Industrial Equipment | BioEnergy Consult

Sand Control Screens: Why Are They Essential In Oil And Gas Sector?

By Salman Zafar | December 29, 2023 - 9:17 am |December 29, 2023 Industrial Equipment, Industry

Active Sand Control

The active sand control technique is all about utilizing the filters in order to control sand production. It is also known as an intrusive measure. Below are the techniques of active and control methods in the oil and gas industry.

Chemical consolidation.
Gravel pack and Frack Pack.
Expandable sand screen.
Stand Alone screen.

Passive Sand Control

Passive sand control always utilizes non-intrusive measures for controlling, reducing, or avoiding sand production from the reservoir. Here are the techniques of following sand control methods.

Sand management.
Selective perforation.
Oriented perforation.

Types Of Sand Control Screens

Now we will talk about different types of sand control screens, along with their mechanisms and usage.

1. Slotted Liner

It is one of the oldest sand control methods. Slotted liner sand control is tubing with a series of slots. All these slots are cut through a wall of tubular, and that too in an axial orientation. The width of slots is designed in such a way that it develops inter-particle bridging across the slots.

Suppose you are looking for the least expensive way to make a standalone screen. The next part of this is very simple. Here the average flow area is around 3%. But it also can go upto 6% of the total pipe area. However, a flow area of more than 6% will be detrimental to the tensile strength of the pipe.

2. Wire-Wrapped Screen

Consider a pipe, which is perforated along with a welded jacket, which is wire-wrapped. The wire, which is wrapped around the vertical ribs, has a space of keystone. It is designed to mitigate the chances of sand plugging on the screen. As there is a self-cleaning action, there is no chance of sand plugging.

In comparison to a slotted linear, a wire-wrapped screen comes with a bigger flow area and thus offers accurate slot opening along with good strength. Here are the different types of wire wrap.

Pipe-based slip-on.
Rod-based screens.
Pipe-based direct build screens.

3. Premium Screens

The premium screen is basically a metal design, which comes with a metal mesh filtration and also a protective metal outer shroud. The ability to flow back the drilling fluid through the particular screen and also the plugging resistance are the main differences between premium screens and other sand screens.

As per the customer’s demand, the service provider produces different types of premium screens with different metal mesh designs. When it comes to pore throat, it can vary from around 60 microns to 300 microns. Her basic idea here is that the mesh will prevent large particles.

4. Pre-Packed Screen

Pre-packed screens are quite similar to wire-wrapped screens, but pre-packed screens have different filtration media. Here, a media gravel layer that can be with or without the resin coating is situated around the initial screen component. An external screen is also there to support it.

On the basis of the good requirements, the size and thickness of the medium layers vary. The requirements are as follows.

Hole size.
Flow rate.
Formation size etc.

5. Expandable Sand Screen

The latest screen technology is the expandable screen; it comes with a perforated pipe, an outer shroud, and, lastly, a filter medium. This screen is usually runs into a wellbore, and when it comes to the usage of the expansion insert, it is for expanding the screen to the production hole diameter.

Here are some of the advantages of an expandable sand screen.

Offers a high inflow area.
Provides maximum hole diameter.
Offers wellbore support.
Effective sand control.

Here are the parts of the expandable screen.

Integral expandable connector.
Outer protection shroud.
Filtration media.
Base pipe.

To conclude

We hope you have developed a proper understanding of the sand control screens and their different designs. We also understand how complicated it actually is to get grapes totally. So in case you have any doubts or queries, feel free to contact us.

How to Dispose of Plastic Equipment Efficiently

By Salman Zafar | December 23, 2023 - 8:35 am |December 27, 2023 Industrial Equipment, Recycling, Waste Management

1 Comment

If your company has plastic equipment that’s no longer needed, you can dispose of it by selling the machinery through the most optimal channels.

Here’s a guide on how to achieve disposal of plastic machinery efficiently.

1. Sell Your Plastic Equipment Through an Established Company

When you offer your used plastic equipment for sale in partnership with an established machinery buyer and vendor that sells the machines on your behalf, your equipment can sell much more quickly.

Why? Because an established third party already has a share of the market and buyers are continually looking for second-hand machinery on its site. It would be much more challenging and typically take longer to sell your plastic equipment by yourself.

You can sell all types of used plastic machinery on the second-hand market, including extruder machines, injection molding machines, blow molding machines, downstream equipment, and thermoforming equipment, to name just a few.

2. Check the Condition of Your Equipment Before You Sell it

Before you start selling your plastic equipment, you should thoroughly check it for any problems. While wear-and-tear is normal for used machinery, if any major problems are found, such as defective parts, you need to be aware of it.

If you sell defective machinery without making buyers aware, you’ll have either a return or a lawsuit on your hands. Transparency is the key to a successful and efficient sale.

Also, by discovering problems with the machinery early on, you could take steps to fix the issue before selling it. That way, you can command a higher price.

However, make sure you calculate whether the cost of the repair is worth it in comparison to the going rate for your make and model of plastic equipment.

3. Have All Required Information Ready Before You Begin the Selling Process

To make sure your plastic equipment sells quickly, which in turn will allow you to free up floor space and create greater efficient operations, make sure you have all the information needed to perform a quick and successful sale.

You’ll typically need to know the make and model of your plastic equipment, the year it was made, and its serial number. You should also provide details of what the machinery was previously used for.

By having all of that information available, not only can you sell your equipment efficiently. You can also command a higher price than machinery without accompanying information.

4. Take High-quality Photographs of Your Equipment

Most buyers will purchase used plastic equipment without seeing it in person, due to geographic differences. That means they need to see detailed photographs of the equipment you are selling before they can choose your machinery over another seller’s items.

Even if buyers come to see the equipment first-hand, they will still begin the buying process online, so providing photos is a crucial step if you want to sell your plastic equipment efficiently.

Furthermore, to increase your chances of an early sale, you need to take photos that are highly detailed. Don’t try to pull the wool over customers’ eyes, either. If the machine you’re selling shows signs of wear and tear, photograph it.

And to stand out against other equipment for sale, make sure you take high-quality photos that instantly attract buyers.

Summing Up

When you take the right preparatory steps, you’ll be able to sell your used plastic equipment much more efficiently.

Check the machinery’s condition, ensure you have all the details that buyers will require such as the equipment’s make and model, and learn how to take high-quality photographs of the equipment.

You’ll then be able to quickly sell your plastic equipment for a good price through an established buying and selling platform.

How To Tackle Vibrations Using A Coriolis Mass Flow Meter

By BioEnergy Consult | December 2, 2023 - 5:46 am |December 4, 2023 Industrial Equipment, Industry

Coriolis Principle

This flow measuring device provides multiple benefits and advantages compared to other measuring instruments. First and foremost, coriolis flow meters calculate or gauge direct mass flow.

For many industries, it is a critical feature because it removes or eradicates inaccuracies induced by the fluid’s physical properties or characteristics. Aside from this, coriolis flow meters are extremely precise and accurate, have no mechanical parts in motion, have immense repeatability, a towering dynamic range, and many more.

The coriolis principle is simple yet very effective. Its operating principle is all around us in this world, such as the rotation of the earth and its impact on the weather. Coriolis flow meters have a tube powered by a fixed vibration. So, when a liquid or gas traverses through this tunnel or duct, the mass flow momentum will, more often than not, create a change or alteration in the vibration of the tube.

Then, the duct will contort culminating a phase shift. This shift can be calculated or computed deriving a linear output corresponding to the flow. As the Coriolis principle calculates mass flow regardless of what’s inside the tube, it can be, for the most part, promptly implemented to any fluid traversing through it, gas or liquid.

While the thermal mass flow instruments are reliant on the fluid’s physical properties, thus, similar to the phase shift in frequency between outlet and inlet, it’s possible to calculate the actual natural frequency change.

This frequency change is incongruity to the fluid’s density, and it can derive a further signal output. It’s possible to calculate the volume flow rate having computed both the density and the mass flow rate.

Working of Coriolis Mass Flow Meters

Coriolis mass flow meters calculate or gauges the mass via inertia. A dense gas or liquid moves or traverse through a tunnel or duct which is pulsated by a small actuator. This vibration generates a measurable contorting force on the duct corresponding to the mass. More advanced models of this flow measuring technology apply dual-curved tunnels for lower pressure drop and higher sensitivity.

Although considered or known as the most precise flow meters, coriolis mass flow meters are prone to errors or inaccuracies when bubbles are existing in the liquid. These bubbles can produce or generate splashing inside the tube, make noise, and modify or alter the energy required for tube vibration. Huge spaces boost the energy required for tube vibration in excess and can end up in complete failure.

Impact of Vibrations on Accuracy of Coriolis Flow Meters

In manufacturing, factory, commercial, business, trade applications, all types of vibrations with various sizes are quite common. Mass-flow controllers measure and control the flow of gas or liquid while Coriolis mass flow meters calculate mass flow through a vibrating sensor duct. The variation gets purposely out of phase when the gas or liquid traverses through.

This technique or approach is relatively susceptible to unnecessary vibrations with a recurrence close to the sensor tube’s resonance frequency or a towering concordant of this frequency. However, it depends on the design of the sensor tube.

The odds of the frequency of these unnecessary vibrations is greater than in an industrial environment. Manufacturers of coriolis mass flow meters do their best to minimize the effect of vibrations on the measurement using some technical solutions including pigtails, active and passive vibration compensation, mass inertia, different sensor shapes, dual-sensor tubes, and higher driving frequencies.

In other words, vibrations can affect the accuracy of the measurements of coriolis mass flow meters. However, only if the frequency of the vibrations is close to the concordant frequency.

Types of Vibrations

In industrial applications, vibrations can be produced by usage-based vibration sources, building-based vibration sources, and environmentally related vibration sources. These vibrations move or traverse through a medium such as the fluid itself, through pipes, in the air, or the floor. If any of these vibrations disrupt the frequency of the device, then the output could be incorrect.

Takeaway

It is helpful to determine the sources to lessen or reduce the effects of unwanted vibrations. Oftentimes, it’s possible to move the measuring device or instrument just a little bit, take advantage of huge mass blocks, use suspension alternatives, or use flexible tubes.

Biomass Conveyors: An Overview

By Salman Zafar | December 1, 2023 - 5:40 am |December 1, 2023 Biomass Energy, Industrial Equipment

4 Comments

A well designed biomass conveyor system should take into account the variability of the material and provide the consistent and reliable flow that is crucial to power generation. Depending upon the type of boiler and conversion system, the fuel is either transported directly to the powerhouse via a belt conveyor, or first processed in a chipper/grinder to produce a finer texture.

For example, municipal solid waste is deposited into pits where cranes mix the refuse and remove any large, non-combustible items. Sometimes, it is further processed to remove ferrous materials, glass, and other non-combustible materials.

For large pellet-fired biomass system, rail dump method is very common where railway tracks are constructed to transport biomass. Station is specified for train and fuel receiving bins are typically located below the track and rail cars dump into bins, either directly or through a rotary dumper. Fuel received is then transferred by belt conveyors to the biomass storage bins.

For small particle size, pneumatic conveying system offer greater flexibility in routing than traditional belt conveyors. Equipment specific to pneumatic systems include positive displacement blowers and rotary feeders that function as air locks.

In a typical biomass thermal power plant, the initial process in the power generation is biomass fuel handling. A railway siding line is taken into the power station and the biomass is delivered in the storage yard. It is then unloaded from the point of delivery by means of wagon tippler. It is rack and pinion type. The biomass is taken from the unloading site to dead storage by belt conveyors. The belt deliver the biomass to warehouse.

The transfer points inside the warehouse are used to transfer biomass to the next belt. The belt elevates the biomass to breaker house. It consists of a rotary machine, which rotates the biomass and separates the light inorganic materials (viz. plastic or other incombustible particles) from it through the action of gravity and transfer it to reject bin house through belt. The belt further elevates the biomass until it reaches the crusher through belt.

In the crusher a high-speed 3-phase induction motor is used to crush the biomass according to the requirement, for gasification size range is usually upto 15-20mm, while for biomass-fired boiler, size of 50mm is acceptable. Biomass rises from crusher house and reaches the dead storage.

Cost-effective production of biomass energy is very much dependent on efficient handling of available biomass sources, as well as the efficiency of each process. An important, but often overlooked, area is the efficient receiving of different types and different capacities of biomass as it enters the plant and then conveying this material to the production equipment. In many cases, the space available for biomass handling is limited.

Receiving equipment can be installed in a pit or at the ground level. The size and volume of the receiving pocket can be suited to vehicle volumes or turn-around times. The receiving pit can be used as small buffer biomass storage or as an emergency or mixing pocket.

Belt conveyors are an economical and reliable choice for transferring biomass over long distances at high capacities with lower noise levels. Designs range from simple, open configurations to totally closed and washable conveyor galleries. Well engineered conveyors have the maximum safe distance between support legs to minimize the cost of civil construction as well as reducing the number of obstructions on the ground.

Chain conveyors are a reliable choice for transporting unscreened or dusty biomass, or when the available space is limited. Screw conveyors are a very economical alternative for transporting biomass over short distances.

Biomass conveyors are an integral feature of all biomass conversion routes

Nowadays, automated conveyor systems are getting traction around the world. Fully automated fuel handling systems employ a biomass storage bin that can hold upto 50 tons (or more) of biomass. The bin is filled by a self-unloading truck with negligible or no onsite staff assistance. From the biomass storage bunker, the fuel is fed automatically to the boiler by augers and conveyors. The fully automated system is a good match for biomass plants where maintenance staff has a large work load and cannot spend much time working with the biomass conversion plant.

Pellet-based hopper systems offer low costs for both installation and operation. In a modern biomass pellet boiler system, fuel is stored in a relatively low-cost grain silo and automatically fed, with no operator intervention, to the boiler or boilers with auger systems similar to those used for conveying feed grain on farms.

The fuel-handling system uses electric motors and is run by automated controls that provide the right amount of fuel to the combustion chamber based on facility demand. Such conveyor systems require minimal maintenance, around 20-30 minutes daily, for ash removal and maintenance of motors and augers, estimated to be about 20-30 minutes per day.

5 Pieces of Equipment That Every Construction Site Needs

By Salman Zafar | November 29, 2023 - 5:24 am |November 29, 2023 Construction, Industrial Equipment, Safety

4 Comments

If you’re the manager of a successful construction company, you will know all too well how important it is to invest in the right tools and equipment.

The success of your business relies heavily on the effectiveness of your construction tools. Without them, it would extremely difficult for your employees to complete their jobs efficiently.

New technologies are being developed all the time and it’s often tempting to buy the latest, most advanced versions of every tool that you use within your business.

You could spend most of your yearly budget purchasing every updated tool for your construction site but this isn’t necessary if you want to succeed. In fact, doing so could have the opposite effect and may slow your growth significantly.

Instead, investing in a select few pieces of modern construction equipment will benefit you more. Allocate a portion of your total budget to get high-quality items that will enhance productivity on your construction site.

Using the best equipment also makes your employees’ tasks much easier to complete and provides you with the opportunity to expand your business operations in the future.

So, if the best option is to spend money on just a few essentials, how do you know which pieces of equipment are crucial for your business?

To help you make a firm decision, here are five pieces of equipment that every construction site should invest in.

1. Welders

There is a range of different welders that you can use on your construction site. The specific types that you choose will depend on your unique needs as a business.

For example, you may wish to invest in a titanium 140 MIG welder. This is an affordable, beginner-friendly option that uses a bare wire and a second flux core. This is an ideal option for welding two thin metal wires together.

Another type of welder to consider is the more versatile TIG welder. This is a more complex option that requires two hands to safely use. You can use a TIG welder to combine a range of metals, including steel, aluminum, copper, and nickel.

Other types of welding that you can use on your construction site include:

Stick welding
Lazer welding
Plasma arc welding

You don’t need to invest in every type of welding equipment. It’s worth doing some deeper research into each option if you’re unsure which type will benefit your business the most.

2. Diggers

Every building or construction needs a foundation to hold it in place and diggers are essential for this task.

Your diggers are needed to dig through stone and rubble, and excavate soil surfaces. They’re sturdy and strong, and can be used on a variety of terrains.

Alongside diggers, you may need additional excavation equipment, loads, and bulldozers to complete your projects.

3. Skips

Construction work accumulated a lot of waste. Keeping a few large skips on your site is necessary to ensure proper disposal of this waste. It also keeps your site clean and tidy.

The best skips for the job are metal options that are welded tightly to prevent leakages or spills.

You might also benefit from getting some dump trucks, which enable the easy transportation of your waste away from your construction site.

4. Mandatory Signs

Signage is necessary on any construction site to ensure the safety of every employee. Often, they are used to indicate potential hazards and warn employees of moving pieces of equipment or heavy loads.

Safety signs can also be used to indicate the different areas of your construction site and inform people of what jobs need to be carried out in these areas.

Some common construction site signs include:

Warning signs
High visibility or safety helmet signs
Site safety hazards or prohibition
Fire points and first aid kits

You can also get custom signs made for your site if there are extra details you want to for your employees.

5. Personal Protective Equipment

It’s vital that you supply personal protective (PPE) equipment to all of your employees on the construction site.

PPE protects your employees from the potential dangers of the construction site and reduces the risk of injury. The most common PPE includes goggles, helmets, ear muffs, and gloves.

High visibility jackets are also a key part of your employees’ PPE. They are made from reflective materials that make every employee visible from a far. They are an affordable, yet effective way to reduce the risk of accidents on your construction site.

Understanding The Impact: The Importance Of Effective Hydrogen Sulfide Removal In Bioenergy Processes

By Salman Zafar | November 28, 2023 - 12:28 pm |December 11, 2023 Biogas, Biomass Energy, Industrial Equipment

2 Comments

Bioenergy plays a vital role in the renewable energy sector, converting organic materials such as agricultural waste into sustainable energy. This approach not only provides a renewable source of energy but also contributes to effective waste management. However, it confronts a notable challenge: the production of hydrogen sulfide (H2S). If not properly addressed, this byproduct can have significant detrimental implications.

Hydrogen sulfide, a byproduct that arises during the breakdown of organic matter, is a critical concern in bioenergy, especially in systems involving biomass and waste-to-energy processes. Its presence poses significant health hazards, making the management of H2S essential for ensuring safe and efficient bioenergy production.

Your role in this process is crucial. Proper H2S removal ensures bioenergy remains a viable and eco-friendly energy source. This article examines the impacts of this byproduct in bioenergy and the importance of its removal, giving you a comprehensive understanding of this aspect of bioenergy production.

Understanding Hydrogen Sulfide In Bioenergy Processes

Hydrogen sulfide, a colorless gas with a distinctive ‘rotten egg’ smell, is a common byproduct in bioenergy processes. It emerges primarily during the decomposition of organic materials, such as agricultural waste or sewage, particularly in anaerobic digestion systems. This breakdown is a core part of converting biomass into energy, but it brings the challenge of H2S production, known for its toxicity and corrosive properties.

The generation of this gas in bioenergy facilities is influenced by various factors, including the type of biomass, process conditions, and microbial activity. For professionals looking for detailed information on managing these variables effectively, resources like MVSeer.com offer insights and solutions tailored to the unique challenges of bioenergy processes.

The presence of this byproduct not only poses health risks but also can corrode equipment, impacting operational efficiency. Therefore, its effective management is imperative, ensuring safe, efficient, and regulatory-compliant bioenergy production.

Health Impacts Of Hydrogen Sulfide

The health hazards posed by hydrogen sulfide are significant and varied, depending on the concentration and duration of exposure.

Respiratory Issues: H2S primarily affects the respiratory system. Even at low concentrations, it can cause eye irritation, coughing, and shortness of breath. For example, workers in bioenergy facilities who are exposed to low levels of this gas over extended periods may experience chronic respiratory problems.
Neurological Effects: Higher concentrations of H2S, often encountered in industrial accidents, can lead to more severe health issues. These include headaches, dizziness, and nausea. In extreme cases, such as in confined spaces with poor ventilation, exposure may cause unconsciousness or even fatalities.
Chronic Exposure Risks: Continuous exposure to even small amounts of H2S can have long-term health effects. Symptoms like fatigue, loss of appetite, and poor memory have been reported in studies of workers in industries where this gas is a byproduct.

Effective management and control of H2S exposure are essential to protect the health of workers and nearby communities, ensuring that bioenergy production remains not only efficient but also safe for all involved.

Environmental Impacts Of Hydrogen Sulfide

The environmental consequences of hydrogen sulfide are diverse, affecting air quality, harming ecosystems, and contributing to broader environmental issues:

Air Quality Degradation: H2S is a significant contributor to air pollution. In areas surrounding bioenergy facilities, elevated levels of this byproduct can lower air quality, affecting not only human health but also the health of wildlife. For instance, high concentrations of this gas have been linked to decreased plant growth and adverse effects on animal populations.
Acid Rain Formation: When H2S is released into the atmosphere, it can react with other elements to form acid rain. This phenomenon has been observed in regions with intense industrial activity, where acid rain can damage crops, forests, and aquatic habitats, as well as corrode buildings and monuments.
Greenhouse Gas Emissions: While H2S itself is not a significant greenhouse gas, it can indirectly contribute to climate change. Certain bioenergy processes that produce this byproduct also emit methane and carbon dioxide. The management of these emissions is important for reducing the environmental footprint of bioenergy.

Prioritizing the reduction of H2S emissions in bioenergy processes is vital not only for environmental protection but also for sustaining the ecological balance and ensuring the long-term viability of bioenergy as a green energy source.

Technologies For Hydrogen Sulfide Removal

Effective removal of hydrogen sulfide is critical in bioenergy processes to ensure safety, compliance, and efficiency. Various technologies have been developed for this purpose, each suited to different operational needs and H2S concentrations:

Chemical Absorption: Chemical absorption involves using reactive chemicals like sodium hydroxide or amines to capture H2S from gas streams. A notable method in this category is the amine gas treating process, widely used in industrial settings, which converts H2S into harmless byproducts.
Physical Absorption: Physical absorption utilizes non-reactive solvents to absorb H2S from gas streams directly. This method is known for its high efficiency in the removal of this harmful byproduct, especially in settings requiring minimal energy consumption. It is widely used in gas processing plants and is advantageous when dealing with large volumes of gas.
Biological Treatment: This method utilizes microorganisms to oxidize H2S into less harmful substances like elemental sulfur or sulfate. Biofilters and bioscrubbers are common biological treatment systems, especially effective for low to medium gas concentrations and favored for their environmental friendliness.
Adsorption Techniques: Adsorption involves materials like activated carbon or metal oxides trapping H2S. Activated carbon is suitable for lower concentrations, while metal oxides are used for higher concentrations, converting H2S into non-hazardous compounds.
Membrane Separation: Membrane technology separates H2S from biogas through selective permeation. This method is particularly valuable in applications where high purity of the product gas is critical.
Catalytic Oxidation: Catalytic converters use catalysts, such as platinum or palladium, to oxidize H2S into sulfur dioxide or elemental sulfur. This technique is effective at various temperatures and gas concentrations.
Cryogenic Techniques: Cryogenic separation involves cooling the gas stream to extremely low temperatures to condense and separate H2S. It’s suitable for large-scale operations where high purity levels are required.

The selection of an appropriate H2S removal technology is crucial and depends on various factors such as gas concentration, operational scale, environmental regulations, and cost considerations.

Ongoing improvements in these technologies aim to enhance efficiency, reduce operational costs, and minimize environmental impact, thereby making bioenergy processes safer and more sustainable.

Final Thoughts

Managing hydrogen sulfide is imperative for the safe and sustainable operation of bioenergy processes. The health risks and environmental impacts of H2S underline the need for its effective removal. With various technologies available, the bioenergy industry is well-equipped to address these challenges. These advancements not only ensure compliance and safety but also contribute to the efficiency and viability of bioenergy as a renewable energy source.

Looking ahead, the ongoing development of removal methods is key to advancing bioenergy’s role in sustainable energy solutions. This commitment to innovation and safety highlights the bioenergy sector’s role in a cleaner, more responsible energy future.

Why Industrial Property Owners Should Own Their Own Transformers

By Salman Zafar | November 26, 2023 - 2:55 pm |November 26, 2023 Electricity, Industrial Equipment

1. You can ensure quality

When you rely on the electric company to loan you a transformer, you can’t guarantee it’s high-quality. And the quality of your transformer won’t change your electric bill. The electric company can give you a brand-new transformer, a used one, or a refurbished one, and they’ll still charge you the same rates. Sure, they’ll replace it when it fails, but that can be inconvenient even though you won’t have to foot the bill. Even when you aren’t paying for it, you still need a reliable transformer.

On the other hand, when you buy your own transformer, you can guarantee its quality by getting it from a reputable manufacturer, like ELSCO Transformers, where the craftsmanship is superior, and they’ve never had an operational transformer fail since 1988.

You just don’t have any control over what the power company gives you, and that can end up being a disaster. A transformer built to last rather than built to sell will give you reliable power and peace of mind at the same time.

2. Owning your transformer will lower your costs

Power companies usually offer lower rates when you own your transformer. However, it’s crucial that you find out the rates and do the math to make sure it makes sense in light of how much you’re going to pay for your new transformer. That doesn’t mean the dollar amount has to add up. Remember to include the value of reliable power that won’t put you in the dark at random times and leave you hanging. Sometimes, the value of peace of mind is worth an extra expense.

3. You can have your transformer repaired faster

When you experience an unplanned power outage resulting from a failed transformer, you’d normally need to wait for the power company to come out and fix it for you. They’re usually pretty good about getting someone out quickly, but that’s not always the case. If they need a specific part that isn’t available, it could take weeks.

Owning your transformer means you can hire a qualified, licensed electrician to fix it for you, and you can even go a step further by keeping spare parts on hand that you’ve ordered ahead of time just for the occasion. However, if you buy a high-quality transformer to start with, the chances of it failing are low.

4. Choice

When left up to the utility company, you’re going to get the cheapest transformer available at the moment. That may or may not be what you want or need, but it’s what you’ll get. They will make sure it meets your basic load needs, but that’s about as far as they’ll go with the extra care. They want to save money, and they aren’t going to give you the Cadillac of transformers.

When you buy your own transformer, you have a choice regarding what you get. You can buy a transformer that is more powerful than you currently need if you know you’ll grow into it, and you can ensure it has all the qualities you’re looking for.

The biggest benefit here is being able to order the specific transformer you want ahead of time, so even if the lead times are long – like one or two years – you can start the order process early to get exactly what you want.

5. Breakdowns are less likely

There are a ton of reasons transformers can break down, and the good news is that when you own your transformer, those situations are less likely to become your reality. For example, poor insulation, too much voltage, power surges, corrosion, lightning strikes, and static electrification area all common reasons for transformer failure.

While you can’t prevent lightning from striking your transformer, you can minimize the potential for all the other reasons for failure by purchasing your own high-quality transformer. The higher the level of craftsmanship, the less likely it is to fail.

A transformer is a worthwhile investment

If there’s one thing that will make life easier, it’s owning your own transformer. It’s the easiest way to get reliable electricity and prevent unplanned power outages caused by inferior equipment.

4 Tips To Prevent System Failures At Remote Power Plants

By Salman Zafar | November 4, 2023 - 1:52 am |November 4, 2023 Electricity, Industrial Equipment

3 Comments

Every day, power plants are tasked with producing enough power to keep homes and businesses running. Remote power plants can be particularly difficult because they’re often located in areas where it’s hard to find qualified workers. These plants tend to fail at an alarmingly high rate due to system failures. Luckily there are methods you can do to help prevent this from happening. If successful, it will help you save time and money as well as improve efficiency in the long run.

Read more to know about the four tips you can apply to ensure your system is running at peak performance.

1. Maintain Your Power Equipment And Systems

You should maintain your equipment and system regularly to ensure they’re running properly. Inspect your entire systems such as generators, switches, surge suppressors, and other equipment for signs of wear or damage every few months. This will allow you to catch any problems before they cause real issues. These concerns may include downtimes, thus costing a lot of lost revenue per hour.

You could also schedule preventative maintenance at least once a year. This ensures everything is repaired correctly the first time around. These repairs may include fixing broken parts and replacing frayed wire insulation that’s about to fail. A power plant asset management software will help to keep your system running at top performance.

Also, ensure all system components are secure in their foundations, so there is no risk of movement over time. This can cause damage or disconnections during use. Thus, check your inverter’s health for signs of failure or damage, especially if it has more than six years of use.

This is an essential task because the last thing you want to deal with during an emergency is downtime due to something as simple and preventable as failing equipment. Some ways to check your inverter include taking measurements, checking system parameters like pressure and temperature, etc.

2. Install A Battery Backup System

Not only will this keep you up and running during an outage, but it can also help prevent future failures. For example, your system was experiencing frequent inverter failures every time there’s a storm. If you have a battery backup in place, it will keep the power on until the storm passes. Thus, you don’t lose any data or equipment due to this issue.

3. Keep The Plant Clean And Free Of Debris

The most common cause of failure in remote power plants is the weather on systems and equipment over time. A buildup of dust can insulate wires enough to reduce voltage output and corrode metal components that are essential for making electricity. This will result in costly downtime or even complete system failures. Cleaning your facilities, like the air intake and exhaust ports, could keep everything running at peak performance.

On the other hand, some ways you can keep your facility free of debris include ensuring walkways surrounding equipment are clear. This is so workers can access everything they need without stumbling around hazardous areas. You must be sure to remove any rocks or other items lying around since these could fall onto machinery if there’s an earthquake or storm and severely damage it.

Also, you must regularly check for rust or corrosion on metal equipment. This is especially important if you live in a particularly wet area since this can cause severe damage with time.

4. Have A Plan In Case Of Emergencies

If an emergency does occur, having a plan in place will guarantee you’re ready to handle it quickly and appropriately. Having spare parts on hand could make repairs immediately with no delays. This is important for ensuring uninterrupted power and avoiding further damage or accidents caused by faulty equipment.

Also, train all your staff members on safely operating any machinery involved and what procedures to take if anything goes wrong. This will ensure that workers can act quickly and correctly in an emergency. Thus, they don’t need too much time figuring out how things work, which could cost valuable minutes.

Another plan includes having a backup power source ready just in case your main one fails for any reason. Even if your generator is still working, a backup system will keep you from losing power again during the downtime of switching to a new system.

Conclusion

As you’ve read, there are several ways to prevent system failures for remote power plants. You must understand how these systems work and what causes them to fail so you can protect your customers from blackouts.

Shedding Light on Non-Destructive Testing with Ultraviolet Lamps

By BioEnergy Consult | November 1, 2023 - 1:27 am |November 2, 2023 Industrial Equipment, Industry, Technology

1 Comment

Non-destructive testing (NDT) can be simplistically described as a method used to conduct an inspection without moving or breaking the item or surrounding area under examination. Although not limited to medicine, aerospace, and industry, these three large sectors are particularly dependent on non-destructive inspection methodologies. One of the most helpful tools for NDT is the Ultraviolet (UV) lamp.

Let’s take a brief look at the presence of UV lamps in NDT settings.

Non-destructive testing is a broad field

The definition of NDT can be quite broad unless one limits its description to a test, evaluation, or inspection, in a particular field of engineering or medicine. As well, the type of inspection that is required also comes from a long list of possibilities.

Fluorescent Magnetic Particle Inspection (FMPI or MT) and Fluorescent Penetrant Inspection (FPI or PT) are strongly associated with the use of fluorescent lighting and NDT.

Let the light come in

UV light is longer than X-rays, and shorter than visible white light, placing it into the 10 to 400 nm wavelength range. Known as black light, non-visible UV light can be harmful. The shorter UV-C rays, up to 290 nm, however, rarely reach the earth, and this is fortunate. Also be wary of UV-B rays, which are responsible for sunburns. The longer rays of UV-A, between 320 and 400 nm, are the least dangerous to humans.

In the past, magnetic particle penetrants used a mercury base, which became fluorescent with a UV-A light of 365.4 nm. This led to the requirement of today’s UV light sources for NDT. The standard requirement for a peak wavelength is between 360 – 370 mm.

The UV lamp advantage

One aspect of UV lighting that gives it the edge is that it provides visibility into the area under inspection where otherwise, there is none. The magnetic particles or penetrants that are applied to the surfaces of the areas to be inspected become fluorescent, providing visibility into the tiniest of flaws, such as cracks, breaks, and positioning changes.

What to look for in a UV lamp

There are UV lamps and then there are UV lamps. To achieve the most efficient, successful, and safe examinations, it is important to choose the correct UV lamp for the task at hand.

LED illumination

UV LED lamps are highly recommended for non-destructive testing. In fact, for the most part, LED lamps have replaced incandescent and fluorescent lamps, which may not be easily available in the near future.

However, some legacy UV lamps can be modified to accept LED bulbs. UV LED lamps are lighter, making them very manageable. The bulbs are long-lasting, not prone to fading, and can be housed in cooler casings.

Handheld or stationary

The advantage of handheld UV LED lamps is, of course, their portability and their low energy consumption. However, unlike their predecessors, the mercury vapor bulbs, they do not offer the intensity and the wide beams that are required in some inspections.

Meeting the challenge, some UV lamp producers are using LED lighting to create stationary overhead lamps with intense, wide beam coverage, and adaptable frames, allowing easy vigilance over production in assembly lines. This is a low-cost alternative to frequently-replaced fluorescent bulbs.

The importance of a filter

With a peak wavelength between 360 – 370 nm, violet tail emissions of visible light above 400 nm can mask flaws and cracks with light glare. A filter improves visibility by providing more contrast.

Additional considerations

Science and engineering are always in flux. Similarly, developments in the field of non-destructive testing brings with it much to consider.

With the introduction of LED bulbs in UV light sources, dangers resulting from potential accidents in non-invasive fault-seeking, are no longer concerns. Burns resulting from filaments in mercury vapor are becoming a thing of the past. With less electrical demands from LED bulbs, power supplies can be lightweight, making the lamp easier to handle in tough conditions.
Just the fact that mercury will no longer be needed is enough of a cause for celebration.
Visibility with LED lamps is instantaneous.
For some conditions, a narrower beam is required. NDT requirements must lead the way when determining the lamp’s specifications for a particular type of inspection.
One challenge that designers are working on is the emission of heat flux at the emitters of UV LED lamps. This is a result of smaller technology with increased energy levels.

Non-destructive testing has broadened its scope over the years, giving rise to compliance standards for specific NDT applications. The most well-known compliance standard to look for in UV-A lamps for NDT with FMPI and FPI, is the ASTM E3022 standard. Whatever the standards of compliance are for a particular industry, non-destructive testing and its reliance on dependable lighting for inspections, is now an important branch of engineering in its own right.

5 Things to Know Before Working With Steel

By Salman Zafar | October 13, 2023 - 12:12 pm |October 13, 2023 Industrial Equipment, Industry, Safety

3 Comments

When preparing to step into the world of working with steel, having a solid grasp of fundamentals can offer dividends in the short or long run. Unbeknownst to many, it takes more than raw strength and wielding the right tools.

For a complete novice or someone with a bit of experience under their belt, diving headfirst into steelwork presents a unique set of challenges. Thankfully, nothing is impossible to navigate with the right knowledge and understanding.

From recognizing various types of steel to minimizing environmental impact and observing safety measures, this piece provides you with vital insights on things to know before working with steel.

1. The Characteristics of Different Steel Types

Steel is a versatile material, which can be found in several types, each boasting its unique properties. For example, carbon steel, known for its strength, is frequently used for structural purposes.

Contrastingly, stainless steel, famous for its corrosion resistance, makes it a choice material in projects exposed to harsh weather elements.

In a nutshell:

Carbon Steel: Renowned for immense strength
Stainless Steel: Offers great corrosion resistance
Green Steel: Characterized by low greenhouse gas (GHG) emissions during manufacturing.
Galvanized Steel: Coated with zinc to prevent corrosion and rust.
Mild Steel: Low-carbon steel with good weldability and versatility.
Alloy Steel: Combines various metals to enhance properties like strength, hardness, and durability.

Being aware of these variations only broadens your understanding. It also helps you choose the right type for every task, a crucial consideration in successful steelwork.

2. Proper Techniques to Cut and Shape Steel

Moving beyond just recognition, working with steel entails knowing the correct methods to cut and shape. Using the appropriate tools like a hacksaw, band saw, or cutting torch can yield smooth, accurate cuts when rightfully done.

Also, remember to cut slightly outside your marked line, so you have room for removing burrs and imperfections during finish work.

Lastly, shaping steel involves different techniques, such as bending or forging. Choosing which method to employ depends on your project requirements.

3. Waste Reduction Strategies in Steelwork

Steelwork projects can generate considerable waste, impacting your overall costs. This is not to mention putting a toll on the environment over time. It’s thus necessary to adopt efficient ways of reducing steelwork-generated waste.

Among these include:

Nesting

This refers to arranging your cutting patterns on the steel sheet to utilize maximum space and minimize leftover material.

Recycling

Additionally, you should also consider recycling. This means selling or returning any leftover steel scraps to a metal recycling center not only for a bit of profit but also to contribute to environmental sustainability.

4. Galvanized Steel Vents May Require Sealing Up After Fabrication

If your project involves galvanized steel vent holes, be aware that they may need sealing post-fabrication. This is to protect them from corrosion, ensure efficiency, and increase longevity.

For this task, you might want to invest in galvanized vent plugs, which are perfect for sealing up any apertures left after fabrication. An additional advantage is its resistance to rust and other environmental factors.

5. Safety Measures for Handling Hot and Cold Steel

When it comes to dealing with steel, never compromise on safety. Here are several measures you should always adhere to:

Always wear heat-resistant gloves when handling hot steel to prevent burns.
Use safety glasses or a face shield. These protect your eyes from sparks or flying debris during welding.
Ensure that the area is well-ventilated when welding or cutting. These processes can release hazardous fumes.
Lastly, never forget to wear steel-toed boots. These will safeguard your feet should any heavy piece accidentally drop.

Remember, staying safe should be your priority when working with steel.

Bottom Line

In conclusion, working with steel needn’t be an intimidating task. To succeed, all it takes is a clear understanding of the material, applying the right techniques, reducing waste, maintaining safety standards, and paying attention to post-production requirements like sealing galvanized vents. Prepared with this knowledge, you’re all set to navigate your steelwork journey with confidence!