#Industrial Induction Heater Market Guide
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Global Industrial Induction Heater Market Growth Prospects 2018 - Inductoheat Europe GmbH, Timken, SKF and Ambrell
Global Industrial Induction Heater Market Growth Prospects 2018 – Inductoheat Europe GmbH, Timken, SKF and Ambrell
This Industrial Induction Heater Market report researchers the industry size (value, capacity, production, and consumption) in key regions like USA, Europe, Japan, China, India, South East Asia, and other regions. This study categorizes the Industrial Induction Heater divided data by manufacturers, region, type, and application, also analyzes the market status, market share, growth rate, future…
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6 Ways Welding Factors Into Successful Plant Shutdowns
6 Ways Welding Factors Into Successful Plant Shutdowns
Whether you belong in the petrochemical, manufacturing or pipeline industry, plant shutdowns are inevitable. Plant maintenance is vital to optimizing peak performance of a facility for increased profits, safety upgrades and regulatory compliance.
From a routine plant shutdown and maintenance period, metrics such as quality, schedule and cost can be measured and planned in advance. However, exceptions such as the global outbreak of COVID-19 global pandemic can pave the way for unexpected maintenance opportunities. In a move to contain the virus spread, companies close up shop temporarily to follow government mandates, protect their employees and take advantage of the opportunity to perform deep-cleaning routines using technologies like dry ice blasting on their factories simultaneously.
Due to decreased market demand and socio-economic factors, ramping up production won’t make sense in this time of crisis. Economically, increased future profits from plant maintenance might outweigh the revenue loss from operations and expenditures from the plant shutdown once all capital assets are calibrated to perform optimally. In this article we discuss the crucial steps on how to manage a successful plant turnaround with welding factored in.
Planning and Scope Management
Plant shutdown or turnaround can fall under project management. Managing complex layers of plant maintenance which revolve around three crucial standpoints of cost, time and quality can make or break the plant turnaround performance.
Stakeholder involvement also plays a part in setting the scope of work for the plant shutdown. Success should be measured from the business, operation, execution and organizational perspectives. Hiring plant turnaround service providers can be beneficial in terms of shutdown expertise, while in-house skilled staff can provide the essential historical data from previous plant shutdowns to set the baseline metrics and benchmarks. These can include:
Calculation of labor hours and rates
Initial work packages
Equipment data records
One example of this client-contractor integration would be a defective pipeline weld requiring repair every few weeks. While a short-term solution by the client would be to weld over the cracks, in due time it will cost more in the long run if failure analysis is not performed by a competent welding engineer. It could be as simple as identifying the root cause, or as complex as examining fractured surfaces under an electron microscope and performing metallurgical tests.
Cost Management
Plant shutdowns can be very expensive, as any profits spread over the years can be slashed in a span of weeks to a few months’ time. Whether on a full-scale or segment basis, you need to factor in two direct costs on your estimates: maintenance fees from execution and profit loss.
As plant maintenance incur costs, scheduled stoppage for plants are often moved from annual to 3-5 years due to upfront investment on quality machinery. However, any lack of routine maintenance on aging equipment can impede the productivity of a plant. Industries who rely heavily on welding can cause major headaches once welding equipment breaks down.
In three words, here’s one way where you can save up on costs: Preventable Cost Efficiency (PCE). Put actual numbers to the problem by dividing cost of service per hour and cost of production maintenance per hour. If a plant turnaround service provider charges $50/hour and downtime costs $500/hour, then PCE is 10%. You could pay $10 now for preventative maintenance of your welding equipment or pay $55 later for repair of hard or soft failures.
Schedule Management
Since plant shutdowns have a direct cost-to-schedule ratio, there’s an enormous pressure to finish the turnaround early or on time for potential savings. This requires efficient resource management: planning for risk mitigation, expert plant turnaround services, lead times on material and equipment procurement, labor availability and duration of work packages. Maintenance systems are grouped into:
Routine
Predictive
Breakdown
Preventive
Turnaround managers schedule the scope of work on a critical path method (CPM) – achieving essential objectives in the shortest amount of time. Red-D-Arc provides two value-based solutions to this time-deficit problem: orbital welders produce quality pipe welds and minimize weld time by utilizing a gear-driven track ring system, while multi-process welders combine 4-in-1 solutions (TIG, MIG, flux core and stick welding) providing a flexible versatile welding solution.
Inspection and Execution
For heavy-impact industries reliant on welding, inspection for plant shutdown should be done in an agile process with control points. Prior to procurement, welding engineers should perform material inspection alongside planning phase to determine in a priority basis what needs removal, replacement, repair or alteration.
To repair weld, knowing the material specification can’t be overstated. Welding engineers or turnaround managers should cross-reference construction drawings with the maintenance handbook and identify any grade markings that require regulatory compliance such as ASTM and AISI/SAE. Welding aluminum and steel on building structures require different welding procedures under AWS D1.2 and AWS D1.1, respectively.
Even far stricter under ASME B31 Code for Pressure Piping are boilers, vessels and tanks with ASME marking stamped on nameplates. Stringent regulations impose that only contractors with “R” stamp issued by National Board of Boiler and Pressure Vessel Inspectors are qualified to perform welding on these components.
For accuracy, cut the weld material for laboratory analysis and identify minimum requirements below:
Welding process used
Welding electrodes or filler metals to be used
Preheating and post-weld heat treating requirements
Heat input control
Defect removal
Final inspection and non-destructive testing (NDT)
Quality Assurance / Quality Control (QA/QC) and Safety
Once plant shutdown is underway, perform safety regulations on-site for welded components per ANSI Z49.1 Safety in Cutting, Welding and Allied Processes. Anytime a welder enters a confined space for repair, local exhaust ventilation measures such as downdraft bench and movable hood should be employed.
Existing building steel have external structural loads to be removed before weld repairs so consult AWS D1.7 Guide for Strengthening and Repairing Existing Structures. To minimize hydrogen-induced cracking and restore ductility, induction heaters can be employed for pre-heating and post-weld heat treatment, resulting in efficient weld quality of high-strength and low-alloy steels.
Restart
Plant shutdowns won’t be complete without final inspection for testing and commissioning. Once all systems are up and running with normal or improved performance levels, regulatory agencies will give you a green light for startup. Final report will serve as a baseline data for future plant turnarounds.
The post 6 Ways Welding Factors Into Successful Plant Shutdowns appeared first on Red-D-Arc Welderentals.
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Electric Cooktop is expected to have the highest growth rate during the forecast period 2025
Worldwide Market Reports added Latest Research Report titled “Electric Cooktop Market - Global Industry Insights, Trends, Outlook, and Opportunity Analysis, 2018-2026" to its Large Report database.
Electric cooktop is a flat piece of equipment used for cooking that is built into a kitchen countertop. The cooktop usually comprises four devices that are called burners, similar to any conventional stoves.
An electric cooktop, also known as an electric stove or electric range, is a stove with an integrated electrical heating device to cook and bake. Electric stoves are gaining popularity, as a replacement for solid-fuel (wood or coal) stoves which required more labor to operate and maintain.
Electric stoves are more convenient than LPG and diesel stoves, thus do not require refilling or relying on these sources. They majorly rely on electricity, which is and can thus be carried anywhere. Thus, demand for electric cooktops is increasing, in turn, boosting growth of the electric cooktop market. Electric stove burners are controlled by a rotary switch with six positions, each of which engages a different combination of resistances and hence a different heating power. Some of the cooktops have an infinite switch called a simmerstat, while other have a thermostat.
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Increasing demand for portable cooking ranges and increasing number of rural areas being provided with healthy supply of electricity are major factors driving growth of the electric cooktop market.
The surface of these cooktops are much flatter than conventional stoves, thus eliminating possibilities of food spoiling over the cooktop. Furthermore, these cooktops are easier to maintain than conventional ones, cause fewer fire hazards and no chances of gas leak. These cooktops are thus gaining traction among customers around the globe, in turn, fueling growth of the electric cooktop market.
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The first electro-heater surface heated by a platinum-wire coil powered by batteries, was developed in 1859.
Fisher & Paykel—major appliance manufacturing company based in New Zealand— provides a full range of cooking solutions. Each product of its cooktops, whether gas, induction or electric, is designed in a way to deliver great performance, from searing heat to a gentle simmer, allowing for easy cleaning with safety in mind. Its 90 cm Front Control cooktop is a ceramic cooktop, which provides a completely flat profile. It provides extra storage space when not in use, while when in use, heats quickly due to high speed ribbon elements.
In 2016, General Electric Co. (GE)—a major electric company—announced the opening of a microfactory in Chicago to create and build innovative industrial products and prototypes.
In 2016, General Electric Co. proposal of a US$ 5.4 billion sale of its appliance business to China’s Haier Group received a green light from the U.S. antitrust authorities.
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