8 Things to Know About Sheet Metal Manufacturing

Metal fabrication is the process of building metal structures. It is done by bending, cutting and assembling. Fabricating metal helps in creating customized metal structures which are then used for different purposes.

Sheetmetal is the basic form of metalworking job which involves cutting and bending the metal in various forms. Sheetmetal is an important raw material component which is used for different type of applications. Metal fabrication is a complex process. There are different professionals involved in doing sheet metal fabrication. There are fabrication shops or fab shops in which these sheetmetals are fabricated. Technically speaking, sheetmetal fabrication is a process in which a piece of metal sheet is given a shape by cutting or deforming. Here are some 8 important things to know about sheet metal manufacturing:

  1. There is no clear definition with regards to how much should be the thickness of the metal sheet. But roughly a sheetmetal is between the range of 0.006 to 0.25 inches.
  2. Metals like Steel, Aluminum, Bronze, Magnesium etc. can all be converted into sheetmetal.
  3. The sheet metal can be customized into any shape. It can be cut, bent or stretched as per the requirement. There are different welding techniques used as well in sheetmetal fabrication. Sheet metal can be of any size. They are used for different applications. They can used in something which is as small as washer or as big as an aircraft. Other applications where sheet metals are used include consumer durables, automobiles, furniture etc.
  4. Sheet metal parts are durable. They can be used for creating proto-types as well as for end-use.
  5. They are built on on-demand. It is possible to up-scale or down-scale the production of sheet metals depending on the requirement.
  6. Nowadays, there is tough competition among many metal manufacturers to provide sheetmetals in quick turnaround time. Some guarantee providing instant quotes as well as turnaround time of between 10-15 business days.
  7. Sheet metals which are made of steel are used widely in construction sector as they provide good strength and are corrosion resistant. They have light weight which as compared to other metals which makes them easy to carry and install.
  8. Sheet metal can be custom finished through variety of different processes like powder coating, painting, anodizing etc.

The future of sheetmetal fabrication seems bright. The only challenge lies in all fabricators coming together for a common cause as the metal fabricated industry is pretty much fabricated. Many small fabricators do not have proper knowledge about sheetmetal fabrication. Some even do not know the basics of materials science. This results in wastage of capital invested for the project and creates excessive scrap.

Through collaborating with each other, many sheetmetal fabricators can improve the overall processes of fabrication. They just need to share their knowledge and expertise with each other. High strength steel and availability of other materials has helped fabricators in manufacturing good quality sheetmetals.

All About Structural Steel Fabrication

Steel is an important element through which one can produce different kind of products. It is widely used for different kind of applications. There is more demand for fabrication of steel as compared to other products. Steelfabrication is done in sectors such automobile, Oil & gas, construction etc. There are machine fabrication shops who do the steelfabrication and then it is assembled on the site. Structural steel is well appreciated by all the metal fabricators in the world. It has got different features which are mentioned below:

  • Strength – Structural steel has high strength to weight ratio. This makes it easy to fabricate steel as compared to other metals.
  • Easy welding – Through welding, the quality of steel can be enhanced which is not the case with other metals. This quality of steel makes them an easy choice for high-pressure applications in construction sector.
  • Cost – Fabricated steel is a cheap raw material component as compared to other fabricated metals. So most of the clients insist on using fabricated steel. This fits their budget and the project gets delivered in the stipulated time.

Steelfabrication is a delicate process. There are three major steps involved in it. They are as follows:

  • Cutting – First of all, the steelsheets are cut according to the requirement. Steel can be cut by using different tools like laser cutters, plasma torches, mechanical saw etc.
  • Bending – The second step involved here is bending. The steel sheets are hammered to give them the required shape. Steel sheets are bent manually or through automated process. There is a tool – Press brake through which steelsheets are bent.
  • Assembling – The fabricator finally assembles the steel on the site or at his shop depending on the need of the client.

Fabrication is a work which requires great precision and care. So it is always recommended to take the help of professional structural steelfabricators. In case of construction industry, they are also well aware about the legal norms to which the builder must adhere to while placing the building structures. Here are some checkpoints which can be used while finalizing a steelfabricator:

  • Reputation in the market – It is necessary that the fabricator has got good amount of professional experience and expertise in handling the kind of job for which you will be hiring him. You cannot afford to go ahead with a shoddy job done by fabricator if you are in the construction sector as this may cost the lives of people. You can have a look at the kind of projects they have handled in the past. A little bit of background research by contacting some of their previous customers can also help you in this matter.
  • Capabilities – You need to understand the production capabilities of the fabricator. He should be able to produce that much quantity which will be required for the project.
  • Machinery – The fabricator should possess the kind of machinery which will be required for your fabrication project.
  • Location – Choosing a fabricator which is nearer to your site or office will always help in better coordination.

Tips For Efficient Heat Exchanger Cleaning

An important aspect to keep heat exchangers in tip-top condition is routine maintenance through heat exchanger cleaning. However, this vital service, which is more necessary in refinery and other industrial organizations, is often not given its due importance, though production remains vital. Hence, there are regular built-up of fouling, and this will be a major cause of drain of money in the form of asset life, lost energy, runtime, etc. and this is more to be seen in exchangers upstream of the fired heater, (which remains as the biggest energy consumer within the plant itself) due to its harder firing to make up poor performance of the heat exchanger. Every year, hundreds of thousands of dollars are lost due to shutdown resulting from the failure of the heat exchanger, and which becomes annoying in the procedure which is technically quite intensive.

To Water Jet or Not to Water Jet

One of the popular heat exchanger cleaning methods is water jet cleaning process consists of multi-lance water jetting at high pressure. If the heat exchanger is lightly or heavily fouled, the first choice should be polishing and projectiles, as they have shown effective and environmentally-friendly. Although the process is costlier, it still gives a better return on investment as the result of cleanliness is of higher degree, which will result in the run-time getting extended, provided the operation is done effectively.

With a pressure of 60,000 psi maximum and 4 liters per minute, the cleaning remains as one of the safest methods that a competent person can work with. This results in lowering the cost of maintenance by not requiring the use of hazardous chemical disposal services, and not requiring the need for cleaning of the heat exchangers when the integrity of the asset is tested by the use of Eddy Current or IRIS.

The usual temptation when it comes to cleaning heat exchangers is to make use of traditional or insufficient equipment or heat exchanger cleaning chemicals is quite a common feature if the site engineers fail to supervise it, and could render damages while doing shell and tube heat exchanger maintenance while leaving the exchanger uncontaminated.

With over 250 years of combined, professional experience, Thompson Industrial Services firmly believe that three cleaning systems in combination, including Ultra-high-pressure water, rotary projective methods, and Mechanical high-speed rotary polishing should be the best choice of cleaning, as the method is already proved to be quicker in comparison to the lancing method, as there is removal of the right fouling to the right technology. Any wrong choice is a costly matter, especially, if there is a wait time of 4 years for the next shutdown.

Keep Cleaning on Schedule

As per the schedule, routine maintenance is executed, but this should be performed using the right cleaning techniques. As per the particular heat exchanger that needs to be cleaned, it is necessary to define correct timings. The difficulty comes up in that neither the onsite maintenance team nor the manufacturer will come to know or have direct experience in cleaning, and in the process leave it to the contractor to make the choice, with the hope that the right cleaning method is selected.

Routine cleaning benefits in that the downtime is saved considerably. With proper execution, the deposit formation is delayed, lessen the under-scale corrosion, extend run time and asset life, while performing inspection the first time as well as every time without requiring the execution of re-cleaning. Performing cleaning and inspection in combination ensures the full operation of the equipment while meeting the first time regulatory standards without any form of delay occurring.

Why dismantle when you can clean in-situ without Pulling

It is possible to clean heat exchanger and inspection maintenance by making use of robotic heat exchanger cleaning technique without the need to pull out the exchangers. This is undoubtedly a great cost saving option to lessen the downtime and related costs for plant operators, by making use of the scaffold, gaskets, bolts, risks of pulling, 3d party costs, etc.

There are many specialists in heat exchanger cleaning companies that do the cleaning of the heat exchanger by doing it at their own facility, and in the process, incur unnecessary downtime. If you heat exchanger is not possible to be cleaned by your contractor in place, you would do well to seek a second opinion from other heat exchanger cleaning professionals who may be using other cleaning methods that can execute the job on-site, and in the process, lessen the time to complete the project.

Heat Exchanger CIP

An effective cleaning method that is often considered in the case of heat exchangers is the Cleaning-in-place (CIP). This method is quite effective in removing mineral scale along with the biological build up within the exchangers within a short time (usually, cleaning is done in eight hours) there are instances when mechanical cleaning remain as effective for certain exchangers. Usually, this service is executed along with a cooling tower cleaning and was executed on-site. However, it is found that even after doing a physical cleaning, the heat exchanger surfaces contain mineral scale that provided considerable resistance to transfer of heat.

Now CIP cleaning is provided for heat exchangers and chillers to every customer. With CIP, it is possible to bring on-site factory reconditioning quality, nearer to customers and in the process, reduce downtime. The whole process of cleaning in place of the heat exchanger or chiller is quite easy. At the start, the approximate volume of heat exchanger is determined, along with the possible fouling mechanism like biological fouling, mineral scale, iron scale, or others, the locations of isolation valves, as well as where it is possible to tap into the line to help in the movement of the cleaning chemicals (usually, a gauge tap or thermowell).

All this information helps in providing a proposal for heat exchanger cleaning, visit on-site and does the cleaning of the heat exchangers. The chemicals are either delivered to the job site or else, they are brought by the technicians. On arrival, the process is reviewed along with the customer. As the cleaning solution is moved around the heat exchanger cleaning equipment, samples of pH are regularly tested to find the cleaning progress. After completion of cleaning, there is neutralization of the cleaning solutions, which is then sent to the local drain.

Thompson Industrial Services handle everything from refineries and tube units to small plate heat exchangers. This is another tool that is used to keep running the heat transfer equipment at its best performance level while doing away with the heavy wrenches.

How to Select a Franking Machine For The Business?

A franking machine or postage meter is a useful device for the businesses of any size. By using this device, a business can save a good amount of money on postage as it is extremely inconvenient visiting the post -office every day for sending mails. This is the main reason for using the postage meter for sending mail in bulk.

Benefits of using Franking Machines in big organizations

Postage meters are best if you need to send high volumes of mail on a regular basis and so it is more used in big-size companies. Big-organizations use this machine because of following features:

  1. Sorting mails is extremely convenient with franking machines and so these machines are used in huge organizations where thousands of mails are organized and send every day.
  2. These machines comprise of many useful features like automatic cleaning, accounting, etc.

Benefits of using postage meters in small organizations

Postage meters are available in the market with an excellent rental option that can easily cater the requirements of businesses of any size. Not only large enterprises, but small companies can also be benefitted from these postage meters in the following manner:

  1. Small businesses invest in postage meters just to save their employees’ time and also from the problem of standing in post-office queue for sending mails.
  2. Furthermore, by purchasing these meters, the companies exhibit professionalism and improve their productivity and branding, which is crucial for business growth.

Salient Features of these postage meters

There is an exclusive range of postage meters available in the market and one should buy it according to his business requirements. It is of no use to buy an expensive postage meter with advanced features from the Franking Machine Suppliers if your business doesn’t have the requirements of those features. On the contrary, you should not restrict your business growth by buying a low-grade postage meter. So, it is extremely important for you to assess your business requirement first and then look for a suitable machine with desired features.

  1. Always buy a machine equipped with integrated weighing scales.
  2. Prefer the one with the alignment system and features such as auto-feeding of the envelopes
  3. Buy the one available with unique control panels to make your navigation easy.
  4. Always buy a machine with inkjet printing for unique and clear printing.
  5. Buy the one with envelope sealing feature.
  6. Buy a machine that has the capacity of handling packages of any size.
  7. Buy a machine with high-grade safety features just to prevent the misuse of the machine.
  8. Buy the one that has reporting and accounting features to keep an eye on the expenses.

These are some salient features of postage meters that you need to think of before buying a one for your business.

An Introduction to Pressure Vessels And Safety

Pressure vessels are used and relied upon each day in applications all round the world. But first, what are they? In its simplest kind, a vessel could be a closed instrumentation that’s built to carry gases or liquids at a considerably higher or lower pressure than the close atmosphere. the foremost basic example of a pressure vessel might be one thing sort of a compressed gas canister. On the additional advanced finish of things vessels are often found in experimental laboratories all over, furthermore as in spacecraft living environments.

However, whereas the look and engineering accustomed turn out vessels is improbably necessary within the method they operate and faithfully do their job – safety is equally (if not more) vital.

Due to the pressure differential that takes place among a vessel, dangerous and fatal accidents have occurred throughout their history round the world. thanks to this, they’re currently designed, factory-made, and operated in line with a strict set of rules, backed by legislation. whereas standards tend to alter from country to country, all of them involve restrictions for values like temperature and therefore the most operational pressure.

For many years, dominant and containing numerous substances struggling has been completely essential for industries all over. However, the operative word here is so “controlling”. correct management of terribly dangerous pressure differentials is polar once it involves avoiding doubtless fatal accidents which will occur thanks to improper vessel engineering and operation.

For the foremost half, the widespread industrial usage of pressure vessels saw its genesis with the proliferation of steam power throughout the economic revolution in nice Britain. throughout now, industrialists took advantage of the pressurised water and steam to power steam engines that were used for everything from trains to producing instrumentality.

However, in line with the yank Society of Mechanical Engineers – the organization that dictates pressure vessel standards – the short rise of steam power came with its own issues. thanks to the technology being comparatively new and untested, secure fittings, valves, and boilers puzzled and toward land “were exploding with terrific frequency.” Despite engineers in America creating major breakthroughs once it came to manufacture, poorly enforced vessels killed fifty,000 and separated 2 million men and ladies each year.

This was a number of the primary measurable knowledge that pointed towards the need for brand spanking new and tight pressure vessel standards. As standards for vessel safety became additional prevailing, the technology continuing to grow to wherever it’s nowadays. trendy applications that accept pressure vessels vary from domestic quandary storage to extremely advanced applications like nuclear reactors, submarines, area ships, and storage containers for gases starting from atomic number 17 to ammonia. With the numerous applications that benefit of pressure vessels in mind, variety of recent scrutiny techniques are pioneered.

Primary among trendy pressure vessel testing techniques is on-line scrutiny. on-line scrutiny generally involves testing the thickness of the metal in important areas, on a daily basis. this can be done to live the health of the pressure vessel, and monitor once it reaches a minimum thickness for the pressure vessel’s application. Once now is reached, repairs should be created to the vessel to forestall failure.

Ty Shaughnessy is associate amateur student and industrial specialist. He finds the interaction between everyday society and therefore the industrial world terribly fascinating, and regularly writes regarding the role industrial technologies play in our present time. last he has centered on the history and role of ASME pressure vessels.

Importance of Choosing The Right Rolling Mill For Every Steel Plant

The need for selecting the right rolling mill is of paramount importance if you have steel rolling mill plant. It is a workplace where the metal is deformed and then reformed by passing it between two rollers. As this is amongst highly used processes in metal rolling industries it is important to know how the quality of a rolling mill can affect your business?

One should never be sluggish while searching for one of the best manufacturers and the reasons are listed below.

Right rolling mill helps in:

Maintaining quality standards: Quality is the prime demand and compromising with it is like putting the business in danger. All the parameters associated with steel mill influence the quality of the ultimate product. This makes it important to make a wise and right choice while selecting rolling mill for the plant.

Avoiding improper mechanisms: Mechanical processes in such industries are long which demand constant running of machinery without any hitch. If the rolling mill or other equipment fails in meeting the standards of production then this can badly affect the steel plant. To ensure proper working of machinery one should ensure selecting a right seller.

Persistent production: Big steel plants work round-the-clock so machinery failure is an unacceptable scenario for them. This can disorder production queue which can lead to delay in delivery, unfulfilled promises and harm on goodwill. Good rolling mill manufacturer ensures the durability of rolling mill and other tools that can help in avoiding unwanted situations.

Achieving target with right dimensions: Well-known manufacturers earned this position because of the quality of machines and their sub-parts they provide. Right machine helps in achieving target easily which is not possible with rolling mills with minute flaws.

Automation of Industrial Processes

The rapid expansion of a huge international market requires the industrial sector to optimize production processes to achieve a greater market share and increase competitiveness. To achieve this, engineering has promoted the development of areas such as mechanics, electronics and robotics to manage and consolidate the automation of industrial processes.

Automation is the implementation of intelligent systems and technologies to operate machinery and control production processes, regardless of human operation in jobs that require greater effort and represent a huge risk to the health and welfare of workers. Currently, there are three types of automation in accordance with the degree of production and needs of a certain industry:

Fixed Automation:

Designed for large-scale manufacturing: A specialized machine or equipment is used to produce a part of a product or the product itself, in a fixed and continuous sequence. This type of automation is ideal for producing large volumes of products that have a long-life cycle, an invariable design and a broad consumer demand. Its main limitations are the high initial cost and the lack of flexibility of the equipment to adapt.

Programmable Automation:

Suitable for a smaller production volume, segmented by batches, programmable automation allows to change or reprogram the sequence of operation, by means of a software, to include the variations of the product. Among the most used equipment for this type of automation are numerical control machines, robots and programmable logic controllers.

Flexible Automation:

Designed for an average production level, flexible automation is the extension of programmable automation. It reduces the programming time of the equipment and allows to alternate the elaboration of two products (in series) when mixing different variables. Flexibility refers to the ability of teams to accept changes in the design and configuration of the product, thus reducing costs for companies.

Advantages of Industrial Automation

  • Decreases manufacturing costs
  • Increases the efficiency of the production process.
  • Speeds the response to market demands.
  • Replaces the man with complicated industrial processes that endanger his physical integrity
  • Favors business competitiveness.
  • Improves the security of the processes and the quality of the production.

Disadvantages of Industrial Automation

  • Generates technological dependence
  • Requires a large initial investment
  • Lack of trained personnel to manage the equipment
  • Susceptibility to technological obsolescence
  • The resistance of the workers to the change

One of the main challenges of the implementation of automated systems in industries is to balance the work done by computerized equipment and robots with the work performed by the operators. While technology helps to optimize processes and limits human intervention, it does not replace it completely. The error is to associate industrial automation with unemployment since human presence is necessary for the management, supervision and control of complex production processes.

Invention Blueprints

Patent Drawings

Patent drawings are one of the most important and key features required from the USPTO while an Inventor files for a patent. These invention blueprints, or patent drawings consist of dimensions, views, and other information to help relate not only the inventions look, but also its functionality. CAD is the tool in most cases that is used in order to design patents. Any Inventor should definitely familiarize themselves with CAD because it is a staple within any type of design now a days, and especially within Inventions and prototype design.

CAD Designers

Invention designers or CAD designers are the ones who actually manipulate CAD software into creating something known as a 3D model. 3D models are used for several different things, and invention blueprints as well as patent drawings are just a few. These complex design files hold all the necessary information to instruct machines that manufacturer rapid prototypes and inventions how to operate. These CAD files are extremely diversified in the sense that one 3D model can perform several task. In the end if an Inventor chooses the right Invention Designer this fact will permit them to save money by purchasing more than one service from the invention design company.

3D Modeling Services

The majority of 3D modeling services perform only certain types of design in which inventions and prototypes are not usually within. 3D modeling services will generally only perform design task such as architectural work, mechanical, electrical, or some specialty field. If you’re interested in finding a CAD design service who specializes in invention design, your best bet would be to search online. Invention design services are out there, but if you’re not careful it’s easy to get mixed up with the wrong one who can turn your patent mission into a complete nightmare.

CAD Prototype

So within the first steps an Inventor takes they are normally notified that they will need a CAD Prototype. Unless an Inventor creates the prototype from hand a CAD file will surely be needed. In all reality when someone thinks of the word prototype they normally associate a high dollar amount for cost with it. Really this is the furthest thing from the truth if you can find an honest invention design service or rapid prototype service to perform your needs. Really an Inventor should look for one service to not only design the prototype, but also make the prototype. If found this service should produce reduced cost to the Inventor since they are purchasing more than one service from them.

Top 5 Techniques to Reduce Manufacturing Costs

Manufacturers are always looking for techniques to reduce their cost. Here are five of them that will help the manufacturers reduce cost irrespective of their sector. The primary step would be to assess their process and do on internal audit. Only when the big picture is at view, methods can be implemented to reduce the costs.

Energy Efficiency

Most of the time without our notice we tend to waste a lot of electricity. Implementing sensors that would stop the machines immediately after usage can reduce quite a lot of cost. Replacing energy guzzling machinery with those consuming less energy can save up to 10% of the cost. Usage of alternative energy sources like solar energy which is the cheapest source of energy can cut down operating cost significantly.

Fixed Cost Reduction

Machinery for a manufacturing industry is very important, but only a few machineries are constantly used. Hence, owning the machinery that is used passively wouldn’t be feasible; renting/leasing such machinery can reduce the fixed cost. Using automation in production process can decrease the labour cost abundantly. Outsourcing advertising, marketing and sales could also help in cost reduction.

Overhead Cost Reduction

Maintaining inventory by not over producing and recycling/selling the wastage or scrap of the raw material can always free up and manage the factory space and reduce wastage. At times, outsourcing supply can reduce the business space, risk, staff, and maintenance of vehicles. Buying raw materials at bulk and sharing it with another manufacturer can reduce the material and inventory space. Intercom and internet calling, conferencing and video calling meetings can help reduce administrative cost.

Reduction in Labour Costs

Usage of technology for the manufacturing process like implementing sensors and automation, robotics can drop down as the number of labours drops as the automation requires less human interference and is more accurate. Using part time workers and free lancers can eliminate the idle time of labourers. Implementing methods to increase efficiency; comfortable positive workplace, eliminating overtime as it reduces efficiency, training employees, getting to know the employees, reskilling of the employees rather than assigning them monotonous task can help the manufacturer make optimum use of the labour force.

Customer related cost reduction

Technology can help the manufacturer cut down the cost in every stage of the manufacturing process and also at marketing. Using technology for marketing, advertising and promoting of goods can reduce cost abundantly. Designing products digitally 3D print of the product would help the manufacturer in better understanding of customer needs and can reduce correction and reproduction.