Bolts that are too long: If engineers are wasting money on excessively large bolts, they must be cutting corners somewhere.
Non-isolated control valves: Maintenance is always required, if there is no way to easily remove a valve then maintenance is not being done on the valve.
Lack of pressure gauges and connections: At some point it will be necessary to monitor the pressure at the valve. Build with future needs in mind.
No air vent caps: Valves that reduce pressure will buildup air pockets during operation, if this air is not vented you can bet a costly repair will be needed soon.
Click here for the full list of signs by Mark Gimson.
Hydraulic systems are dependent on every part within the system, any small leak or failure from one piece will bring the system to a grinding halt. The fluids used in particular systems can even harm personnel nearby or the environment in the occurrence of failure. Valves are critical to hydraulic systems as they control the flow of hydraulic fluid through the system to perform work. A preventative maintenance program should focus on valves more thoroughly than any other component.
Reactive maintenance expects to run components to failure, often valves fail first, and then enact repairs while productivity is zero and then make up for lost production time later. This process is costly and usually fraught with high tensions. A preventative maintenance schedule uses time or specific conditions to “schedule” repairs and replacements. This scheduling process can be in terms of time; i.e. replacing seals and gaskets every 2 years, or it may be based on operations; i.e. after every 5,000 cycles, or both depending on which “schedule” comes first.
Industry data shows that performing maintenance on a scheduled basis is three to five times less expensive than the same repair being made on a reactive basis.
Click here for the full article by Mickey Heestand.
Hot bolting, or tightening bolts on flanges and other pipeline connectors while in operation, brings dangerous liabilities into fluid control operations. One example of the dangers occurred in 1992 where a hot bolted heat exchanger exploding killing 17 when a gasket-retaining ring slipped upon tightening. One common flaw in operators during maintenance practices is to believe they are more experienced and knowledgeable than is true, the Dunning-Kruger effect.
Bolts are only capable of shifting so far under stress, and during thermal loads the bolt materials may have reduced limits. Hot bolting adds stress to the material and combined with the lower limits these stresses may exceed resulting in ruptures or explosions of hot fluids. To reduce the risks of failure from thermal expansion springs may be added to bolted connections allowing more travel yet providing the needed sealing forces.
A good design to a control room will facilitate efficiency and minimize liability. The design will enhance an operator’s efforts to produce the desired results in production. Since 2000 the International Organization for Standardization has produced a set of standards, ISO 11064, for control room design. Most of these standards deal with ergonomics and layout for the room, and adherence to these standards can greatly protect a company from injury lawsuits.
ISO 11064 helps establish good design standards with measurable results to avoid control rooms like many of us have experienced. Designed control rooms, control buildings and operation camps that feature a user-driven approach, work with ISO 11064 requirements, and integrate architectural, interior design and human-factors elements optimize performance.
First and foremost in the design process focuses on safety; locating the control room outside of blast zones, pathways of heavy equipment, and insecure environments. Further efforts deal with employee access and localities.
Turbine flow meters are a popular way of measuring liquid and natural gas flow. Also known as an axial turbine, this type of meter consists of a turbine wheel that is placed in the stream of the flow. The flow pushes the meter’s angled blades, causing the turbine to rotate. Flow rate can be determined based on the turbine’s rotation rate once it becomes steady. The rate of rotation is typically picked up by electronic coils that are connected to the meter’s housing, and then turned into readings that can be accessed by the user.
Minimal Flow Disruption
One advantage of a turbine flow meter is that it offers minimal disruption to the flow. Because the flow can continue right through the turbine, there is little pressure loss and speed can remain fairly high. For this reason, they are often preferred for purposes water distribution, fire protection and for large commercial projects, where a high rate of flow and high pressure is desirable. On the other hand, applications where flow rates are low will typically use meters that are considered more accurate but tend to impede flow rates, such as displacement meters.
Ensuring Maximal Accuracy
Turbine meter measurements can be affected severely by factors such as flow profile, temperature and flow rate and content. Strainers installed near the meter can help protect the turbine from debris that could damage it. Depending on specific conditions, users may choose to put additional protective measures in place to ensure maximally accurate and consistent flow measurements.
New Developments
With today’s advancements in technology, turbine flow meter accuracy has also improved. Increased sensitivity allows for the precise measurement of even extremely low flow rates in some models. Manufacturers also continue to develop blade and rotor materials that are highly sensitive, durable and less vulnerable to drag and other factors that have traditionally decreased accuracy. Some types of turbine meters are also able to measure and record variations in flow with a high degree of precision. Another way in which flow meter makers have reduced inaccuracy is by reducing the rotor’s inertia. A high inertia would keep the rotor spinning fast even after flow had decreased, leading to inaccurate results. A low inertia lets the turbine reduce speed together with the flow.
Maintenance and Calibration
Regular inspection and calibration is essential to keeping a turbine flow meter accurate. For best results in calibration, test your meter under conditions that are as close to normal operating settings as possible, keeping the flow composition, rate and temperature substantially similar. In addition to regularly scheduled inspections, check your meter in the event that you are receiving inconsistent or unusual readings that cannot be explained by actual variations in the flow.
Malfunction may occur as a result of regular wear and tear, impact by debris, corrosion, or buildup of dirt or viscosity. Problems may also happen if your meter is calibrated incorrectly or was not properly installed. While some problems can be fixed by recalibrating or performing minor repairs, others may necessitate partial or total replacement. If you are using an older turbine flow meter, be aware that recent developments have substantially improved measurement accuracy; thus, it may be wise to invest in an updated model.
Intrigued by the fascinating world of turbine flow meters and their precision in fluid measurement? Explore our diverse range of high-quality turbine flow meters, where cutting-edge technology meets reliability. Visit our products page today to discover the perfect solution for your flow measurement needs.
Microsoft and General Electric are partnering to improve the online cloud industry with the industrial internet of things in mind. GE’s focus on the industrial and manufacturing sectors will synergize with the technological innovation from Microsoft to provide cloud resource servers and analytics on demand for the burgeoning industry of smart connected devices.
“Companies worldwide will be able to bridge the divide between the operational and information technologies that make up the Industrial Internet of Things,” -Microsoft
This collaboration is set to bring analytics from equipment to a wide variety of operations, with even more reliability for future adopters. GE’s cloud platform Predix will be integrated into Microsoft’s Azure for a final service of; Predix of Azure.
Turbine flowmeters are a common component for machines used in the aviation,chemical and energy industries. Crucial for measuring the flow rate of fluids or gases, quality turbine flowmeters are necessary for determining accurate metrics, and by extension creating a quality product or carrying out an important service. Engineering innovation and design has made it possible for many well-built turbine flowmeters to enter the marketplace. While shopping around for a flowmeter, keep in mind these important features:
Reliable digital reading – Current day products allow for easy measurement reading by possessing a digital output sensor that keeps track of the rate and amount of gas or fluid traveling through the flowmeter.
Versatility – Ideally, your flow meter should measure both pulsating and fluctuating flow with a quick response time.
Low rotor inertia – Lower inertia ensures better efficiency and accuracy during operation.
Plan Your Project With a Professional
Whether you need one flowmeter or several dozen, consulting with someone who is an expert in the industry can be beneficial both in terms of financial savings and product knowledge. A knowledgeable company representative can assist in determining which flowmeter product is the most economically viable and expertly designed for your needs. Simply looking at brochures with specific product specifications might not truly tell you what you need to know.
Take care to speak with someone who is open to collaboration. A representative willing to listen to the details of your project can offer input pulled from previous clients and an in-depth understanding of the flowmeter industry. In fact, major flowmeter companies often offer engineering services if there is no flowmeter on the market perfect for your project. Offering state-of-the-art design techniques and meticulous testing, these companies are able to create a product that can take your project to the next level.
Rely on a Product Warranty
Whether pre-made turbine flowmeter or custom designed flowmeters come with a product guarantee ensuring that your part will be replaced free of charge if it breaks because of a design error. Usually valid for up to one year after your purchase, this warranty is an excellent way to ensure that your purchase is protected in case of a breakdown. Without a warranty, your company is at risk for profit loss for an event that could have been easily remedied with no loss of collateral.
Install Your Product Properly to Ensure Maximum Functionality
The best way to protect your machine from malfunctioning is ensuring that everything is installed correctly. While many have in-house employees able to complete this job, others chose to rely on professionals from the company delivering their product. In some cases an outside professional is able to install your product more precisely, especially if it is custom designed. Proper installation ensures that your flowmeter is taking accurate measurements and working correctly in conjunction with other parts of the machine.
Whether you need a turbine flowmeter for an airplane or a manufacturing plant, taking the time to choose a quality product from a company just as passionate about engineering as you is the key to a successful project. At Flowmetrics, we share your passion for engineering excellence. Explore our range of top-notch turbine flow meters to find the perfect solution for your needs.
The Haitian electric utility company E-Power S.A. began construction of a 30 Megawatt power facility for Port-au-Prince in 2008. While under construction the 2010 magnitude 7.0 earthquake struck. Along with immense loss of life and mental wel-being for the people, the electric infrastructure of Haiti was irreparably damaged. Recovery was in danger.
“So much was destroyed in 2010 that we had no way for Hyundai to unload the equipment for the new plant near Port-au-Prince,” says Ludwig von Lignau, operations manager at E-Power. “There was also no bridge from the Dominican Republic that could handle this equipment, and so the U.S. Army agreed to build a makeshift dock near the site.”
E-Power’s facility was commissioned to run outdated software as their control system, but in order to better aid with the recovery endeavors leaders implemented a custom controls system redesign. By adapting non standard implementations and culling excessive operator interactions the plant is now providing 35% of the local power with unimaginable reaction time.
“We’re able to respond very fast to changing electricity demand because we can start units in just 10 minutes. We can react quickly to high-frequency requirements.” -von Lignau
Click here to reed the full article by Jim Montague.
Technology has advanced beyond physical buttons, switches, and indicator lamps, but these components are still widely used in manufacturing and processing facilities. Even though main control interfaces could be graphic interfaces with touch panels, the physical abuse it receives may easily overwhelm the hardiness of the device. In situations where heavy machinery is utilized or bulky safety gear is worn, a large start-stop button and flashing red light are more effective for operators.
There are standard ratings for the degree of protection, or ruggedness, of equipment components; NEMA or IEC (IP) ratings. Both rate how much physical and environmental abuse a component can withstand, but differ among each other over the exact scaling of the ratings. Something as trivial as a button may be rated quite highly on either scale simply for being designed with repeated pressing in mind, “A case in point is the repeated pressing of a door close button on an elevator when someone is in a hurry.”
Stack lights and indicators are used to give an operator a quick snapshot of the state of a machine. Green lights most often signal everything is in order; red typically indicates some type of problem. NFPA 79 lists some recommended colors for different situations.
Click here for the full article on Control Design.
For versatility and power, nothing beats the gas-fueled internal combustion engine. It can output enough power for those demanding tasks, be reliable for long hours and years of service, or mobile for sporadic fringe uses. Over the years gas engines have been improved through copious research and careful adaptations in compression ratings and fuel economics.
Many processing facilities utilize gas engines in medium- to large-scale mechanical drivers. These engines can power compressors, pumps, generators, and other equipment. As engine technology improves to provide more power with less fuel usage, processing plants utilize smaller engines and more processing room. Large engines are usually operated at under 1,000 rpm to preserve life while generating enough power to operate the machinery. Running at lower speeds requires significantly larger engines, reducing plant floor space, while faster speeds increase wear and tear damage to the engines.
