Latest Case Studies & White Papers

Fender Fortified with Polyurethane Resin on US’ First Zero Emissions Tugboat

 

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Figure 1. US’ first zero emissions, all-electric tugboat, the eWolf

In order to keep the planet on track for achieving net zero carbon emissions by 2050, at COP28, negotiators from 200 Parties agreed on the science from the Intergovernmental Panel on Climate Change (IPCC) that: ‘[…] limiting warming to around 1.5°C (2.7°F) requires global greenhouse gas emissions to peak before 2025 at the latest, and be reduced by 43% by 2030.’

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Figure 2. Image: IREANA

Prior to COP28, in July 2023, the UN agency, the International Maritime Organisation (IMO), considerably vamped up its strategy on the reduction of greenhouse gas emissions from ocean freight. The Organisation’s revised targets aim to reduce carbon emissions from international shipping by 40% by 2030, and to achieve net zero by 2050, based on 2008 levels.

The Maritime Industry’s ‘Most Important Mitigation Measure’

One of the fundamental ways in which this sector can achieve this is through ‘scalable zero emission fuels’. According to a 2023 Report from one of the world-leading authorities on climate science, Climate Action Tracker: ‘To achieve full decarbonisation, the shipping sector will need to adopt alternative fuels, otherwise known as scalable zero emission fuels, to power vessels.’ The Report goes on to describe how: ‘This is the most important mitigation measure.’ Scalable zero emission fuels typically refer to hydrogen, ammonia, e-methanol and electric battery.

Considering the seismic reduction in global greenhouse gas emissions required by the maritime industry by 2030, advances in technology, such as the US’ first zero emissions, all-electric tugboat, the eWolf, is a huge step forwards in terms of decarbonising this sector.

The US’ First Zero Emissions, All-Electric Tugboat

Launched in 2023, the 25 metre (82 ft) eWolf is leading the way in terms of mitigating the

climate impact of the maritime sector. Over the first 10 years of its use, the operation of the new ‘eTug' will reduce 178 tons of nitrogen oxide (NOx), 2.5 tons of diesel particulate matter, and 3,100 metric tons of carbon dioxide (CO2), versus a conventional tugboat.

The eWolf is capable of speeds of up to 12 knots, and will be powered by a 6.2 megawatt-hour main propulsion battery and two electric motors. The electricity comes from a charging station that is part of a microgrid facility, equipped with two energy storage containers. Battery modules in each container have a storage capacity of nearly 1.5 megawatt-hours.

Bonding Solution Required for Front Fender

The front fender for the eWolf needed to be bonded together using a strong adhesive that would withstand pushing and pulling forces during the process of adhering the fender to the eTug. Having established confidence in Belzona technology from using their polymeric systems in previous applications, the Customer chose Belzona once again for the application.

System Specification: Elastomeric Primer and Polyurethane Resin

Following an inspection by Micah Heath, Technical Consultant at Belzona Distributorship, Belzona Alabama Belzona Alabama, the fast curing, one-part elastomeric primer, Belzona 2911 (Elastomer QD Conditioner), was specified. This conditioner is optimised for adhesion to a variety of substrates including rubber, as required for this particular application. For the bonding, the polyurethane resin, Belzona 2211, was specified. This flexible rubber repair material is optimised for applications where high build, durability and elasticity are required.

Application Procedure

Commenting on the application procedure, Micah said: “Once the required surface preparation was completed using grinding wheels and MBX Bristle Blaster, the conditioner, Belzona 2911 (Elastomer QD Conditioner), was applied. As soon as the conditioner was touch dry, Belzona 2211 was used to attach the plugs into the fender, and then attach the 3-part fender together. The application team used a manual cable puller to apply the necessary pressure to ensure the various surfaces were sufficiently pressed together. Once completed, the application was left for 36 hours to cure, achieving an excellent mechanical bond.”

Figure 3. Fender plugs prior to attachment

 Figure 3. Fender plugs prior to attachment

 

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Figure 4. Polyurethane resin, Belzona 2211, applied to prepared surface

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Figure 5. Come-alongs used to hold the sections together during curing process

Policy is Key Driver in Roll-Out of Zero Emissions Technology

Over the past few years, numerous policies have been launched worldwide which have provided huge cash injections for technologies and industries that support the net zero by 2050 pathway. One of the world-leading policies is the US’ Inflation Reduction Act (IRA) Inflation Reduction Act (IRA) which includes $369 billion (US dollars) of investment.

According to the Climate Action Tracker, ‘[…] thanks to the passage of the IRA in the United States, companies are announcing hundreds of clean energy manufacturing facilities, turbocharging battery and electric vehicle production and creating tens of thousands of new jobs.’ A continued investment will continue to ‘[turbocharge]’ advancements in technologies such as the eWolf. In turn, technology like this will help the sector to achieve its decarbonisation targets.

Decarbonising the Marine Sector with Polymeric Technology

In addition to pioneering technology like the eTug, polymeric systems also play a key role in the decarbonisation of this sector. Belzona’s circular economic business model is grounded in the practice of repairing and improving damaged assets, rather than decommissioning and replacing them. Not only does this allow the asset owner to make considerable financial savings, but it also mitigates the carbon footprint incurred during the process of replacing damaged assets. In turn, this supports a net zero by 2050 pathway, in line with the Paris Agreement. Maritime Approvals In addition, Belzona systems are manufactured according to the ISO 9001 quality management systems and are approved by classification societies from all around the world including: Lloyd's Register, American Bureau of Shipping, Bureau Veritas, RINA Services, DNV, China Classification Society and the Korean Register of Shipping.

For more information, please visit: www.Belzona.com

 

VIBRATION MONITORING SYSTEMS MEET THE CHALLENGES OF TODAY’S MARITIME TRANSPORTATION

Maritime transportation is a big deal accounting for approximately 80% of today’s international trade logistics with volumes of seaborne trade having almost doubled over the last 20 years with around 11 billion tons loaded. The upward trend correlates with the advent of containerised trade and the streamlining of supply chains between container ports globally. Despite the major challenges stemming from global crises, such as the war in Ukraine, maritime transportation has proven to be resilient with trade expected to grow by around 3% from 2024 to 2028.

Given the scale and importance of this global trade, ensuring the highest level of safety is paramount and is why Vibration Monitoring Systems have become an established tool in helping to achieve optimum safety on board oil tankers and other cargo ships.  SENSONICS are a leading supplier of turbine supervisory and high integrity protection equipment for maritime applications offering over 40 years of experience in developing a full range of sensors and API 670 compliant measuring and protection equipment.

So what exactly are Vibration Monitoring Systems, and how do they work?

Today’s vibration monitoring systems are designed to detect and analyse vibrations in various equipment, enabling the early identification of potential mechanical issues, helping to prevent breakdowns and accidents. For example, detecting abnormal vibration patterns in machinery such as; engines, pumps, compressors and generators. Also, identifying mechanical problems like misalignment, imbalance, bearing wear and other issues that can lead to equipment failure. They also provide operators and maintenance engineers with real-time data for timely decision-making and intervention.

What are the key components in Sensonics Vibration Monitoring Systems?

Vibration Sensor, these are strategically placed on machinery to measure vibrations, whilst  also detecting vibration intensity, frequency and direction.

 

Data Acquisition System, which collects data from the sensors and converts it to usable information. Signal Processing and Analysis Software, this collects data which is processed and analysed to determine vibration patterns and deviations from normal conditions. Finally, a Display and Notification Interface, which provides visual displays, alarms and notifications to alert operators and maintenance engineers about abnormal levels.

The Benefits?

Implementing vibration monitoring systems delivers several benefits. For example; early detection of vibration anomalies promotes proactive maintenance – before issues escalate. Reduced downtime, timely maintenance based on vibration data can prevent unexpected breakdowns, reducing downtime and associated costs. Preventative maintenance is often more cost-effective than reactive repairs. Safety Enhancement, detecting issues before they lead to catastrophic failures enhances crew safety and prevents accidents. Extending Equipment Life, regular monitoring and maintenance can extend the operational life of machinery. Data-Driven Decision-Making, data collected can inform equipment replacement, or overhaul decisions. Efficiency, machines that run to full capacity produce less emissions and pollution and are much smoother to operate.

Sensonics offers a wide range of proven monitoring systems, which can help to detect potential issues, before things get out-of-hand. By detecting and addressing mechanical issues early our vibration monitoring equipment can make a valuable contribution to efficient operations, helping to prevent accidents and downtime.

More at: https://www.sensonics.co.uk/vibration-position-monitoring

Cutting Costs and Carbon Footprints with Polymeric Technology

For over 72 years, Belzona polymeric technology has helped numerous asset owners across a myriad of industries to not only make seismic financial savings, but this technology has also enabled them to considerably mitigate their carbon footprints as well. This latter benefit is particularly paramount when considering the drive towards a net-zero by 2050 future for the planet, as outlined in the Paris Agreement.


At the COP28 Summit, negotiators from nearly 200 Parties came together in Dubai with a decision on the world’s first Global Stocktake. The Stocktake recognises the science that indicates global greenhouse gas emissions need to ‘be cut by 43% by 2030 compared to 2019 levels, in order to limit global warming to 1.5°C (2.7°F).’

However, the Stocktake notes that Parties are off track when it comes to meeting their Paris Agreement goals. As such, the Stocktake has called on Parties to take actions towards achieving, on a global scale, a ‘tripling of renewable energy capacity and doubling energy efficiency improvements by 2030.’

The Belzona Solution: a Circular Economic Business Model

Amongst the ever-growing arsenal of carbon mitigation technologies and initiatives, industrial coatings and repair composites can help numerous industries to significantly reduce their carbon footprints, in line with Paris Agreement targets.

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Figure 1. Established in 1952, Belzona is a global leader in polymeric technology

With a comprehensive range of polymeric systems such as epoxy repair composites, high-temperature coatings, liquid waterproof membranes, flexible roof coatings and pipe wraps, amongst others, these systems have been proven to not only repair and protect damaged assets across many different industries, but to also intrinsically improve them for the long term as well.

The environmental implications of this circular economic business model are astronomical. By bypassing the need to replace damaged assets and instead actively improving them, industries can make great strides in minimising their environmental impact.

In addition, by investing in these systems, this mitigates the fees that can accumulate in the process of asset replacement. These fees include: the cost of the asset being replaced, the labor required during the removal, disposal and installation process and also the downtime that can be incurred during this procedure. 

For these reasons, an increase in investment into these technologies would help many different industries in the process of ratchetting up their 2030 emissions reduction plans, in line with the net-zero emissions by 2050 scenario, in a way that is also financially advantageous.

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Figure 2. Corroded and eroded pump repaired and protected with Belzona 1111 (Super Metal) and Belzona 5821

Conventional Protective Coatings Won’t Survive

At the core of Belzona technology is polymer chemistry. In the Company’s laboratories located in Harrogate, UK and Miami, US, the Company designs, formulates, and manufactures a comprehensive range of polymeric solutions. These systems enable their industrial customers to repair and protect assets that would otherwise be damaged by aggressive service conditions.

For example, slurries and strong chemicals cause abrasion and corrosion as they pass down pipes and through production equipment. Factors such as these as well as elevated temperatures mean that conventional protective coatings won’t survive. As such, companies must turn to a high-performance polymer technology to protect their assets to an appropriate standard.

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Figure 3. Pipes in Oil Refinery coated with Belzona 1593


The Evolution of Belzona


The Company was established in 1952. The Founder, Jorgan Svendsen, was fascinated with the mechanisms of corrosion, and how to repair, protect and improve assets against corrosion damage. Initially utilising a flame-spray method to protect fire extinguishers against corrosion, the Business moved away from hot work applications and developed a pioneering cold-applied, zinc-rich corrosion protection technology. This technology could be applied to a variety of steel structures. It worked by creating a polymer-zinc barrier that would resist aggressive corrosion and also protect the integrity of the steel beneath it.

Following on from this, Belzona then developed a range of polymer coatings and repair pastes. The original being Belzona 1111 (Super Metal), which has since been widely replicated over the years. This system was specifically designed for the repair and rebuilding of assets, before then coating and protecting them against any future damage. Applied onto damaged or worn surfaces in thick layers, these Belzona 1000 Series metallic pastes allow the substrate to be reshaped and reformed back to its original profile. The paste then sets, almost like the steel itself, and gives the original asset a new lease of life.

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Figure 4. Damaged ship caisson repaired and protected with Belzona 1111 (Super Metal), Belzona 1331 and Belzona 5811 (Immersion Grade)

Since then, Belzona has gone on to develop a range of high temperature immersion linings. These are widely used in the oil and gas industry on structures that are subjected to water, steam, oil, sand, and aggressive chemicals throughout their processing life. Belzona has also developed composite repair systems made from densely woven structural fabrics made from glass fiber or carbon fiber, that can be used to return strength and fortify compromised pipes or other structures.


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Figure 5. Desulfurisation unit rebuilt with Belzona 1511 (Super HT-Metal) and protected with high-temperature lining, Belzona 1593

The Company has found the composite repair method to be a rapidly growing market. For that niche, Belzona developed a brand called Belzona SuperWrap, now known as Belzona SuperWrap II. This system is comprised of a fluid-grade resin system and a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre. The major benefit of the Belzona SuperWrap II system is its ability to re-instate/restore strength to the original substrate.

When a steel pipe is damaged or corroded, through chemical attack for example, then it will ultimately lose strength and can even leak. This can mean that entire plants or facilities will be shut down for lengthy periods of time. This is clearly a major issue as it could result in millions of dollars being lost every day. In addition, this system can be applied as a composite patch, pad or plate, bringing increased rigidity, corrosion resistance and chemical resistance to the asset.


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Figure 6. Pipe strength restored using Belzona SuperWrap II

Design, Develop, Manufacture

Belzona’s Chemists are involved at all stages, through design, development and manufacture. The Chemists work at the metaphorical drawing board, all the way through to supervising the first batch of a new polymer solution being made. As part of the development and manufacturing process, the Company focuses on sourcing materials that are commercially available, can provide the requisite performance, are of the highest quality, and which are as safe and sustainable as possible. By working with different chemical manufacturers, who create the building blocks of these solutions, the Chemists are able to apply their scientific knowledge and expertise, creating an easily appliable, safe, high-performance polymer product.

Testing is another key step in the development process. Belzona has fully equipped testing laboratories at their UK and US sites. These facilities allow the Company to study and characterise the performance of its products, and thereby optimise the formulations. Every solution undergoes an extensive programme of testing, the majority of which is carried out in-house. The testing is defined by the intended end-use for the product; for example, weathering testing for an exterior anti-corrosion coating or abrasion resistance testing for a slurry pump lining. It is Belzona’s investment in this testing capability which sets the Company apart from most competitors.

While the UK and US serve as the two core bases for Belzona’s global operations, the Company also has a global Network of 159 Distributors in over 120 countries. It also has corporate presences in the form of training and support centers in Thailand, Canada and China. Increasingly, Belzona is turning its attention to expanding its portfolio of sustainable solutions.

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Figure 7. CEO, Barry Nisill, presenting Belzona solutions at Belzona’s Asia Pacific Office

Polymeric Solutions for a Sustainable Future

Repairing damaged assets instead of replacing them has always been fundamental to Belzona’s philosophy. This is encapsulated in the Company’s strapline ‘Polymeric Solutions for a Sustainable Future’. Originally, though, that philosophy was primarily driven by cost: it’s considerably cheaper to repair an asset than to buy a new one, so the asset owner can make significant financial savings.  

For example, over the course of several years, a Steel Fabricator in the UK’s East Coast managed to save millions of pounds by deploying polymeric repair and protection systems onto more than 2,000 metres of its gas pipeline. This included epoxy repair mortars and stainless-steel protective coatings.

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Figure 8. Steel Fabricator saved millions of pounds thanks to Belzona technology

To this day, this philosophy of repair instead of replace remains. However, the need for industries to reduce their environmental impacts is more pressing now than ever before. As such, Belzona polymeric repair materials and protective coatings have an important part to play in supporting this net-zero journey. They can help to reduce the carbon footprint across many different industries such as (amongst others):

Petrochemical, Oil and Gas:
Belzona has a wide range of epoxy-based metal repair composites and high temperature coatings and linings which have been used in the petrochemical and oil and gas industries since the late 1970s. These materials are specifically designed to provide outstanding erosion and corrosion protection, as well as chemical resistance for equipment operating offshore and onshore at various pressures and temperatures.

Belzona systems can be applied in the following areas within the petrochemical and oil and gas industries (amongst others): internal and external of process vessels, pipework, cold bonding, splash zones, storage tanks and secondary containment areas, carbon capture, decommissioning, fenders and hoses, heat exchangers, seawater filters and separator vessels.



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Figure 9. Flange protected against corrosion with flange encapsulation system, Belzona 3412

Marine:
Belzona's comprehensive range of cold-curing marine coatings and metal repair composites has been used by the marine industry for over 60 years. These products have been specifically designed to withstand harsh offshore conditions as well as provide exceptional resistance against erosion and corrosion.

Providing metal repair composites to shipyards around the world, long-term protection is proven by years of successful experience with ships and offshore structures. Manufactured according to the ISO 9001 quality management systems, Belzona materials are approved by classification societies from all around the world including: Lloyd's Register, American Bureau of Shipping, Bureau Veritas, RINA Services, DNV, China Classification Society and the Korean Register of Shipping.

Belzona systems can be applied in the following areas within the marine industry (amongst others): rudders, shafts, engines, shimming and chocking applications, rubber components, at sea repairs, storage tanks, exhausts, turbo blowers, stern tubes, auxiliary diesel engines, alternators/generators, tank cleaning systems, oily water separators, steering gears, pumps, heat exchangers, pipework, deck winches, lifeboats and access ladders.

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Figure 10. Voith Schneider propulsion unit built up with Belzona 1311 (Ceramic R-Metal) before being overcoated with Belzona 1321 (Ceramic S-Metal)


Mining and Quarrying:
Belzona's wide range of polymeric metal and rubber repair composites and durable protective coatings and linings have been used in the mining and quarrying industry for decades. These materials are specifically designed to provide outstanding erosion, corrosion and abrasion protection, as well as chemical resistance, for equipment operating in highly aggressive environments.

Belzona systems can be applied in the following areas within the mining and quarrying industry: solids handling equipment, fluid and gas handling equipment, mechanical equipment, chocking and shimming applications and facilities maintenance.

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Figure 11. Expansion joint repair at Coal Mine using combination of Belzona systems

Steel:
From rolling mills to blast furnaces, critical equipment in the steel industry is susceptible to abrasion, erosion, corrosion and chemical attack. Belzona’s range of metal repair compositeserosion corrosion resistant coatings and durable linings have been engineered to meet the aggressive demands of this industry.

Belzona systems can be applied in the following areas within the steel industry (amongst others): fluid and gas handling equipment, solids handling equipment, storage tank and secondary containment areas, shimming of worn equipment and facilities maintenance.

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Figure 12. Tank and concrete saddles fortified with Belzona technology at Steel Production Site


Supporting Renewable Energy Industries  

Not only can Belzona technology help to mitigate the carbon footprint across multiple industries, but these polymeric systems can also safeguard valuable assets within the renewables sector. For example:

Wind:
For both onshore and offshore environments, Belzona solutions for the wind power sector can help to repair and protect assets from these problems, whilst simultaneously making wind farm maintenance procedures more efficient and less time-consuming.

Belzona systems can be applied in the following areas within the wind industry (amongst others): blade restoration and leading edge protection (LEP), nacelle and generating components, rebuild solutions for mechanical components, turbine base and tower, damaged concrete, corrosion resistant encapsulation systems, corrosion and erosion protection for splash zones, surface-tolerant solutions for transformer leaks.

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Figure 13. Emergency repair of leaking transformer at Wind Farm with Belzona 1212

Hydropower:
Within the hydropower industry, polymer technology can offer a plethora of benefits including resistance to cavitation, excellent resistance to erosion and corrosion and efficiency enhancement.

Belzona systems can be applied in the following areas within the hydropower industry (amongst others): Francis turbines, Kaplan turbines, wicket gates, inlet valves, switchgears and turbine casings, pipework, penstocks, dams/spillways and facilities maintenance.

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Figure 14. Corroded Francis turbine repaired with efficiency-enhancing coating, Belzona 1341 (Supermetalglide)

Biomass and Waste-to-Energy:
Belzona offers a wide range of epoxy-based repair composites and protective coatings to repair and protect biomass and waste-to-energy processing facilities and equipment from common problems occurring in the industry, including: abrasion, erosion, corrosion and chemical attack.

Belzona systems can be applied in the following areas within the biomass and waste-to-energy industry (amongst others): facilities maintenance, pipework, FGD units, chimneys and roofs.    

Range of Systems to Repair, Protect and Improve

For each of these industries and application areas, Belzona has designed high-performance solutions spanning across five product ranges:

Belzona 1000 Series - for the repair and protection of machinery and equipment.
Belzona 2000 Series - for abrasion resistant linings and the repair and protection of flexible components.
Belzona 3000 Series - waterproofing systems for the repair and protection of buildings and structures.
Belzona 4000 Series - for the repair and protection of concrete subject to abrasion, impact, and chemical attack.
Belzona 5000 Series - for protection from physical, chemical, or bacterial attack in a diverse range of environments.
Belzona 6000 Series - Zinc rich epoxy materials for corrosion protection to steelwork.
Belzona 7000 Series – for structural bonding, shimming and chocking.  



Sustainable Solutions

The focus on sustainability and conservation of the planet’s resources is informing much of Belzona’s future endeavors. For example, the Company has been supporting a UK-based Power Distribution Company and their customers whose assets are subject to SF6 leaks in their transformers. SF6 is described as the world’s worst greenhouse gas and is 23,500 times more potent than CO2.
 

In early 2022, Belzona created a tailor-made solution to stop leaks on a transformer owned by an electrical distribution operator. After several stages of prequalification, a trial repair was completed and has now been in service for several months. With Belzona’s support, the organisation is now achieving a 90-95% leak reduction rate, with an ambition to reach 100% in the near future.

The SF6 project reflects an increasingly important mission being adopted by Belzona: creating products that solve industrial problems in a safe and sustainable way.

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Figure 15. Belzona created a tailor-made solution to stop leaks on a transformer

Development of Products with High Levels of Renewable Carbon Content

Another important part of Belzona’s sustainability drive is its investigation into the efficacy of bio-based polymer solutions. One of the negative aspects of working with polymers is that the chemical building blocks used throughout the performance coatings sector are derived from oil - this means that an environmental impact is incurred.

However, Belzona has set out to address this challenge through its exploration and development of high-performance polymer solutions that use feed stocks derived from a renewable carbon source: plants. While bio-based chemicals have been available for low-performance solutions such as decorative paints for some time, the use of these types of chemicals has not previously been possible in the heavy industry market.

However, it is increasingly becoming apparent that chemical manufacturers are recognising the need for plant-derived polymers, in order to meet sustainability targets.

It is now possible to achieve very similar performance to oil-derived equivalents. Belzona is passionate about this ongoing change within the chemical industry. As a down-stream producer, the Company intends to work closely with manufacturers to encourage the adoption of more renewable-carbon solutions that don’t compromise on performance or quality.

Polymeric Systems: A Welcome Addition to the Arsenal of Carbon Mitigation Strategies

An increase in investment into industrial protective coatings and repair composites would help countries in the process of ratchetting up their 2030 emissions reduction plans, in order to achieve the net-zero emissions by 2050 target. Not only this, as discussed, these technologies are also instrumental in helping asset-owners across many different industries to make significant financial savings as well.

Indeed, Belzona recognises the critical role polymeric systems play in helping to support a more sustainable future for the planet in a way that is also financially advantageous. As such, they are committed to making ongoing investments into the development of polymeric systems that meet the ever-growing and changing demands of industries as they evolve towards a net-zero future.

About Belzona: Mission and Values

In April 2023, Belzona announced its new values – ‘Investment, Innovation, and Integrity’. These values are encapsulated in all five sectors of the Belzona philosophy - Corporate, Distributors, Consultants, Contractors, and Customers. These sectors work in harmony to provide the best products and services.

‘Investment’, the first of the new values, represents Belzona’s commitment to investing in its people, technology, and infrastructure. This includes investing in its employees’ training and development, as well as in the research and development of new and innovative products. Belzona’s focus on ‘Investment ensures that it stays ahead of the competition and continues to provide its customers with the best possible solutions.


Figure 16. Belzona invests in the ongoing training and development of its staff members

‘Innovation’ is the second value that Belzona has adopted. This value represents the Company’s commitment to continuous improvement and finding new and innovative solutions to its customers’ problems. For example, Belzona’s focus on ‘Innovation’ has led to the development of cutting-edge products, such as our range of high temperature linings.

The third and final value that Belzona has adopted is ‘integrity’. This value represents the Company’s commitment to honesty, transparency, and ethical behaviour. Belzona’s focus on ‘integrity’ ensures that it operates with the highest standards of conduct and maintains the trust and respect of its customers and partners. Strong work ethic and education across all areas ensures that the Business gets it, as best they can, right the first time from products to marketing, to technical support.

For more information, please visit: www.belzona.com

 Case study: Increase safety during machine intervention

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Groupe Lactalis is the world’s largest dairy company. Safety is one of the top priorities in all factories of the group. In its production sites in the Netherlands, called Royal Lactalis Leerdammer B.V., where Leerdammer cheese is produced, Lockout/ Tagout procedures were implemented to improve safety during maintenance activities. Read the inspiring case study!

Royal Lactalis Leerdammer B.V. wanted to increase maintenance safety by reducing machine intervention risks in its production sites in the Netherlands. The company wanted to implement Lockout/Tagout, a proven safety procedure that enables the complete isolation of machines from their entire energy supply while maintenance is ongoing. The procedure can remove all safety risks related to moving machine parts, premature machine energisation, and residual machine energy. Royal Lactalis Leerdammer B.V. wanted to set up their very own Lockout/Tagout programme, and sought guidance from an established expert. Learn how Brady has helped them to answer this safety challenge.

Solution: Procedure consultancy and reliable tools

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Brady Corporation offered to train the company safety experts in creating best-in-class machine-specific Lockout/Tagout procedures. A Brady Engineer created an example procedure on-site to enable a perfect lockout for a single machine. Using the procedure as a guide, safety experts expanded the Lockout/Tagout programme to a lot more machines, with Brady in standby to consult. Machines to prepare milk for cheese production, conveyor belts and also electrical cabinets were all in scope of the Lockout/Tagout project to maximise maintenance safety.

Every lockout procedure, managed in Brady’s LINK360 software, included step-bystep instructions to fully isolate a specific machine by blocking all of its energy control points in the off-position. Pictures were added to illustrate where to find each valve, button or fuse that controls the energy supply to a specific machine.

 

Brady supplied all of the Lockout/Tagout tools needed to block access to the energy control points used in the production sites of Royal Lactalis Leerdammer. Our customer’s maintenance specialists can lock these tools in place with their personal Brady SafeKey padlocks . From a wide range of available locks, our customer selected nylon body padlocks with 38mm, and with 25mm nylon shackles. Compact, and lightweight, the 25mm nylon padlock is ideal to lock out fuses in small electrical cabinets.

Brady delivered the padlocks and keys in red, blue, green, yellow, white, black, orange and purple, so Royal Lactalis Leerdammer can visualise specific padlock purposes. These include neutralising maintenance risks such as electricity, compressed air, process fluids, gas, steam, mechanical energy and machines, as well as highlighting padlocks for individual protection.

Brady also offered BBP12 Label Printers to enable on-site padlock personalisation. With the printers, our customer can easily print names, phone numbers and other data on self-adhesive labels that perfectly fit their SafeKey padlocks.

To complete the solution, Brady created large shadow boards to distribute all Lockout/Tagout tools in the workplace. The boards include a tool shadow for each Lockout/Tagout device in use and provide an easy tool return point, as well as a clear overview of available tools and lockouts in progress. Next to tools, the boards also offer space to attach work specific Lockout/Tagout/Tryout procedures.

Results: Safe machine interventions

With the ability to isolate any machine from its complete energy supply, maintenance specialists at Royal Lactalis Leerdammer can work safely, and efficiently. After a machine intervention, all maintenance specialists remove their personal padlocks and restore the flow of energy so production can resume as planned. Tools are returned to the shadow boards and immediately available for the next safe maintenance intervention. Brady was able to deliver and help implement the entire solution from A to Z.

Download the free Lockout/Tagout Guidebook and get visual inspiration!

Case study: Increase safety during machine interventions

Groupe Lactalis is the world’s largest dairy company. Safety is one of the top priorities in all factories of the group. In its production sites in the Netherlands, called Royal Lactalis Leerdammer B.V., where Leerdammer cheese is produced, Lockout/ Tagout procedures were implemented to improve safety during maintenance activities. Read the inspiring case study!

Royal Lactalis Leerdammer B.V. wanted to increase maintenance safety by reducing machine intervention risks in its production sites in the Netherlands. The company wanted to implement Lockout/Tagout, a proven safety procedure that enables the complete isolation of machines from their entire energy supply while maintenance is ongoing. The procedure can remove all safety risks related to moving machine parts, premature machine energisation, and residual machine energy. Royal Lactalis Leerdammer B.V. wanted to set up their very own Lockout/Tagout programme, and sought guidance from an established expert. Learn how Brady has helped them to answer this safety challenge.

Solution: Procedure consultancy and reliable tools

Brady Corporation offered to train the company safety experts in creating best-in-class machine-specific Lockout/Tagout procedures. A Brady Engineer created an example procedure on-site to enable a perfect lockout for a single machine. Using the procedure as a guide, safety experts expanded the Lockout/Tagout programme to a lot more machines, with Brady in standby to consult. Machines to prepare milk for cheese production, conveyor belts and also electrical cabinets were all in scope of the Lockout/Tagout project to maximise maintenance safety.

Every lockout procedure, managed in Brady’s LINK360 software, included step-bystep instructions to fully isolate a specific machine by blocking all of its energy control points in the off-position. Pictures were added to illustrate where to find each valve, button or fuse that controls the energy supply to a specific machine.

Brady supplied all of the Lockout/Tagout tools needed to block access to the energy control points used in the production sites of Royal Lactalis Leerdammer. Our customer’s maintenance specialists can lock these tools in place with their personal Brady SafeKey padlocks . From a wide range of available locks, our customer selected nylon body padlocks with 38mm, and with 25mm nylon shackles. Compact, and lightweight, the 25mm nylon padlock is ideal to lock out fuses in small electrical cabinets.

Brady delivered the padlocks and keys in red, blue, green, yellow, white, black, orange and purple, so Royal Lactalis Leerdammer can visualise specific padlock purposes. These include neutralising maintenance risks such as electricity, compressed air, process fluids, gas, steam, mechanical energy and machines, as well as highlighting padlocks for individual protection.

Brady also offered BBP12 Label Printers to enable on-site padlock personalisation. With the printers, our customer can easily print names, phone numbers and other data on self-adhesive labels that perfectly fit their SafeKey padlocks.

To complete the solution, Brady created large shadow boards to distribute all Lockout/Tagout tools in the workplace. The boards include a tool shadow for each Lockout/Tagout device in use and provide an easy tool return point, as well as a clear overview of available tools and lockouts in progress. Next to tools, the boards also offer space to attach work specific Lockout/Tagout/Tryout procedures.

Results: Safe machine interventions

With the ability to isolate any machine from its complete energy supply, maintenance specialists at Royal Lactalis Leerdammer can work safely, and efficiently. After a machine intervention, all maintenance specialists remove their personal padlocks and restore the flow of energy so production can resume as planned. Tools are returned to the shadow boards and immediately available for the next safe maintenance intervention. Brady was able to deliver and help implement the entire solution from A to Z.

Download the free Lockout/Tagout Guidebook and get visual inspiration!

Download the free Lockout/Tagout Guidebook and get visual inspiration!

Hoist & Winch designs bespoke electric winch system for ‘wet room’

Among many notable recent successes, Hoist & Winch Ltd has come to the assistance of a large UK plant rental company with a very specific request. The company wanted a bespoke electric-powered winch lifting system to raise and lower large vinyl-type sheets in a purpose-built ‘wet area’. With no challenge too demanding, Hoist & Winch stepped up to the task.

At the heart of the Hoist & Winch system are four floor-mounted Yale RPE 400V three-phase winches offering 150kg swl (safe working load) and 20 Pfaff roof-mounted diverter pulleys coupled to four 12m long tubular spreader beams. Each winch raises and lowers one of the 12 m long spreader beams which attach to the vinyl sheet via load-bearing karabiner clips. Each vinyl sheet weighs approximately 60kg.

The customer can operate all four winches individually via their own wall-mounted, low-voltage pendant controls, allowing the lifting of a single vinyl sheet as required at any time. The innovative winch system raises the vinyl sheets safely and in a level position. This capability permits easy drying of the vinyl sheets after pressure washing, a process that removes any unwanted residual substances from the most recent hire job.

Each winch sits in purpose-manufactured mounting frames secured to the floor using four Hilti expansion anchors. The frame design allows orientation of the winch rope pay out at 90° to the first diverter pulley.

                                                                                                                                                            

The room in which the washing, lifting, drying and lowering of vinyl sheets takes place is a purpose-built and enclosed ‘wet area’ with a cambered floor and drainage around the perimeter to support the removal of excess water during cleaning. Hoist & Winch Ltd provided PVC weather covers for the winch control panels to ensure safety at all times.

Ultimately, the system designed by Hoist & Winch Ltd significantly improves the whole operation to facilitate a quicker and far less labour-intensive turnaround of the vinyl sheets during busy periods of hire.

The scope of supply for Hoist & Winch Ltd included all pre-installation survey work to ensure correct the alignment and positioning of each winch, diverter pulley and all associated equipment, including top and bottom hook geared limit switches. The company also provided installation (using electric scissor lifts for working at height) over a seven-day period and subsequent commissioning. Further responsibilities included all wiring and load testing of the whole system. Once complete, Hoist & Winch Ltd issued a LOLER (Lifting Operations and Lifting Equipment Regulations) ‘Thorough Examination’ report.

To ensure smooth handover, Hoist & Winch Ltd undertook comprehensive operator training covering: overview of the winch units and main components; operating controls and features; periodic checks and lubrication; annual inspection, service and certification requirements; and practical operation by each operator.

Hoist & Winch Ltd Director Andy Allen says: “This project set out a number of important stipulations to which we had to respond comprehensively and efficiently. A successful outcome that meets with the project’s ambitions, delivered on-time and on-budget, is our primary aim. Once again our professional and experienced team of engineers here at Hoist & Winch Ltd came up with a safe, reliable, high-performance solution to the satisfaction of our valued customer.”

                                                                                                                                                            

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

Evergreen Landia mixers all part of Gardner’s high standards

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Some might consider the relentless maintenance regime at a treatment plant in Kansas to be almost too pro-active. But the longevity and reliability of this site’s equipment speaks volumes for the way this wastewater facility is run; not to mention the multiple awards it has won.

At Gardner, just south west of Kansas City, Site Superintendent Scott Millholland is a firm believer in keeping the Kill Creek Water Resource Plant clean, fully serviced and at optimum efficiency – at all times.  Protecting the environment, waterways and his team are paramount.

Scott recently completed 25 years’ service (the past 12 as Site Superintendent), seeing in the Kill Creek facility when it was built in 2002 by Kruger as a Bio-Denitro-phased oxidation ditch technology plant. Also there since the plant first opened are two mixers made by Landia, which help keep everything in suspension in the ‘racetrack’ nitrification/denitrification set-up.

“These Landia mixers continue to keep everything moving and do a very good job for us,” said Scott. “We pull them up every Spring and Fall to pull off any rags and make sure there’s nothing on the magnetic plug rings – and after checking them over, put them right back into service. They’re an integral part of what we do here.”

In the corrosive world of wastewater treatment that Scott knows very well, his view on all that pro-active maintenance is partly summed up with the statement that ‘oil is cheap!

“We didn’t have to carry out any type of rebuild on the first Landia mixer until it had completed 14 years of service,” he said.

“We look after them properly, but they’re a strong, solid design and very easy to maintain. Equipment should always be maintained properly, but clearly, the mixers made by Landia are truly built to last. After our rotors have been on for an hour and a half, we run the mixers for 45 minutes. At just 13 amps, they are super-low on energy usage, especially when compared to blowers. We’ve just replaced 130-amp (125HP) blowers with new units that are just 50 amps, so it has been a very quick payback.”

Keeping 21-year-old mixers in tip-top condition is just one of the many reasons that Gardner has rightly been recognized as an outstanding wastewater treatment facility. Each of the 23 lift stations in and around Gardner are also checked every day to ensure that all of the wastewater is getting through properly. Serving a population that has leapt from 6,900 people (in 1998) to a figure approaching 25,000 today, Kill Creek has won the Kansas Water Environment Association (KWEA) Wastewater Treatment Plant of the year seven times, and in 2020, Scott Millholland received the William D. Hatfield Award for Wastewater Operator of the Year. The coveted title honors operators who have contributed positively to preserving and enhancing the water environment through their leadership, example, enthusiasm and hard work. Scott not only oversees the entire facility, leading and mentoring his team, but also still works as an operator and mechanic/engineer.

‘Never Compromise On Treatment Quality’

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“Building a better community today for future generations really inspires me,” added Scott, “and our team takes great pride in protecting the local environment and waterways. We haven’t had a permit violation for over two decades. The plant here was originally designed to serve a population of 25,000 with a processing capacity of 2.5 mgd. We’re currently running at about 2.3 mgd, with room to expand (because it is modularized) to 7.5 mgd without disrupting operations. Gardner is one of the fastest growing cities in the US; very much on the up with new jobs and an expanding economy, so it is very important that we keep at least one step ahead with our operations. We try to save money wherever we can, but never compromise on treatment quality.”

In addition to significant population growth, Kill Creek Water Resource Plant is also having to meet the new task of reducing phosphorous and nitrogen outputs to meet ever stricter discharge permits.

‘A Long Way On Its Journey’

“We’ve made some operational process adjustments to tackle this,” said Scott, “and will continue to keep on top of it. “Gardner has come a long way on its journey from lagoons, fixed film plant with trickling filter, rotating biological contactor, chlorine, package plant – and then full treatment plant. We used to do pretty much everything on an on-call basis, from checking the water and wastewater plants, water breaks, turning meters on and off, and anything and everything else that needed to be done. For new challenges such as reducing phosphorous and nitrogen, all of our equipment, no matter how new or old, including the mixers from Landia, will play their part.”

Hoist & Winch designs and manufactures outdoor-specification tandem-lifting hoist for Environment Agency

Hoist & Winch Ltd recently supplied a special tandem-lifting hoist system as part of improvements to Environment Agency flood defence assets at Taplow Weir on the Jubilee Relief Channel, an 11.6 km asset that reduces flood risk to 3,200 properties by diverting water from the River Thames when flows are high. The tandem hoist units lift 7 m long galvanised steel stop logs each weighing 2000 kg. These stop logs provide a temporary barrier to the Jubilee Relief Channel so that workers can perform maintenance on the hydraulically controlled sluice gates.

Working for a large water industry engineering contractor, Hoist & Winch designed the remote-controlled tandem-lifting system to bespoke Environment Agency requirements. In terms of operating concept, the tandem lifting hoist system raises and lowers the stop logs in a level position so they locate correctly in the guide rails without any misalignment.  At the heart of the system is a pair of Yale CPV 2500 kg swl (safe working load) single-fall, electric-powered chain hoists mounted in motor trolleys to provide fast and slow speed operation.

A Danfoss/Ikusi wireless remote control handset offers individual control of either hoist raise/lower motion for initial levelling of the load hooks prior to lifting operations. The wireless remote also provides dual tandem hoist control for the precise level positioning of the stop-log load during lifting and lowering.

In the event of power loss or activation of a raise/lower limit switch, special software ensures that the system fails safe and the load does not lift unevenly. As a point of note, mechanical linking of the hoist units ensures correct load-hook separation at all times, while both hoist units also feature audible and visual operating alarms.

                                                                                                                                                            

From an electrical perspective, Hoist & Winch Ltd provided rugged, heavy-duty plug and socket connectors for ease of maintenance and installation. In addition, the company utilised a fully enclosed (outdoor specification) power-feed system to provide safe maximum hoist-hook coverage across the entire gantry. PVC covers provided added protection for the IP55 hoist enclosure and electrical control panels from outdoor weather conditions.

The criticality of the project and close proximity to water demanded closely monitored working practices, with very stringent planning of all activities and the provision of additional PPE, including life-preserver jackets. Site work was also subject to CDM regulations and required all site engineers to hold a valid CCNSG Safety Passport/CSCS competency certification.

Installation took place over a five-day period and involved a barge-mounted hydraulic crane. Testing of the complete system took place using a dynamic test load of 2.5t + 2.5t + 125% proof load. Additional repeated function tests involved the dynamic test load and actual stop-log load to prove system functionality and satisfy Environment Agency requirements. On completion, Hoist & Winch Ltd issued a LOLER Thorough Examination report and provided operator training for site personnel.

 “The project to install the special tandem-lifting hoist system supports the Environment Agency’s annual maintenance programme, which is essential to ensure its flood defence assets remain in good working order,” says Andy Allen, Director of Hoist & Winch Ltd. “This type of tandem-lifting system would prove ideal for many other applications, such as lifting steel blast doors used in explosive/hazardous environments or handling valuable or delicate long loads in the manufacturing sector. Essentially any task that demands very precise and failsafe level lifting.”

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

Deeside Cereals find wastewater solution with Watermark and Landia

Investment in new wastewater treatment equipment has enabled a leading producer of cereals and cereal bars to overcome the challenges it was facing with a very problematical effluent.

Deeside Cereals had first introduced a new DAF unit (Dissolved Air Flotation) from Watermark (a division of WA Cooke Group) to separate suspended solids and for the thickening of sludge.

However, the FOG (Fats Oils and Greases) caused by ingredients such as chocolate, rape seed oil and lecithin (phospholipids) had at one point sent COD (Chemical Oxygen Demand) up to 78,000.

‘Very Strict Compliance Levels’

Karl Johnson, Safety, Heath & Environment Manager at Deeside Cereals, commented: “The DAF unit from Watermark has proved very successful, bringing COD down to 6,000 initially, but with very strict compliance levels to meet for Dŵr Cymru Welsh Water, we wanted to make further improvements to our treatment regime.”

He added: “Working closely with Watermark, we agreed that the introduction of a high-quality aeration system would be best. Based on their previous good experiences, Watermark recommended the AirJet from Landia. I’d read about how reliable and effective their equipment is for the long-term, so we decided to first take one on trial for our new 60m3 wastewater treatment tank.”

To suspend the solids from Deeside Cereals’ effluent, the Landia AirJet was soon put into operation. Comprising a 5.5kW Chopper Pump (invented by Landia in 1950) and a venturi nozzle, the low-energy AirJet can mix and aerate down to a water depth of approximately 7.5 metres, without the need for a compressed air supply.

Alistair Fielding from Watermark said: “It’s a simple set up; easy to install, and very effective.  Based on our preceding work with Landia, we had no hesitation in recommending them to Karl. We want our customers to benefit from equipment that not only provides the right solution, but also offers the best possible value in total cost of ownership.”

Watermark had previously teamed up with Landia to help introduce a mixing system to handle wastewater at an expanding organic poultry producer in South Wales. Here, the AirJet eliminated the need for compressors, bottom-mounted diffusers and advanced controls.

‘Very Challenging To Treat’

 

Karl Johnson from Deeside Cereals, continued: “When our sugary water used to become entrained, it was very challenging to treat and fulfil our compliance obligations . It took us a little while for the AirJet and the DAF to harmonise, with some minor adjustments required around the length of time to aerate the trade effluent. We’ve also found that it is easier to control the COD by only half filing our tank, but we always test it before discharge – and if needs be, can aerate the effluent a little longer until it is below our compliance threshold. The Landia pump needs nothing more from us than a quick visual inspection each day to check on oil. We’re now looking at setting up a service agreement for a twice-yearly maintenance check. The guys at Landia are very good to work with. Landia have provided excellent support at all times and the installation was very straightforward. The purchase was a judicious decision on our part and I would highly recommend Landia as a service provider. Air-Jet has paid for itself in less than 10 months.”

Success Story: SONOTEC X PD energy GmbH

“Low-speed machines like our sewage sludge dryer are difficult to monitor with vibration measurement technology. With SONOTEC's ultrasonic technology, it was possible to detect roller bearing damage and assess its condition," says Tobby Brümmer, Head of Machinery Maintenance at PD Energy GmbH

Ultrasound is the technology for the first step in damage detection and has the advantage over other methods in that it can be used at all bearing speeds. Even with extremely low-speed bearings, damage can be detected at the earliest possible stage.

Focus on sewage sludge incineration

As a 100% subsidiary of PD energy GmbH, KSR sewage sludge recycling Bitterfeld-Wolfen GmbH operates a mono sewage sludge incineration plant in the Bitterfeld-Wolfen chemical park. The plant is designed for a rated thermal output of 19.9 MWth. Running more than 8,000 hours a year, the incinerator consumes up to 260,000 tons of dewatered sewage sludge from municipal sewage treatment plants. The thermal utilization of sewage sludge in mono-incineration plants will be an important disposal path in the future. With the construction of the plant, KSR sewage sludge recycling Bitterfeld-Wolfen GmbH is making a contribution to the phosphorus recovery that will be required in Germany starting in 2029. The finite resource is filtered out via various systems and fed back into the material cycle.

Slow-speed disc dryer

The core process in the treatment of sewage sludge is drying. Two disc dryers are used at the site for this purpose. The redundancy of the systems is important so that one dryer can always process sewage sludge. However, the system capacity is designed in such a way that both dryers are always running, if possible, in order to be able to achieve the appropriate utilization. Downtimes must be kept as short as possible, and if they are necessary, they should only affect one dryer at a time. "The availability of both disc dryers is extremely important to us," says Tobby Brümmer, Head of Machinery Maintenance at PD Energy GmbH. In the disc dryer, the material is slowly transported from one end to the other, reducing the residual moisture. Disks heated with steam form a large contact surface where indirect drying takes place. Scrapers ensure an even process and transport of the material. The rotor turns very slowly with only 7.5 revolutions per minute.

Roller bearing damage detected and evaluated

During the commissioning phase, noises were detected on a roller bearing on one of the two dryers, whereupon a vibration measurement was initiated. “The results of the vibration measurement were not useful for us. They showed no indication of damage to the examined roller bearing,” says Tobby Brümmer. After a short research it was clear that ultrasonic measurement technology could help. "We then contacted SONOTEC GmbH and asked for a measurement using ultrasonic technology," adds Tobby Brümmer.

During the on-site measurement, the damage could be narrowed down to the corresponding roller bearing. The measurement effect was clear and in comparison to the second dryer, a statement about the severity of the damage could be made on-site.

The subsequent evaluation by the application engineer from SONOTEC provided further insights. Tt could be confirmed that the damage to the roller bearing had to be severe and very advanced. Furthermore, the data analysis revealed that the outer ring must have been severely damaged and, in particular, that one race of the double-row bearing was more severely affected. “Such details are extremely important for us to be able to identify the causes as precisely as possible. This is the only way to take appropriate preventive measures to prevent the problem from reoccurring,” says Tobby Brümmer.

Solution for slow-movers: condition monitoring with ultrasound

The advantages of ultrasonic testing technology from SONOTEC are very apparent in this application. The broadband data evaluation enables an optimal adjustment to the conditions on site. In this way, characteristic values ​​can be calculated in the range from 20 kHz to 128 kHz. Frequency ranges with background noise can be suppressed with the adjustable filter function. The high sensitivity of the sensors enables early detection of roller bearing damage, making ultrasonic monitoring a very effective solution, especially for slow-running roller bearings. “We are excited about the statements that can be made with the help of the ultrasound data. Ultrasonic roller bearing monitoring will be an integral part of our maintenance measures for our slow-moving machines in the future,” explains Tobby Brümmer.

SONAPHONE: A modular approach with different apps and sensors

With the ultrasonic testing technology from SONOTEC, other applications in preventive maintenance can also be performed. The device makes it possible to locate and evaluate compressed air leaks, and steam traps can be tested and their condition evaluated. Both applications are moving more and more into the focus of many companies due to ever increasing energy costs. "We are also interested in the other possible applications of ultrasonic technology," says Tobby Brümmer.

With various apps and corresponding sensors, the ultrasonic testing device SONAPHONE can be easily adapted to the respective application. “This means that the investment in the testing equipment pays for itself very quickly. And the device is better utilized by using different departments. It is used between the regular routes on the disk dryers for other applications," says Tobby Brümmer.

Interview partner: PD energy GmbH, Tobby Brümmer, Head of maintenance for machine technology

Find more about SONOTEC here: https://www.sonotec.eu/en/

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KSR sewage sludge recycling Bitterfeld-Wolfen GmbH (Source: PD Energy GmbH)

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Data acquisition at the disc dryer (Source: SONOTEC GmbH)

 

 

 

Boost for wastewater aeration business as Mapal hit investment target – and more

Mapal has surpassed its fund target of £400,000 via Crowdcube, with 475 new investors choosing to inject over £467,000 into the business that has completed over 100 installations of its energy-saving, wastewater aeration solutions.

Due to the high demand, the deadline to invest was extended by 14 days as more and more parties expressed their interest in becoming part of the Mapal success story, which has seen projects delivered worldwide, including the UK, Australia, Israel, South Africa, and Chile - with critical acclaim.

Mapal’s Chairman/Director, Ilan Diamond, commented: “It is very encouraging to not only achieve our target, but beat it.  Investors can clearly see the major benefits and huge potential of our innovative systems that are 50-60% more efficient than traditional mechanical surface aeration.”

He added: “As well as providing general working capital, this new boost in funds will enable us to further develop our sales and marketing teams. We can also fund a pre-sale trial (rental) fleet and continue to develop our key research into ammonia removal in aerated lagoons.”

Diamond explained that while some aeration methods partly address higher than ever energy (and maintenance) costs of conventional surface treatment, they often require very specific conditions. This can prove price-prohibitive as a new-build, and requires the process to be shut down for upgrades, resulting in costly and potentially damaging downtime. In contrast, Mapal’s floating and retrievable fine-bubble aeration solutions, which do not need a levelled floor, can be installed and maintained while the plant is operating; without personnel having to enter the wastewater.

mapal-ge.com

this article can also be found in the issue below.

 

AIR LLC At AIR LLC, Limble powers a new generation of maintenance services focused on transparency and customer satisfaction.

Introduction

Advanced Indoor Resources (AIR) LLC is a mechanical services start-up located in Baltimore, Maryland. Launching in April 2021, their mission is to provide a new generation of HVAC, plumbing, and building automations to commercial properties in Baltimore and the surrounding counties. Their use of cutting-edge technologies, like Limble, differentiates them from their competitors. Through this, they’re able to empower their technicians and provide transparency and real-time communication to their clients.

The Challenge

Advanced Indoor Resources (AIR) LLC wanted to do something innovative. They knew technology existed that could streamline maintenance services and improve transparency for customers. But what if they took that a step further and used that technology as the foundation for a new kind of maintenance service?

In order to provide the service they wanted, they needed technology that could provide several efficiencies. 

  • Transparency in the form of dashboards for customers and staff
  • Communication and work order management efficiencies that could keep costs low
  • An easy-to-use system that kept staff stress-free and ready for interactions with customers

``Limble is really the center of our business model.``

Bob Maloney, Senior Account Manager

The Solution

AIR LLC worked with Limble to build their operating model around the technology that differentiates them from their competitors. The result was a degree of transparency and efficiency that offered higher satisfaction for their customers as well as significant cost savings.

The Customer Benefit

With Limble, AIR LLC creates customized dashboards for their clients and better prepares technicians be efficient when they arrive. When technicians show up with the equipment and knowledge they need for each job, it saves the client both time and money.

The Employee Benefit

Limble also helps AIR LLC prioritize their employee experience. “Anything we can do to reduce work-stress for our technicians is a huge thing for us,” Martin Knott, President says. With Limble, the employees are not only able to have all the information at their fingertips, but it is also easy to use. This helps them work more effectively and efficiently.

The Result

AIR LLC achieved almost $5 million in sales during its first year of business and is poised for further growth. “There’s not a sales conversation that doesn’t include our Limble capabilities,” says Bob Maloney, Senior Account Manager. “We utilize the platform as a way to show individuals that we’re technologically savvy and we have command of their information.”

Access to all that information helps AIR technicians minimize repair time by being prepared with correct the information and necessary parts in advance. Also, having the job information visible to customers helps them stay informed and manage their expenses more easily. This contributes significantly to customer satisfaction. 

As the company continues to grow and innovate, they plan on utilizing Limble even more and getting every benefit from it they can.

Start a free trial 

 

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