Eccentric disc pumps work to pump liquids by spinning an off-center disc inside of a pump housing. As the disc spins around inside the housing two low pressure and two high pressure zones are formed. These opposite high and low pressure zones move fluid through the pump. Because the volumes of these pressure zones is known, a constant, regular, measured flow rate can be achieved by varying the speed of the pumps spinning. This consistent flow is necessary for accurate chemical processing or distributors.
Because eccentric disc pumps are by design seal-less, fluids that would react with or corrode common seal materials are able to be pumped through a processing line. By protecting against unintended reactions valuable chemical materials are preserved saving the processing facility in materials costs.
Click here for the full article by Mike Solso.
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The commodity market is ever-changing and in business predictions are key to securing profitability. When the cost of raw materials fluctuates manufacturing can quickly eat into profit margins and smaller companies can quickly turn south. There are some basic tips to building a safety net against the fluctuations in the commodity market.
Planning for eventual ups and downs is the best step you can take to dealing with commodities. By adding in a sliding scale for prices into your contracts, the changing costs of raw materials can be accounted for up to a predictable swing. If this method is taken, communicate with your clients that the prices are tied to the commodities used in your manufacturing. Stress that prices could go down just as much as go up to assuage any feelings of unfairness.
Another method to prepare for price changes is to build in prices of commodities higher than the predicted price. If you find that the market has shifted downwards you can offer a “discount,” yet if an increase occurs there is no change.
Click here for the full article by Tommy Wyher from Business.com.
The US Energy Information Administration has released a study with results on wellhead drilling costs. Findings from this study show that upstream costs in 2015 have dropped by 25% to 30% below 2012 levels. These costs have even dropped up to 20% under the average over the past 5 years.
The EIA attributes the lower costs to technological advancements creating higher productivity per well. To standardize the findings the team created a measurement unit of Barrels of Oil Equivalent, BOE, and analyzed the effectiveness of wells in that unit of effectiveness. While certain strategies in oil drilling have increased costs per well, namely deeper longer wells, the increased performance overshadows these expenses for a lower cost per BOE.
The study forecasts a 15 percent reduction in deepwater costs in 2015, an additional three percent reduction in 2016, and a modest rise in costs from 2017 to 2020.
Click here for the full article from Industrial Equipment News.
Oil and gas companies as an industry are placing higher priorities on waste water management for operational and economic challenges. This trend is in response to the current 2.5 billion barrels of waste water produced yearly by American O&G operations.
Current procedures for oil and gas refining call for a water to oil ratio of 8:1, showing the massive quantities of water required for daily operations. To reduce this vast usage certain engineering feats will have to succeed in improving efficiency or broadening the optimum ranges for processing. One refinery was faced with an exponentially growing cost if a conventional reverse osmosis filtering system was to be placed within the plant. To solve this problem without raising the budget, a 750-gpm unit was installed in a three-tiered skid arrangement and placed in a non-hazardous area of the plant. This resolution saved the refinery from erecting another building for its water management, and kept all extra processing equipment nearby.
In certain locations and climates, severe droughts are raising doubts about heavy water using industrial plants. High water prices are causing increased costs for operations and drawing needed water away from residents in neighboring counties. New legislation in California has required O&G operators to submit monthly water usage statements to the government to be approved before operation occurs. Being able to reduce the necessary water for cooling, dilution, and transport of these products would improve the chance of continued operations.
Click here for the full article by Mike Jenkins.
Data is exploding around the world in every industry, and manufacturing is running into a logistics problem. With the increase in data points and measurements, how can we use it to efficiently organize and improve performance of our processes?
The entire industry of manufacturing makes up a significant portion of global energy consumption, but on a per unit basis that has been decreasing continuously. Manufacturers are using data to work smarter and reduce their use of energy. The best use of data analysis for improving energy efficiency is determining untimely consumption and excess usage. It can also prioritize specific retrofits for machinery that consume more energy per unit than newer models.
By garnering data as granular as machine specific measurements a production manager can see troublesome machinery in detail, and plant managers can coordinate repairs or replacements before production is halted from breakdowns. In certain energy production situations catastrophe can be avoided before start-up by knowing the precise condition of pipelines and machinery.
Click here for the full article by Bill Kenworthy.
Bearings reduce friction between two moving surfaces, and from that job they wear down and eventually break. To best keep bearings rolling for as long as they can, some maintenance is required in various parts of the lifespan.
Bearings are shipped and stored with a thin layer of manufacturing oil to preserve the bearing. If this coating is wiped off, smudged through handling, or dries out the bearing can rust or the lubrication can become useless. While storing bearings make sure to keep the bearing coated with preservative oils.
Bearings are designed to have an interference shaft fit on the shaft during application. This fit is built into the dimensions and is accounted for. If a bearing is installed onto a shaft too big or too small, the difference in clearance can wear the bearing much quicker than specified.
Proper lubrication is necessary to reduce heat, and friction within the bearing itself. Due to the properties of lubricating oils, bearings may leak and can be sealed by silicone rings or sealing grease.
Through continuous use of bearings, lubricating greases and oils with wear out just as much as the interior rollers in the bearing. Properly replacing and refilling the lubricant of a bearing will extend the life of the bearing. Some manufacturers provide charts for re-greasing intervals, check with the OEM of your bearing for details.
Click here for the full article by Mike Pulley.
There are many flow meter variations out there, and each application requires a different style of meter. Depending on the fluid being measured each style of flow meter may be more suited to that situation. Everything from the viscosity to the potential contaminants plays a part in choosing the perfect flow meter for your needs.
Accuracy Coriolis flow meters are highly accurate, but may impinge the flow of fluids through the pipeline.
Consistency Nutating disk flow meters are simple to replace, but may need repeated calibrations as parts wear down.
Minimal Flow Restriction Electromagnetic flow meters do not block or reduce flow, but can be costly to maintain.
Click here for the full article from Chemical Processing.com.
Human-machine interfaces are the terminals we use to interact with the digital world. In industrial applications these are the monitors on the plant floor that allow informed, safer choices. Developers and users continue to improve HMIs and apply them in newer environments.
In dairy processing acilities, incoming milk is chilled rapidly to 4° C and distributed to various silos for different end products. Each product has different tolerance during processing, and HMIs display this to plant operators in real-time for analysis and decision making. New models of HMIs and monitoring sensors have standardized these silos with new features like alarms for high or low temperatures as well as flow meters and float switches for distribution data, batch reports, and overflow warnings. Some new features can control pumps, and agitators for each individual silo as well.
Click here for the full article on Control Global.
Heat is a severe bottleneck in electronics and the progress towards bigger and better things. Researchers from Chalmers University of Technology have applied graphene nanoflakes to efficiently cool electronics, and this feat is bound for small initial productions in the near future.
From their studies on the heat transfer enhancement of graphene films, the researchers found that different functionalized amino acids added to the film can increase already improved heat transfer properties.
Click here for the full article from Science Daily.
Rupture disks have been the go-to system for protecting vessels from over-pressurization. Miniaturization of these rupture disks has brought new setbacks in materials and designs.
Burst disks are widely chosen over safety valves due to their quick response and evacuation of the vessel. These disks are produced to “fail” at a predetermined pressure difference between both faces of the disk. It is when they fail at that pressure that they protect the vessel from failing in a more disastrous manner.
As rupture disks are made smaller and smaller, low rated disks must use paper-thin metals easily broken during handling, assembly, and operation. It is recommended to use these disks when operation pressures are 75% or less of the rated burst pressure.
Click here for the full article from Product Design and Development.