Techniques in Thermal Analysis: Hyphenated Techniques, Thermal Analysis of the Surface, and Fast Rate Analysis STP 1466

Techniques in Thermal Analysis:
Hyphenated Techniques, Thermal
Analysis of the Surface, and Fast
Rate Analysis
STP 1466


In May 2004 a two day symposium titled “Techniques in Thermal Analysis: Hyphenated Techniques,
Thermal Analysis of the Surface, and Fast Rate Analysis” was held at the ASTM Headquarters in
West Conshohocken, PA. Twenty-two presentations were given at the symposium. Additionally, the
presenters were given the opportunity to submit to the Journal of ASTM International and for their
papers to be included into a special technical publication (STP), thirteen papers were received.
The symposium itself was timely and reflected leading edge research in thermal analysis. Of major
interest now is fast scan calorimetry in both instrument development and techniques. Through the
use of a thin film nanocalorimeter scanning rates as high as 10,000 °C/sec can now be achieved. This,
for example, allows for the better study of semicrystalline polymers where the reorganization process
can be inhibited and the original metastable crystal can now be analyzed. Through the use of current
technology, fast heating rates were employed to study epoxy curing. Fast rate analysis allowed the
separation of the glass transition and cure exotherm.
The Hyphenated Techniques session brought some interesting papers mostly using thermogravimetric
analysis (TGA) with another technique. It should also be noted that other techniques that have hyphens
were also presented such as a paper on temperature-modulated differential scanning calorimetry,
which is more prevalently written modulated temperature differential scanning calorimetry
without the hyphen. An interesting study of the combined use of TGA with DTA (differential thermal
analysis) and Raman spectroscopy was presented. The spectroscopy was performed on the sample
itself as it underwent physical changes. This allowed the more precise study of dehydration of
pharmaceuticals. Also presented was a paper advocating improved modeling when using hyphenated
techniques such as TGA/FTIR (Fourier transform infrared) allowing kinetic parameters to be determined
using both sets of data. Also of note was a simple calibration method for the quantitative use
of mass spectrometry with TGA for a variety of encountered off gases.
Finally, a number of papers were given on thermal analysis of the surface. Many of these papers centered
on the use of a modified atomic force microscope (AFM), or Micro-Thermal Analysis, that uses
the AFM probe as a thermal device. A technique that shows promise is the use of micro-thermal analysis
in combination with other techniques such as FTIR. This technique is referred to as photo thermal
micro-spectroscopy (PTMS). PTMS uses the AFM probe to detect temperature fluctuations after
a sample has been exposed to IR radiation allowing the construction of an infrared spectrum. This
permits for a fast identification of an unknown material with minimal sample preparation.
The symposium chairs would like to acknowledge and extend our appreciation for all who have
helped with the organization of the symposium and subsequent publications. A special thanks goes
out to the reviewers who took the time and provided the needed commentary. Finally, we would like
to recognize the sponsorship of both ASTM International Committee E37 on Thermal Measurements
and the Thermal Analysis Forum of the Delaware Valley.

download

RADIANT HEAT TRANSFER CASE STUDY

RADIANT HEAT TRANSFER CASE STUDY



Introduction

Radiant heat transfer involves the transfer of heat by electromagnetic radiation that arises due to the temperature of a body. Most energy of this type is in the infra-red region of the electromagnetic spectrum although some of it is in the visible region. The term thermal radiation is frequently used to distinguish this form of electromagnetic radiation from other forms, such as radio waves, x-rays, or gamma rays. The transfer of heat from a fireplace across a room in the line of sight is an example of radiant heat transfer.
Radiant heat transfer does not need a medium, such as air or metal, to take place. Any material that has a temperature above absolute zero gives off some radiant energy. When a cloud covers the sun, both its heat and light diminish. This is one of the most familiar examples of heat transfer by thermal radiation

Black Body Radiation

A body that emits the maximum amount of heat for its absolute temperature is called a black body. Radiant heat transfer rate from a black body to its surroundings can be expressed by the following equation.

Q =𝜎AT⁴

where 
Q =  heat transfer (W)  (Btu/hr)
𝜎  = Stefan-Boltzman constant  5.6703 10⁻⁸ (W/m².K⁴) (0.174 Btu/hr-ft²-°R⁴)
A = surface area (m²) (ft²)
T = temperature (K)  (°R)

Two black bodies that radiate toward each other have a net heat flux between them. The net flow rate of heat between them is given by an adaptation of Equation

Q =𝜎A(T₁⁴-T₂⁴)

where
A = surface area of the first body (m²) (ft²)
T₁ = temperature of the first body (K)  (°R)
T₂ = temperature of the second body (K)  (°R)

All bodies above absolute zero temperature radiate some heat. The sun and earth both radiate heat toward each other. This seems to violate the Second Law of Thermodynamics, which states that heat cannot flow from a cold body to a hot body. The paradox is resolved by the fact that each body must be in direct line of sight of the other to receive radiation from it. Therefore, whenever the cool body is radiating heat to the hot body, the hot body must also be radiating heat to the cool body. Since the hot body radiates more heat (due to its higher temperature) than the cold body, the net flow of heat is from hot to cold, and the second law is still satisfied.

Emissivity Coefficient

Real objects do not radiate as much heat as a perfect black body. They radiate less heat than a black body and are called gray bodies. To take into account the fact that real objects are gray bodies

Q =𝓔𝜎AT⁴

where:
𝓔 = emissivity of the gray body (dimensionless)

Emissivity is simply a factor by which we multiply the black body heat transfer to take into account that the black body is the ideal case. Emissivity is a dimensionless number and has a maximum value of 1.0.
NOTE : The emissivity lies in the range 0 < ε < 1 and depends on the type of material and the temperature of the surface. The emissivity of some common materials are:

• oxidized Iron at 390 ^oF (199 ^oC) - ε = 0.64
• polished Copper at 100 ^oF (38 ^oC) - ε = 0.03

Radiation Configuration Factor

Radiative heat transfer rate between two gray bodies can be calculated by the equation stated below.

Q  = fa fe 𝜎 A(T₁⁴- T₂⁴ )

where:
fa = is the shape factor, which depends on the spatial arrangement of the two objects (dimensionless)
fe = is the emissivity factor, which depends on the emissivities of both objects (dimensionless)

The two separate terms fa and fe can be combined and given the symbol f. The heat flow between two gray bodies can now be determined by the following equation:

Q  = f 𝜎 A(T₁⁴- T₂⁴ )

The symbol (f) is a dimensionless factor sometimes called the radiation configuration factor,
which takes into account the emissivity of both bodies and their relative geometry.

Once the configuration factor is obtained, the overall net heat flux can be determined. Radiant heat flux should only be included in a problem when it is greater than 20% of the problem.

Radiation Constants of some common Building Materials

The radiation constant is the product between the Stefan-Boltzmann constant and the emissivity constant for the material

The radiation constant of some common materials can be found in the table below:

Radiant Heat Transfer Summary

- Black body radiation is the maximum amount of heat that can be transferred from an ideal object.

- Emissivity is a measure of the departure of a body from the ideal black body.

- Radiation configuration factor takes into account the emittance and relative geometry of two objects.

Bursting disc safety devices ISO 4126-2

Safety devices for protection against
excessive pressure —
Part 2:
Bursting disc safety devices
ISO
4126-2

A bursting disc safety device is a non-reclosing pressure relief device used to protect pressure equipment such as pressure vessels, piping, gas cylinders or other enclosures from excessive pressure and/or excessive vacuum.
A bursting disc safety device typically comprises an assembly of components including a bursting disc, a bursting disc holder and, where necessary, other components such as back pressure supports, stiffening rings etc.
The bursting disc is a pressure-containing and pressure-sensitive part of the bursting disc safety device and is designed to open by bursting at a pre-determined pressure. There are many different types of bursting disc safety devices manufactured in corrosion resistant materials, both metallic and non-metallic, to cover a wide range of nominal sizes, burst pressures and temperatures.

download

Pressure Relief Devices ASME and API Code Simplified Mohammad A. Malek, Ph.D., P.E.

Pressure
Relief
Devices
ASME and API Code Simplified
Mohammad A. Malek, Ph.D., P.E.

Within the boiler, piping and pressure vessel industry, pressure relief devices are considered one of the most important safety components. These Devices are literally the last line of defense against catastrophic failure or even lose of life. Written in plain language, this fifth book in the ASME Simplified series addresses the various codes and recommended standards of practice for the maintenance and continued operations of pressure relief valves as specified by the American Society of Mechanical Engineers and the American Petroleum Institute. Covered in this book are: preventive maintenance procedures, methods for evaluation of mechanical components and accepted methods for cleaning, adjusting and lubricating various components to assure continued operation and speed performance as well as procedures for recording and evaluating these items.

download

Application, selection and installation of bursting disc safety devices ISO 4126-6

Safety devices for protection against
excessive pressure —
Part 6:
Application, selection and installation of
bursting disc safety devices
ISO 4126-6

This standard gives guidance on the application, selection and installation of bursting disc safety devices used to
protect pressure equipment from excessive pressure and/or excessive vacuum.
Annex A provides a checklist for the information to be supplied by the purchaser to the manufacturer.
Annex B gives guidance on the replacement period of a bursting disc and annex C guidance on determining the
mass flow rate, for single phase fluids, of a pressure relief system that contains a bursting disc safety device
Annex E is a non-mandatory procedure for establishing the flow resistance of a burst bursting disc assembly.
The requirements for the manufacture, inspection, testing, marking, certification and packaging of bursting disc
safety devices are given in Part 2 of EN ISO 4126

download

Safety valves and bursting disc safety devices in combination (ISO 4126-3:2006)

Safety devices for
protection against
excessive pressure —
Part 3: Safety valves and bursting disc
safety devices in combination
(ISO 4126-3:2006)


This part of ISO 4126 specifies the requirements for a product assembled from the in-series combination of safety valves or CSPRS (controlled safety pressure relief systems) according to ISO 4126-1, ISO 4126-4 and ISO 4126-5, and bursting disc safety devices according to ISO 4126-2 installed within no more than five pipe diameters from the valve inlet. It specifies the design, application and marking requirements for such products, which are used to protect pressure vessels, piping or other enclosures from excessive pressure, and which comprise the bursting disc safety device, a safety valve or CSPRS and, where applicable, a short length of connecting pipe or spool piece. In addition, it gives a method for establishing the combination discharge factor used in sizing combinations.

DOWNLOAD

The Safety Valve worksheet

The Safety Valve worksheet

The Safety Valve worksheet should be used primarily to determine reactions due to discharge of steam safety valves.  The results can be entered in pipe stress analysis programs.  Refer to ASME B31.1 Appendix II for complete application of the rules, including open discharge systems, closed discharge systems, installations with single and double outlet valves, multiple valve installations, etc.

ا DOWNLOAD

Safety devices for protection against excessive pressure Part 1: Safety valves BS ISO 4126-1:2013

Safety devices for protection
against excessive pressure
Part 1: Safety valves
BS ISO 4126-1:2013

This part of ISO 4126 specifies general requirements for safety valves irrespective of the fluid for which
they are designed.
It is applicable to safety valves having a flow diameter of 4 mm and above which are for use at set
pressures of 0,1 bar gauge and above. No limitation is placed on temperature.
This is a product standard and is not applicable to applications of safety valves.

DOWNLOAD

PSV Pressure Safety Valve Selection Guide

PSV Selection for Beginner,
Pressure Safety Valve or PSV, is one of safety devices in oil-and gas production facility, which ensure that pipes, valves, fittings, and pressure vessels can never be subjected to pressure higher than their design pressure. Therefore, the selection of PSV to be installed must be conducted in a careful and proper manner. These are the questions worth to be asked when you are going to specify details of PSV. What type of PSV we will have for our process requirements? Is there any easier way for PSV sizing or PSV calculation rather than calculate it manually? What kind of material shall be chosen for our process requirements? Now we are going to discuss the first question, What type of PSV we will have for our process requirements?In fact, there are three types of PSV you can select to suit the process requirement. They are, Conventional, Bellows and Pilot types. Conventional type of PSV,Conventional PSV is the simplest one . This type of PSV is used whenever the existence of back pressure is relatively small and less than 10% of set pressure, or nearly zero. Due to its low immunity to back pressure, the conventional type outlet is vented into atmospheric, and mostly, the fluid to be vented is non-hazardous fluid like water, air and steam. Bellows type of PSV,PSV with bellows or balanced-bellows type is used when there is backpressure and the backpressure does not exceed 50% of the set pressure. This type of PSV is almost the same with the conventional ones, but there is additional bellows in it. The bellows itself has a function to reduce the effect of the backpressure force over the disk. The bellows contained the upper side of the disc and the rod which connected to the spring from pressure force of process fluid or pressurized system – in which connected through PSV outlet – and the inside chamber of the bellow will be vented to the atmospheric, which obviously has constant pressure. Commonly, this type of PSV does not have a wide range of PSV, hence, it is not so flexible in alteration of set pressure. Pilot type of PSVA pilot-operated pressure safety valve consists of the main valve, which normally encloses a floating unbalanced piston assembly, and an external pilot. The piston is designed to have a larger area on the top than on the bottom. Up to the set pressure, the top and bottom areas are exposed to the same inlet operating pressure. Because of the larger area on the top of the piston, the net force holds the piston tightly against the main valve nozzle. As the operating pressure increases, the net seating force increases and tends to make the valve tighter. This feature allows most pilot-operated valves to be used where the maximum expected operating pressure is higher than 90% of Maximum Allowable Working Pressure. PSV Sizing guide

Pilot Operated Relief Valve Animation

Created as part of my Final year project at university. I Modeled the valves components, assembled them in Creo Pro Engineer then transported them into 3D studio max where I animated the valve working. I edited a number of renders together and made this short animation showing how the valve works.

Controls and Safety Devices for Automatically Fired Boilers ASME CSD-1–2015

Controls and
Safety Devices
for Automatically
Fired Boilers
ASME CSD-1–2015


The rules of this Standard cover requirements for the assembly, installation, maintenance, and operation of controls and safety devices on automatically operated boilers directly fired with gas, oil, gas-oil, or electricity, subject to the service limitations, exclusions, and acceptance of other listings in CG-120, CG-130, and CG-140, respectively. Burner or burner assemblies installed on boilers or as a replacement burner shall comply with the requirements of CF-110 and CF-410 for gas and oil firing, respectively. The use of a gaseous or oil fuel not listed in the definitions has not been evaluated, and
special considerations may be required.

download

Safety And Relief Valve Main Parts Photo

Safety  And Relief Valve Main Parts  Photo

Specification for Steel globe and globe stop and check valves (flanged and butt-welding ends) for the petroleum, petrochemical and allied industries

Specification for
Steel globe and globe stop and check valves
(flanged and butt-welding ends) for
the petroleum, petrochemical and
allied industries
BS 1873

This British Standard specifies requirements for cast or forged carbon and alloy steel outside screw
and yoke globe and globe stop and check valves, straight pattern, angle pattern and (oblique) Y
pattern, with flanged or butt-welding ends in nominal sizes within the range of 15 mm to 400 mm
(; in to 16 in) and Classes 150 to 2500. This standard can also be used as a general guide where
valves of material composition outside the scope of section three of this standard are required as, for
example, for use in highly corrosive services or environments or for low temperatures

The standard can be adapted to apply to valves with needle type seats in 15 mm (; in) an 20 mm (< in) nominal sizes which will meet all requirements of this standard, except that the valve seat bore is
reduced and the needle point may be either integral with or loose on the stem.

download

An Introduction to Relief and Safety Valves

An Introduction to Relief and Safety Valves


Introduction 
Relief and safety valves prevent equipment damage by relieving accidental over-pressurization
of fluid systems. The main difference between a relief valve and a safety valve is the extent of
opening at the set point pressure.

Principle And Operation
 relief valve 
As in Figure 1,Relief valves are pressure relieving devices actuated by the static pressure upstream of the device. They open in proportion to the increase in pressure over the valve set pressure and are used primarily in liquid service. Relief valves function in the following manner. First, an initial downward force is applied by compressing a spring with an adjusting screw. When
system pressure increases, upward force on the disc is developed. As long as downward force applied by spring load is greater than upward force created by the fluid acting on the disc area, the valve will remain closed. Also, valve opening will be proportional to over pressure since the disc area that fluid is acting upon remains the same.
Relief valves do not need a large opening to relieve over pressure as do safety valves since the fluid being discharged does not expand. System pressure drops rapidly once valve discharge begins. Therefore, slow opening is acceptable in liquid service applications. As the inlet pressure reaches the valve set pressure, the disc lifts a minimal amount and small steady stream of fluid begins to flow. When the pressure begins to decrease, the flow and the lift decrease until the valve closes at a pressure at or below the set point.
Relief valves are normally designed with a closed bonnet. The bonnet is usually vented to the discharge side of the valve to avoid adverse effects on the performance of the valve. The set pressure of the relief valve is determined by the force of the spring acting on the disc and the back pressure on the valve. The amount of the back pressure effect is directly proportional to the area exposed to the back pressure. Figure

FIG 1

Safety Valves
As in figure 2 Safety valves are pressure relieving devices actuated by the inlet static pressure and are characterized by rapid opening or “popping” action. Safety valves may be spring loaded
or pilot actuated.
In the spring loaded design, the force of the system pressure on the disc is opposed by a main spring. In the pilot actuated design as in figure 3, the system pressure acts on a small pilot valve, which opens at the set point of the valve and creates a pressure imbalance in the main valve, causing the main disc to open. Both types of valves actuate automatically when the fluid pressure in the protected system reaches a predetermined set pressure. Safety valves are used on steam, gas and vapor services. Since the fluid contained is compressed, a larger valve opening is required to achieve a given pressure drop in the system. The "popping" characteristic results since the fluid being discharged is acting on a larger disc area when the valve opens and suddenly expanding to a larger volume. Safety valves have essentially two disc areas for fluid to act upon. The "initial" area corresponds to the inside diameter of the nozzle. The "final" area is larger, therefore, more upward force is created as the valve begins to discharge fluid.
They are designed to mitigate pressure rise in the system to below a defined design value. Subsequent to the pressure transient, the safety valve reseats and is prepared to provide pressure relief again, if required.

FIG 2

FIG 3

Safety -relief valves
As in figure 4 .are pressure relieving devices actuated by the inlet static pressure and characterized by rapid opening or “popping” action, or by opening in proportion to the increase in pressure over the opening pressure, depending on application. Safety -relief valves can be used for either liquid or compressible fluid service. The primary difference between a safety- relief valve and a safety valve is that the safety-relief valve has a fluid tight bonnet, allowing it to be used for liquid service. Similar to the safety valve, safety-relief valves may be spring loaded or pilot actuated.
A variation of the safety-relief valve is the “balanced safety-relief valve”. In this design, the uncompensated area of the disc is isolated from the back pressure by a bellows, which is vented to the atmosphere.

FIG 4

Power operated relief valves   (PORVs) are pressure relieving devices which require an external power supply for actuation. These valves are typically controlled by an electrical signal resulting from high system pressure or manually from the control room. The electrical signal initiates the relief action by activating the valve actuator, either electrically or pneumatically. The primary function of PORVs is to inhibit pressure increases due to anticipated operational transients, and minimize the probability of safety or safety-relief valve actuation by mitigating pressure rise. PORVs are commonly used in steam and primary side applications in nuclear power plants.

Definitions
Maximum Allowable working Pressure: Maximum Allowable Working Pressure (MAWP) is
the highest or lowest pressure a vessel is expected to be exposed to during various operating
conditions. The vessel may not be operated outside these set conditions. Consequently, this
is the highest or lowest pressure at which the primary pressure relieving valve is set to open.
Set Pressure: Set pressure is the inlet pressure at which the pressure relieving valve starts to discharge under service conditions.
Accumulation: Pressure increase over the MAWP of the vessel during discharge through the valve. It is expressed as a percentage (eg. 10% accumulation). Consequently, it is the increase in pressure above MAWP that occurs.
Over pressure: Pressure increase or decrease beyond the set pressure of the primary relieving device. Over pressure is the same as accumulation when the relieving device is set to open at the MAWP of the vessel.
Blow down: Blow down is the difference between the set pressure (“popping” pressure) and the resetting pressure of a pressure relieving valve. This pressure is commonly expressed as a percentage of the set pressure such as 5% Blow down. Another way of describing blowdown is to say that it is the difference between set pressure of the valve and system pressure when the valve recloses.
Sequential Lift Series: Sequential lift series applies when there is more than one pressure relieving device in the system. It is an important concept to understand since ASME codes dictate the percentage of operating pressure at which the first relieving device must open (e.g. 105%, 107%, etc.) and the required capacity which all the relieving devices must have when open.
Simmer: Simmer is leakage between the seat and disc just prior to the valve opening.
Nozzle: The nozzle performs three functions:
        · Acts as the valve seat
        · Directs the flow under the valve disc
        · Controls the rate that fluid is allowed to escape from the system.
Adjusting Rings: Adjusting rings regulate blow down and simmer. Rings vary from one manufacturer to another; some have upper and lower rings while many have only a lower ring. Adjusting ring(s) affect simmer and blowdown since a change in position changes/alters the effective area that fluid acts upon.
Blow down Adjustment: If the valve has both upper and lower adjusting rings, altering the position of the upper ring changes the size of the huddling chamber giving a greater/lesser percentage of blow down when the valve opens.
Huddling Chamber: A ring shaped pressure chamber located beyond the valve seat diameter. It gives safety and safety-relief valves a “popping” action by providing additional surface area once the valve initially comes off its seat.

Calculations 

Calculate relief valves in gas and vapor systems

The minimum discharge area of a relief safety valve in a gas or vapor system can be calculated as

A = m T^1/2/ (C k_d k_bp P M^1/2)  

 where

A = minimum discharge area (Square Inches)

m = relieving capacity (Lbs per Hour)

T = absolute temperature (^oR = ^oF + 460)

C = coefficient determined from ratio of specific heats - depends on the gas 

k_d = discharge coefficient - 0.975

k_bp = back pressure coefficient - 1.0 for atmospheric discharge systems

P = relieving pressure (psia) - set pressure (psig) + over pressure (psig) + atmospheric pressure (14.7 psia)

M = molecular weight of gas

pilot operated relief valves in liquid systems

The minimum discharge area of a pilot operated relief safety valve in a liquid system can be calculated as

A = q SG^1/2 / (36.81 K_visc dp^1/2)

 where

A = discharge area (Square Inches)

q = relieving capacity (Gallons per Minute)

SG = Specific Gravity of the fluid

K_visc = correction factor due to velocity - 1.0 for most water systems

dp = differential pressure - set pressure (psig) + over pressure (psig) - back pressure (psig)

safety valves in saturated steam systems

The minimum discharge area of a relief safety valve in a steam system can be calculated as

A = m / (51.5 k_d k_bp P^1/2) 

 where

A = minimum discharge area (Square Inches)

m = relieving capacity (Lbs. per Hour)

k_d = discharge coefficient - 0.975

k_bp = back pressure coefficient - 1.0 for atmospheric discharge systems

P = relieving pressure (psia) - set pressure (psig) + over pressure (psig) + atmospheric pressure (14.7 psia)

spring operated relief valves in liquid systems

The minimum discharge area of a spring operated relief safety valve in a liquid system can be calculated as

A = q SG^1/2 / (28.14 K_bp K_visc dp^1/2) 

 where

A = discharge area (Square Inches)

q = relieving capacity (Gallons per Minute)

SG = Specific Gravity of the fluid

K_bp = capacity correction for back pressure - 1.0 for atmospheric pressure systems

K_visc = correction factor due to velocity - 1.0 for most water systems

dp = differential pressure - set pressure (psig) + over pressure (psig) - back pressure (psig)

SF Pressure Drop Version

SF Pressure Drop Version 4.1

SF Pressure Drop Version 4.1 for Windows 95/98/NT calculates the  pressure drops (caused by friction) of flowing liquids and gases in pipes.
Additionally you can calculate pressure changes caused by vertical difference and caused by changes of kinetic energy.
SF Pressure Drop calculates also pressure drops in pipe elements (example: changes of direction) and diverse valves. It's possible to combine diverse elements and so to calculate the total pressure drop. To calculate the pressure drop you need data of pipes (rougness) and data of flow medium (density, viscosity). These data are available in several databases, which are editable by the user
partly. An additional possibility to save your own data is the user-defined database.

Additional are the following futures:

- Calculation of pressure drop dependent on rate of flow  (showing and printing of the characteristic curve)
- Calculation of an economic pipe-diameter at a known rate of flow
- Calculation of NPSH; the needed vapor pressure and weight density   are available in a database
- Calculation of volume of pipe and filling time of the whole project or of a part of the project
- Conversion of rate of flow to velocity and inverse at a known pipe diameter
- Input of data of pipe element and flow medium in a lot of unit  (metric and US units); output in metric or US units alternatively
- Database of resistance coefficients of fittings, editable and extensible by the user
 - Possibility to save and open SF Pressure Drop project-files.

download

https://www.facebook.com/pro.mechanical.engineer/

Investigation of Fixed-Bed Combustion Process in Small Scale Boilers Rafal Buczynski

Investigation of Fixed-Bed
Combustion Process in Small
Scale Boilers
Rafal Buczynski

This thesis was realized in the frame of the agreement between Silesian University of Technology and Clausthal University of Technology

download

Machine Tools Embrace Industry 4.0 as Manufacturing Evolves Adam Turner

Machine Tools Embrace Industry 4.0 as Manufacturing Evolves

ABOUT THE AUTHOR

Adam Turner

The physical and digital worlds are colliding on the factory floor as traditional machine tooling undergoes a smart overhaul in order to meet modern manufacturing demands. We spoke with Gérard Gousset, Marketing Manager for machining systems with Italian industrial automation company Comau.

The basic concepts of machine tooling come from the earliest days of the industrial revolution, each designed to handle a different task in the mass production process. As we enter the disruptive age of Industry 4.0, these tasks are being combined into new universal, hybrid devices with the goal of shortening the process chain, says Gérard Gousset.
Ten years ago, a five-axis machining center was a very particular machine with very specific uses, Gousset says, but today there is a growing demand for such machines even for very traditional processes.

 Then there are hybrid machine tools such as combining turning and milling, or milling and additive manufacturing, in one machine. This hybrid trend is in pursuit of improved efficiencies, aiming to shorten the process chain by reducing non-value-added time.

industrial automation company Comau.

The basic concepts of machine tooling come from the earliest days of the industrial revolution, each designed to handle a different task in the mass production process. As we enter the disruptive age of Industry 4.0, these tasks are being combined into new universal, hybrid devices with the goal of shortening the process chain, says Gérard Gousset.

Ten years ago, a five-axis machining center was a very particular machine with very specific uses, Gousset says, but today there is a growing demand for such machines even for very traditional processes.

Then there are hybrid machine tools such as combining turning and milling, or milling and additive manufacturing, in one machine. This hybrid trend is in pursuit of improved efficiencies, aiming to shorten the process chain by reducing non-value-added time.
The need for greater flexibility is also driving the trend of modular, reconfigurable machine tools. Specialist machine tools can require a significant capital investment which can be a struggle for small, nimble manufacturers looking to compete against larger rivals. More flexible modular designs, which can handle a wider variety of advanced tasks, can make for a wiser investment.

THE NEED FOR AUTOMATION

The rise of more flexible machine tools is also driven by the need for automation. While Comau mostly works with the automotive industry, machine tools with the flexibility to support integrated automated loading and unloading can reduce the footprint and complexity of the production line across the manufacturing sector, which also help shorten the process chain.
All of these efforts to blend traditional manufacturing processes within more advanced machine tools are tied to the rise of Industrial IoT, or Industry 4.0. While this is set to underpin the next wave of productivity enhancements, Gousset says it is still very early days.
Industry 4.0 is at the early phase of collecting data and is only just beginning to analyze that data in search of insight, but manufacturers are not yet experiencing its full potential for added value and foreseeing issues before they arise.

The need of the customer is not simply to collect data, the need of the customer is to improve their productivity and to reduce the breakdown of their machines – we are at the stage of early warning, or condition-based maintenance, which is the preliminary step towards the total predictive maintenance stage. Also in parallel to this is the emerging trend of applying the predictive approach to the process, in order to have predictive process control and thus improve the quality of production.

THE DIGITAL TWIN CONCEPT

The growing wealth of real-time data which can underpin predictive maintenance is also driving the use of digital twin technology which can generate a virtual doppelganger of both the machine tools and the objects they create.
Universal machine manufacturers and customers are beginning to understand the added value of the digital twin concept, such as the ability to anticipate the need for a new part and then simulate the machining of that part. We are still at the beginning of this new concept of thinking, for many managers the digital twin just seems like a fancy visualization tool but I am sure it will add much value in the future.
Meanwhile, the changing nature of European economics is also driving machine tool trends. For the last few decades manufacturers have leveraged globalization in an effort to curb costs, but now the industry is looking for other ways to remain competitive and improve their bottom line.

A WISE INVESTMENT

The European trend towards nearshoring and backshoring makes Industry 4.0 a wise investment, Gousset says, as it offers new ways for manufacturers to find a competitive edge.

The trend for nearshoring or backshoring is the opposite of the offshoring trend we experienced in the last 10 years, and this shift is justifying the huge investment for Industry 4.0 – from enterprise R&D investments to government funding. One of the drivers of Industry 4.0 is to improve the productivity of manufacturing systems and to reduce the cost of production in Europe.

This desire to bring manufacturing back closer to home while remaining economical is also driving demand for more flexible modular designs which support greater automation while reducing the footprint of the production line.
At the same time, Gousset says another machine tools trend is the growing demand for ease of use, reflecting the changing nature of society and the modern workforce.

The combination of higher employee turnover and more rapid advances in technology requires machine tools which demand less training and experience to operate than in days gone by.

ABOUT THE AUTHOR

Adam Turner

SOURCE LINK