Print

Save up to 60% time and 70% water with this new powerful tank cleaning machine

Fast and cost effective cleaning

Saving time and water are some of the KPIs which have the most attention in the hygienic industries. The new Alfa Laval TJ40G rotary tank cleaning machine uses a high-impact jet stream to effectively clean tough tank residues and minimize the risk of product contamination. This four-nozzle rotary jet head also cleans tanks 60% faster than static spray ball technology, which increases production uptime. And because it cleans faster, this new device uses less water and less cleaning agents thereby reducing operating costs by up to 70%.

2017 03 20 094445The Alfa Laval TJ40G is capable of handling tough tank residues as well as solids up to 1mm in the cleaning fluid in tank sizes 50-1000 m³. This is particularly important for demanding process lines, such as applications within the brewhouse, where both the size and the amount of particles may be re-circulated in cleaning media before completing the cleaning cycle.

Complete self-cleaning system

Not only does the Alfa Laval TJ40G rotary tank cleaning machine provide spotless cleaning of the tank interior, it also cleans itself – inside and out.

Its hygienic self-cleaning construction ensures that the flow of the cleaning fluid reaches the exterior surfaces of the rotary jet head, as well as the critical interior components such as all bushings, bearings and inner surfaces. This minimizes the risk of product contamination and ensures a high product quality.

Alfa Laval's rotary tank cleaning machines are designed with numerous of features to ensure self-cleaning of the machine, such as directional flow from small jets in the hub that cleans the exterior of the machine. A low pressure loss over the machine provides increased cleaning efficiency compared with other tank cleaning machine running at same inlet pressure. This result in lower cleaning cost as the unit can run at lower pressure/flow compared to other tank cleaning machines.

All Alfa Laval rotary tank cleaning devices comply with Good Manufacturing Practice (GMP).

About Alfa Laval
Alfa Laval is a leading global provider of specialized products and engineering solutions based on its key technologies of heat transfer, separation and fluid handling.

The company’s equipment, systems and services are dedicated to assisting customers in optimizing the performance of their processes. The solutions help them to heat, cool, separate and transport products in industries that produce food and beverages, chemicals and petrochemicals, pharmaceuticals, starch, sugar and ethanol.

Alfa Laval’s products are also used in power plants, aboard ships, oil and gas exploration, in the mechanical engineering industry, in the mining industry and for wastewater treatment, as well as for comfort climate and refrigeration applications.

Alfa Laval’s worldwide organization works closely with customers in nearly 100 countries to help them stay ahead in the global arena.

Alfa Laval is listed on Nasdaq OMX, and, in 2015, posted annual sales of about SEK 39.7 billion (approx. 4.25 billion Euros). The company has about 17 500 employees.

www.alfalaval.com

 

Print

Industrial automation trends for 2017: Predictions for the future of manufacturing

As manufacturing facilities incorporate greater levels of automation, the demand for new technologies continues to grow. Recent years have seen several trends create a shift in the way the industry operates. Here, Martyn Williams, Managing Director of industrial software expert, COPA-DATA UK, examines three of the most prominent automation trends of 2017 and discusses how these trends are changing manufacturing operations.

Machine learning: improving accuracy at every phase

Promising an answer to many modern manufacturing challenges, machine learning is one area of technology that has been subject to rapid development in the last year. Machine learning describes computer science techniques that allow a machine to independently learn a task, rather than being programmed to complete that task.

In the era of big data, the greatest advantages of machine learning will come to manufacturers with data-rich production lines. Using the technology, machines can derive patterns and information from existing datasets.

Potential uses include optical part sorting, automated quality control, failure detection and improved productivity and efficiency. In fact, according to a smart manufacturing study by the National Institute of Standards (NIST), machine learning can improve production capacity by up to 20 per cent and lower material consumption rates by four per cent.

Machine learning algorithms have the potential to bring greater predictive accuracy to every phase of production and there are many manufacturing systems that can - and do - use machine learning to improve operations.

2017 03 16 110109

Modularisation: fulfilling the need for flexibility

Fulfilling customer demand will always be a priority for manufacturers. Changing consumer needs and habits require manufacturers to offer a wider range of products, without reducing product quality and consistency. Considering the competitive nature of today’s industry, the potential to create flexible production lines could not be more valuable.

Modularisation allows manufacturers to separate, connect or combine different production modules to create customised and varied products in one facility. This change requires the interconnection of industrial machinery and the implementation of intelligent control software.

Increasingly, manufacturers are using modularisation as a technique to seed a new market with a particular product, in order to prove customer demand before a full scale implementation, therefore saving time and resources.

SCADA: more than data acquisition

SCADA applications already play a key role in smart manufacturing. However, according to a report by global market research firm Technavio, the manufacturing industry is set to experience a significant growth in the adoption of analytical software through SCADA.

The integration of predictive analytics in modern SCADA software has made it easy for manufacturers to collect and archive production data and make future predictions based on this intelligence. However, SCADA systems provide much more than an insight into the lifespan of machinery. The integration of cloud computing with SCADA systems has enabled operators to control production from any location, further improving the flexibility of the plant.

As with any cloud migration, there are security concerns. However, as cloud security features become more sophisticated and SCADA providers increasingly adopt a security by design approach to their software, this concern is unlikely to deter manufacturers from embracing – and benefitting from – cloud-based SCADA.

These industrial automation trends are just a taste of the intelligent applications still to make waves in the industry. The coming year will be all about the great influx of supervisory control technologies that are designed to improve the flexibility, accuracy and security of production.

On COPA-DATA
COPA-DATA is the technological leader for ergonomic and highly dynamic process solutions. The company, founded in 1987, develops the software zenon for HMI/SCADA, Dynamic Production Reporting and integrated PLC systems at its headquarters in Austria. zenon is sold through its own offices in Europe, North America and Asia, as well as partners and distributors throughout the world. Customers benefit from local contact persons and local support thanks to a decentralised corporate structure. As an independent company, COPA-DATA can act quickly and flexibly, continues to set new standards in functionality and ease of use and leads the market trends. Over 100,000 installed systems in more than 90 countries provide companies in the Food & Beverage, Energy & Infrastructure, Automotive and Pharmaceutical sectors with new scope for efficient automation.

On zenon
zenon is COPA-DATA`s highly versatile product family for industry-specific ergonomic process solutions: from sensors through to ERP. It consists of zenon Analyzer, zenon Supervisor, zenon Operator and zenon Logic. zenon Analyzer provides templates to create tailor-made reports (e.g. on consumption, downtimes, KPIs) based on data from IT and automation. zenon Supervisor, an independent SCADA system, allows comprehensive process monitoring and control of redundant systems, even in complex networks and with secure remote access. zenon Operator guarantees, as an HMI system, safe control of machines and simple, intuitive operation – including Multi-Touch. zenon Logic, which is an integrated IEC 61131-3-based PLC system, allows optimum process control and logical data processing. As a platform-independent portfolio for process solutions, the zenon Product Family integrates smoothly into existing automation and IT environments and provides set-up wizards and templates to enable easy configuration and simple migration from other systems. The principle of "setting parameters instead of programming" is a characteristic feature of the zenon Product Family.

Print

ABB introduces new Dodge® product selection tool

Passport is an easy-to-use selection program for Dodge shaft mounted reducers and belted drive products.

ABB introduces Passport, a new selection program for Dodge mechanical power transmission products. A Web based tool utilizing an intuitive process, Passport quickly guides users through the selection of Torque-Arm II and Motorized Torque-Arm shaft mounted reducers, as well as belted drive products.

Passport takes both novice and experts, with or without knowledge of Dodge products, through a step-by-step process helping them identify the reducer and accessories that best meet their needs. Product offerings and units of measure are tailored to the users’ local market.

2017 03 09 120617

“This user-friendly tool also offers customers a path to create an application-based gearing package,” says Joe Maloney, Vice President of Dodge International Sales. “Passport offers all of the components, including the reducer, motor mount, accessories, mechanical drives, and motors to create a complete packaged solution. This tool will be especially helpful to bulk material handling customers, as well as those with air handling applications.”

After the selection process is complete, Passport delivers a comprehensive summary that includes part numbers, supporting performance data, engineering drawings and links to literature and additional resources. 

Future Passport capabilities will incorporate additional Dodge mechanical power transmission products, as well as offering an application based approach to develop packaged product solutions for a wider range of common industrial applications.

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader in electrification products, robotics and motion, industrial automation and power grids, serving customers in utilities, industry and transport & infrastructure globally. Continuing more than a 125-year history of innovation, ABB today is writing the future of industrial digitalization and driving the Energy and Fourth Industrial Revolutions. ABB operates in more than 100 countries with about 132,000 employees. www.abb.com

Print

Compressor repaired in just 8 weeks following catastrophic failure

Industrial compressors are used for a range of applications and usually perform a central role in a manufacturing process, requiring them to deliver a reliable service. All operators carry out preventative maintenance routines to protect against unexpected failures, but if the worst does happen the repair needs to completed quickly and efficiently. For one blue chip company, Sulzer was able to get operations back up and running swiftly using the experienced, local service center in Leeds.

In this particular case, the operator of the compressor required more air pressure and unfortunately believed this could be achieved by closing the surge valve. The consequence of this action was to cause the rotor to become unbalanced and hit the top diaphragm, resulting in damage to the impellers and all of the labyrinth seals.

2017 03 07 083940

The compressor was originally manufactured by Sulzer and the operator made two calls with a view to having the equipment repaired - one to the local service center and the other to an alternative original equipment manufacturer (OEM). Sulzer agreed to be on site immediately to inspect the damage and offer a proposal for the repair. With time being a crucial element in this project, Sulzer was contracted to complete the repair.

The initial inspection took place at the operator’s site and it was immediately apparent that of the three stages, number two had suffered catastrophic damage, along with the labyrinth seals. The decision was taken to transfer the complete compressor to the Leeds Service Center, where the turbomachinery repair service operation has recently relocated to, so that the repair process could begin.

2017 03 07 084000

As the local point of contact for the client, the Leeds Service Center coordinated the project and as it progressed, kept the client up-to-date with progress and timings. Projects involving complex equipment may need to involve the expertise of several service centers and it is essential that all aspects of a repair are carefully monitored to ensure that the client’s expectations are met.

The damaged rotor was sent to Sulzer’s Rotterdam Service Center, which is equipped with specialist facilities for remanufacturing rotors. Here, a new stage-two impeller was manufactured along with new labyrinth seals and sleeves, while the remaining impellers were refurbished. Meanwhile, a new diaphragm for stage two was manufactured and installed in the Leeds facility.

Dale Jarvis, Business Development Engineer for turbomachinery at Sulzer’s Leeds Service Center, comments: “During the communications with the client, our engineers recommended that the bearings in the gearbox should also be checked for damage following the original failure. Since this drivetrain was already out of operation, the client agreed and the subsequent inspection highlighted a need to replace the bearings. By looking at the bigger picture we were able to deliver a more reliable solution without adding to the overall downtime of the project.”

2017 03 07 084022

Having completed the rebuild of the compressor, the field services team together with the client’s maintenance team reinstalled it, which completed the commissioning. In all, the repair was completed in 8 weeks, a time frame that had been agreed with the client at the start of the project; the refurbished compressor now has a significantly increased service life.

As a result of this project, further work will be carried out on similar compressor drivetrains in the same area, with special attention being paid to the gearbox bearings which may be reaching the end of their service lives.

About Sulzer

Sulzer is the leading worldwide, independent service provider for large rotating equipment. With technically advanced and innovative service and maintenance support solutions, Sulzer provides a turnkey service that provides its customers with the peace of mind to focus on their core operations.

Included in this package is a highly efficient and dependable high-voltage coil manufacturing and supply service, delivered from a purpose built facility within the Birmingham Service Centre, UK. It is recognized for producing very high quality coils for high voltage motors and generators; designed, manufactured and shipped by a highly skilled and dedicated team to ensure fast and reliable service.

With an in-house copper rolling mill, Sulzer customers can benefit from round-the-clock manufacturing to ensure that every coil is delivered on schedule. In conjunction with constant quality control and full HV on-site testing facilities, Sulzer can deliver quality, precision and speed, any time, day or night.

Print

New gas turbine fuel nozzle seal design means zero leakage and improved emissions

For operators of gas turbines, the introduction of more stringent emissions regulations continues to have an impact on the daily operations and maintenance strategies of the plant. In order to provide a solution, gas and steam turbine repair specialist Sulzer has developed a new solution that solves the primary fuel nozzle leak issue on two GE gas turbine models.

Richard Vogel, Fuel Nozzle & Flow Test Engineer at Sulzer, provides some background and explains how the new option has changed his approach to fuel nozzle maintenance.

The solution, which can be implemented during routine scheduled maintenance, effectively reduces previously tolerable minor leaks at the primary fuel nozzle tips to zero. This enables the turbine to run at optimum parameters for power, efficiency and component lifespan, while assisting to meet stricter emissions regulations.

The growing importance of embracing the environmental responsibilities associated with power generation has led to tighter local and national legislation being imposed on the industry. This, in turn, has led gas turbine operators to change operational parameters and make decisions to meet these tighter emissions requirements, which may conflict with what is ideal for the equipment, and in achieving targeted turbine output.

2017 03 07 083107

Maximizing revenue and minimizing emissions

In order to adjust emissions levels, plant operators must alter the fuel/air ratio, which then affects firing temperature and mechanical output of the turbine. In effect, there is a balancing act between the cost in terms of avoiding environmental fines for exceeding emissions targets and the lost revenue and increased maintenance costs associated with adjusting the operational characteristics of the gas turbine.

One of the main focus points when adjusting the emissions levels of the gas turbine is eliminating sources of increased emissions, such as leakage from the primary fuel nozzle.

This issue has been identified on some 6B DLN and 7EA DLN primary fuel nozzles. However, meeting more restrictive emissions limitations may require operators to adjust the fuel/air ratio, change the firing temperature or alternatively to make an attempt at reducing fuel nozzle leakage. Excessive leakage at the primary fuel nozzles comes at greater cost to the operators, which may have to implement costly emissions scrubbing at the exhaust stack.

Changes to the fuel/air ratio cause the combustion temperature to be altered and can also affect the ability of the plant to meet power demands as the mechanical output may be reduced. In addition, increased firing temperatures can have a negative effect on the longevity and the reparability of the components in the combustion system and the hot gas path of the turbine.

One practical alternative to adjusting the fuel/air mix is to address the issue of fuel nozzle seal leakage and eliminate it. Taking the GE 6B DLN and 7EA DLN gas turbines as examples, the OEM seals used on the primary fuel nozzles have been known to leak in some cases with minimal operating time.

2017 03 07 083126

Zero leakage, without welding

As part of a standard maintenance program, the primary fuel nozzles are typically exchanged for spare components that are kept by the plant owner; this keeps the downtime to a minimum and allows the spare set of primary fuel nozzles to be refurbished without affecting plant operations and outage duration. Ideally, operators would prefer to have fuel nozzles with zero leakage and some have opted to fully weld the fuel tip to the primary fuel nozzle body using a welded band interface to avoid seal leakage.

This solution has a short term benefit, provided the welding has been carried out correctly. However, when primary fuel nozzles using this solution need to be refurbished, the process of removing the welds means that the primary fuel nozzles may require further refurbishment than necessary to be rebuilt. Depending on the amount of base material removed, premature replacement of endcover inserts or fuel tips may be required, increasing the maintenance and repair duration.

For those operators that are looking to improve this situation, an alternative solution has been created that uses a new seal design and is now field proven to deliver zero leakage before and after installation/operation in the turbine. The collaboration between engineers at Sulzer and some of its customers has resulted in the development of new seals designed for direct replacement of the original C-seals in 6B DLN and 7EA DLN primary fuel nozzles.

Cost effective solution

The revised fuel nozzle refurbishment process follows a stringent repair methodology to ensure that the seal contact surfaces are prepared with precision to ensure the best possible fit with the improved seals. The repair technicians use custom-designed fixturing in the process of seal landing refurbishment, which ensures a high quality repair and improves the efficiency of the process.

Flow tests and dynamic leak checks are performed on a highly accurate and repeatable flow test bench. After refurbishment, final flow testing and dynamic pressure testing are performed to validate the seal integrity above normal operating pressure and confirm the zero leak status of the assemblies. Typically, the refurbishment process using the improved seal design can be completed in less than two weeks, which is both more cost effective and time efficient compared to assemblies that have employed the full tip-to-fuel nozzle body welding process.

Sulzer’s proprietary seal design can be used on both the GE 6B DLN and 7EA DLN gas turbines and initial customer feedback has shown evidence of additional benefits. Gas turbines running with the new seals achieved the required output while remaining within the prescribed emissions limits as expected. Another benefit found was improved exhaust-temperature spread, which assists in a more balanced combustion and lends itself to increased turbine reliability.

In conclusion

Maintaining fuel nozzle performance on gas turbines is one of the most crucial steps in actively reducing the emissions levels of the plant while achieving the required power output. Making adjustments to the fuel/air ratio to compensate for nozzle leakage is the typical solution used resulting in a reduction in output and revenue, as well as increased maintenance costs.

By reviewing the primary fuel nozzle refurbishment procedure, plant owners now have the option to achieve zero leakage. This gives operators the ability to achieve emissions limits while maintaining targeted turbine outputs, without increased expense and time involved in the alternate solution of welding. The emissions levels eliminated by using Sulzer’s improved seal design also reduce the costs associated with exhaust stack emissions scrubbing.

Sulzer is one of the largest global repair and maintenance providers for gas turbine and other rotating equipment and provides a repair and replacement service anywhere in the world.

About Sulzer:

Sulzer is the leading worldwide, independent service provider for the repair and maintenance of rotating machines including turbomachinery, pumps and electro-mechanical equipment. With a global network of over 150 technically advanced manufacturing and test facilities, Sulzer offers a collaborative advantage that delivers high-quality, cost-effective, customized and turnkey solutions, providing its customers with the peace of mind to focus on their core operations.

Sulzer Rotating Equipment Services, a division of Sulzer, can accommodate all brands of rotating equipment including turbines, compressors, generators, motors and pumps. With an enviable track record, dedicated teams of on-site engineers provide best-in-class solutions to ensure that the most effective service is delivered.

Sulzer is dedicated to providing superior service solutions to a range of industries including power generation, oil and gas, hydrocarbon and chemical processing, water and air separation. Every solution is customized to suit the business needs of each application – whenever or wherever that may be.

With a long history of providing engineering service support, Sulzer is headquartered in Winterthur, Switzerland where it began in 1834. Today, with sales over US$ 3 billion and with approximately 15,000 employees, the Sulzer footprint spans across the globe. The core aim is to deliver a flexible and cost-effective service that optimizes customer operational efficiency and minimizes downtime.

For more information on Sulzer, visit www.sulzer.com