31/05/2017

Prevention is better than cure

Author : Neil Ford

Whatever type of plant you are responsible for, industrial boilers are probably one of the most expensive items that you need to keep running at optimum levels around the clock. So ensuring their longevity is prolonged by taking proactive steps to identify performance issues and address them before they result in downtime is crucial.

Green's has been designing and manufacturing boilers and waste heat recovery systems in the UK since 1845. Our exceptional engineering and manufacturing skills combined resulting in what we believe are the world's most durable economisers. Our systems are used across a wide range of industrial applications around the world from a leading chemical plant just up the road from us in Yorkshire to pulp and paper plants in Russia, Europe and Indonesia as well as pharmaceutical producers and oil refineries.

However, while our products are shipped from our factory in perfect condition, they are used to generate steam for a whole range of processes day after day. They are often utilised in very harsh environments, handle varying quality of feed water and operate throughout demanding work patterns. This can result, over time, in reduction in efficiency or even total machine failure.

To prevent this, it is vital to commission a proactive inspection service to spot potential problems with boilers and ancillary equipment so that they can be assessed and plans put in place to maintain optimum efficiency and before they become unnecessarily costly or result in avoidable outages.

Professional companies that provide this sort of service will usually provide comprehensive reports on their findings to highlight potential problems, make recommendations and offer practical advice so that plans can be put in place and unnecessary cost and downtime is kept to a minimum. Many will work with the site engineering/facilities team to arrange boiler inspection, servicing and repairs during annual inspection and outage periods so that they can get back to full steam production with their boilers at peak performance with minimal disruption to normal operations. Indeed, our own inspection teams are on call 24/7 and available for worldwide mobilisation 365 days of the year at very short notice.

However, purchasing managers looking for help in this area should check that the company they choose is familiar with the specific challenges that working in the industrial steam boiler sector brings and also that they are competent to deal with a wide range of products and parts which may have been brought together over time.

It is also highly valuable if the chosen supplier can provide other complementary services such as asset integrity assessment, failure analysis, chemical cleaning and repairs tailored to customers' needs. If this can be supported by a spares supply and commissioning service it means that any problems can not only be identified and action plans agreed, remedial action can be taken quickly and efficiently to ensure fast return to optimum boiler performance.

CASE STUDY

Established in 1966, John Samonas & Sons manages a global fleet of dry bulk carriers, which transport a range of commodities including iron ore, coal and agricultural products.

Efficient operation of its vessels is key to the company's success. So when it was recently discovered that some of the tubes had failed on the Samjohn Dream's Aalborg economiser, one of its key carriers with a deadweight of 206,610 MT, it was vital that the faulty equipment was replaced quickly and professionally.

Green's was called in to manufacture the parts needed, meet the ship on arrival at Drydocks World Dubai where Samjohn Dream was due for its five-year survey and replace all 27 H Fin economiser coils. Coils were manufactured and Lloyds Register of Shipping (LRS) class approved in 16 days and installation was completed before the vessel left the dry-dock.

John C Samonas says: "Green's previously worked on Samjohn Liberty and we were impressed by their problem-solving skills and their ability to complete projects in a way that fits in with our tight schedules."

Green's provides a wide range of aftermarket services so that its marine and land customers' boilers, economisers and waste heat recovery systems keep working as efficiently as possible for their entire lifetime. From proactive inspections and surveys to reactive repairs and spares supply, Green's provides global, fast and reliable aftermarket support.