How to Select the Best Vendor For Your Plastic Machined Components

Not all plastic machining vendors are equipped to offer all parts. Others may not be able to give you the best prices. The following guidelines can help you locate a fully qualified, cost effective plastic machining specialist:

Material Knowledge

Quiz potential vendors on their knowledge of various materials and applications. Ask them to share the information they have from the material manufacturers. Do they have any property charts or plastic material handbooks to give you?

Specialists in plastic machining should have a wealth of up-to-date information. Material knowledge is a critical area. Good plastic machining firms must be willing to help educate you with the best choices and help find the most appropriate material for your application.

Purchasing Practices

A metal machine shop is not likely to have the material knowledge you need, or have the plastic purchasing power to provide you with the best price.

Likewise, find out if the plastic machining vendor candidates you are considering can purchase materials directly from the material manufacturer. If they rely on plastic distributors for materials, make sure their vendors are up on the latest material technology. Plastic technology is constantly changing, with new materials being introduced all the time.

One of your goals should be to make sure that your plastic machining firm's materials purchasing practices are as good as yours.

Equipment

Ask about the type of equipment your potential vendor is using. The well-equipped plastic machining vendor will look pretty much like a well-equipped metal machining shop, but the bona fide plastic specialist will have equipment that has been adjusted, retooled and re-built expressly for machining plastic material.

The right equipment will machine plastic using the correct speeds, feeds and tooling, and won't pose the threat of contamination faced when metal-machining equipment is utilized. Proper equipment will also insure higher quality parts, with better finishes free of chips, burrs and other imperfections.

Quality and Price

Quality, of course, is directly related to price. Make sure the vendors you interview can provide the highest quality part at the lowest price. Plastic machining vendors can keep errors to a minimum if they are highly process driven, are ISO Certified, use documented SPC procedures, and own the proper inspection equipment such as CMM or video inspection systems. The company with the fewest errors will produce the highest quality and at the lowest cost.

Make sure the supplier is familiar with each machining process you need for your application, as well as with the specific plastic material you will be using. Experience, more than anything else, will help make sure a supplier offers you the most cost-effective part with the best quality.

Looking For The Best

Selection of a truly qualified vendor is extremely important in today's business environment. The time it takes to ask the right questions will pay big dividends - helping you obtain high quality machined plastic parts. Even though the rules for service and quality seem to be continually evolving, getting the best part at the lowest possible cost is still the golden rule of purchasing.

Engineered Plastic Products Corporation is the premier supplier of plastic machined parts. EPP Corp has extensive experience manufacturing critical parts to the aerospace, military, fluid handling, instrumentation, and medical industries. Capabilities include: custom plastic milling, custom plastic turning, custom plastic screw machining, custom plastic manifolds, and assembly.

EPP Corp is ISO 9001:2008 certified, SBA certified, CCR Registered, and has over 35 years of experience providing cost effective plastic machining with minimal production times.

Electric Fork Lift Trucks - Nice Surprise, or Nasty Shock?

With us all becoming more and more aware of our carbon footprint - and with legislation to stop us forgetting - alternatives to the standard combustion engine are beginning to introduce themselves in the retail markets; and the industrial sector has largely made the switch already, only relying on fossil fuelled machinery for external work. So, an impetus exists to reduce this carbon foot-print, but what are the advantages & disadvantages to this new technology?

Whilst it is true that, for many applications, diesel powered, heavy-duty forklift trucks are indispensable, such as on construction sites - where the terrain, distances, and tasks demand diesel tanks to be practical and efficient. No electric forklift can really match the diesel engine in practical applications, having to recharge batteries is a ruinous hindrance for heavy industrial usage. In fact it is not recharging of batteries that disgruntles electric forklift owners, but the hugely costly replacement of batteries, with a lifespan which - although not directly comparable - is just a few years, compared to older technology that can last decades. So even in these 'softer' environments, the electric lift trucks, whilst unlocking work opportunities previously impractical or illegal, come with a potentially heavy financial burden attached.

Electric Fork lift trucks, like standard electric cars, have few internal moving parts, this makes them extremely quiet during operation. For indoor environments then, particularly those where the public or a large workforce is present, this quietness can make the difference between being able to work around them within the law or not at all. This lack of noise pollution - and associated health and safety legislations - means that lifts can be used 24 hours a day in warehouse settings, or even on retail sites. Low noise equipment like this is also perfect for use during exhibitions, conferences and residential areas - where noise pollution laws exist here too. Though as I shall disclose later, this quiet and almost gentle demeanour may not be without its consequences.

While reduced noise is a huge advantage, many reasons to choose electric trucks is their eco-friendliness. Businesses with any commitment to reducing their carbon footprint should explore using electric vehicles whose emissions are an easily crunchable and digestible 0%.

Electric trucks therefore, facilitate reaching 'those targets' without sacrificing efficiency and increasing running costs, and could even open up new opportunities to work closer to the layman and unsociable hours.

But wait. There's a problem here. It's all very well 'savings the planet' and being able to work around the public, saving their hearing. And even saving the business money. However, these benefits - at least in the short-term - may well be unavoidably off-set by increased litigation, time off work, and a decreasing reputation. Why? The answer is that these super quiet machines, that encourage working around the public and at night, risk your business suffering increased incidences of both minor and serious accidents. There are about 8000 reportable accidents involving fork lift trucks every year in the UK. These are often where people have been rammed or crushed, or where the vehicle has attempted a load that's either to heavy or unbalanced and collapsed.

So how can we keep this new technology, improve safety and off-set some of the introduced maintenance costs?

Many forklift trucks already come with added lights and reverse sirens, however the tines are often neglected. This is exactly the area we can now target to increase safety and decrease costs. How? The products are known as forklift protective sleeves. It is a type of extremely durable, yet energy dispersing, poly-urethane, that is fixed to the end of the forklift tines. They primarily save you money by reducing product damage/wastage, and damage to racking and fixtures. They look simple, but the amount of energy effectively absorbed and dispersed is quite incredible on impact (it has to be seen to believed really, luckily there are videos on their website) Colliding into objects at forces that would normally pierce right through a strong ABS crate/pallet, or severely damage racking, is diminished to not even a scratch in most cases where the sleeves are fitted.

They are a high visibility color which improves safety naturally. This bright yellow color at the ends of the tines provide a visual reference point for the driver (a marked improvement on metal that reflects its surroundings). This feature is particularly useful when the tines are at high levels, aiding co-ordination for the driver. And this visual reference point is - equally - able to help the staff loading products on to the forklift to better judge where, say, one load ends and another begins.

So for dramatic reductions in damage to both warehouse facilities, product and people, protect your tines with the only product in the world specifically designed to do so.

For more information about the product, and how we can save you money and improve safety, please visit our UK website.

Engineering Maintenance for Machine Safety

Machines are an important part of modern society. They are needed in almost all walks of life from small machines such as coffee grinders to the massive industrial machines which manufacture our consumer products. All of these machines need to be properly maintained in order to ensure that they continue to work correctly. Without this machine maintenance, the devices could break down, stopping production and sometimes risking the health of the people operating them. In large industrial machines, engineers need to regularly maintain the system, often stripping it down and inspecting every part.

Engineering Maintenance is a discipline which ensures that machines are serviced and maintained regularly. This practice helps to ensure machine safety, helping to keep it running for longer and preventing accidents which could seriously damage the business. By regularly arranging machine maintenance, whether it needs repairs or not, companies keep their tools working for longer and ensures that they comply with government health and safety directives. Effective Engineering maintenance should be performed at a time when the machine is not needed for quick jobs, in order to allow the engineer to closely inspect the device and ensure that it is in good working order.

As well as ensuring machine safety through the inspection and maintenance of the machine, workers need to be protected against the possibility of harm. Engineers can help in this process by installing custom-built machine security guards. These are designed to defend the operator against flying parts or broken pieces from the production line. Working rather like riot shields, these machine security guards deflect the pieces causing them to fall harmlessly to the ground. With new health and safety laws being implemented every year and with people struggling to catch up with the latest design improvements in machinery, these safety guards have become an important part of factory life.

By operating a regular engineering machine maintenance schedule owners of factories can ensure their productivity and the safety of their workers. Machines which are serviced regularly will last for many years and the production line will continue to function. Regular inspections, either yearly or bi-yearly, will allow the engineers to spot problems the minute that they occur and also guarantee that the machines will keep working. Breakdowns cost an industry hundreds of thousands every year and there is no alternative to maintenance. The cost of an annual inspection, even if it means shutting off part of the production, is nothing compared with the cost of losing several weeks work due to the failure of a machine. Keeping the maintenance regular will also keep the machine working safely, which is vital if owners and managers of factories which wish to keep their business running.

Shot Blasting Machines

In Tumblast, a conveyor belt rotates inwards, inside the chamber of the shot blasting machine & the components are loaded on it as per the size & capacity of the machine. The door is than closed. Rotor is switched on for throwing Shots or Grits on the components. By this process, the loaded components get a universal finish. Abrasive medias such as Shots or Grits are continuously fed by the elevator of abrasive media. All the dust extracted in the process goes to the attached dust collector. On completion of desired time period, the door is opened & than the conveyor belt is driven outwards. As a result the components can be removed from the chamber. An automatic loading system can also be attached to the shot / grit blasting machine.

The Tumblast shot / grit blasting machines are available in many sizes, right from a 2 cu ft capacity machine to a 15 & 20 cu ft capacity machines. Some of the sizes are: 20" x 27", 20" x 42", 27" x 36", 30" x 43", 36" x 42", 42" x 42" as well 48" x 48".

Similarly, Hanger model Shot blasting machines are available in Single / Double door type, Centralised hanger type as well a monorail type. In this model, the components are hanged instead of loading on the conveyor belt. Rest of the process is same. The hanger rotates for a universal finish using multiple rotors depending upon requirement. The benefit is that the components do not touch each other in the process of finishing and hence are scratch free.

Swing table model shot blasting machines are suitable for bigger or heavier components or if the smaller parts are to be shot blasted only one side. Many sizes are available from a minimum 36" of table to 120" of table in sngle as well double doors.

Continuous conveyor model shot blasting machines are suitable for smaller components which are to be shot blasted only one side with a single rotor. Multiple sides can be finished by using multiple rotors. Components are fed from one side & removed from the other side duly finished.

The spare parts mostly wearable are made from ni hard or alloy steel to get the maximum life.The main spare parts include the Rotor, Blades, Spring locks, Cage & Impeller, Cage adapter, centre plate, Top segment, Side liners, Round plates as well the conveyor belt. Few precautions are necessary while running the machine.

The Tumblast model of Shot blasting machine if to be used for finishing of smaller components is best suitable and very cost effective. we can be contacted with details of your components for a suitable size & model of shot blasting machine.

Preparing for Christmas Orders

As we begin to enter the autumn and winter months many companies and factories will be preparing for the busiest time of the year. For some companies this time of year yields 80% of their business orders and preparation for this is key to success. How do they manage to keep up with the huge demands?

Large warehouses and despatch depots ramp up their production annually. The last two months of the calendar year in America take many business from the negative red to the positive black. Companies plan for this huge spike in spending, benevolence, giving gifts, and personal consumption of gifts. The season brings a rapid explosion of purchases that must be met with professionalism and timeliness.

Therefore, large companies with large amounts of capital prepare for this surge in sales through increased productivity. The productivity of these warehouses and despatch depots is based on both human capital, brick and mortar capital, and technology capital.

While a surge in machinery is not really possible due to specialized training, maintenance, costs, etc., it still does happen to some degree. Additional forklifts are employed for use through rental companies. Pallet turners are used in abundance. Picking and packing robots are used throughout the calendar year and are really tested for productivity during the final two months of the calendar year.

Surprisingly, while machinery and technology maintain an increasing hold in our economy, nothing can really replace human capital, especially in a time pinch. Without fail, most warehouses experiencing a spike in seasonal productivity rely heavily on human capital. Temporary hiring agencies experience a frenzy of activity during November and December annually. Often, October also displays increases in temporary hiring movements.

Temporary workers are efficient for many reasons, thus making them ideal choices for seasonal spikes in productivity. Seasonal workers can be paid less, do not require certain types of insurance, can do basic labor with minimum training, and do not require long-term investment by the company. Furthermore, they can more easily be released due to the seasonal nature of purchases in material goods in America.

Companies will begin to hire these temporary workers as early as September and as late as December. For the most part, these seasonal workers will be let go immediately after the spending frenzy has ended in the first two weeks of January. Their work in warehouse productivity is not seen by most of America, but is certainly necessary to field the amount of demands that the American people present during the final months of the calendar year.

Choose the Right Loader for Your Forestry Job!

The increased demand for wood in the world market has caused the forest industry to double its amount of production. To increase the level of productivity, heavy-duty vehicles such as forestry bucket trucks are being used in the harvesting, hauling and sorting of timber. Transporting cut timber is extremely difficult without using the proper machinery. Log loaders are a very common type of equipment used in the loading and unloading of large logs. With the many types of this vehicle on the market, it is important to focus on finding the right one to do the job.

Specifics to Assess

There is certain information that a buyer must know in order to purchase the right loader for the job. In fact, many buyers find the buying process easier if they already know exactly what type of equipment they need. This is to ensure that they purchase equipment that is suitable for their intended applications. Following are some of the specifications that should be considered in finding the right piece of equipment for the job.

• Boom Specifications - There are a few things to consider when choosing the right log loader. Primarily, the first thing is to check the individual preferences of the business, especially the boom specifications. Two types of boom lifts are available on the market: the telescopic boom and the knuckle boom. Between these two types, the knuckle boom is probably the best choice due to its versatility.

• Grapples - In addition to choosing the right loader is making a choice of the best grapple. This is a decision that must be made when selecting the size and degree of rotation of the grapple. Sizes vary from one application to another and the attachments have the capacity to fully rotate 360 degrees with great precision. These two factors must be considered when selecting the right log loader. Therefore, a business owner should always consider the long-reach capacity of knuckle boom forestry bucket trucks. Long reach knuckle booms are necessary for picking up logs at a considerable distance.

• Small or Large - When choosing the right log loader, there are many factors to consider. Most of the time, this piece of equipment is used to carry cut timber from the stock pile to the transportation trailer and commonly requires increased boom lifting capacity in order to have more power and reach for better clearance. Some businesses may need to choose a small, yet powerful loader that can be easily rolled down the road to pick up a pile of logs. A stationary version with hydraulic outriggers to increase steadiness may also be needed for stability and balance to provide safety while performing and finishing the job. It is imperative to determine the type of tasks the business performs in order to choose the proper equipment to complete all the jobs in an efficient manner.

Log loaders are necessary to transport cut timber onto transportation trucks. Since this equipment is very important, buyers must have vital details about what type of jobs are performed by the business in order to choose the proper piece of equipment to perform these tasks. Boom length, rated lifting capacity, and grapple size are only a few of the components of the vehicle that must be considered when choosing the right loader to do the job!

Cobalt - A Critical Rare Industrial Metal Vital to US Energy Policy

Cobalt was discovered around 1736 by Georg Brandt a Swedish chemist. The element was found to give glass a hint of blue. For centuries cobalt has been used as a pigment in glass and porcelain. Chinese artisans used it to color their vases and other ceramics. Over the last few decades cobalt has had a grand resurgence. In the late 1970´s Zaire, now Democratic Republic of Congo had a bloody civil war which cut off the world from much of the production of cobalt. During this time alternatives had to be found because the price of the rare industrial metal accelerated beyond what industry was willing to pay. Since then the amount of uses for Cobalt have expanded to the point where the US Department of Energy added cobalt to its, ¨Critical Materials¨, list.

This metal has found its way into many of our technological applications used today. Cobalt´s uses include aerospace, green tech, pigments, dyes, batteries, wireless technology, computers, magnets, desulfurization of crude oil, orthopedic implants and high-strength superalloys. The use of cobalt in superalloys is mainly due to its corrosion resistance, temperature stability, and wear resistance. These attributes make it highly suitable to aircraft engines and gas turbines. The US Department of Energy predicts that electric powered vehicles (PHEVs and EVs) will need an estimated 9.4 kg each of cobalt. By 2012 the estimated sales of hybrid and electric vehicles worldwide is approximately 2.2 Million, and by 2015 to be at least 10% of the world auto market. Wind energy also uses large amounts of cobalt within its turbine blades and samarium-cobalt magnets.

The US Department of Energy has made it clear that any rare industrial metal used in clean energy technology such as electric vehicles, solar cells, wind turbines and energy efficient lighting will be deemed critical. The problem for the USA lies in its supply of cobalt. Still today over 40% of global production is from The Democratic Republic of Congo. China has an agreement with the DRC to export all of the cobalt to China where it is refined. Once again China has a stranglehold on rare industrial metals similar to what is happening in the rare earth market. The big difference is with rare industrial metals it is much more difficult to expand supply. There are very few known deposits of cobalt, most production is a by-product of copper production. The USA has been recycling 15% of its cobalt and importing 85% from foreign sources. The bad news for the USA is that China needs cobalt as well. Currently the USA has only one mine that is being prepped for production in Idaho. This mine will primarily produce cobalt totaling 3% of the global supply. The main players in cobalt refining are China, Finland and Canada. According to the USGS in 2010 the total world production of cobalt was around 88,000t.

If a person is looking for a way to profit from cobalt there are a few options. A person could buy stocks of mining companies that have rights to cobalt mines, which is the traditional method. Recently the London Metals Exchange (LME) launched a cobalt contract traded in 1 metric ton lots of 99.3% pure cobalt. The other option is buying cobalt in Germany and having it stored 100% allocated in Switzerland. A company that offers the option of buying cobalt in smaller quantities is Swiss Metal Assets. Although cobalt is only one of the various rare industrial metals they offer.

Manufacturing Computer Components Through Plastic Injection Molding

Electronics have been propelled to ubiquity in today's modern age, with new devices and new versions of existing ones being developed at a pace that would surprise consumers. What most people don't know is that a considerable number of these electronic devices rely heavily on the plastic injection molding process to function effectively.

Today, electronics manufacturers focus on ensuring functionality and convenience. Electronics such as computers and mobile phones must have more functions while being slimmer and more streamlined. Before manufacturers used plastic in creating parts, it was understood that when things were bigger, it was better by virtue of the size of its internal mechanisms. But today, gadgets are able to do so much more and yet come in significantly more compact packages.

All these technological developments can be partially credited to advances in machining and molding technology. In order to make smaller, more convenient machines, it naturally follows that internal components must also become smaller. Manufacturers of today rely on plastic injection molding to create small yet complicated parts out of plastic, which has proven to be a highly durable, reliable and affordable material.

While crafting large parts may be difficult, creating smaller items is often even more so. Unlike bigger parts and products, small components are usually more detailed, requiring precise crafting and machining. These small parts must be able to work with other different parts to function as a unit. They must also be precise, as the slightest error can render these ineffective and even useless.

To create small yet complicated parts, companies use the combination of CNC machining and injection molding. With the use of a 3D render of the final product, the computer generates a mold that matches the design with high accuracy and close tolerances. The computer then automatically mills, cuts and creates the mold from which the final product is made.

The process of plastic injection molding involves inserting a heated mixture of thermoplastic and thermosetting plastics into a mold. When it cools, the plastic is released. After the parts have been die cut, the plastic component is ready for installation. This technology allows manufacturers to create identical yet detailed parts in large runs.

Manufacturing electronics, particularly those will small parts, requires sophisticated equipment and specialized skills to ensure high quality output. Given this, the injection molding process is best entrusted to professionals who not only possess these, but also implement stringent quality assurance measures.

Renewable Energy Training Opportunities

The popularity of renewable energy sources and renewable technologies is constantly increasing. Homeowners and business owners are becoming ethically aware consumers. As a result they are prepared to invest thousands of pounds in to renewable technologies such as solar panels, in the knowledge that they will reap the financial rewards and take advantage of the governmental incentives available to them.

As demand for these products continue to grow, there is a need for more qualified technicians and installers to cope with this demand and help the government push towards delivering a more sustainable future. With unemployment at an all-time high, and demand for sustainable products always increasing, there may be no better time to take advantage of these training opportunities than now.

• Introductory Courses - Introductory courses into sustainable technology are available to you for a range of technologies which include solar thermal, solar panels, rainwater harvesting and under floor heating to name a few. For those looking to start a career in a completely new line of work or for those looking to expand their current repertoire, this is a great opportunity to get started and learn the basics of these technologies and how to correctly install them. Generally the courses will only be two days, which means you can quickly complete and claim your new qualification in no time.

• City & Guilds Qualification Courses - There are a range of building and construction qualifications available from City and Guilds, which can help any building professional kick-start their career, enhance their skills and improve their employability. The range of construction qualifications available will help to make you a master when it comes to installing a range of renewable technologies which include solar panel and heat pump installation and solar hot water installation.

• Solar Photovoltaic Micro-generation Certification Scheme (MCS Accreditation) - Obtaining an MCS accreditation can do wonders for your professional career, your prospects and the perception of your company. The course is available to new or existing installers looking to obtain MCS accreditation, installers who have previously failed their inspection or their yearly MCS audit and any MCS installers who are looking to further expand their skills in MCS certified technologies. MCS schemes are also heavily related to sustainable incentives from the government which include feed-in-tariffs and the renewable heat incentive.

• Assessor Courses - Due to the European Energy Performance of buildings directive and the UK regulations for any homeowners who are looking to sell or let their domestic property, it is now standard procedure to have an Energy Performance Certificate (EPC) for any domestic or commercial property. As such, there is huge demand for qualified building assessors who would be able to examine and approve any new build property and confirm it meets with building regulations. The Domestic Energy Assessor (DEA) Training and Certification, Construction Energy Assessor (OCEA) Training and Certification and Non-Domestic Energy Assessment (NDEA) Training and Certification will all provide you with the skills and qualifications to carry out these jobs and become a qualified assessor.

Looking for Improved Accuracy in Gas Flow Measurements?

The looking to improve accuracy and ease of operation, in a historically challenging gas measurement application.

In Canada the implementation of Enhanced Production Audit Program (EPAP) will increase the need for more accurate flow measurement data.

Technical Challenge

Energy producers are constantly looking at ways to improve their standard natural gas measurement points within their operations. One critical area that requires consistent and reliable measurement is fuel gas meters typically located at compressor sites. On larger compressors or sites with multiple compressors where daily average consumption exceeds 0.5 em/day ERCB Directive 17 stipulates that a permanent measurement device must be installed for all fuel gas consumption.

A Case study: 2 large energy producers with part of their operations in Northwestern Alberta and Northeastern B.C. were faced with finding and standardizing on a solution that would meet the challenges posed by measuring fuel gas accurately and consistently in a reliable and economic package that would also meet Directive 17 compliance. The importance is being underscored with the full scale implementation of EPAP (Enhanced Production Audit Program) in 2011 industry wide.

Traditional means of measuring fuel gas fell short of their goals in meeting this standard. Orifice plates lacked the turndown range required to measure both the nominal fuel gas consumption and the start gas when a compressor is activated. The companies preferred a device that could handle both measurements seamlessly. Additionally, the lower flow ranges typically found on a fuel gas line posed a problem due to an orifice plate's high pressure drop and accuracy was compromised as a result.

While a standard pressure and temperature coefficient can be applied to complete the flow measurement rate, this introduced a manual process by which the operators/supervisors had to adhere to for completion of their calculations. In addition, PD meters were susceptible to damage due to over ranging when a compressor was started resulting in costly maintenance and downtime. A solution was needed.

The Flowstar Solution

Both companies found their solution in a gas measurement system consisting of a high accuracy, robust gas turbine in concert with an electronic flow computer (EFM).

The gas turbine provides excellent accuracy profiles (+/- 2%) in a 316 stainless steel constructed body and internal components that utilize ceramic, self lubricating, low drag bearings. A 40:1 turndown ratio ensures that both the nominal fuel gas and the compressor start gas are accurately measured. As fuel gas lines are typically smaller in design (1") the low flows seen are easily measured by a 1" turbine. Flexibility is built into the turbines as the rotor pitch can be changed to as low as 45 degrees to capture even lower flows at similar pressures. The standard pitch is 15 degrees.

The Hawk 9500 EFM delivers exceptional operational performance with a rated accuracy of +/- 0.05% full scale on pressure and +/- 0.5% C on temperature. The Hawk 9500 performs fully compensated flow rate calculations to AGA7 (rotary turbines) and AGA8-92 (gas compressibility) standards. It is also API Chapter 21 audit trail compliant. With its Class I Div I IS rating and IS lithium ion battery pack, area classifications are not an issue and offer the end user ease of installation and smaller footprint. A communication board can be activated to support RS 485 Modbus communications to a SCADA host or PLC.

Results

Both energy companies have implemented the Flowstar gas measurement solution on a number of compressors with excellent results to date. With this arrangement it minimized operator involvement and interruptions and also provided them with a 1 stop service point for any future technical adjustments or troubleshooting. When producing a trending graph of historical data on one particular 1" line it produced a flow rate of 0.5 em/day at 110 psi. The peak volume on compressor start up, however, reached as high as 14 em/day, representing a turndown ratio of 28:1, well within the range.

In certain cases, as with the other energy producers, a mechanical pipe run with the gas turbine was provided without the Hawk9500 at certain locations as an existing RTU was already on site. The introduction of a pre-amplifier easily supported this type of integration. Their operators have commented positively on the overall reliability of the gas turbine and the relatively small footprint of the meter run piping package. Process conditions are favourable on the fuel gas line as the meter is typically installed downstream of a fuel gas scrubber. The operators also like the convenience of noting instantaneous data on the Hawk 9500 display (current flow rate, pressure and temperature and up to 40 previous days of historical production) and the ability to download stored data onto the SD card (over 1 year with 1 minute logging). This data is easily transformed into production reports that are provided to the companies' production accountants electronically.

EPAP will help guide the producers to measure gas more accurately and there are only a few options available to ensure accuracy with ease of use out in the field.

SIGIT Products

Article Source: http://EzineArticles.com/?expert=Sean_A_Sandhurst

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How to Select Simple Primary and Secondary Protection for a Transformer

For this example, we'll use a 3-phase transformer rated at 500kVA, 12470V Primary to 480/277V Secondary.

The first step is to calculate the primary and secondary amps.

There are a number of shortcuts you can use to get you there, but I prefer to break the problem into single-phase pieces and calculate in steps.

1) 500kVA / 3.0 = 166.7 kVA per phase.

2) 12470V L-L / sqrt(3) = 7200V L-N
note: even if the primary is Delta, this approximation still works.

3) 166700 VA / 7200V = 23.2 Amps on the Primary

4) 166700 VA / 277V = 602 Amps on the Secondary

The second step is to pick out a primary fuse.

As a rule of thumb, pick out an "E" rated (Also known as a "backup" fuse) that has a basic ampacity of 150% of the primary current. Where 150% of the primary current doesn't correspond to a standard fuse size, pick the next size up.

In this example, we'll work with the Edison/Cooper brand.

Google "edison e-rated medium voltage 15.5 kV fuses" and open the first PDF that comes up in the search results.

Under the 15.5kV class fuses, we would choose the 40E model MV155F1DBX40E

The 40E simply means it's a 40A rated fuse, with an E-Class curve.

Refer to NEMA for more information on what the "E" means - it's a pretty loose definition and you'll find that different manufacturers E-rated fused can vary quite significantly.

So... the next thing we need to do is check that the transformer inrush current can pass without blowing the fuse.

Look at the chart on the left of page 3 of the above Edison/Cooper PDF.

Now a conservative approach to determining transformer inrush is to simply take the primary current and multiply it by 12, and plot that on the chart at 0.1 second.

On that chart, we see that 278A @ 0.1s is well below the 40E curve. In fact, it just fits below the 25E minimum-melt curve.

If we wanted to minimise the arc-flash hazard on the secondary side, using this model of fuse, we may want to select the 25E for the fastest possible clearing time that still allows the inrush current to pass. The 30E or 40E would also be acceptable, especially if you have large downstream motors or other loads with large inrush currents.

Next, select a circuit breaker for the secondary side.

When choosing a breaker, check carefully the % rating. Breakers <1000A are often "80% rated" meaning, for example, a 100A breaker can only be relied upon for 80A of continuous load current.

A 100% breaker, on the other hand, means just that.

In this case, the easiest choice is a 600A breaker that is 100% rated.

Alternatively, 600/0.8 = 750, you could choose a 750A breaker that is 80% rated, although an 800A breaker is probably the nearest standard size available.

Vision Systems for Automation

Vision systems are the eyes that help automation complete the manufacture of products in the most accurate way. Usually a vision system is made up of any one of various cameras or sensors that is connected to the controller of the manufacturing operations. Through the connection the vision system sends images or other feedback to the controller to continually let the "brain" know what is the current state of manufacturing operation at every moment. The controller can make a decision about a next step in the manufacturing process based on the images that it receives from one or more vision systems or sensors. Instructions that can come from the controller to the manufacturing devices as a result of images it receives can be anything from "continue on to the next step" to "totally shutdown manufacturing" and everything in between. Vision systems have become part of the safety process that keeps manufacturing running. It is important for devices to be stopped when parts are products are out-of-place or not available for other devices to process. In some cases if devices are not shut down when parts are not available, equipment could be damaged, bringing the entire manufacturing operation down for costly repairs.

Vision systems have moved from being devices that are nice to have in manufacturing to necessities for making manufacturing as efficient as possible. When these systems were first introduced for use in manufacturing the technology was adequate, but did not give vision devices all the abilities that they have today. The main purpose of vision systems are to examine the state of parts and products during the manufacturing process. This inspection is done to determine positions of pieces, accuracy of production, and availability of products. The accuracy of production relates to the inspection of products in the various phases of manufacturing. If a product has been partially assembled in such a way that the completion of its assembly would cause the manufacturing process to be put into jeopardy, the controller will likely shutdown the process. In some cases the controller will have the option to send an improperly assembled product off the production line so that a full shutdown is not necessary. Technology has brought forth the 3-D and high definition cameras that the work of any vision system very effective.

Another use of vision and sensor systems is in the determination the position of parts and partially assembled as they move down the production line. In some production scenarios parts move down a belt toward an assembly operation. The part are in random positions as they move along. In order for the next step in the manufacturing to be completed, a robotic device is required to pick up each part so that it can be joined with another part to continue the process. The vision system make the robotic aware of the position of each incoming part so that it can be picked up efficiently. Without the vision system in this case high-speed production would not be possible. It is also possible that the vision system in this case would act as a safety mechanism. It would alarm the controller if there were no parts available on the production line so that precautions could be taken.

Usually the setup of a vision system is not very complicated and the system can be used in production with very little training of personnel. The benefit of a well-coordinated vision system brings a great deal of utility to your production environment without very much expense and effort. In some cases such a system includes a controller for the vision, an operating system, an intelligent camera, and the applications software to run the camera, all bundled together as a single unit. Usually the operating system is Windows, which is well-known and easy to use. Often these types of systems are used in packaging functions like inspecting the inside of containers or reviewing the amount of contents in containers in a filling operation. Sometimes they are also used in label placement inspection or in the inspection of tamper-resistance seals on containers. Vision is effective in reviewing package and container integrity or inspecting for contaminants inside product containers. Package counting and the confirmation of product inserts are other applications.

Considerations for applying a vision application to your manufacturing should include such thoughts as the speed that your production line will require for reduced impact on overall line speed. You should review all the areas that will need vision in your manufacturing to make sure that adequate vision coverage is in place to get optimum return. Review the environmental requirements of a possible vision option o make sure your production will allow what the system needs to do the job as you expect it to be done. This would include temperature and lighting considerations.

Purchasing Tips for a Construction Business

Since I was very young, I have been exposed to the business world. My dad owned a construction company and every day, he would bring me to work with him. I learned so many things about construction tools and equipment. I remember there came a time when we needed to buy new equipment and trucks because the old ones were no longer working well. I was excited as we checked out the different models that we needed for my father's business.

After so many years in the construction business, my father decided to retire. With everything he taught me, he was sure that I would be able to manage the business. So he handed down not only the management, but the ownership as well.

Until today, I still look forward to buying new trucks and equipment. I know all the details and specs of the equipment we needed. I am familiar with all the brands and am always eager to learn about equipment advancements.

Another thing that I inherited from my father is practicality. He said that when I needed to buy new equipment, I should not use the profits or the savings from the business. Getting a loan is always the best way to look for a source of funds. This is so there is enough money going around the business. A truck loan helped in managing the expenses and the cash easier. The advantage of a truck and equipment loan is that even if I hadn't fully paid it yet, I get to use the equipment in my business already. Productivity and profits were increased simply because the lending company immediately provided me with the needed down payment to get the ball rolling.

With the popularity of truck and different kinds of loans, more banks and lending companies have started offering these. So I would advice those who need new equipment to consider getting a truck and tractor or equipment loan. Compare the different interest rates that banks and lending companies have. Aside from this, you should thoroughly do a research and read about their loan policies. Although much information seems boring, you have to be patient about it. Missing out the fine print can lead to mistakes.

I suggest that you get an unsecured loan so you don't have to provide any collateral anymore. This type of loan is also easier to apply for. In fact, many companies have websites where you can just fill out the form and send immediately. As per my experience, loans get approved on the day of application, given that your requirements are complete. You may get the needed cash within 48 hours from approval. If you have a bad credit history, then you can get bad credit loans from lending companies.

Before purchasing brand new equipment, remember to:

• Do a research on the latest equipment needed
• Set a budget for your purchases
• Personally visit the equipment store and check the details of the item
• Look for a company that can give you a loan
• Apply for the loan and wait for a few days before obtaining the cash
• Buy the needed equipment so you can use it in your business immediately

Mast Boom Lifts

Mast boom lifts (also known as 'stick booms') are a type of aerial work platform with a fixed arm, or mast, which can be extended to provide access to high areas via a work platform. The outreach and capacity of mast booms varies between manufacturer and type.

Choosing between a scissor lift and a boom lift depends on the requirements of your job, such as the space you have to work in and the outreach and manoeuvrability you need. A mast boom is a great powered access option as it sits somewhere between a scissor lift and an articulated boom lift.

It's important to choose an aerial work platform that suits your needs correctly, but you also don't want to pay for an expensive machine that is not entirely essential. A mast boom is appropriate for many different jobs, as it provides a good outreach and versatility.

Mast booms have a telescopic mast which provides access to your desired working height and they often have very compact dimensions, which means they can work in small spaces. Mast booms also have a slewing capability of 180 degrees or more. A scissor lift, in comparison, can not move horizontally (unless you move the entire platform), and may not provide the same access when you need to reach 'up and over' and obstacle. Articulated boom lifts are slightly different in that they have arms that hinge, and so provide a more flexible way of accessing different areas. All these different types of aerial platform have their own benefits and should be chosen for their attributes in relation to the job at hand.

Mast booms are often seen as a niche product, despite being around for over 20 years, and providing the same access as many of the same jobs as other platforms, including:

• Electrical work
• Painting
• Construction
• Maintenance and repairs
• Installation
• Events

Working heights of mast booms can extend up to a massive 135m, and can provide large outreaches for dealing with tricky access issues. These large booms are generally powered by diesel. Though scissor lifts are most commonly used for access in many industries, boom lifts can be even more versatile and provide additional reach and access that scissor lifts cannot.

All types of aerial work platform can be rented as well as bought, and this can be a cost-effective option if your needs are only temporary. Used boom lifts and other powered access machines are another way to save money, though check carefully that the model you are purchasing has been fully refurbished and preferably comes with a warranty.

Platform Sales provides a comprehensive sales and hire service, providing powered access equipment and training to a range of industries in the UK - whatever your access requirement, we have the solution.

Power Generation Services for Commercial Buildings

Most buildings require one or more services offered by a commercial power solution provider, especially if they contain a backup generator system (a.k.a. Genset). Electricity generation systems need scheduled maintenance and testing, occasional upgrades to improve efficiency, and safety inspections. If you have recently implemented a backup generator, or are considering implementing one, it is important to be familiar with the services offered by commercial power solution providers. Below are seven power generation services that are commonly needed in commercial buildings.

Scheduled maintenance
There are several types of scheduled maintenance, including maintenance for transfer switches, switchgear, and generators. Performed monthly, scheduled maintenance is one of the most critical power generation services, and should always be performed by an expert in commercial electrical systems.

Arc Flash Analysis
Arc flash analysis is a critical safety practice that reduces the likelihood of arc flashes that could lead to fires, injuries, and even fatalities. Arc flash analysis should comply with the guidelines of National Fire Protection Association (NFPA) Code 70E.

Load bank testing
In a load bank test, a Genset is tested using a portable load bank that delivers a load to the Genset. A load bank test is performed on generators that fail to operate at a minimum of 30% of their nameplate Kilowatt rating for at least thirty minutes during monthly tests. Guidelines for load bank testing are contained in the NFPA 110.

Breaker testing
Testing a building's breakers is a critical safety practice that helps to protect equipment and workers from dangerous arc events. In the absence of breaker testing, the first sign that a breaker needs replacement or repair could be an ejected arc flash that causes electrocution and fire.

Modernization and retrofits
Modernization and retrofit measures can improve the technology of existing generators, extending their lifespan. Modernization measures and retrofits can add several years to a generator's life-a valuable option considering the price of a new industrial Genset.

Generator rental
Generator rentals are useful in the following situations, among others: when an existing Genset is down for repairs or upgrades, when an existing generator is being replaced, or when a building project requires more electricity than can be provided by a building's electrical system. If you need to rent a generator, calling a generator service provider is the best option.

Infrared scanning
Infrared scanning is a preventative maintenance measure that identifies abnormal heating patterns in electrical components, patterns that could signify a serious problem in its infancy. Often, an entire facility can be scanned in a single day, and some repairs can be made on the spot. Infrared scanning should be performed annually, and can lead to significant cost savings by identifying problems early.

What services does your building need?

Different buildings need different power generation services. If you have recently purchased a building, the best way to determine its service needs is to contact a commercial power solution provider, and schedule an appointment with a technician. With the right services performed on the right schedule, electrical equipment can remain safe and free of unexpected problems.

Standby Power Systems: Frequently Asked Questions

A standby generator offers different benefits to different facilities. From facilities that require constant power to ones that do not, the electricity supplied by an industrial generator can range from critical to convenient. In each case, however, generators are part of emergency power supply systems (EPSS) that consist of several components, require various services, and have multiple implementation options. If you are considering implementing an industrial generator to provide electricity during outages, but you have questions about standby power systems, the answers below may help.

How much does an EPSS cost to implement?

Depending on the amount of electricity a facility uses, an industrial system could cost from under $50,000 to over $1 million. In general, the more electricity a building requires, the greater the cost of its EPSS. Instead of depending on ballpark figures, the best approach is to have your building evaluated by professionals.

How long can an industrial EPSS last?

Due to its industrial grade construction, it is not uncommon for an industrial system to last over thirty years. With occasional modernization measures and/or retrofitting, some systems can last for around fifty years. Buying an industrial generator is a significant investment, but it can last for decades.

What types of maintenance does an EPSS require?

Standby power systemsrequire certain types of regular maintenance, particularly: switchgear maintenance, transfer switch maintenance, and generator maintenance, which are carried out on a monthly basis in accordance with guidelines set forth in National Fire Protection Association (NFPA) Code 110.

What types of testing does an EPSS require?

Standby power systemsrequire monthly and annual testing that assesses their readiness to respond to outages. Manipulating circuits to trigger reactions that should occur during an outage is done in monthly testing, while annual tests fully simulate an outage. Other types of equipment testing, such as breaker testing, are often performed on the same date as generator tests. Guidelines for Genset testing are set forth in NFPA 110.

When is load bank testing performed?

A load bank test is usually performed when a generator fails to operate at a minimum of 30% of its Kilowatt nameplate rating for thirty minutes during a monthly test. A portable load bank that delivers the load to a generator is typically used for the test.

How can you tell when an EPSS needs replacement?
Generator replacement is recommended when the cost of repairing, retrofitting, or modernizing a generator exceeds the worth of performing the measure in question. Due to its high cost, the failure of a generator's motor often leads to the purchase of a new Genset.

How should a commercial power solutions provider be selected?
A provider should be selected on two counts: the range of its services, and its level of customer service. A company should contract with a provider that can supply all the services it could possibly need-now and in the future-and can deliver them on a timely basis. For example, a provider arriving onsite within two hours is much better than one that takes four hours.

NFPA 110 Generator Testing: An Overview

The National Fire Protection Association (NFPA) creates minimum standards for fire safety, egress safety, and other types of safety in commercial buildings. Included in the NFPA's safety standards is a code for testing and maintaining emergency power supply systems (EPSS): NFPA 110. If your building contains a generator, practicing the code can ensure that it performs as expected during a power outage. Below are the basic testing requirements for industrial generators according to NFPA 110. For a full list of requirements, building managers should contact the NFPA, or a commercial power solutions provider.

NFPAtesting for industrial generators
If a building is required to have a Level 1 or Level 2 generator, the following types of NFPA 110 generator testing should be performed in preparation for a power outage. Experts trained in EPSS technology should carry out these tests.

Section 8.4.2
An EPSS must be exercised under load once a month for at least thirty minutes. The test should be conducted using one of the following two methods:  

• Loading that achieves a minimum temperature for exhaust gas based on the manufacturer's recommendations.
• Under normal operating temperature while running at a minimum of 30% of the nameplate Kilowatt rating.

For generators that cannot operate until their water pressure and oil pressure have stabilized, the tests above should be terminated before the thirty minutes expire. This reduces the time a generator is unavailable for operation.

Section 8.2.4.3
Diesel powered generators that do not meet the requirements set forth in Section 8.4.2 should be exercised monthly for at least thirty minutes using the available EPSS load, and yearly for two hours using a supplied load. For yearly tests, the two hours should be broken down as follows:

• 30 minutes at 25% of the nameplate Kilowatt rating.
• 30 minutes at 50% of the nameplate Kilowatt rating.
• 60 minutes at 75% of the nameplate Kilowatt rating.

A load bank can provide the "supplied load" required for tests under Section 8.2.4.3. Load banks, as well as diesel-powered generators, are available for short-term and long-term rental from commercial power solution providers.

The scope and benefits of NFPA EPSS testing

The requirements above are not a complete list of NFPA 110 generator testing requirements. To determine the necessary maintenance measures and tests needed for your unique generator, consult the code in its entirety. By following its requirements, the following benefits can be realized:

• Improved reliability of emergency backup lighting.
• Reduced possibility of electricity interruption in critical facilities.
• Reduced layover time in break before make generators.
• Improved emergency power generation capacity.

Implementing an EPSS is the first step toward powering your building in the event of a power outage, and regular maintenance and tests are needed to ensure its function. To have monthly and annual tests performed; building managers should consult commercial power solution providers. Other services provided by commercial power solutions providers include: retrofitting and modernization measures, new installations, infrared scanning, breaker tests, arc flash analysis and training, healthcare utility management, generator rentals, scheduled maintenance, and repairs.

NFPA 110 Requirements for Transfer Switch Maintenance

The National Fire Protection Association (NFPA) develops and maintains minimum safety standards for commercial and large residential buildings. Expressed as safety codes, the standards address the safety of various building systems, including emergency power supply systems (EPSS). Requirements for EPSS maintenance inspections are contained in the NFPA 110, which also addresses generator testing. Below are requirements for generator transfer switch maintenance according to the NFPA 110.

Transfer Switch Maintenance Requirements
The following is an overview, not a complete documentation, of transfer switch inspection requirements. For full documentation of NFPA 110 requirements, building managers should contact the NFPA, or an emergency power solution provider.

Maintaining a transfer switch is a critical part of generator maintenance. The NFPA's inspection requirements for switches for Level 1 and Level 2 generators are as follows:

Examination for Overheating
Overheating eventually produces visual evidence, particularly the discoloration or blistering of insulation found on conductors. The surfaces of conductors may also show signs of pitting or melting. These signs may be the result of arcing, and usually precipitate repairs and/or parts replacement.

Examination for Dust and Dirt
Regardless of the cleanliness of a generator room, dust and dirt gradually accumulate on the surface and inner workings of switches. Removing dust and dirt prevents their accumulation from sabotaging electrical connections and contacts.

Examination of connections
If the electrical connections of a switch malfunction, it will not transmit the signal to initiate generator startup. Connections should be inspected for looseness and signs of overheating. If looseness or overheating is detected, connections should be tightened or replaced.

Examination of contacts
Contacts should be inspected for looseness, signs of corrosion, and overheating. Signs of corrosion may appear as oxidization or acidic deterioration, and overheating may leave carbon traces. If the first two signs are present, contacts should be replaced. If the third sign is present, further examination should occur.

The inspections above are recommended on an annual basis. However, the 2005 edition of the NFPA 110 recommends them on a quarterly basis, with a single major inspection and three minor inspections every year. This inspection schedule could be valuable for buildings that require constant electricity to support critical functions, such as hospitals, data centers, and first response organizations.

Scheduling Transfer Switch Inspections
Maintenance and testing requirements for transfer switches are contained in Chapter 8 of the NFPA 110. Section 8.4.5 states that a "properly instructed individual" (i.e. a person with extensive training in EPSS examination procedures) should oversee routine EPSS inspections. If you do not employ a worker who is trained in EPSS inspection, hiring a commercial power solution provider that specializes in emergency power equipment testing and inspection is the best option.

In addition to performing the inspections above, a commercial power solutions provider may also perform infrared scanning-a preventative maintenance measure that identifies problems in EPSS components before they cause more extensive problems. Other services performed by a commercial power solutions provider include: retrofits and modernization measures, breaker testing, new installations, repairs, arc flash analysis and training, healthcare utility management, generator rentals, scheduled maintenance, and load bank testing.

Pick and Place Automation

The ultimate in pick and place automation is being able to control an entire product handling system from a single controller. In a lot of cases in the past pick and place automation has been accomplished by having a series of pick and place robotics working in tandem with each other, but each was controlled by its own controller. There was a need for very fine synchronization between the controllers to accomplish the tasks required in manufacturing. Anyone can see that the coordination of application programs that instruct each device in the tasks that they need perform needs to be fine tuned since the actions of one device will impact the actions of another device. There is a domino effect established in work that is done on the production line. Add to the scenario the requirement of super high speed and the synchronization becomes even more critical.

Fortunately technology has been able to come up with an effective replacement for the pick and place automation scenario as described above. The state-of-the-art solution lies in the fact that there are controllers available now that combine motion, logic, and robotic control into a single controller. These highly controlled and high speed devices allow for efficient multitasking. Synchronization with belt speed allows the multiple devices that are instructed by a single controller to do insertion of products into primary and then secondary wrapping. It is possible to operate three robotic devices from the controller, but a fourth can be added that does not cause degradation in performance.

Logistics for this type system are made much easier because of the characteristics of the devices. It is much easier to install this controller and it subordinate devices. There is no need for interfaces to be installed so that each device can communicate with other devices. This says nothing of the tuning that must be done to synchronize several automation machines hooked to separate controllers. All the coordination happens in the single controller. The synchronization has to make sure that collision prevention is in place and setup correctly. With the single controller, this is not needed. The space that the single controller occupies is much less than its counterpart of multiple controllers. There is a dramatic reduction in the space for the single controller and the amount of space and time required for installation of cabling.

These state-of-the-art controllers also offer significant expandability in kinematics, being able to control 16 kinematics simultaneously. There is also the ability to add more axes and synchronized belts for further utility. Reducing the number of interfaces for such a system while cutting the cost of added components for automation are great attractions for such a set of devices. As technology continues to contribute to automation it is likely that this package of devices will become smaller in size and greater in flexibility and utility.

The application of the pick and place automation is very well-suited to the packaging of food and other products. Manufacturers of multiple lines of small food products can readily apply this set of devices in their manufacturing lines with almost immediate payback. Such a scenario lends itself very well to being used for multiple production jobs where pick and place and multiple product wrappings may be required for each product. The changeover from one production job to another is very efficient and will cut down significantly on the expense of setup for each production job. To make the entire production environment as efficient as possible it would be necessary to have a complete library of application programs completed and tested, ready to be loaded into the controller. This would further streamline the changeover process between jobs that could be done on the line where these devices are installed.

The combination of pick and place automation and vision or sensor systems makes for a very efficient automation solution for manufacturing. The sensory component gives feedback to the robotic component as to the location of parts that should be the attention of the pick and place operation. Add the speed component into this combination of devices and you have a very speedy automation operation. Feedback from the sensory device to the controller is so fast that it easily stays ahead of the movement of the pick and place device. The next instruction is ready for the robotic as soon as it has told the controller that it is ready to receive it. Having three pick and place robotics attached to the controller does not cause any degradation for the overall process. A high degree of accuracy is also achieved by all the material movement devices as they complete the manufacturing instructions.

Welding Tips for Plant Maintenance

Maintaining a plant can encompasses many tasks, welding typically plays a significant roll. As welding repairs may not occur on a day-to-day basis, here are some tips to ensure that your welding skills are kept up to par.

1. Safety.

First you must ensure that you have read the instruction manual for your equipment. This will include important safety information plus instructions to get the most out of your welding equipment. Even if you're only doing a quick weld, you should wear the proper safety equipment: welding gloves, non-flammable pants and shoes, welding jacket, beanie or hat, and proper welding helmet. You should also cover all exposed skin to avoid effects of arc rays. You should also try not to breathe in any of the welding fumes as it can be quite hazardous to your health. Another excellent tool is a helmet that automatically darkens. This way you can position your gun or electrode without having to remove your helmet.

2. Preparation.
You should always wipe the area that you're going to weld first before starting. This will ensure the best quality of weld. It is common for plant welders to use one wire for MIG welding. The one with the most flexibility is.035 in. along with a 75/25 Argon gas mixture. Your contact tube, gun liner and drive rolls should always match the wire size you are using. You should also clean the gun liner and drive rolls every once in a while, and keep your gun nozzle clean of spatter. The contact should be replaced if it is blocked or not feeding well. Stick welding usually calls for a 3/32 in. diameter for material that is one-eighth of an inch or thinner and a one-eighth diameter rod for anything larger. The common electrodes are 6010, 6011, 6013, 7018 and 7024. If you are working on higher strength steels, you should use a 7018 rod. This will also present a better bead appearance.

3. A good weld.

One of the most important things to making a good weld is the position that you hold the gun. Always find a comfortable position that will allow you to use both hands to steady the gun if necessary. If you are making an especially long weld, it is always a good idea to rehearse the weld beforehand so that you can keep up a steady travel speed, arc length and electrode angle. To create a good weld, you must also keep a steady speed along the length of the weld, as going too fast or going too slow in certain spots will be obvious on the weld when complete.

For all your plant welding needs contact Ace Custom Fabrication today. Our team of certified welders will ensure that your project is completed quickly and efficiently.

Biomass Fuels - What Are They and Why Are They Important?

"Biomass" has become something of a buzzword in recent years but what exactly does it mean? It means woody materials or agricultural waste, (such as rice hulls, sugar cane, or corn stalks), as well as animal waste. These can be used as fuels to produce bioenergy. Biomass fuels are currently second only to water as a source of renewable power. Even garbage (carbon, hydrogen, and oxygen based) can be used as a BF (Biomass Fuel). Waste products from the pulp, paper, and paperboard industries are a large source of biomass fuels in the United States. BF sources range by geographic region. Forest byproducts are the largest source of biomass fuels in the U.S., while rice hulls are big in southeast Asia.

Mankind has been using biomass fuels ever since we discovered how to make fire and what we needed to keep it burning. Everything from urban wood waste to animal dung can be burned to produce bioenergy. The best thing about BF is that it consists of things we already have or can easily produce - things that might otherwise go into the landfill. Speaking of landfills, even the methane gas that is emitted from landfills can be burned as a BF to produce electricity. The fact that these things are already available on earth means that they are already emitting carbon into the atmosphere, as opposed to coal, which, when burned, releases carbon that has been sequestered underground for thousands of years, adding significantly to the present carbon load.

According to the U.S. Energy Information Administration (EIA), biomass fuels provided about 4% of the energy used in 2010. Biomass advantages include reducing our reliance on fossil fuels, which has both environmental and geopolitical benefits. Using biomass power helps reduce the amount of waste that goes into landfills, which clearly has both environmental and economic advantages.

Biomass fuels are readily available around the world, making them a clear winner in the search for a renewable fuel source. Biomass engineering is essential to convert coal-burning power plants to biomass power plants capable of burning both coal and BF. It is vital that companies interested in converting their plants consult a knowledgeable biomass energy company to help ensure that they've got the latest in biomass technology, the best biomass engineering, the right equipment and fuel conveying systems, and a steady supply of BF. It is critical that power plants using biomass fuels have a long-term supply of biomass fuels, often referred to as a "fuel supply contract" or "fuel supply agreement." Without such an agreement, biomass power companies run the risk of losing their advantage.

Biomass power plants will have an important role in the global search for renewable energy sources, and readily available biomass fuels will make that role even more essential. Converting older coal-burning power plants into biomass power plants can create jobs, provide continued employment, and prevent a power plant from falling into disuse. Designing these conversions to allow for fuel flexibility can help offset potential fuel supply problems down the road.

Properly engineered, biomass power plants can be one of the most significant energy advances in the 21st century.

Used Plastic Pelletizing Systems: A Purchasing Guide

A plastic pelletizing system is equipment that creates plastic pellets and is one of the most important intermediate processes in plastics. There are four main processes: strand pelletizing, underwater, hot ring, and hot cut. The technology has not changed significantly in recent years and used plastic pelletizing equipment offers a high return on investment. The typical life of a new plastic pelletizing system from a reputable manufacturer will exceed 20 years if properly cared for and maintained. The most important considerations when buying a new or used plastic pelletizing system are cost, quality and delivery time.

How Plastic Pelletizing Systems Work
Plastic pelletizing systems add raw materials, often powders, to the barrel of an extruder. Inside the barrel, heat and pressure are applied to melt the powders and a rotating screw mixes it together. This creates a uniform and consistent molten product. The molten product is passed through a screen that creates pressure in the extruder barrel, filters impurities, and controls flow to the die. The diameter and shape of the molten plastic is determined by settings on the die. From this point, four different processes can be applied.

Different Plastic Pelletizing Processes Strand Pelletizing
One option to process compound plastic is strand pelletizing. After the extruder process, a strand die creates a series of spaghetti-like strands that are cooled in water. Once cooled, an air stripper removes excess water. The strand pelletizer then cuts the cooled strands. In the case of the strand die, the number of holes is proportional to the size of the extruder. Another consideration is heat source: electric or oil. Electric systems are cleaner and easier to maintain at a constant temperature, however some applications require oil. The most common manufacturer is Extrusion Dies Industries (EDI). It can be difficult to determine the brand of the die without documentation.

Water Bath

Issues to consider when purchasing a used water bath include the length, width, and depth of the submersion chamber. It's important to ensure the water bath is big enough to hold the strands. The size of the water bath is generally matched to the throughput of the extruder. Construction material is also important with stainless steel the best choice because it doesn't rust. Other materials include carbon steel and aluminum.

Air Stripper

When purchasing an air stripper, make sure the width of the lips are wide enough to allow the strands to be pulled through and ensure the horsepower is strong enough.

Strand Pelletizing

When purchasing a used strand pelletizing system, ensure the entrance width and strand guide matches the size and number of strands. Examine the type of rotor: either removable blades or solid helical. In both cases, the number and width of the blade on the rotor is important. Make sure the unit has adequate horsepower to spin the rotor to cut pellets. Manufacturers include Conair and Cumberland.

Screen

Screens can be round or rectangle. Ensure the size of the screen matches the extruder. Screens with more decks allow greater levels of filtration. Manufacturers of round screens are Sweeco, Midwestern, and Kason. Manufacturers of rectangular screens include Witte and Rotex. Screens need to be sized to match the rate of the extruder.

Underwater Pelletizing

Another option to process compound plastic is underwater pelletizing. In this process, an adapter connects the extruder with or without a screen changer to a system comprised of a die, a cutting system, a water system, and a spin dryer. In this process, molten material is cut into pellets after moving through the die and into a water slurry. Pelletizing takes place underwater. After this, pellets are dried in a spin dryer and sorted according to size by a screen. The underwater pelletizer must be sized so that the flow of water in gallons per minute is appropriate for the production rate of material from the extruder. Each manufacturer has a different calculation. The most common manufacturers are Gala and Farrel.

Water Ring Pelletizing
A third option to process compound plastic is water ring pelletizing. This works in the same way as underwater pelletizing except the pellet is cut when hot and cooled in a ring of water. As the plastic moves through the die, the pelletizer throws the pellets against the wall of the ring with water instantly cooling the hot pellets. The pellets are dried in a spin dryer and sorted by size through a screen. When purchasing water ring pelletizing systems, consider the model, capacity and manufacturer. The most common brands are Beringer, Xaloy, and PTI. It's common for water ring pelletizing systems to include the die, cutter, water system, spin dryer and water trough.

Hot Cut Pelletizing

The fourth option to process compound plastic is hot cut pelletizing. In this case, pellets are cut when hot and cooled by a blower before being sorted by size through a screen. This process is typically used with PVC pellets. The best-known brand is Cincinnati Milacron.

Used plastic pelletizing systems
When purchasing a used plastic pelletizing system, consider its age, manufacturer, horsepower, type of rotor, and screen holes. The advantages of buying a used plastics pelletizing system includes immediate installation and competitive price. Choose a reputable brand with maintenance records.

Modular Balustrades - One of the Best Investments

Whether you are focused on a commercial or industrial setting, choosing modular balustrades can prove to be one of the best investments many people can make. These specialized railings not only are incredibly safe, but they add a great deal of style to whatever location they are in. Many people are beginning to invest in handrails and modular balustrades, not just for commercial safety purposes, but also to add aesthetic appeal.

Increase Safety

Business owners understand the importance of safety in the workplace. Whether a simple handrail needs to be installed to keep staircases safe or pedestrian railings to keep visitors to commercial or industrial premises out of harm's way, steel balustrades could be the ideal solution.

Modular handrails can be an excellent solution for crowd control in some commercial applications. Keeping pedestrians safe from heavily trafficked areas, or keeping staff separated from workplaces where heavy machinery is being operated can increase overall workplace safety. Installing steel handrails around a mezzanine area can prevent falls, and can also help to clearly indicate ramps, steps, or other potential workplace hazards.

Simplified Installation

In many cases, modular balustrades are the preferred choice for business owners due to the ease of installation. As the primary sections of balustrade can be pre-fabricated, this means there is no need for welding pieces together onsite. Balustrade systems can be ordered from pre-engineers designs, which decrease design and manufacturing time significantly. Ideally, all designs chosen by any business owner should always be designed and manufactured to comply with Australian Standards.

Durability and Strength
For maximum durability and strength, modular balustrades constructed from solid steel that has been galvanised can help extend the lifespan of the barrier, and reduce the need to have them replaced or maintained as frequently. To add to the overall strength of the balustrade system, choose an installation that features stainless steel locking screws that will further extend longevity.

Colour Choices

Depending on the intended use, modular balustrades can be left as plain steel finish, or they can be painted to suit a particular intended use. For example, using a bright yellow or orange finish can instantly indicate to workers that the rail is intended as a safety barrier.

However, for outdoor applications around stairwells, along pedestrian walkways, or even as protective barriers around outdoor industrial work areas, plain steel may be more unobtrusive.

For most business owners, the decision to invest in modular balustrades should be logical. Handrails and protective barriers offer an increased level of safety to the location where they are installed, which can help to minimise the danger of accidents occurring on or around business premises.

Investing in a modular balustrade is not only a wise decision, but one that will improve safety in any commercial or industrial setting.

Why Use Synthetic Motor Oil When Good Old 20w50 Is Cheaper?

In any group of petrol heads the talk will invariably turn to engine oils, engine oil price and the inevitable subject as to why use synthetic motor oil?

Let's overlook engine oil price for a minute and weigh up the performance of full synthetic oil. To keep this piece brief I'll focus on full synthetic oil, API Group V, as opposed to semi synthetic oil.

Synthetic engine oil is specifically blended to meet the operating requirements of the ever evolving engine. The following properties are common in contemporary full synthetic lubricants:

1) Highly developed friction modifiers cut energy sapping friction. This not only increases power output, but also reduces fuel consumption and can also lessen operating temperature.

2) Since synthetic lubricant is engineered to be thermally stable, and utilises better anti oxidation technology (over mineral engine oils), varnish build up is reduced. This keeps the internals of the engine reasonably clean and reduces the sludge build up that plagued vehicles operating in heavy traffic conditions in cold climates.

As Turbo chargers grow to be more long-lasting (Largely thanks to the strides made in synthetic lubricants) more OEM's are opting to fit these to Increase engine efficiency. The reluctance to fit turbo chargers on "everyday" vehicles has basically revolved around the perception that turbo chargers were unreliable.

When one considers the environment that a turbo charger operates in - turbines rotating up to 200,000 RPM and housings reaching surface temperatures of 900 deg. C it's quite obvious that mineral engine oils (Even highly refined semi synthetic oil) would be hard pressed to survive.

The dilemma with the Turbo, is that when the engine is shut down temperatures climb rapidly, while at the same time oil circulation (That also cools the bearings) ceases. At this stage it's common for mineral oils to carburise. These diamond hard particles then act as a grinding paste on the bearings, resulting in premature failure! Fully synthetic engine oil has been proven to prolong the life of the Turbo, and is an important reason why to use synthetic motor oil.

3) In theory, using synthetic oil can also delay oil-change intervals. I say in theory, merely as technically synthetic motor oil can comfortably cope with intervals of up to 40,000 km's, although OEM warranty and service interval contracts will not tolerate this. Of course if you're using synthetic engine lubricant in an out of warranty vehicle you can determine if you'd like to delay intervals.

Another rationale why extended synthetic motor oil change intervals may be undesirable, relates to dirt ingress via the air filter element. Typically a new element, filters +10 micron (Around the cross section of a human hair), however as the element becomes clogged with dirt the vacuum increases, resulting in larger particles being sucked into the engine. Regrettably even the best synthetic engine oil can't do anything about the damage this can cause.

There's no uncertainty that synthetic oil out performs crude based engine oils, and with the engine oil price discrepancy between the two reducing, the smart choice is almost certainly a fully synthetic motor oil.

Conveyor Systems Overview - The Different Types

Conveyor systems are typically used to transport goods of various kinds and sizes to different parts of a warehouse or distribution hub. Kinds of products that can be transported include: large products, white goods, car parts, boxes and food products.

Uses involve moving products or storage of products.

There are various kinds of conveyor including roller, belt, powered, pallet, in-floor, gravity. All these different kinds have purposes and reasons for use.

Roller conveyor and gravity

Using roller and gravity conveyor allows the easy transport of products around a warehouse. This uses rollers on the conveyor which allows the products to be pushed around or using gravity to move the products. An advantage for using gravity conveyor is that it is that the cost is less than powered conveyor.

Pallet conveyor

Pallet conveyor can be used to move bulk storage and bulk sized products. The differences are the size of products that are transported. Using pallet conveyor make's the moving easier and faster.

Powered conveyor

Powered conveyor allows the transport of the products around a warehouse being able to be controlled. This means that the products can be transported up to another floor or round to other parts of the warehouse. Being able to control the stopping and started and which way the products go and to which area they sent makes the efficiency greater and the process faster.

Belt conveyor

Belt conveyor is used a lot of the time for a vertical change in the system, allowing the warehouse to use multiple floors on different levels. Other methods include vertical lifts or spiral conveyor that allow the products to be taken up or down to other levels.

A conveyor system puts these different kinds of conveyor together to suit the purpose of the project to make it work in saving time, allowing better movement or storage in the warehouse or distribution hub. By putting all these parts together they allow the movement of goods in a way that makes the warehouse run effectively. Having the various parts together in a complete system allows the control and fast working of the conveyor to suit the purpose of why it is built.

Benefits of a conveyor system include: 

• Being able to move multiple products around a warehouse    Control where products and goods go
• Automate your production line
• Speed up the transport of goods
• Stop and start the movement of products to fall inline with production timimgs