Latest Case Studies & White Papers

What Is a Gas Detection Wearable? Frequently Asked Questions About Connected Safety Technology

The number of workplace injuries remains nearly unchanged year-over-year, with more than 2 million nonfatal workplace injuries and illnesses reported by provide industry employees in 2019.[i] And up to 90% of workplace injuries can be attributed to human error.

While PPE has not traditionally had the technological capabilities to help prevent worker injury due to human error, the latest safety innovations, such as gas detection wearables, can help provide the visibility and data-driven insights to help your organization create an adaptable, proactive safety program and establish a culture of behaviour-based safety. Connected, wearable technology is leading the way for gas detection programs to evolve and enhance both their approach to worker safety and their approach to record-keeping, compliance, and fleet management.

But transforming your organisation to a connected program does not happen overnight. The first step is understanding the benefits of wearable technology and how a connected program can work for your organisation.

To start, what is a gas detection wearable? What are the benefits of connected safety technology? Here are answers to those top questions:

  1. What is a gas detection wearable?

A gas detection wearable is designed to be worn by each individual worker, on his/her person, while on the jobsite. With a wearable detector that can simply clip directly on to apparel or other PPE, such as a fall harness, lone workers can be monitored in real-time to help provide critical data points about on-site workers to off-site safety managers, including emergency monitoring.

A wearable device can be a useful way to monitor workers’ safety, location, and behaviors; however, it may not always be enough to help build a proactive, adaptable gas detection safety program over time.

But a wearable gas detector that comes with automatic connectivity can be much more impactful in terms of driving transformation, efficiency, and reaching long-term safety and productivity goals of a gas detection program.

  1. What does the term “connected” mean for gas detection hardware?

The term “connected” not only means a connected device – one that comes with out-of-the-box, cutting-edge cellular connectivity through leading national networks – but also a comprehensive solution inclusive of hardware software. It’s not necessarily enough to simply have cellular connectivity; hardware should also be connected to software, so that connectivity can provide the real-time data and insights to help drive adaptable, proactive safety programs.

This connectivity transforms hardware from traditional PPE to a technology-based, future-forward solution.  Successful integration of this advanced technology requires that not only are devices smarter and capable of providing visibility and insights to help curb risk, boost productivity, and simplify compliance, but also that they continue to perform with the durability and functionality to maintain their first and foremost mission of helping to protect the worker. As a wearable device, the detector should maintain the IP-rating, sensor technology, and battery life expected of today’s most durable portable gas detectors.

A wearable device that comes with automatic connectivity right out-of-the-box allows for quick and seamless implementation, no IT required.

  1. How can wearable, connected technology help improve worker safety?

The most common industries for lone workers include oil and gas, telecommunications, utilities, construction, and industrial contractors. With wearable devices, safety managers can help ensure these lone workers are not completely alone. By digitally assigning a wearable device to individual workers at the start of each shift, safety managers can gain insight into key individual worker data including:

  • Compliance of device use and faulty safety behaviours, including turning off an instrument or changing settings
  • Workers’ locations, gas readings, and alarms
  • Safety behaviours in the field, and whether new training specific to individuals is needed

A connected work program for gas detection can provide the visibility that is needed to manage large teams of workers and help establish a behaviour-based culture of safety. With real-time visibility of lone workers, safety managers can help make sure those workers are protected, with instant alerts. And  connected hardware and software solutions can provide real-time data such as worker location and how the detector is being used by each worker – which can all help inform safety training to both drive worker safety day-to-day and enhance an organisation’s safety culture over time.

  1. How can wearable technology improve worksite safety?

 

It can be difficult to difficult to manage assets across different worksites and keep remote teams safe and productive. Connecting worksites with wearable, connected technology gives safety managers visibility into:

  • Teams and assets, including worker position and activities and which devices require maintenance
  • External and environmental factors, such as temperature or humidity
  • Equipment status, maintenance, and asset management information across all worksite locations
  • Centralized reports and data logs for automated compliance
  • Intelligent mapping and zone segmentation, automated digital follow-ups, alarm sharing, and heatmapping to help drive operation-wide safety

With notifications available on both desktop and mobile devices, safety managers can get alerts when alarm exposure or SOS event occurs. Other details such as GPS location, gas readings, and compliance data are readily available within these immediate notifications provides safety managers with the visibility needed to manage safety and productivity across multiple worksites at once, all from remote, off-site locations.

 

  1. How can wearable technology improve compliance and accountability across an organization?

Since a non-compliant detector can lead to potentially disastrous outcomes, it’s essential to ensure that every device is optimised. In other words, every device operates and protects the worker as it should. Technology not only makes this possible, it also makes it seamless. Advanced features that wearable technologies for gas detection should include are:

  • Automatic bump tests and calibration when devices need it
  • Visual indicators with green, yellow, and red lights representing “compliant,” “non-compliant,” and “in alarm,” respectively
  • Device lock out to ensure that non-compliant devices are not inadvertently used
  • Real-time historical data into specific workers
  1. Can wearable devices help improve compliance and overall workflows?

Connected wearable devices allow you to connect workflows across your organization by providing insight into compliance and productivity issues. This information, coupled with connected cloud-based software, can allow you to:

  • Automate compliance and help to reduce false alarms, remove asset-related risks, and lower the cost of downtime
  • Determine if instruments have been configured correctly and are compliant in testing and while in use
  • Create comprehensive reports in an industry standard format
  1. What type of investment should an organization anticipate for implementing new wearable and connected technology across their workers and worksites?

 

With the latest technology, often comes newer business models to help drive your organizations’ transformation to a connected safety program. Subscription models that include both detector hardware and software options can help enable faster implementation, along with increased warranty coverage and ongoing software and firmware upgrades.

The right partner can help support your organisation’s connected safety journey with the right solution to fit your needs, from the number of wearables to various software options and features capabilities, giving you flexibility.

A seamlessly integrated solution of connected wearables and cloud-based software can provide visibility of your workers, worksite, and workflows that can make all the difference and help organizations drive a proactive safety culture over time.

Find out more about the latest innovations in connected gas detection wearables here.

 

 

What Role Does Polymeric Technology Play in Burgeoning Wind Industry?

There has been considerable growth in the wind power industry over the past few years. However, further exponential growth of the industry is required in order to ensure that the net-zero by 2050 pathway (outlined in the Paris Agreement) is successfully reached.

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Figure 1 - Maintaining the integrity of wind turbines with polymeric technology

In order to support this seismic growth, polymeric repair and protection technology has an important part to play. Designed to safeguard the integrity of wind turbine blade leading edges for the long term, this technology plays a critical role in supporting this burgeoning industry.

Wind Electricity Generation Needs to Grow Fourfold by 2030

According to the International Energy Association’s (IEA) Wind Electricity Tracking Report

(September 2022): “In 2021 wind electricity generation increased by a record 273 TWh (up 17%). This was 55% higher growth than that achieved in 2020 and was the highest among all renewable power technologies.”

While the industry has undoubtedly experienced impressive levels of growth in these years, according to the IEA, wind electricity generation needs to reach four times the record levels set in 2020 by 2030. The Report said: “Our pathway calls for scaling up solar and wind rapidly this decade, reaching annual additions of […] 390 GW of wind by 2030”.

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Figure 2- Wind electricity generation needs to grow fourfold by 2030 (IEA. License: CC BY 4.0)

How is the Scale-Up of the Wind Industry Being Financed?

According to the IEA’s Report: “Policy support remains the principal driver of wind deployment in the majority of the world.” Indeed, over the past few years, several policies have been launched that are designed to drive forward the roll-out of renewables.

For example, in August 2022, the US brought in the Inflation Reduction Act (IRA) which includes $369 billion (US dollars) of investment, in the European Commission’s Green Deal Industrial Plan, $270 billion (US dollars) was pledged, and since the UK government’s Ten Point Plan was launched in November 2020, over £26 billion of government capital investment has been mobilised.

Safeguarding Expanding Fleets of Wind Turbines with Polymeric Technology

Given the critical role wind power plays in the transition to a net-zero future, as well as the significant amount of capital being invested into the renewables industry, the wind power sector is poised to experience considerable exponential growth in the upcoming decades. In order to support this growth, polymeric technology plays a significant role when it comes to maintaining the operational efficiency of the rapidly expanding fleets of wind turbines.

Polymeric systems such as the rebuild, blade filler material, Belzona 5711 and the cartridge-applied leading edge protection coating, Belzona 5721, are specially designed to repair damaged leading edges and protect them against rain erosion and impact damage for the long term.

In addition to the performance capabilities of these systems, maintenance engineers are investing in this technology due to the simple, in-situ application method and fast cure times the cold-curing systems facilitate. In turn, this helps to keep downtime to a minimum, and allows the turbine to be returned to service in the same day.

Belzona 5711 can be directly overcoated with Belzona 5721 in as little as 30 minutes at 20°C/68°F without the need for any additional surface preparation. At the same temperature, Belzona 5721 will be fully cured within five hours.

Below is a case study featuring the repair and protection of a wind turbine leading edge with Belzona 5711 and Belzona 5721.

Wind Turbine Blade Repaired and Protected

Belzona, a global designer and manufacturer of industrial protective coatings and repair composites, successfully addressed the wind turbine blade damage issue at Electricity Generating Authority of Thailand’s (EGAT) Khao Yai Thiang Windfarm in Thailand.

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Figure 3 - Leading edge damaged by erosion

Leading Edge Erosion Damage

The windfarm features wind turbines with 40-metre-long (131.2 ft) blades. During routine inspections, evidence of damage measuring 300 cm x 14 cm x 2 mm (118 in x 5 in x 0.08 in) on the leading edge of one of the blades was discovered.

System Selection

Representatives from the 35-year-old Belzona Authorised Distributorship, Pan Mechanic Engineering, recommended the solvent-free, two-part repair paste, Belzona 5711, to reconstruct the damaged area on the blades, followed by the high-performance coating, Belzona 5721, to overcoat the area.

Application Procedure

The application procedure involved surface preparation using an orbital sander, followed by the direct application of approximately 1.4 kg (3.1 lbs) of Belzona 5711 from a self-mixing cartridge onto the blade. The repair area was contoured using a piece of Belzona mixing board.

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Figure 4 - Surface preparation using an orbital sander

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Figure 5 - Self-mixing Belzona 5711 cartridge

After a two-hour curing period, a visual inspection was conducted to ensure the application's readiness for overcoating with approximately 3.5 kg (7.7 lbs) of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure. The blade was back in service 24 hours later.

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Figure 6 – Application of repair paste, Belzona 5711

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Figure 7 – Application of high-performance coating, Belzona 5721

EGAT's technicians were trained at the Belzona Asia Pacific facility to perform the application, with two representatives from Belzona's Technical Service Department present on site to observe and provide guidance.

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Figure 8 – Completed repair and protection of leading edge

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Figure 9 – Successful application of Belzona polymeric systems

Commenting on the application, an EGAT representative said: "We are extremely satisfied with

the results achieved by Belzona's leading edge repair and protection system. The application procedure was very simple, and could be carried out quickly, which ensured that downtime was kept to a minimum. We plan to place an order for more Belzona 5711 and Belzona 5721 .”

Supporting a Net-Zero Future

In order to support the seismic growth of the wind power sector, polymeric technology, such as Belzona 5711 and Belzona 5721, plays a critical role. By safeguarding the integrity of wind turbine blades, this helps to keep windfarms functioning at their optimum efficiency, which in turn, supports a net-zero by 2050 pathway for the planet.


More information about Belzona’s solutions for the wind industry can be found at: http://www.belzona.com/en/industries/wind_power.aspx

 

The ins and outs of thermal fluid analysis

How do you know when a kitchen sink is about to clog and overflow? Most residential pipes are hidden, so food waste and product build-up can go unnoticed until it leads to damage. In manufacturing, leaving pipework unmonitored can lead to unexpected downtime and safety issues, particularly when working with thermal fluids, so proactive monitoring is the best way to prevent these problems. Here Clive Jones, managing director of thermal fluid supplier and condition management expert, Global Heat Transfer, outlines the steps of thermal fluid analysis for proactive fluid monitoring and how businesses can use the results to increase fluid lifespan.

 

Thermal fluids are designed to operate effectively for many years, but over time, operating at and maintaining high temperatures means that the oil will naturally degrade. Thermal fluid analysis provides a deep dive into the condition of the oil and allows businesses to gain expert advice about how to effectively maintain the fluid and the system. Analysis also ensures health and safety compliance with The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) of 2002 and UKEX (formally the Explosive Atmosphere Directive ATEX 137 in the UK).

To comply with relevant safety regulations, such as DSEAR in the UK, manufacturers must take proactive steps to reduce the risk of fire or explosion caused by working with dangerous substances. If this fluid is left unattended, for example, fluid degradation — where thermal oils can be broken down into carbon molecules that stick to the pipes — can occur, reducing heat transfer efficiency. If not monitored effectively, degradation may go unnoticed until it causes significant production issues and system failure, leading to costly downtime and risk to health and safety.

Instead of reacting to issues, regular thermal fluid sampling and analysis enables businesses to proactively monitor fluid condition and intervene before issues impact production, extending thermal oil lifespan and reducing maintenance costs.

 

Analysing a sample

Effectively monitoring heat transfer oil condition requires engineers to regularly take samples of the oil and send it to a specialist for analysis. Historically, thermal fluid experts conducted seven tests, however, in our experience conducting eleven tests provides results that best reflect the reality of what’s happening inside the system.

Once the sample arrives to an impartial lab for testing, an analytical chemist will look at its appearance, looking at the colour and for any particulates in the fluid. Fluid colour can range from clear and bright, which is common to newer fluids, to hazy, which can be a sign of high-water levels, to dark, which shows there is a high level of carbon build up in the system. These initial observations are confirmed in later steps to ensure the thermal fluid specialist provides the best recommendations.

Testing the water content of the oil is vital to regulatory compliance. Any water in the system and oil will convert to steam and expand, increasing the pressure in the system. By analysing water content, analysts and heat transfer fluid specialists can advise on how best to reduce the risks associated with high pressure.

The next step is to test viscosity and assess the impact the fluid has on the system pumps. If a fluid is too thick, flow rate will reduce, increasing the pressure on the pumps. This reduced flow rate can create hot spots in the system, leading to inconsistent heating or cooling of products that results in waste products, increased damage to the system and rising maintenance costs.

Measuring the level of carbon in the system is key to understanding the degree of system fouling. If the thermal fluid expert detects high levels of carbon deposits, it suggests that there is more carbon in the system, which can harden in the pipes, acting as an insulator. As a result, the entire system heat transfer efficiency will reduce and more energy is required to heat up the system. Manufacturers should consider how they can prevent carbon build-up as it can create hot spots that accelerate wear on the pipes and increase the risk of leaks.

Analytical chemists will then test the total acid number (TAN). If there is a high level of acid in the fluid, it can lead to increased corrosion of the system and accelerated carbon creation. By measuring this parameter, manufacturers can understand how the fluid impacts the pipes of the system, ensuring that they can slow down degradation and reduce the frequency of scheduled maintenance needed to replace corroded parts.

Particulate quantity and iron tests highlight the degradation of components of the heat transfer system. Both tests can show signs that there is wear in the system that needs addressing so that manufacturers can intervene before the wear turns into a dangerous leak.

Manufacturers should also look at the results of the Pensky-Martens Closed Cup flash point, Cleveland Open Cup flash point and fire point tests to reduce health and safety risks. The industry standard suggests that closed flash point of the fluid cannot be below 100 degrees Celsius, because it means the fluid could ignite at lower temperatures, so these tests are vital to understanding if the fluid is safe for use.

Reporting

Once analysis is complete, the thermal fluid expert delivers a report to the plant manager, organising points into cautions, actions, or serious findings. At this point engineers can take the recommendations and plan interventions based on the priorities in the report. Making a record of each result will also help plant managers in the long term. By monitoring thermal fluid condition over time and looking for trends, helping them to anticipate when the system will require maintenance before downtime occurs.

Maintaining an efficient heat transfer system is integral to productivity, so unlike domestic pipes where a blockage may cause a minor overflow, manufacturers should consider how they can effectively monitor fluid inside the system. Thermal fluid testing can be complex, so manufacturers can work with thermal fluid experts, like Global Heat Transfer, to ensure they complete the process effectively and get an accurate representation of what’s happening inside the system. For example, by including Global Heat Transfer’s Thermocare® as part of a preventative maintenance programme that aligns with the ATEX triangle, experts can offer both on-site and remote technical support to help manufacturers rapidly sample and analyse fluid. From this, manufacturers can track fluid condition, anticipate and resolve issues quickly and implement preventative measures to extend fluid lifespan, reduce downtime and the facility’s environmental impact, and ensure system compliance.

To learn more about the thermal fluid testing and tailored solutions available, visit the Global Heat Transfer website www.globalhtf.com/heat-transfer-management/heat-transfer-fluid-analysis/.

This artilce can also be found in the issue below.

 

Cyber security of HMI systems

Horst Friedrich, Director Product Management and Documentation, R. STAHL HMI Systems GmbH

HMI systems are the staff's main window to processes. However, certain ground rules are necessary to prevent them from becoming an open invitation to hackers. The choice of systems is key to success: state-of-the-art technology as is used for R. STAHL's new ORCA HMI device platform can exclude a great many sources of human error right at the start.  

You can always depend on human error, both in environments such as company IT as well as in OT (operational technology), which includes automation systems. A careless click of the mouse on a link or file accompanying what seems like a mail sent by a colleague or business partners can create havoc in integrated company IT systems. Operational systems such as control or process control systems also increasingly come under attack by hackers. A recent study by Trend Micro – a company specialising in network security – showed that in 2021, 90% of German companies in electricity, oil and gas supply as well as in the manufacturing sector were the target of cyber-attacks. On average, a successful attack resulted in damage to the tune of 2.9 million Euros. 

Automation systems are increasingly becoming the primary target of such attacks. After all, whilst office IT becomes ever more secure, there are still a lot of companies with gaping holes in their OT security. When machines that used to be operated in isolation are being integrated into the company networks during a digitalisation drive or as part of IoT projects, these security gaps become the entry point for hackers. Latest at this point operators should check whether there is unprotected maintenance access to the machines, whether the security of all control systems is up to date, whether USB interfaces are deactivated, and, last but certainly not least, whether the default password of an operator station or a SCADA system has ever been changed. If the answer to any of these questions is "no", the door to the system is wide open for anyone to enter – as a simple internet search for "scada system passwords" will show.

Recent legislation has also recognised the importance of this subject, in the European Union for example by defining key requirements for operators of critical infrastructure in the DIRECTIVE (EU) 2022/2557 OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL by numbering chemical companies amongst critical infrastructure, in addition to assets essential for the functioning of society and economy. Such companies have to go to great lengths to meet the statutory requirements for IT security and cyber resilience, and non-compliance could lead to fines of up to 2 million Euros. 

Authentication as the most common blind spot

Efforts to ensure cyber security have always suffered from moving goalposts: although staff awareness of cyber risks is on the increase, cyber criminals are constantly upping their game. Social engineering and phishing attacks are becoming ever more sophisticated. But the good old USB trick also still works: plausibly labelled USB sticks left lying around are connected by unsuspecting staff to operator stations and control stations. Private mobile phones are also often connected to company systems. Then there are easy to guess passwords or passwords written down on pieces of paper stuck to the screen, a notice board or a whiteboard for any visitor or video conference member to see. A post-it note under the keyboard is also not a safe hiding-place for passwords. A Trend Micro study from 2018 showed just how important safe authentication is: according to the study, almost half of the successful cyber-attacks on HMI systems were down to unsafe passwords and insufficient access authority management. 

Often it is a question of ergonomics that leads to laughably easy passwords being used: which operator using several stations within a plant takes the time to enter a complex, 16-digit password via the screen keyboard every single time? Also, the software and hardware used in the process industry has often been in place for many years and has been developed at a time when integration, digitalisation and the Internet of Things were neither relevant terms nor development targets. Many operators simply have no idea exactly which devices and software systems are running in their plants.

Thin Clients reduce on-site cyber risks

During the development of the ORCA HMI series, launched in the summer of 2022, R. STAHL has addressed many aspects of cyber security. The Thin Client approach forms the basis: unlike independent on-site computers such as the ones used in Client/Server environments, the actual logic processes and data back-up for Thin Clients take place on a centrally administrated server. This means that many IT risks are immaterial for the on-site operator station. The operator's IT specialists can focus on security measures for the server. The ORCA HMI operator devices are closed systems with industrial-grade security. They have neither hard disk nor drives where malware could attack. To prevent manipulations at the level of the operating system, the UEFI-BIOS with the "secure boot" function is used: Windows is only booted up once it has been ascertained that parts of the firmware such as the boot loader have not been manipulated by unauthorised access. Also, the configuration supports customised security concepts.

R. STAHL is using the Remote HMI firmware for its Thin Clients. This has been designed as a closed system and is based on the Microsoft Windows 10 Enterprise 2019 LTSC operating system. LTSC stands for "Long Term Servicing Channel", an update channel through which the company guarantees a 10-year long support with security updates. The firmware is used to configure, establish and secure remote connections to application servers, or, in the simplest case, to a workstation. This allows remote access from one operating station to one or more workstations within a network. This is not only the case for the new ORCA devices, but also for the manufacturer's earlier device platforms.

Ergonomics relevant to security

Easy handling in day-to-day work is a precondition for maintaining a high level of security:security solutions that hinder staff in their daily routines provoke workarounds. For example, when passwords are constantly requested at different workstations users tend to choose a simple, short password, or they simply do not log off when leaving the work area. With the ORCA devices, users can log on by means of contactless RFID authentication. This ergonomic solution allows staff to easily log onto a workstation without even taking their gloves off, ensuring a high level of access protection. 

The RFID readers support the particularly user-friendly LogOnPlus software from i.p.a.s-systeme. This is a modular server-client application that manages log-on control for production applications. Users are, for example, identified through their RFID ID card, authenticated vis-a-vis the company's active directory and then logged on to a target application such as a distributed control system by LogOnPlus via an application-specific connector. 

But it isn't just the question of usability where R. STAHL is looking after the operators' interests. The hardware was designed such that the devices can be used for a long time: Thin Client and display box can be easily disconnected, with no cables involved, making replacements that might be needed for a more powerful system easy and simple. R. STAHL guarantees a service life of at least 15 years for the modular ORCA design. This enables us to achieve the balancing act between short IT innovation cycles and long-term plant operation– without having to compromise on cyber security.

www.r-stahl.com

 

 

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The future clicks into place

 

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During the development of the ORCA HMI series, cyber security was given utmost priority

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The new ORCA device platform design, specifically developed for long availability.

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With the launch of the new, modular ORCA HMI platform we are introducing the new, cordless EasyConnect click-fit system.

This artilce can be also found in the issue below.

 

 

 

 

 

The Hydropower Industry and Epoxy Coatings

Introduction

Hydropower is a renewable energy source that has been harnessed for thousands of years. Today, it is one of the most important sources of electricity in the world, and its use is only expected to grow in the future. One of the key components of the hydropower industry is the use of epoxy coatings, which are used to protect the machinery and infrastructure used in hydropower operations. In this blog post, we will explore the role that epoxy coatings play in the hydropower industry and the benefits they provide.

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Figure 1 Grand Coulee Dam in the United States

The Benefits of Epoxy Coatings in Hydropower Operations

Epoxy coatings are a popular choice for use in the hydropower industry because of the many benefits they provide. One of the primary benefits of epoxy coatings is their ability to protect machinery and infrastructure from corrosion. Corrosion is a major problem in hydropower operations because the equipment used is often exposed to water and other corrosive substances. Epoxy coatings provide a protective barrier that prevents corrosion from occurring, which helps to extend the life of the equipment and reduce maintenance costs.

Another benefit of epoxy coatings in hydropower operations is their ability to provide a smooth surface for water to flow over. This is particularly important in turbines, where a smooth surface is essential for optimal operation. The use of epoxy coatings can help to reduce friction and improve the efficiency of the turbine, which can lead to increased power generation and lower operating costs.

Finally, epoxy coatings are also resistant to high temperatures and can withstand exposure to UV radiation. This makes them an ideal choice for use in the harsh environments found in hydropower operations, where machinery and infrastructure are often exposed to extreme temperatures and intense sunlight.

Hydropower Industry Case Study

Belzona had the opportunity to improve the condition of a 60-year-old Kaplan hydropower unit that was showing signs of wear and was due for a full mechanical overhaul.

Operators at the Hydropower Plant grit blasted and cleansed the unit with solvent. Belzona 1111 (Super Metal) was used to smooth over the wear and cavitation in a full skim coat. Once cured, the Belzona 1111 (Super Metal) was sanded down to the required profile, and frost blasted. Two full coats of Belzona 1341 (Super Metal Glide) were applied. The coating can provide increased efficiency on new and refurbished equipment while also providing full corrosion and erosion protection while immersed.

Surviving 60 years with minimal wear is impressive. However, by using Belzona 1341 (Super Metal Glide), the unit can continue to operate for many more years, providing reliable service and cost savings over the long term. The use of this product can improve the unit's resistance to wear and tear and can also provide an additional layer of protection against environmental factors such as moisture and chemicals.

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Figure 2 Hydropower unit during surface preparation for Belzona 1111 (Super Metal) application

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The Future of Epoxy Coatings in the Hydropower Industry

As the demand for renewable energy sources continues to grow, so too does the necessity for hydropower. This is expected to drive an increase in the use of epoxy coatings in the hydropower industry, as more and more equipment is needed to meet the growing demand for electricity. In addition, advances in epoxy coating technology are likely to make them even more effective at protecting machinery and infrastructure from corrosion and other forms of damage.

One area of particular interest is the development of epoxy coatings that are more environmentally friendly. As the world becomes increasingly concerned about the impact of industrial processes on the environment, there is a growing demand for coatings that are engineered with plant-derived ingredients. The Belzona Research and Development Team are currently in the process of formulating products made from bio-based materials that are produced from sustainable plant-based feedstocks, rather than the traditional fossil-fuel based ingredients.

Conclusion

Epoxy coatings play a critical role in the hydropower industry, providing protection against corrosion, improving efficiency, and withstanding the harsh environments found in hydropower operations. As the demand for renewable energy continues to grow, the use of epoxy coatings in the hydropower industry is expected to increase, and advances in technology are likely to make them even more effective. By working together, the hydropower industry and coating manufacturers can help to develop coatings that are both effective and environmentally conscious, ensuring a sustainable future for the industry and for the planet.

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  • Streamline Data Management: Access a case study from an operator who saved $800k in one year and optimized operations by reducing information retrieval times by up to 50%
  • Create A Culture of Change: Learn how data digitization is being implemented across different organizational structures and the key strategies for businesses to become increasingly efficient and future-focused
  • Technology Execution in Action: Gain vital insight into the successes and challenges of industry pioneers such as the VP of Energy Transition USA at Shell, Chief Data Officer at Chevron, EVP of Digital Solutions at Baker Hughes and more

Whitepaper: The Need for Cultural Change In a Legacy Industry

According to the World Economic Forum digitization is a $1 trillion opportunity for the oil and gas supply chain. While contemporary discourse around digitization largely focuses on technological innovation, the issue of cultural change management is often neglected.

Reuters Events’ latest whitepaper, The Need for Cultural Change in a Legacy Industry, addresses the growing demand for new digital talent and the importance of upskilling your existing workforce to unlock innovation and propel your digitally integrated oilfield into the future.

Download the whitepaper for free by clicking the link below

What to expect from the whitepaper:

Staying Competitive: Discover how converting from legacy technology to the latest innovative solutions will attract young talent into your team and investors to your business
Fostering Trust in Digital: Understand the importance of orienting and driving employees to develop new knowledge, mindset, and behaviors

Future-focused Workflows: Learn how workplace changes post-Covid-19 have impacted the oil and gas community and the cultural and financial benefits of adapting to a new way of working through scalable digital enhancements.

Data Management - the Key to Digital Transformation in Oil and Gas

Digitalization can enable $2 to $12 in savings per barrel in upstream oil and gas production according to Offshore Technology. To take businesses to the next level of the digital transformation, data must be prioritized and leveraged effectively to scale digitization across upstream operations.

Reuters Events’ latest whitepaper, Data Management – the Key to Digital Transformation in Oil and Gas proposes vital solutions to key data management challenges in Oil and Gas to help you reach your full digital potential.

Download the whitepaper for free here

What to expect from the whitepaper:

  • Unlocking Value: Break down siloes and discover new pathways to increased efficiency
  • Getting Ahead: Understand the critical need to commit to a data-oriented business strategy to scale up your digital oilfield
  • Case Study: Read about a real-life example from an operator who saved $800k in one year and streamlined operations by reducing information retrieval times by up to 50%


Industry-Agnostic Solutions: Read about adaptable data strategies that have transformed the finance industry and what the oil and gas sector can learn from them

Download the whitepaper for free here

Hoist & Winch elevates success of large construction project

Hoist & Winch Ltd has recently completed a challenging project for one of the UK’s biggest construction companies involved in large-scale new home development projects. Faced with a demanding and highly technical brief, Hoist & Winch rose to the task, providing a turnkey lifting system solution to ensure complete success for its client.

The requirement was to install a concrete ceiling mounted 7.5t swl (safe working load) lifting beam and manual chain hoist into the basement energy room of a large new tower block. This development is part of a large-scale prestigious regeneration project providing 5500 sustainable new homes in North London. 

At the design stage, following formal tender and contract award, Hoist & Winch set about identifying the optimal solution. Due to restricted access into the basement area, the company decided to utilise a two-piece lifting beam design with an overall length of 7m. To join the two lifting beam sections, Hoist & Winch designed a central splice joint of bolted construction with a reinforced bottom beam flange.

In order to spread the lifting loads over a greater area of the concrete ceiling slab it was decided to mount the lifting beam via four intermediate cross members, each having a four-bolt/anchor fix into the concrete ceiling at both ends. Featuring a robust bolted construction design it was possible to deliver the lifting beam to site in fully dismantled form for ease of transportation and access.

M24 resin anchors with an embedment of 255 mm into the 400 mm deep reinforced concrete slab fixed the intermediate cross members directly to the ceiling for maximum security. 

​​​​​​​​​​​​​Continued ……

For approval by engineers at the main contractor, Hoist & Winch submitted design drawings and calculations for the structural design of the lifting beam and loading of the resin-type ceiling anchors. 

With the design approved, Hoist & Winch could progress to manufacturing, followed by delivery to site. Using building column positions as datum points, the installation line of the lifting beam was marked out while working from scissor lifts and an aluminium scaffold tower located on the upper mezzanine floor. A surveyor’s laser line initially identified the correct lifting beam position, prior to overlaying with red chalk to ensure accuracy for the duration of the installation work.

Raising the two lifting beam sections into position required the installation of eight 1t swl hand chain blocks, with each one suspended from M16 swivel eye bolts supported from flush-mounted anchored resin inserts drilled into the concrete ceiling slab. 

Following sample pull load testing, Hoist & Winch raised each lifting beam section into position using four 1t swl hand chain blocks. To raise the lifting beams to the full height and clamp them hard against the concrete ceiling slab ready for drilling, the company used two special lifting rigs per beam section.

The first lifting beam section manoeuvred into position also included the 7.5t swl hand chain block, which was rolled on to the lifting beam at low level using a 1t swl hand chain block temporarily suspended from local steelwork. Once both lifting beams were in position, Hoist & Winch joined the two lifting beam sections using the aforementioned bolted splice plate.

Next, the company undertook ceiling slab drilling operations and resin anchor installation for all 32 ceiling anchorpoints after very carefully cleaning each hole with a special heavy-duty internal brush and suction pump. Following the specified resin curing time, Hoist & Winch could tighten each anchor bolt to the required torque levels.

​​​​​​​​​​​​​Continued ……

The final installation and test operation was LOLER (Lifting Operations and Lifting Equipment Regulations) inspection of the lifting beam and manual chain hoist unit. This activity included dynamic load testing of the entire runway beam length with a 7.5t skid-mounted test load followed by 125% static proof load test in accordance with BS 2853 2011. 

“Working as a subcontractor for the company supplying and installing the plant and services in the basement energy room, we delivered an entire turnkey lifting system solution,” states Andy Allen, Director of Hoist & Winch Ltd. “At completion we provided the client with an overall project records and documentation package, before clearing all site equipment and undertaking customer handover. This project is just one of many exemplifying the meticulous, competent and professional approach that Hoist & Winch customers can expect from our highly knowledgeable team.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.