ATEX & IECEx Zone 1 accredited robot incorporated with the ION Science Falco for the detection of VOCs in flammable and explosive environments

Throughout unmanned facilities within the oil and gas industry, a human presence is generally still needed for regular inspection work, so deploying Ex certified robots (ATEX and IECEx Zone 1) incorporated with the ION Science Falco, can have a significant positive impact on safety by minimising worker field trips, which in turn reduces operating costs.

Atexxo Manufacturing has released an Apple iPad mini 5 which is suitable for use in Zone 1 and Zone 2 hazardous locations. The explosion proof iPads are originally manufactured by Apple then converted and certified according to ATEX and IECEx by Atexxo Manufacturing.

This makes the ATEX and IECEx tablets suited for safe use in gas/vapour Zone 1 and zone 2 hazardous areas. Sim-card can be installed by the end-user themselves, or eSim can be used. The devices are suited for Apple (open) DEP enrollment program.

High-pressure compressor manufacturer, Reavell, part of the Ingersoll Rand Group, has launched Boost, a plug-and-play range of four nitrogen boosters.

Designed for easy integration with any nitrogen generation system, the four models (H075, H110, H150 and H185) deliver up to 350 bar pressure outlet and flow rates up to 56 m3/hour on the H185 model.

On-site nitrogen generation has been gaining popularity over recent years, using existing compressors to convert air to guaranteed purity nitrogen. The process can save operators up to 90 per cent of the cost of bought-in gas with payback in less than two years for a company using liquid nitrogen, or as little as one year where gas cylinders are being used.

When Fabricon Design Ltd replaced its existing compressor installation with an Atlas Copco VSD+ unit to sustain the air supply of its state-of-the-art CNC machining operation, it also gained the benefit of annual energy savings in the region of 51%. 

Starting life in 1984 as a design-led steel fabrication company by founder and managing director, Mark Bushdyhan, Fabricon Design has expanded over the last 30 years to include rapid prototyping capabilities and full-scale production, with all services embracing the latest advances in fabrication technology. 

Leybold strengthens the trend towards smart solutions in research and laboratory applications

Leybold expands its ECODRY plus product family of dry multi-stage Roots vacuum pumps for laboratory, research and development and analytical applications. The current ECODRY 40 and 65 plus models are now joined by the new, smaller pump sizes ECODRY 25 and 35 plus. Leybold thus completes its range of quiet, low-maintenance and economical fore-vacuum pumps and fills the gap between SCROLLVAC 18 plus and ECODRY 40 plus.

CMT expands the CMA advanced mobile valve family

The power management company Eaton has announced the launch of the CMT mobile valve section, a streamlined new section option for the CMA advanced mobile valve. With the capability to control two bidirectional services from one section – an industry first – the CMT valve section increases design flexibility and reduces CMA valve bank size, weight and overall system cost.

Studies collected by the Hydraulic Institute and Europump* reveal that pumping systems account for nearly 20% of the world’s electricity energy demand and from 25 – 50% of energy usage in certain industrial plant operations.  This highlights the significant potential that exists to cut a company’s running costs and put a dent in its carbon footprint too by maintaining or improving pump efficiency.

There are several ways to improve the energy efficiency of an industrial pump and the application of a protective coating is one of easiest and most effective.  This is typically a ceramic reinforced epoxy that can extend the life of new pump components and restore the worn surface of old ones.  They create a sacrificial and renewable working surface, protecting the structural integrity of the original substrate.

Castings impellers and volutes all wear due to corrosion, erosion, cavitation and mechanical damage but all these outcomes can be significantly delayed or prevented with the application of a protective coating.  The time it takes to apply is much lower than other remedial methods, such an installation overhaul and impeller trimming and it also achieves the shortest return on investment, typically 4 – 12 months.

30% energy reduction

A UK automotive manufacturer provides an excellent illustration of what can be achieved.  To demonstrate potential gains in pump energy costs a 22kW ELPO pump, used for handling process water, was selected for analysis and it was found to be under-performing by a minimum of 30% against the manufacturer’s original test data. 

The unit was then dismantled and all components examined for wear.  The pump was heavily corroded and pump impeller worn, burred and imbalanced.  The mechanical seal had seized and the pump was out of alignment with the motor.  The volute was cut-water worn, the bearings showed evidence of fretting and corrosion and the motor was not inverter rated.

All components that required coating were first steam cleaned to remove any residue and salts and then bead blasted to achieve a surface roughness of 75 microns.  LOCTITE^® 7515 was used to pre-treat the substrates to prevent corrosion and improve adhesion between the metal parts and the polymer composite coating. 

Next, LOCTITE 7177 was applied as a ‘hold coat’ to smooth the surface imperfections and provide a key for the thicker layers required to return the pump to its original dimensions.  A ‘build coat of LOCTITE 7226 was then used to replace many years of wear a create tough surface, resistant to future wear. This was followed by another coat of LOCTITE 7177 to achieve a finish that would reduce friction within the pump and improve its energy efficiency. 

The pump was then fitted with new bearings and both oil and mechanical seals. The impeller was dynamically balanced, the pump re-assembled and a new 22kW high efficiency motor fitted. Motor and pump were finally installed on the bedplate and laser aligned. 

The second performance test was then conducted and the results were outstanding.  The remedial work had restored the pump to original specification, increasing its efficiency by 30%.  The cost of the repair amounted to £5,542.  But offsetting this, in the first year alone, was an estimated energy reduction of £3,936.  This was calculated at £0.08/kWh at 12 hours per day with an 80% load.

The ‘before’ and ‘after’ analysis from other manufacturing companies confirm similar findings.  One reported a 19.9% energy efficiency increase with 4.55 months payback and a carbon emission saving of 10.2 tons per year and another a 12.67% energy efficiency boost, a 5.11 months payback time and carbon savings of 49.5 tons per year.

Ceramic reinforced epoxy coatings are available in a choice of grade for fine particles through to coarse and also specific products for pure chemical attack, corrosion and high impact. 

For more information on the LOCTITE^® range and advice on surface treatments in general, please visit our website:
www.henkel-adhesives.com

JT Tool & Plant Hire Ltd is a fast growing tool hire service situated in the heart of London.

 We pride ourselves in providing outstanding customer service to our customers by putting their needs and demands first. Offering Access Support, Handling, Air Tools and Compressors, Cutting and Grinding, Heating Cooling and Drying systems for hire.

Our aim is to go above and beyond the requirement of our customers in order to allow for the smooth and efficient progress of their projects by providing a wide range of tools on demand.

King’s Boiler Hire have worked tirelessly throughout the COVID-19 pandemic keeping hospital, care home and food processing clients running during this difficult time.

Offering boiler units ranging from 1,500lb/hr to 17,500 lb/hr with fast, Nationwide delivery available 24/7,  King’s Boiler Hire is the UK’s No.1 choice for emergency boiler hire.

Since 2015, SKF has decreased its manufacturing carbon footprint by 36% and is already operating two carbon neutral factories. Today, SKF announces its aim to achieve a fully carbon neutral manufacturing footprint by 2030.

The 2030 target will cover SKF’s own manufacturing operations, i.e. SKF’s scope 1 and 2 emissions. It will be achieved by a combination of process improvements, energy efficient machinery, and procurement and generation of renewable energy. As a last resort, SKF may also purchase high quality carbon offsets.