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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.

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 NO_x 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

Leading high-pressure hydraulic tools maker, Enerpac, announces the E-Pulse electric hydraulic pump with ‘Smart Controls’ that raise the standard for portable pump performance, precision and durability. In addition to maintaining constant motor power across the pressure range, the E-Pulse provides higher flow than traditional one-half horsepower pumps, and adjustable speed control for precise operation.

The E-Pulse’s high-efficiency .85hp direct-drive motor offers a six-piston block design that provides even flow and smooth operation for a wide range of tools and torque wrenches. Easily configurable with a choice of valve configurations to operate single or double-acting cylinders and tools, the two-stage pump has high by-pass pressure: 2,13 l/min up to 175 bar, and 0,52 l/min up to 700 bar. When configured as a Torque Wrench Pump, users can set pressure and operate in manual or auto-cycle mode. Intelligent Auto Cycle enables press and release actuation to cycle wrench until final torque is achieved. Precise speed control for tools and cylinders is facilitated by motor speed adjustment on the back of the pump.

New Interactive Pendant Control

Other E-Pulse features include a 24V DC power regulator to minimise the effects of poor power supply, built-in thermal protection, a 6 metre pendant cord for the torque wrench pump and a 3 metre pendant cord on the other four pump configurations. All models come with a convenient cord management system.

Designed to be used either horizontally or vertically to suit the working conditions, the E-Pulse Hydraulic Pumps feature a new interactive pendant that delivers visual and tactile feedback, programming and diagnostic status to the operator. The innovative, IP 67-rated pendant can be stored in the handle of the pump and is secured via magnet.

Long Lasting Durability

The E-Pulse’s integrated roll-cage design features an IP 54-rated durable aluminium housing enclosing the system components for maximum protection and easy service accessibility. The torque wrench pump comes with a pre-calibrated, 10cm gauge and features an integrated heat exchanger that cools the pump during operation.

For more information on the E-Series E-Pulse hydraulic pump, visit www.enerpac.com.

Snickers Workwear’s Kneeguard™ is a market-leading, fully certified^[1] system for protecting knees against kneeling injuries and knocks at work.

Combining trademarked Kneeguard™ pads with the Kneeguard PRO positioning system in Snickers Workwear trousers is one of the most ergonomic solutions for effective knee protection.

Snickers Workwear has a range of 8 Kneepads to fit different types of trousers to suit different jobs on site. Such as the specialist Squarefit™ Kneepads for the Floorlayer trousers and the slim-fit Kneepads for street-smart slim-fit trousers. Or the D30® Ergo kneepads that mould around your knee to provide enhanced impact protection. They’re great for tradesmen and women who spend a lot of time working on and off their knees and who want to ensure maximum long-term comfort and wellbeing.

Snickers Workwear trousers come in 5 different leg lengths as standard and what’s more, the design of the kneepad pocket allows you to adjust the kneepads to different heights to ensure the correct positioning to maximise protection.

https://www.snickersworkwear.com/list/product-guide/all-about-our-kneepads  

The long-term effects of working on your knees could cause a lifetime of discomfort and restricted movement without proper protection. Even the most innocuous bumps to the knees can result in reduced working efficiency and time off work so, check out Snickers Workwear’s Kneeguard PRO system, the market-leading alternative to help prevent long-term discomfort.

^[1] Snickers Workwear, Protective Standards, Knee Protection, https://www.snickersworkwear.com/list/protective-standards/en-14404-knee-protection

Halving your energy bill is quite an eye-catching achievement, especially in an energy crisis (!), but in Herefordshire, it’s just part of the journey to self-sufficiency; including the handling of slurry as an asset, not a liability.

“There’s so much value in it,” says Harry Davies at Hopes Ash Farm, near Ross-on-Wye, “so now, and looking ahead to the future, we must look at how to get the best out of it.” After achieving a BSc (Hons) Agriculture degree at Harper Adams University that included his dissertation about stripping nutrients out of slurry, it is no wonder that the enterprising 23-year-old is keen to implement solutions and dig deep to find more answers.

The core of the Davies’ fifth-generation family business remains its 130-head dairy herd, but with beef, sheep, poultry, arable and 100kW of solar, there’s a very bold tick in the box of diversification as Harry, with input from Dad (Rob), and Grandad (Bryan) determinedly push forward with sustainable solutions.

Latest addition to future-proofing the Davies’ business is a new Anaerobic Digestion (AD) plant. Not that Harry wants to deter any dairy farm from making the same investment, but his experience so far shows that getting a biogas plant up and running never seems to be straightforward!

“I never thought it would be simple,” he said, “but the benefits we’re already seeing make all the effort very worth it. I might have given you a slightly different answer when we were trying to deal with the pipework, planning issues, pumping and road closures! For all of the complexities and nurturing of the biological process, the biggest challenge initially was how to transfer slurry from one side of the road to the other.”

‘The long-term well-being of the farm’

With robotically-milked cows (who bed on dried, recycled paper crumble), an automated scraper system, and a standard slurry pump all ticking along nicely, one could be forgiven for sitting back and admiring the view, but for Harry, all those slurry nutrients just had to be captured for the long-term well-being of the farm; not to mention his passion for the agricultural sector to not just survive, but prosper.

From the underground slurry reception pit (approximately 120m³), the existing pump had no issues, but it wouldn’t have had enough pressure to send it more than 200m over the road to the farm’s new AD plant. So, the Davies family sought advice from their long-standing dealer, Midland Slurry Systems (MSS), who had previously supplied the scraper system. Their recommendation was a long-shaft chopper pump from Landia, which they’d installed on numerous farms, as Giles Russell, Director at MSS, explains:

“This would be the furthest distance we’d asked a Landia pump to move slurry, but we were confident. In over 20 years, we’ve never had to take a Landia pump out of commission; they’re fully repairable, but the pressure was well and truly on. This was our largest value job of the year, including getting all the pipework installed under the road and making sure that the installation was bob-on for Hopes Ash Farm.”

The new 6” pipework successfully linked into the new AD plant, taking in slurry sent from the 15kW Landia long-shaft pump, which runs four times per day. From the AD plant (maintained at 43 degrees), the processed slurry is then mixed in a 30m³ pit before being pumped up to the screw-press separator (also supplied by Midland Slurry Systems, together with a control panel for all the equipment by the 290m³ AD plant). As the important nutrient-rich solids are collected in the bunker beneath, the separated liquid goes into a 10,000-litre above-ground tank, before being pumped via a 4” pipe back under the road to the main slurry store.

“Everything is joined up and working away, fully automated, from the moment it falls out of a cow,” continued Harry Davies, “but, the challenge is to now fine-tune the whole system to make it as efficient as possible, though the weather can take some of that out of our control. We had a few initial foaming problems with the AD plant, but that’s now sorted.

“Another learning curve is the very fine line of managing the thickness of the slurry, especially when rainfall can affect the viscosity. On the one hand, we want to keep it as liquid as possible, but then the thicker the slurry, the greater the calorific value. The Landia long-shaft pump can run from just 100 seconds to up to 5000 seconds, depending on the thickness of the slurry, but at 15kW, with a 22kW AD plant, we obviously want to minimise the run-time.

“I know some farmers who are paying 50p per kWh for their electricity, whereas the numbers add up here with it only costing 30p per kWh from our new AD plant. Plus, we have solar, which makes us pretty much self-sufficient in renewable electricity.

‘Recognising the nutrient values and applying them appropriately’

“Our aim wasn’t to export energy, but there’s a 30kW export limit anyway, due to restrictions on the grid. Typical politicians, unable to look into the future, so their underinvestment impacts on us, and I’m sure many other farms who’ve made investments and are trying to do the right thing with renewables. This also includes our efforts here with the purchase of the separator; adding value by putting most of the phosphorus in the solid, where it is needed, and most of the nitrogen in the liquid. In our part of Herefordshire, we have fragile, sandy, hungry soil, so we need organic matter to bind it together. We don’t want it to end up in the brook, so again, a very careful balancing act, maintaining organic manures, but recognising the nutrient values and applying them appropriately. Exporting the solid creates some lively debate between, me, my Dad and Grandad (!), but I’d just say that it’s all part of our very carefully considered nutrient plan!

‘Biogas is a learning curve.

One size doesn’t fit all’

He added: “Working with some suppliers in biogas is also a learning curve. Despite what some say, one size doesn’t fit all. A rigid approach does not work, whereas with Midland Slurry Systems, they did what they said they were going to do, and did it when they said they would. If only all suppliers were like that! Just before Christmas, we had a small, non-critical issue that I told Giles about. He said he’d be there between Christmas Day and New Year to sort it out. I said: ‘Giles, for goodness’ sake, I don’t want to be in the bloody slurry pit over Christmas, and I certainly don’t want you in there either, so, ‘Merry Christmas’, but now, please…… go away!!!!

“We’ve already come a long, long way with our AD plant, which we knew made total sense to include as part of our business. Looking ahead, we also need to learn how to best harness the heat from it.

“Dealer back up is vital with this investment, and we have exactly that with Midland Slurry Systems. There’s never any waiting time for spares, and since installation, the Landia pumps and mixers (five in total) just keep on working, with no issues whatsoever. Solid support and long-lasting, reliable equipment play a significant part in helping us create ‘a new known’ with real stability moving forward.”

Landia 01948 661 200

www.landia.co.uk

Midland Slurry Systems 01608 664219

www.midlandslurrysystems.co.uk

When dealing with large-scale physical infrastructure, maintenance isn’t just a formality, it’s a necessity. The challenge? Minimising downtime and spotting problems early to avoid damage.

Though they play a crucial role in ensuring safety, traditional maintenance processes are often reactive, expensive and time-consuming. For instance, structures and assets that require routine preventative inspection can be difficult or hazardous to reach, exposing technicians to a degree of risk of falling and injury.

But as we enter the era of ‘the eye in the sky’, high-resolution camera-equipped drones are becoming more accessible, transforming the way the maintenance industry handles routine inspections.

High speed, low cost: Soaring toward a new maintenance era

Lightweight, remote-controlled, airborne devices open up a world of opportunities for predictive maintenance. Drone-mounted, or integrated cameras provide the visual data that allows technicians to assess large, difficult-to-reach structures quickly and safely. This technology can be used on anything from bridges and tall buildings to wind farms and beyond, allowing technicians to nip issues in the bud before they snowball.

Without drones, organisations often rely on manual inspections, which are prone to human error and require a long list of resources — technicians, cherry pickers, scaffolding and large-scale machinery, to name a few. That’s where drone imagery has enabled a paradigm shift from reactive to efficient predictive maintenance, reducing costs and supporting safety in the long run.

With the ability to zoom into the small details and pull back to observe the bigger picture, inspectors can capture minor structural defects in HD while gaining a comprehensive overview of structures. Electricity grids are a key example of complex maintenance significantly simplified by drone technology. Consider Pedernales Electric Cooperative’s power-line inspections. With the assistance of drones, each pole was fully inspected within 10 seconds, smashing the 15 minutes it took for a lineman to examine. Not only did this approach boost overall time efficiency by an astounding 88%, but it was also 80% cheaper to run, with less CO2 output, reduced risk of downtime and a 97% return on investment for the first year.

Since then, drone camera quality has skyrocketed, as exemplified by HHLA Sky’s critical crane safety inspections. The sheer scale of cranes typically distorts radio signals during inspection, requiring images to be captured from a minimum distance of 15 meters. In such cases, high-resolution camera quality is crucial for collecting accurate data. With Sony cameras, the maintenance team could cover a larger area with a single image, detect even the smallest scratches, and complete their inspections with fewer shots. As such, it’s clear that a new standard for time efficiency and cost-effectiveness has been set for maintenance operations.

Beyond the human eye: The power of drone data

Technicians can only address what they’re able to see. In routine maintenance checks, it can be easy to miss smaller issues, such as leaks or installation faults. But these undetected problems can cause serious damage. While drone cameras are ideal for providing a wide range of data without compromising on quality, they can do much more than magnify visual data. Captured images can merge together to form detailed 3D models of structures and assets. Aerial photogrammetry is a fantastic way to achieve this.

In a nutshell, aerial photogrammetry is the process of stitching together a cascade of images captured from an airborne device. These pictures comprehensively cover all sides of the target object. Then with this data, technicians can obtain a drone-captured 3D replica of the structure or asset, allowing them to get insights that surpass what’s possible with manual maintenance. The outcome? Precise defect detection and effective progress monitoring.

Furthermore, drone imagery can be used in conjunction with other tech, such as thermal imaging sensors, which highlight temperature anomalies to uncover issues such as condensation, dampness and water ingress. And of course, we couldn’t have this conversation without mentioning the integration of AI.

Let’s explore how drones can push the boundaries of efficiency even further.

Marrying drone-captured imagery with ML and AI

AI and machine learning (ML) are complete game changers when it comes to drone-captured imagery. With AI, drones can identify and flag minuscule details such as cracks, chips and general wear and tear. They’re also able to adapt their navigation paths to avoid collision, which is integral for keeping the hardware intact when observing confined spaces.

How is this possible? Using data from images, flight logs and 3D models, AI can be ‘aware’ of its surroundings and spot patterns and anomalies taught through ML – an ongoing training process that allows the AI model to continuously enhance its ability to recognise and interpret data. These advanced AI/ML algorithms support proactive maintenance by facilitating data-driven decisions, reducing the likelihood of unnoticed faults and increasing the overall reliability of the drone fleet.

Not only are AI/ML-enhanced drones great at sleuthing out issues early on, but they’re also impressively scalable. AI-based systems can process vast volumes of data from multiple drones and sites, giving technicians the freedom to conduct and complete multiple inspections of varied project scopes within a remarkably short time frame. This time efficiency translates to cost savings, reduced labour and minimised disruption. Drones can be employed for a diverse range of projects, from small plots of land to vast landscapes.

Flying high with drone-enhanced maintenance

The shift from reactive maintenance to predictive maintenance marks a momentous change, driving a more proactive and reliable approach to maintenance strategies. And drone capture technology is only getting more advanced, with cameras like the ILX-LR1 offering exceptional imaging capabilities and enabling custom applications for specialised tasks. Designed specifically for drone payloads, this camera comes with an SDK that’s compatible with Linux, Windows, and MacOS, giving programmers a comprehensive software library to control the camera, API specification, and demonstration code.

With AI thrown into the mix, the outlook for drone-based image capture is becoming even more promising. This synergy not only enhances the precision and efficiency of operations, but also sets the stage for a smarter, safer and more cost-effective future in maintenance.

Article written By Matthew Swinney, Head of Image Sensing Solutions at Sony Europe 

AirTower AT is designed to clean ambient factory air, removing the remaining pollutants that existing extraction is failing to capture.Full hall extraction assists extraction systems, removing coolant mist, smoke, and weld fume from the workplace.Designed to extract at high level, where weld fume and atmospheric pollution settles; returning clean air to the working space at low level to create a healthier working environment.AirTower from AirBench uses high power, energy efficient EC fans alongside a filter system selected to suit your application, to clean high volumes of air.Alongside our dust, fume, and mist extraction systems, the new AirTower AT helps you create the right working environment.

Contact us to arrange a site survey.

www.airbench.com

We all know what happens to a spin drier with unevenly distributed washing (i.e. an unbalanced load). It will vibrate, which often results in the spin drier jumping all over the place! Let’s think about that for a minute. To bounce around a 70kg washing machine requires quite a bit of effort (i.e. force) and all that force has to go through the bearings!  They’re not going to like it!

Imagine the situation where the machine is running 24/7, as with an exhaust fan or a continuous process pump for example. It won’t take long before you’re replacing those bearings! But it’s even worse than you think. To bounce around that unbalanced washing machine also requires a lot of energy, in other words it requires more electricity. So, by running machines even slightly out of balance, not only are you unnecessarily wearing out your bearings faster, you are also paying extra for the privilege!

But how do you know when a machine is unbalanced? Well, in theory a perfectly balanced machine would not vibrate. But in practice there is no such thing, so all machines vibrate. The more unbalance, the more vibration and bearing damage. Fortunately, the International Standards Organisation (ISO) has drawn up a set of guidelines for acceptable levels of machine vibration. Modern low-cost vibration analysers like the TPI 9070 (pictured) are available, pre-programmed with the ISO levels, to give a traffic light system of colour coded vibration readings. Basically, if it’s in the red it needs balancing!

There are two techniques commonly employed in balancing. The no-phase balancing technique (a.k.a. the 4-run method) allows you to approximately balance a machine by using a series of four runs, three of them with a trial weight attached to the rotor. By positioning the trial weight around the rotor’s circumference in 120 degree increments and measuring the resulting vibration, the balancer automatically calculates the location and magnitude of the “heavy spot” around the 360 degrees of the rotor‘s circumference. It also then calculates what weight, and at what position, will re-balance the motor, pump or fan. This is then done either by adding the weight to the rotor at a position opposite the heavy spot or easier still, by drilling holes to remove the equivalent weight at the heavy spot.

The 4-run method works well enough for cases where an approximated balance is all that is required. However, for larger machines that require more precise balancing or for dual-plane balancing (e.g. for longer rotors that need to be simultaneously balanced at both ends) we generally require more precise measurement of the unbalance. This is done by providing a reference position on the rotor’s circumference, known as a “key-phasor” input. Often this can easily be obtained from the machine’s tacho signal or alternatively, simply by affixing a piece of reflective tape to the rotor and using a low-cost laser tacho to give a reference pulse, once per revolution. This reference pulse is then used by the balancing software to accurately determine the location of the “heavy spot” around the 360 degrees of rotor circumference and calculate precisely how to counterbalance it.

It doesn’t take very much to unbalance a machine, e.g. dirt build-up on fan blades or a chipped pump impeller. Thankfully, it also doesn’t take much to re-balance it either, provided you have the right instrument. These days that’s not a problem, as simple to use, low-cost field balancers are now available that take you through the process on an easily followed step-by-step basis. For example, TPI’s Ultra III vibration analyser is now available with both built-in no-phase and single/dual plane key-phasor balancing. For the latter, the included laser tacho (TPI 505L) can be used by the Ultra III to calculate precisely what is required to re-balance the motor, pump or fan.

For more information, please contact TPI Europe on +44 1293 530196 or www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.