Hi-line Industries, a UK-based leader in the design, manufacture and installation of energy-efficient compressed air purification equipment, is announcing its acquisition by US multinational Ingersoll Rand. Important to note is the assurance of complete customer continuity. Hi-line will continue to build and sell all of its products with no price increases. Steve Smith will also remain as Managing Director to maintain the next-day delivery expectations of customers.
The acquisition, effective from 1 July 2024, marks the start of a new and exciting chapter in the history of Hi-line as a progressive UK manufacturing business. It follows 12 months of intensive negotiations and due diligence. With Steve Smith as the sole owner of Hi-line, funding was always going to be the issue in reaching the next level. Now, with the backing of Ingersoll Rand’s financial might, the Burton-upon-Trent based company can grow quickly to become the market’s number one in compressed air treatment solutions.
To celebrate the bright future that the acquisition promises, Hi-line staged a launch day in July at nearby St George’s Park, home of the Football Association’s national football centre. The football analogy is quite pertinent.
“At the launch day I explained to our staff that the acquisition by Ingersoll Rand was akin to a wealthy investor buying a football club,” says Steve Smith. “The investor recognises potential in the team, invests in the purchase of the club, and provides funding to buy players and grow.”
Among the first results of the Ingersoll Rand investment will be the addition of Industry 4.1 IoT capabilities to all Hi-line controllers by the end of 2024. Another change will see Ingersoll Rand companies gain access to Hi-line’s highly popular range of alternative filter elements and its coveted series of Hi-PLEX dual technology dryer skids (fridge and desiccant on the same skid).
“What will not change is our outstanding level of customer service,” states Steve Smith. “Headed up by Craig Watson and Oliver Loewenbach, these guys work tirelessly to support our distributors. In fact, we are looking to grow our ACRIB-registered team of service technicians via a new recruitment drive that will deliver even more support for our broad product range.”
Energy-efficient compressed air equipment available from Hi-line includes desiccant and refrigeration air dryers, nitrogen/oxygen separators, filtration equipment, and condensate systems. A five-year warranty reflects Hi-line’s confidence in its high-quality workmanship and materials. Supplying both standard and bespoke solutions, the company serves customers in sectors that include food and beverage, medical, general manufacturing, automotive, breathing air, and laser cutting to list but a few. The company is a member of the British Compressed Air Society and carries accreditation to the ISO 9001:2015 quality management standard.
Gravotech, an international leader in the marking and engraving markets for over 80 years, is proud to announce its acquisition by Brady Corporation, an international manufacturer and marketer of complete solutions that identify and protect people, products and places.
Arnaud Linquette, President and CEO of Gravotech said, “The sale of Gravotech to a market leader in printing and high-performance adhesive material solutions provides us with an excellent opportunity to expand into new markets and generate long-term profitable growth. Over the past several years, we have enhanced our new product development and manufacturing capabilities and broadened our portfolio of precision direct part marking and engraving solutions. We look forward to further developing and growing our business with Brady.” “The acquisition of Gravotech by Brady, a strong and innovative industrial company, opens a new era of development for Gravotech. Complementarities between Brady and Gravotech are very
strong, and I am truly convinced that the combination of both companies will generate significant and robust value creation,” said former Gravotech President Gérard Guyard, who helped develop and drive the company over the past 28 years.
“We are pleased to welcome the Gravotech team to Brady,” said Brady’s President and Chief Executive Officer, Russell R. Shaller. “Gravotech offers specialty laser and mechanical engraving capabilities intended for direct part marking within a variety of industries and applications. The addition of Gravotech expands our product offering into precision direct part marking and engraving, which aligns with Brady’s market leading position in product identification solutions and specialty adhesive materials. We intend to expand Gravotech’s addressable market utilizing Brady’s global footprint throughout Europe, Asia and the Americas.”
Gravotech is an international manufacturer and marketer of engraving, marking and traceability solutions addressing applications of personalization, identification and signage. Gravotech’s product portfolio includes innovative and high performing marking and engraving machines based on laser and mechanical technologies, and a comprehensive range of engraving materials and consumables. Over the years, Gravotech has become a key player and industrial partner for many major industrial corporations as well as luxury goods manufacturers and retailers.
Brady Corporation is an international manufacturer and marketer of complete solutions that identify and protect people, products and places. Brady’s products help customers increase safety, security, productivity and performance and include high-performance labels, signs, safety devices, printing systems and software. Founded in 1914, Brady has a diverse customer base in electronics, telecommunications, manufacturing, electrical, construction, medical, aerospace and a variety of other industries. Brady is headquartered in Milwaukee, Wisconsin and as of July 31, 2023, employed approximately 5,600 people in its worldwide businesses. Brady’s fiscal 2023 sales were approximately $1.33 billion.
Mike Bacon, Internal Technical Applications Engineer atMatara, addresses the issue of quality when it comes to pneumatic cylinders: what constitutes quality, why does quality matter and, just as importantly, when does it matter.
From its origins in the first part of the 19th Century, pneumatic cylinders have been used in countless industrial processes around the world to move something along a linear path. A relatively straightforward mechanical device, pneumatic cylinders use compressed air to drive a piston inside a cylinder. The piston rod transfers the force it develops to the object to be moved.
Although it depends on the application at hand, pneumatic cylinders are often preferred to hydraulic cylinders as they don’t come with the associated risks of leakage and cross-contamination. Furthermore, they are quieter and, overall, take up less space as there is no requirement to store fluid.
Over the years, a wide array of pneumatic cylinders has been developed to meet specific needs, including roundline, guided, precision slide, compact, clamp and stopper cylinders. Rodless pneumatic cylinders are also available - and becoming more popular - which have been design to perform as a self-contained linear actuator for improved flexibility.
As with all mechanical devices, quality differs between types of pneumatic cylinders and between manufacturers.
When it pays to invest in quality
Whilst I’d like to say that quality always matters, the reality is that quality matters more in certain applications.
When it comes to miniature ‘brown’ cylinders, typically used in moving items off a conveyor belt for example, these are generally low cost items that don’t tend to be long lasting. You could invest in better quality versions but the return on investment doesn’t add up, mostly because they are very low cost so it’s not worth repairing them, and they are incredibly easy to replace – you literally swap out the broken one with the new one in ten minutes.
Where quality most certainly does matter is when it comes to the bigger cylinders - 125, 100, 6200 bore cylinders – which are lifting heavy weights. Replacing a big pneumatic cylinder is costly and rarely quick, as they generally aren’t stock items and therefore have to be machined and cut, which could easily take several days. At Matara, we have a large UK based machine shop and are able to build many pneumatic cylinders in-house, which means we can frequently deliver a replacement cylinder in two to three days, but that isn’t the case for all suppliers. Time is also required for the on-site engineers to fit the replacement, which will take several hours, not minutes. All of this time is clearly disrupting the process at hand. That’s why you really want these larger cylinders to be reliable, repairable (where possible) and long lasting.
Then, of course, you have the health and safety implications to take into account, especially if the cylinders are lifting several tonnes of machinery or items vertically. The last thing anyone wants in this scenario is the cylinder to fail and everything to plummet. If this did happen, other machinery could be damaged and you would probably have to shut down the whole area, which could last for days. To skimp on the cylinder, saving a few pounds, really wouldn’t be a good idea here.
What constitutes quality in a pneumatic cylinder?
As I’ve said, pneumatic cylinders are fairly simple devices in that they’re composed of just three or four parts. This actually makes it quite straightforward to tell when they're not good quality by just looking at them. Typically, there will be gaps, such as around the seals, and they may not quite line up.
But there are other important aspects to consider when assessing the quality of a pneumatic cylinder that need you to probe a little further.
Let’s start with the materials used in the construction of the cylinder. Aluminium, steel and stainless steel are essential. When it comes to the rods, chromed rods are ideal if the cylinder will be lifting heavy weights as these are far less prone to breaking. The seals are the items that are most likely go wrong on a cylinder as they can be easily damaged, especially in dirty, dusty site. In harsher environments, it pays to invest in better quality seals. In food environments, for example, corrosive resistant stainless steel seals would be a good option, but there are also PTF, PTFE and wiper seals.
To ensure you end up with a pneumatic cylinder that meets the demands of your site and application, its important that the manufacturer is able to offer a range of accessories. These include external accessories, such as mountings and crevices, and accessories fitted within the cylinder itself, including scrapers and bellows to protect the rod from dust and debris. Not every manufacturer will have a comprehensive range of accessories, but the better known, better quality ones will. At Matara, we produce a range of accessories including clevises such as male/female, rear and offset variations, as well as flange mounts, flow controllers, foot brackets, and reed switchers.
Next, check that the pneumatic cylinder adheres to the relevant standards: ISO 15552, ISO 21287 and ISO 6432. All reputable companies manufacture to those international standards, so that shouldn’t be an issue. What is an issue though is how those manufacturers test their products. Avoid batch tested products as you cannot be sure your specific cylinder has been tested. At Matara we test each and every cylinder we manufacture in house, which means we very rarely have any returned.
Lastly, what level of support can the manufacturer bring? This is a much under valued area, but one that definitely impacts the overall quality of the product and service. Is the manufacturer willing to visit site and provide advice on the cylinder? Maybe it can be repaired rather than replaced. Would a high temperature seal solve any issues?
Don’t forget maintenance
No matter how good quality the pneumatic cylinder, regular maintenance will help reduce unexpected downtime. This will generally involve checking the cylinder, tube, and rod seal for damage and applying lubricant where necessary. As the seals are most prone to damage, pay particular attention to these and replace where necessary. Matara supplies seal kits which make this process very straightforward.
Keeping the pneumatic cylinder clean also pays dividends. In particularly dusty environments it’s worth considering an easy clean cylinder where the surfaces are smoother all around so they don't collect dust and debris in the first place and can be easily cleaned. Tie rod cylinders are also slightly easier to clean as well.
Horses for courses
Ultimately, the nature of the site and the cost implications of repairing or replacing a pneumatic cylinder are the determining factors in just how much you are willing to invest in them. If it’s a hostile environment or one where hygiene is paramount, such as food or pharmaceutical, then quality really does matter. Choose well and your pneumatic cylinder should perform reliably and consistently for a long time. We were asked to replace a Matara cylinder recently that had been operational for over 13 years, which is an astonishing length of time to be fully operational. It goes to show that quality counts!
Based in the UK, Matara is a linear motion, automation and pneumatic component specialist. For more information go to www.matara.com
What could you achieve with a label printer that combines rapid output, stunning color accuracy, and the flexibility to handle diverse printing needs?
Brady’s new BradyJet J7300 Colour Label Printer prints industrial-strength labels in vibrant full colour. Optimally support safety, lean efficiency and maintenance in production environments. Use the toughest materials on the market, complete with automatic setup, calibration and printing on the very first label.
Why should you consider equipping your operation with a BradyJet J3700?
Ideal for industrial labelling that changes frequently, from regulatory signage and Lean visuals to barcoding, lab ID, GHS labelling and UL/component ID
LabelSense™ technology enables printer, materials and inks to talk to each other for automatic part recognition, setup and adjustments
Dual CMY and true black (K) ink cartridges deliver vibrant colours, deep black, dark tones, readable barcodes and sharp text job after job
Prints smear-free inks on labels that resist water, chemicals and abrasions for up to two-year outdoor durability (even longer indoors)
Print Utility dashboard helps you plan, budget and troubleshoot with status alerts, a job cost calculator, remote monitoring and more
Exterior LED lighting and clear cover communicate real-time printer status
Ships with the free Brady Workstation Basic Software that includes fundamental apps and features to create labels.
Optimized Windows® driver lets you connect to third-party software and print PDFs
Unleash your true colours with the BradyJet™ J7300 Colour Label Printer. Enjoy fast, industrial-grade full colour for variable print jobs from the production line to the lab.
For those of us within the maintenance and reliability industries, we would have come across the topic of oil analysis as a method to monitor the health of the oils in machines. This monitoring method has been around for decades but is it still relevant with all of the new, shiny gadgets and technologies that we have today? In this article, we will explore some of the benefits of oil analysis, how it compares to other technologies and why we still need it today.
What is oil analysis?
For those not familiar with oil analysis, it can be likened to performing blood tests for the human body. Oil in our machines is often compared to the blood in our bodies. Blood circulates throughout the body taking important blood cells with food and oxygen in it to the various organs, similarly oils follow this behaviour. However, oils transport additives which provide varying functions including reducing wear or friction or even preventing corrosion or oxidation to name a few.
When performing a blood test, we can test for a few things; the overall condition of the organs or we can test for specific things such as the presence of bad cholesterol. With oils, we do a very similar practice where we can test for the overall health of the machine or pinpoint exact components and look for distinct changes which are reflected in the characteristics of the oil.
Basically, oil analysis can help you to determine the condition of your oil (if it is degrading or if the additives have depleted such that it no longer protects the equipment) and the health of your asset as the oil can reflect if there is wear occurring in the components. As such, it can provide very useful information to help operators and maintenance personnel to plan effectively for any type of maintenance to be done on the components.
Why oil analysis?
The P-F curve is one that is used throughout reliability to demonstrate the point at which a component is expected to have a functional failure. There are many variations of the PF curve, and different monitoring technologies can be placed in specific orders accordingly. However, it remains dominant that oil analysis is among the top three techniques used for early detection of failure.
Oil analysis can be used to detect the presence of contaminants, metals and other molecules at a microscopic level and quantify these appropriately. Most OEMs (Original Equipment Manufacturers) publish their acceptable standards for various tests (usually standardized tests by some accredited body such as ASTM) and have these available to laboratories around the world. When an oil analysis test is performed (as per the stipulated standards), the lab will compare the actual values to the expected values (from the OEM) and then provide some guidance to the user on possible steps forward.
Every lab will have a specific format for reporting the results of your oil analysis (similar to the labs for reporting on blood samples). Typically, the actual value is shown and then there may be an expected range for the various characteristics or just an indication of whether the actual value falls outside of the range (on the higher or lower end of the scale).
While this is their reporting standard, other labs will have a different format, but the tests will all conform to the same internationally recognized standard. As such, if oil is tested in the United States (as per a particular standard) and then tested in Italy (as per the same standard) then there can be some comparisons of these results. However, one must also be aware of the types of instruments being used and their calibration as this can account for slight differences in test results. As such, oil analysis provides a global standard for which equipment performance can be compared across regions.
Oil analysis vs other technologies
Just as oil analysis is similar to blood testing, we can think of our bodies as a critical machine with various components which need to be monitored. If we get a fractured bone, a blood test will not help us to assess if the bone is broken or can be repaired. In this case, we may need an x-ray. Similarly, with machines, there are various types of tests to determine different aspects to be monitored.
Typically, oil analysis can provide the operator with insight into whether there has been any internal damage to the equipment in the form of wear particles which can be quantified. As with most condition monitoring methods, being able to trend the patterns over time helps the operators to identify if wear is occurring at an increased rate or whether the oil is degrading.
On the other hand, other technologies such as vibration analysis or ultrasound analysis or even thermography are not able to detect the presence of molecules. These other types of analyses focus on alignment, or other mechanical issues as they occur and can trend them over time. However, oil analysis can accurately detect the presence or absence of contaminants or additive packages which could affect the health of the oil and by extension that of the machine.
Oil analysis should not be used as the only technology in your condition monitoring artillery. Other technologies can be used alongside oil analysis to provide the user with a more comprehensive overview of the health of the asset. For instance, if the oil analysis discovered high wear, the next step would be to identify where the wear was coming from. Perhaps in this case, one of the other technologies could identify a misalignment or other mechanical issue which could be the source of this wear. Thus, these technologies should be used to work together to achieve better reliability for their asset owners.
Is Oil Analysis still relevant today?
With the many advancements in Artificial Intelligence, Machine Learning and the advent of countless different sensors on the market, the question arises, “Is Oil Analysis still relevant today?”. Granted that these advancements have significantly transformed the industry, we need to recognize that they are here to help evolve what we already do and not necessary replace it.
These advancements build upon the foundations of the techniques of oil analysis. With artificial intelligence and machine learning, we can train models to interpret oil analysis data and trigger alerts accordingly but there should always be a human present to overview these. In the real world, not every situation has occurred or been recorded yet hence the models do not have that particular data to learn from nor can they make decisions about it since it simply doesn’t exist in their “brain”.
Humans can “think outside the box” and formulate patterns or trends which may not be triggered by the models simply because these models have not been taught these patterns. Hence it is important to always have a human in the loop and not rely solely on these models especially when million-dollar decisions can be negatively initiated with the wrong interpretations.
Lately, sensors have gained more traction and a wider adoption as they can be integrated into warning systems to alert users to potential deviation from known characteristics of the oil. However, as noted above, sensors rely on data sets to compare the information and on some form of capacitance which must be converted into a signal before it can be interpreted.
With lab equipment performing the actual tests, there is a higher rate of accuracy plus the added advantage of having humans review the results for discrepancies before sending off the report. While sensors can be the first warning system for some users, lab equipment should be utilized for those more precise tests which require a higher level of accuracy.
In essence, oil analysis remains very relevant today. However, it has significantly evolved over the last few decades. Today, oil analysis can achieve a higher efficiency level with the integration of the advancements in technology (AI, machine learning and sensors) and other available monitoring technologies. Together, these should all be used to create a greater impact on improving the reliability of the machines.
Sanya Mathura is a highly accomplished professional in the field of engineering and reliability, with a proven track record of success in providing solutions to complex problems in various industries. She is currently the Managing Director of Strategic Reliability Solutions Ltd, a leading consulting firm that specializes in helping clients improve their asset reliability and maintenance practices.
Sanya holds a Bachelor's degree in Electrical & Computer Engineering as well as a Masters in Engineering Asset Management from The University of the West Indies and has over 15 years of experience in the industry. She has worked with several well-known companies and has been recognized for her exceptional work in the field of reliability and lubrication engineering. Her expertise in developing and implementing asset management strategies, risk assessments, and root cause analysis has earned her a reputation as a subject matter expert.
As the head of Strategic Reliability Solutions Ltd, Sanya leads a team of highly skilled professionals who provide a wide range of services to clients across various industries, including oil and gas, manufacturing, and transportation. Under her leadership, the company has expanded its services and is now recognized as a leading provider of reliability engineering services in the industry across the globe.
In addition to her work at Strategic Reliability Solutions Ltd, Sanya is an active member of several professional organizations, including the International Council for Machinery Lubrication and writes technical papers for several organizations. She is also a sought-after speaker and has presented at various conferences and seminars on the topics of reliability engineering and lubrication. She is also an avid advocate for women in STEM.
At HANNOVER MESSE 2025, the international drive technology and fluid power sector will once again demonstrate its strength and importance as the largest supplier segment of the international engineering business, under the "Motion & Drives" label. The exhibiting companies will present innovative and intelligent individual components and complete systems across all sectors.
Hannover. Traditionally, drive technology and fluid power has been represented at HANNOVER MESSE by a large number of companies from Germany and abroad, especially in odd-numbered years. This will also be the case in 2025 when manufacturers will present their latest applications and components for intelligent and sustainable production. All this, under the Motion & Drives label, will be focused in Halls 4, 5 and 6. Drive technology and fluid power plays a key role in many industries, because nothing can move without these technologies. For the strongly export-oriented industry, HANNOVER MESSE is the ideal platform for boosting global business thanks to its highly international character. Companies that have already registered include Atos, Bosch Rexroth, Cantoni, Festo, Flender, IMM Hydraulik, SEW-EURODRIVE and Schaeffler.
"With HANNOVER MESSE, we are offering exhibitors the opportunity to be embedded in a unique industrial innovation ecosystem. It is one in which companies from the engineering, electrical and digital industries as well as the energy sector present efficient and sustainable solutions for current and future industrial value creation. The mix of representatives from research, business, start-ups and politics meeting in one place at the same time is unique. This results in unique business potential and access to top-level decision-makers, technology scouts, experts and media representatives from all over the world," says Hubertus von Monschaw, Global Director Trade Fair and Product Management HANNOVER MESSE at Deutsche Messe AG.
"In 2025, HANNOVER MESSE and its Motion & Drives community will be the driver of innovation and center of gravity when it comes to the best new solutions for the engineering world. The Motion & Drives companies supply power, torque, positioning, data, and solutions for our real and virtual worlds," emphasizes Hartmut Rauen, Deputy Managing Director of the Machinery and Equipment Manufacturers Association (VDMA).
According to the VDMA, German drive technology companies alone exported goods worth EUR 17.9 billion last year. The most important customer countries were China, the USA, France, Italy, Poland, Austria, the Czech Republic and the UK.
Fluid power is also a very export-oriented segment: in 2023, goods worth EUR 8.4 billion were exported, corresponding to an export quota of 60 percent. The most important customer countries are the USA, China, Italy, France, Austria, the UK and the Netherlands.
In addition to the individual stands, the Motion & Drives area will offer an exclusive joint stand for VDMA members as well as a forum accompanying the trade fair, the "Motion & Drives Conference Stage", which will be organized by the VDMA Drive Technology and Fluid Power associations. Current industry topics will be discussed there, including digitalization, interconnectivity, Manufacturing-X, OPC UA, umati as well as energy monitoring and efficiency, carbon footprint, digital product passport and recycling management. In addition, a special show organized by the EU-funded Fluid 4.0 research project will demonstrate digital and sustainable solutions in fluid and drive technology. One focus will be on the challenges of system architecture, energy consumption, PCF calculation, and recycling management.
With umati, the VDMA has launched an interface initiative to make data more easily accessible. With umati, data – including from drive technology – can be used without additional outlay.
HANNOVER MESSE
HANNOVER MESSE is the world's leading trade fair for industry. Companies from the engineering, electrical and digital industries, as well as the energy sector, come together under the main theme of "Industrial Transformation" to present solutions for production and energy supply, today and tomorrow. The main exhibiting areas for 2025 will be Smart Manufacturing, Digital Ecosystems, Energy for Industry, Compressed Air & Vacuum Technology, Engineered Parts & Solutions, Future Hub and International Trade & Investment. A conference program with around 1,600 speakers complements the program. This trade fair will be held next in Hannover from March 31 to April 4, 2025. The partner country is Canada.
Upon completion of the acquisition, the combined team will operate from over 35 locations throughout Sweden, Norway and Denmark, delivering end-to-end industrial services, support decarbonisation projects and improve operational performance. The integration of both teams, consisting of approximately 1,300 employees, will contribute to expertise knowledge in industrial maintenance and projects from various industries and enable seamless service delivery across the region.
This acquisition further cements Jernbro's position as a leading industrial service provider in the sector. By integrating Veltec's expertise and established presence, Jernbro will enhance its capabilities and market reach. The acquisition will bring several key benefits, including an enhanced geographical presence and local support across Sweden, Norway, and Denmark, which allows for greater service reach to customers. It also strengthens capabilities across diverse industries such as petrochemical, steel, mining, food & beverage, pulp & paper, automotive, metals manufacturing, pharmaceutical, energy, water & sewage, maritime infrastructure, and chemical sectors. Furthermore, Jernbro is committed to ongoing growth, alongside a continued focus on training and development through its established Maintenance School training academy.
Jernbro is backed by Bluewater, a specialist international private equity firm focused on the energy sector.
Deal completion is expected in September subject to customary closing conditions.
Enerpac announces a Low-Height Skidding System, expanding the jack and slide options for heavy lift and machinery movers. The modular LH-Series Low-Height skid beams can fit in tight spaces, as small as 92mm, while still offering up to 400 ton skidding capacity with two push-pull units
Part of the Enerpac HSK-Series Skidding Systems range, the Low-Height Skidding System’s modular design comprises a series of skid beams allowing quick setup. Loads are moved by hydraulic push-pull units, travelling over special PTFE-coated pads placed on the skid tracks to reduce friction.
The skidding system’s push-pull cylinders are powered by a standard Enerpac split flow pump to ensure each skid beam travels synchronously. It also allows bi-directional operation – at full capacity, avoiding the need to reposition cylinders when switching skidding direction.
2-in-1 design In addition to its low height, the LH-Series offers a 2-in-1 design. It can be used either on a fully supported surface or combined with the optional track support for added rigidity when the support surface is not fully supported or when spanning a gap is necessary. This two-part design means contractors do not need to own two sets of track for various ground support conditions.
Enerpac offers several options for controlling the LH-Series skidding system. Wireless control allows the operator the freedom to view the skidding operation from multiple locations while providing complete control of all system functions. Manual controls offer a cost-effective solution by utilising manual or electrically operated hydraulic valves mounted directly on the skidding system power units.
For more information on the Enerpac LH-Series Low-Height Skidding System, visit www.enerpac.com.
Fluke Reliability has entered into a formal partnership agreement with Augmentir to integrate their connected worker platform with Fluke Reliability’s AI-powered enterprise asset management solution to increase productivity, enhance employee experiences and improve Maintenance, Repair, and Operations (MRO) for industrial customers.
Augmentir is a leading connected worker solution, providing a suite of AI-powered connected worker tools that help industrial companies deliver effective skills management, training and collaborative digital workflows, by digitising and optimising frontline work processes.
Fluke Reliability enables customers to adopt a connected approach to their reliability strategies, bringing together hardware, AI-powered software, services, and their eMaint platform within one workflow. The solution helps customers shift from reactive to predictive maintenance strategies, assessing the health of their assets and utilising their AI diagnostic engine which means customers can predict faults up to six months in advance.
The mutually beneficial partnership enables customers’ maintenance and operations departments to engage in integrated digital operations on the plant floor. Augmentir boosts efficiency with digital tools that reduce onboarding and increase productivity. Fluke Reliability enhances decision-making, meaning workers can shift from reactive to proactive in their approach. Both prioritise the end-user while benefiting overall operations.
Fluke Reliability Chief Technology Officer, Aaron Merkin commented, “Our ethos has always been to simplify processes for the end-user. With a growing skills gap and aging workforce, we know the workers of tomorrow are best supported with technology that helps them get the job done quicker and more efficiently. Augmentir’s connected worker platform supports workers with that in mind, utilising AI technology that complements our own. I’m confident our collective customers will see value in our ongoing partnership.”
Augmentir CEO and Co-Founder Russ Fadel added, “We know that there’s a growing need for digital support for workers across manufacturing operations. Augmentir’s solution is aimed squarely at solving manufacturing’s biggest challenge: the skilled labour crisis - helping operators onboard workers faster, enabling targeted reskilling and upskilling of their current staff, and supporting workers with individual guidance. This goes hand in hand with Fluke Reliability's focus on helping workers make the right decision at the right time – prioritising people, which are the foundation of any successful business.”
Augmentir has been added to Fluke Reliability’s Industry and Technology Partner Program, which is designed to enable customers to better integrate and automate connected reliability workflows for improved operations. This move underpins the commitment from both companies to help customers shift to more digital manufacturing operations; empowering them with decision-making capabilities that accelerate efficiency across global operations.
A major contractor has chosen Hart’s shutters to protects its new building in a high crime area in the North West of England.
Brian Woodcock, Hart’s regional sales manager, said the client moved to purpose-built premises located in an area known for high levels of criminal activity. “The client chose to protect themselves from theft by installing tubular driven window/door shutters around the entire building,” explains Mr Woodcock.
“A total of 14 shutters have been installed along with two Sectional overhead doors all finished in a mixture of anthracite grey and goosewing grey. These provide comprehensive protection. This order shows that we are capable of delivering a comprehensive range of door products all manufactured by Hart which is the crucial point.
“Hart has invested heavily in designing and testing exceptional high security rolling shutter systems. Hart high security shutters are tested and certified by the BRE under LPS1175 and to BSEN 12453:2005; BSEN 12604:2000; BSEN 12635:2002; BSEN 12978.2003
“ In particular Hart’s Terror Screen, which is not relevant to the North West order, has set exceptional standards of protection of up to 20 minutes against cutting, drilling, crowbars and axes due to its exceptional robustness. This allows enough time for security teams to arrive on site.
“Hart’s Terror Screen SR1-4 high security roller shutters have been installed at a number of high security locations worldwide including power stations, nuclear facilities, government buildings, data centres, banks and museums.
“A further development is Hart’s Typhoon shutter which has an enhanced guide channel, heavier gauge curtain and Hart manufactured wind locks.
By Derek Sumsion, R&D Manager at Integrated Global Services (IGS)
In the space exploration industry, renowned American physicist and science writer, Michio Kaku remarked, "It's very dangerous to put astronauts on a moon base where there's radiation, solar flares and micro meteorites. It'd be much better to put robots on the moon and have them mentally connected to astronauts on the Earth."
While Kaku's vision may seem futuristic, it underscores a universal truth: the potential of robotics and automation to revolutionize dangerous and complex tasks is limitless. In fact, according to a recent GlobalData article, sales of industrial robots are predicted to be worth $352 billion by 2030, growing at a compound annual growth rate (CAGR) of 38%.
The adoption of robotics and automation is being seen across industrial applications, particularly in the energy industry. It has been embraced by Integrated Global Services (IGS) to improve safety standards, reduce fuel consumption/ increase capacity, and significantly reduce scope 1 and scope 3 emissions. Over the past decade, the research and development team at IGS has been dedicated to delivering next-generation technologies to solve long-standing challenges.
One of these technologies is the automated convection section fouling removal rover (ROV) by IGS Tube Tech. This article will discuss the problem of convection section fouling, the development of the technology, a case study, and its diverse application across various assets.
The Challenge of Convection Section Fouling
The focus of efforts at IGS Tube Tech has been on finding solutions to safely, precisely, and cost-effectively remove fired heater convection section fouling. It’s a significant issue that costs facilities worldwide millions of dollars in lost revenue each year. Fired heaters, which consume expensive fuel to provide essential heat energy for various processes, can see their efficiency drop by 1-2%. This inefficiency alone can result in an additional $1 million in fuel costs annually.
Traditional cleaning methods have proven inadequate, often reaching only 20-30% of the surface area and sometimes exacerbating the problem, particularly concerning chemical use. To address this challenge, the R&D team at IGS Tube Tech has been continually developing and refining a robotic system that restores heat transfer efficiency by removing 90 – 95% of fouling from the convection section.
The Evolution of the Technology
The first version of the convection section fouling removal system was developed in 2010 to meet the needs of a client facing a specific fouling problem. The nature and location of the fouling were unknown, and other methods had failed to remove the deposits. The system Tube Tech developed and deployed was a huge success and went on to complete many more projects around the world.
Since then, there have been six previous versions of the technology:
2010: The original Remotely Operated Vehicle (ROV) was fully air driven, no visual aid or cameras
2011-2013: A flush bar was added
2013-2015: A redesign to include a better track system and lights
2015-2017: Added a camera and a control station screen for the operator
2017-2019: More robust caterpillar tracks, improved gearboxes
2019-2024: Removed air motors, now all-electric with improved lighting, programable lance, and encapsulated motors.
2024: The latest version improves on its predecessor by automatically crawling over intermediate tube support plates and across tubes, requiring fewer access points and enhancing its ability to access hard-to-reach areas. This defining feature enables the system to clean more in less time.
How the System Works
The robotic system is designed to be deployed during a plant's regular turnaround schedule. Utilizing ‘as-built’ drawings from the facility, a detailed visual representation of the bundle is created for technicians to use before each project. This preparation ensures the robot is pre-programmed and tailored specifically to each convection bank, saving valuable time on-site.
Once on-site, the robot is placed at the starting position on the tube rows of the convection section. A Tube Tech technician remotely starts the system and it moves up and down and across the tube rows. Its patented lance system penetrates between the tube rows, using high-pressure water (typically 10,000 psi/700 bar) to oscillate and adjust its angle to each bundle. The system features an HD camera that records images and videos for reporting and future maintenance purposes, producing a detailed digital report at the end of each project.
Case Study: Tüpraş Izmir Refinery in Turkey
A great example of the results achieved by the system is at the Tüpraş Izmir Refinery in Turkey. The plant faced reduced heat transfer, higher fuel consumption, and increased flue gas temperature due to fouling on the convection bank tubes of its steam methane reformer. This fouling resulted from adsorbents being transported by the tail gas stream and accumulating on the tubes.
Tüpraş contacted IGS Tube Tech to deploy the convection section fouling removal system.
The Results:
Hydrogen Production Cost: Reduced by $24.6/t, with a payback period of less than 60 days.
Flue Gas Temperature: Decreased from 278°C to 220°C, translating to a 3% increase in thermal efficiency.
Steam Production: Increased by approximately 20%, with generated steam temperature rising by 10°C-15°C.
Key Advantages and Industry Impact
The fouling removal system offers several key advantages, driving industry acceptance and transformation:
Improved Safety: Eliminates the need for manual entry into confined spaces, reducing worker risk.
Increased Efficiency: Removes up to 90% of fouling deposits, significantly improving heat transfer efficiency and reducing fuel consumption.
Reduced Emissions: Optimizes combustion efficiency, reducing CO2 emissions by up to 15% and NOx emissions by up to 30%.
Real-time Inspection and Reporting: Provides valuable data for asset monitoring and proactive maintenance planning.
Cost Savings: Enhances efficiency, lowering fuel costs and offering payback periods as short as two months.
The Future of Automated Solutions in Industry: Metalspray® Pipe ID Rover
IGS’s commitment to innovation extends beyond convection section cleaning. The rover has also provided a break-through solution for pipeline corrosion protection. The rover system offers a no-man-entry, field-applied alloy upgrade for pipelines, slug catchers, and flare lines to address the challenges of wet CO2 corrosion and internal corrosion in pipelines with precision.
The system navigates through pipelines, applying a durable alloy coating to interior surfaces without the need for direct human intervention. This approach ensures comprehensive surface preparation, alloy application, and quality control in environments previously considered challenging or impossible to treat effectively.
Conclusion
The development of automated solutions like IGS Tube Tech's convection section fouling removal rover and the Metalspray® Pipe ID Rover represents a step-change in addressing long-standing challenges in industrial maintenance and inspection. These innovations demonstrate the transformative potential of robotics and automation in enhancing safety, efficiency, and environmental performance across energy sector applications.
The continuous evolution of these technologies promises even greater future advancements. The ability to access previously unreachable areas, perform precise operations, and provide real-time data for informed decision-making is set to reform how plants approach maintenance and asset integrity.
Success stories from facilities like the Tüpraş Izmir Refinery demonstrate the tangible benefits of these automated solutions, from substantial cost savings to significant reductions in emissions. As the global push for more sustainable and efficient industrial processes intensifies, technologies like these will play a crucial role in helping companies meet their operational and environmental goals.
In conclusion, the journey from the first remotely operated vehicle in 2010 to today's sophisticated robotic system illustrates the rapid pace of innovation in this field. As we continue to push the boundaries of what's possible with automation, we can expect to see even more groundbreaking solutions that address complex industrial challenges, ultimately leading to safer, cleaner, and more efficient operations across the globe.
To keep up to date with the latest maintenance and inspection technologies, visit: www.integratedglobal.com
