolley wheels. Also present is a non-sparking load hook, brass anti-tip device and polycarbonate pendant control ensuring explosion protection up to Zone 1 II B T4 classification.

The power supply to each hoist unit is via a festoon cable track system complete with sliding trolleys and support arms clipped to the top flange of the hoist runway beam. Each hoist unit also features an Italkrane heavy-duty geared top/bottom limit switch and friction-type slipping clutch overload protection device.

“Although we provide a full spectrum of lifting equipment services, Hoist & Winch is particularly at home supplying equipment for demanding industries, including the distillery sector,” explains Hoist & Winch Director Andy Allen. “We have extensive knowledge of this industry, where our quality of service and flexible approach ensure the highest levels of customer satisfaction.”

Due to the critical nature of the project and the risk of explosion throughout the high-risk site, it was clear that very stringent planning and close monitoring of working practices would be necessary at all times. In addition, the site work was subject to Construction Design and Management (CDM) Regulations, supported by a requirement for all site engineers to hold a valid CCNSG Safety Passport/CSCS competency certification.

Installation took place over seven days, with a Hoist & Winch CompEX-certified electrical installation engineer completing all connection work. The load testing of each hoist unit and complete runway beam took place using a dynamic test load of 2t + 125% proof load. Additional functional testing using the vessel lids and raw material baskets proved system functionality in line with customer requirements.

Following the issue of a LOLER (Lifting Operations and Lifting Equipment Regulations) Thorough Examination Report for all installation work, Hoist & Winch provided on-site training for the distillery’s operating personnel.

Although providing the optimal solution for this large distillery, Italkrane ATEX-rated electric chain hoists are also suitable for many other applications requiring safe lifting operations in explosion risk environments. In addition, Hoist & Winch can offer ATEX wire rope hoists for longer lifting tasks, heavier loads up to 50t swl and higher duty applications.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

• Incorrect mounting and dismounting of rolling bearings, as well as imbalances in machine shafts, can result in damage to the bearings and other components
• Schaeffler’s new white paper provides all you need to know about the correct preparation, installation and removal of rolling bearings, and how to ensure machine shafts are properly aligned.
• The paper includes basic knowledge, expert tips and guidance, as well as case studies showing how customers are profiting from using the right tools for the job.

Birmingham, UK | August 6, 2024 | Global motion technology company Schaeffler has published a white paper on the mounting and dismounting of rolling bearings and shaft alignment.

Learn from the experts on how to avoid damage during bearing mounting and dismounting, how to simplify mounting work, how to save time and ultimately money by protecting the bearing and optimally aligning your machines. Schaeffler’s practical white paper contains valuable knowledge that you can incorporate directly into your maintenance process.

Our 10-point checklist for safe mounting work will help you avoid premature bearing failures in the future:
    

• Protect your workspace and the rolling bearing from dust, dirt, and moisture.  
• Use drawings to familiarise yourself with the design.  
• Make sure that your bearing matches the specifications on the drawing.  
• Check the housing bore and the shaft seat for dimensional, shape and positional accuracy, as well as cleanliness.  
• Ensure that the mounting of the bearing rings on the shaft or in the housing bore cannot be impaired by edges. A slip angle of 10° to 15° is helpful.  
• Wipe off any corrosion protection on the seat and contact surfaces.  
• Apply a very thin layer of suitable mounting paste to the cylindrical seating surfaces of the bearing rings.   
• Do not cool the bearings. Condensation can lead to corrosion in the bearings and bearing seats. 
• After installation, apply a suitable lubricant to the rolling bearings.   
• Check the bearing to make sure it’s working properly.

These are just a few of the basic recommendations, though to explore further and delve into things like which tool is suitable for certain bearing or bore types, Download the White Paper here.

An underground oil pipeline at a Refinery in Spain was suffering from severe corrosion. If left unchecked, the pipeline, 872 metres (2860.8 ft) in length, would have incurred severe metal loss. As a result, disastrous consequences, both financially and also from an environmental perspective, would have ensued.

Figure 1. Corroded pipeline restored with composite wrap

Solution Sought to Mitigate Cost and Carbon Footprint of Pipeline Replacement   

A prompt repair was required for the carbon steel pipeline, 55.9 cm (22 inches) in diameter, in order to mitigate any further corrosion damage being incurred. In fact, if left unchecked, this would have caused the substrate to completely corrode through and, therefore, serious environmental issues would have ensued.  

A potential solution would have been to completely replace the pipeline. However, considering its mammoth length, this process would have required considerable financial expenditure and, furthermore, would incur a hefty carbon footprint.

For every ton of steel that is produced, 1.85 tons of CO₂ - nearly double the amount - is released back into the atmosphere (Carbon Clean). In addition to this, the process of removing and disposing of the damaged pipeline further ratchets up the carbon footprint of this process.

As well as the environmental impact of replacing the corroded pipeline, this process would also require a considerable period of downtime which would lead to further profit-loss. The combination of these factors, costly in both a financial and environmental sense, led the Customer to seek out an alternative solution to replacing the steel pipeline.  

Expensive Replacement Process Bypassed with Composite Wrap

The Customer decided to repair and protect the pipeline with a combination of polymeric technology in order to bypass the drawbacks associated with replacing the pipeline.

The following systems were specified and applied following an inspection from Elena Expósito Fernández, AMPP (NACE) Certified Coating Inspector Level 2 and Technical-Commercial Delegate at authorised Belzona Distributorship Rodator Composites:  

“The 2-part epoxy paste, Belzona 1111 (Super Metal), was specified to fill in any gaps in the weld seams to ensure the pipeline had a smooth profile. For heavily corroded areas, plate bonding was required using steel plates which were 50 cm x 60 cm (19.9 in x 23.6 in) in size, with a thickness of 5 mm (0.2 in). These were bonded into place using the epoxy structural adhesive, Belzona 7311. To reinforce the pipeline, the composite wrap, Belzona SuperWrap II, was specified. Finally, the anti-corrosion coating, Belzona 5811 (Immersion Grade), was chosen to provide long-term corrosion protection.”   

Figure 2. Elena Expósito Fernández, Technical-Commercial Delegate at Rodator Composites

Figure 3. Application of composite wrap, Belzona SuperWrap II, to the steel pipeline

Figure 4. Anti-corrosion coating, Belzona 5811 (Immersion Grade), applied to pipeline

Polymeric Technology Supports Decarbonisation of Oil and Gas Industry    

The Customer was able to successfully bypass the drawbacks associated with complete pipeline replacement by instead, opting to repair and protect the pipeline with a combination of polymeric technology. As well as making huge financial savings, this solution enabled the Customer to also minimise its environmental impact as well.

As the oil and gas industry continues to decarbonise, this latter point is particularly paramount. Polymeric technology is an extremely viable way in which oil and gas asset managers can make great strides in mitigating the carbon footprint of their facilities. An increased uptake in the use of cold-applied repair composites and protective coatings would help to accelerate the decarbonisation of this industry.

For more information, visit: www.belzona.com