Martin and Colwell: Minimizing time to experience, maximizing human performance | ISA.

I encourage everyone to read the full article, but I have highlighted a couple of sections below that are pertinent to the Heat Treat Industry.

“While the effectiveness of on-the-job training has been accepted for decades, its traditional approach usually involves highly experienced workers overseeing the behavior of less experienced workers. While this is good, the objective is still merely to make the less experienced workers only as efficient as their mentors.”

The above is my experience within a Heat Treat shop, the article continues to explain some new methods to enhance the abilities of new workers:

“KPIs and other data allow plant personnel to see and understand how their domain of responsibility impacts the operational and financial performance of the plant (and entire enterprise) in a format that corresponds with their individual experience, training, and capability. For example, after the KPIs are established, “dashboards” or “scorecards” that provide real-time performance feedback are embedded in the training environment. With this immediate data, everyone can assess their performance and understand how their actions have influenced the operational and financial potential of the plant. On average, such enhanced experiential training realizes a 100% return on investment within three months.”

Invensys Operations Management on the back of the widely used Wonderware Software Platform and Eurotherm Controls/Recorders have added to capabilities of KPI displays with Workflow modules and Energy (CEM) modules, these allow for contextualizing of energy use against batches processed as well as utilizing Workflow techniques to ensure ‘Business Rules’ are followed on the shopfloor.

If you are interestd in more  information, please contact me via email for more information peter.sherwin@invensys.com

This situation is usually caused where the electrical suppliers peak charge is based on the  highest 15 minutes of  energy use  during the month.

Heat Treaters can practically minimize this situation by scheduling the start-up of furnaces at different times but this is not always possible due to the requirements of Just-In-Time manufacturing. Other methods include using energy saving devices provided by companies such as Dibalog or powering electric furnaces with intelligent SCR’s such as the Epower from Eurotherm; the special PLM feature in the Epower product reduces peak demand by intelligent shedding and sharing of loads across individual multi-zoned furnaces  and using the same feature(s) to provide reduced peak loads across multiple furnaces.

Visit Eurotherm at the ASM show 15/16th September #2025 to discuss your energy saving requirements.

Just released – white paper.

The load tap changer is a powerful solution for applications that require phase angle firing due to the nature of the load or for convenience. By dramatically improving the power factor compared to a traditional phase angle solution, it results in limiting the harmonic generation thus reducing any associated issues. Even more important, it reduces the Demand Charge of the utility company resulting in substantial savings.

Load tap changer White Paper

Who should attend:
Combustion equipment end-users and manufacturers (furnaces, ovens, oxidizers, etc.)
Why you should attend:
Hear a concise summary of important proposed changes to NFPA 86
Get an early start on preparing comments
Ask the NFPA 86 Committee Secretary questions and hear his responses live.

Click on the following link to register

https://event.on24.com/eventRegistration/EventLobbyServlet?target=registration.jsp&eventid=142465&sessionid=1&key=A6898DC9FE980EFBC37A2BE4EF9EBB31&partnerref=tileIH&sourcepage=register

In this application, the PLM function of the SCR power controller manages the heating elements and regulates power input across the combustion process, combining improved communications and data accuracy with real-time networking and load analysis.

The EPower controller sends live furnace-load and network data directly to the control room, enabling operators to modify their process strategy immediately in accordance with the incoming data feed. Changes made to the control type, firing mode and load configuration all facilitate improved process efficiency.

<full story:   Intelligent Control Saves Energy to Generate Energy>

Detailed information on the PLM function can be found in a newly release white paper written by Mikael LeGuern, our Power Product Specialist, entitled Energy cost reduction through Load Balancing & Load Shedding.

Visit the Eurotherm websitge for more information on the new SCR power controller .

So why use Pulse-Firing……?  Simple answer is to reduce costs!

Although putting in a Pulse-Firing system may mean a higher capital outlay, this is offset by reducing energy costs.  Costs are reduced through improved burner efficiency, better heat transfer through improvement in circulation and penetration of heat enabling  reduced heat-up times thus shortening overall cycle times. Some benefits are also seen with the quick acting nature of this system compared to conventional modulating motors systems – this also reduces energy wastages due to quick reaction to changes in temperature demand.

Pulse-Firing systems may also improve the versatility of the equipment by improving its working range from as low as 300degF through to over 2000degF (depending on heat input!).  Reduction in overshoot enables tighter temperature control and aids conformance to specfications such as AMS2750D.

Along with all these benefits of Pulse-Firing, Eurotherm offer this control in a package which comes with cascade control, recipe manager, an intuitive HMI enabling easy alteration of setup – security controlled – as well as a full data management package (all standard in our Eycon Visual Supervisor!).

Click on picture to access the EPower video on:

How Predictive Load Management reduces energy cost.

Gas or Electric – Eurotherm has solutions that save money!

Improving the efficiency of Burner systems as well as improving temperature uniformity through intelligent burner control.