Be Aware!
When asked one time how thick a pipe work should be for an application, a colleague came out with a new set of tables from his drawer. Wow! That’s an instant solution, and how convenient. It is well in order, however, to know how the table was reached and calculated. So, one must check the assumptions indicated in the table, whenever you have one, in order to understand it more intelligently and not misuse the same valuable resource. Know your basic assumptions and fundamentals, and it is more difficult for you to commit a mistake.
Written by: Sanoy Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
Saturday, December 26, 2009
Tuesday, December 22, 2009
Fluid Mechanics!
The volume flow formula!
The volume flow formula Q=AV; where Q=flow rate; A=cross sectional area of pipe or duct; V= velocity ; is a formula largely applied to non-compressible fluids. This same formula, however is applicable to compressible fluids, if the flow is undisturbed or approaching the laminar flow conditions, and is used to estimate flowrate in a constant condition of temperature and pressure in a pipeline, for practical purposes with little error.
Written by: Sanoy C. Suerte, RME/ MBM; Http://www.linkedin.com/in/sannysuerte
The volume flow formula Q=AV; where Q=flow rate; A=cross sectional area of pipe or duct; V= velocity ; is a formula largely applied to non-compressible fluids. This same formula, however is applicable to compressible fluids, if the flow is undisturbed or approaching the laminar flow conditions, and is used to estimate flowrate in a constant condition of temperature and pressure in a pipeline, for practical purposes with little error.
Written by: Sanoy C. Suerte, RME/ MBM; Http://www.linkedin.com/in/sannysuerte
Thursday, December 17, 2009
Steam Metering and other similar gases!
Gas and Steam flow metering!
When we are engaged in monitoring consumption or generation of gaseous materials, many people in management, or even among technical people, have the natural impulse of resorting to metering of the substance for purposes of budget monitoring and control. This in effect, results to either the purchase of sophisticated measuring facility with some computerized calculating functions for changes in the parameters on line, or inaccurate readings given by supposedly monitoring instruments that are put on line, but does not have the capability to measure instantaneous changes in parameters, like temperature and pressure.
We know for a fact that when temperature fluctuates, or when pressure does have changes, the fluid density also changes. Ordinary orifice meters and rotating-meters or displacement meters can measure volume, and mass based on fixed conditions as assumptions. These meters, in the absence of pressure and temperature corrections therefore are useful only for monitoring mass flow at fixed conditions. They become less useful and inaccurate with frequent changes in temperature and pressure over long periods , and can create confusion in the interpretation of metered data.
It is not easy to explain this to some management people. In this regard, other means of measurement have to be done in cases, where computerized systems for temperature-pressure corrections are not available. Usually, a competent operations man would measure fluid usage by indirect means, like measuring the tare-weight of containers or tare liquid level of tanks holding the gases or the water usage in the case of steam systems. These methods are far more reliable and accurate, than simply putting in the pipelines a non-correction capable meter.
Understandably, these appear crude to top management, but technically, it is more accurate. There is no sense in putting on line, a beautiful meter that will just create a confusion and a lot of inaccuracy and subsequent controversy. This explains, why you seldom see a metering device in a compressed air system, and a steam system output pipeline. If they are there, they are used more for short period experiments and tactical observation purposes, wherein temperature and pressures are monitored to be constant, but seldom used as an integrating system for a long period of measurement, unless corrective computational capability is also put in place. So, the next time you see a non-correction capable metering device in a gas or steam line, be cautious , be aware and knowledgeable of the limitations and manner of their usage or applications. An inaccurate device is no better than a seemingly crude method that provides accurate measurements.
Written by: Sanoy C. Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte
When we are engaged in monitoring consumption or generation of gaseous materials, many people in management, or even among technical people, have the natural impulse of resorting to metering of the substance for purposes of budget monitoring and control. This in effect, results to either the purchase of sophisticated measuring facility with some computerized calculating functions for changes in the parameters on line, or inaccurate readings given by supposedly monitoring instruments that are put on line, but does not have the capability to measure instantaneous changes in parameters, like temperature and pressure.
We know for a fact that when temperature fluctuates, or when pressure does have changes, the fluid density also changes. Ordinary orifice meters and rotating-meters or displacement meters can measure volume, and mass based on fixed conditions as assumptions. These meters, in the absence of pressure and temperature corrections therefore are useful only for monitoring mass flow at fixed conditions. They become less useful and inaccurate with frequent changes in temperature and pressure over long periods , and can create confusion in the interpretation of metered data.
It is not easy to explain this to some management people. In this regard, other means of measurement have to be done in cases, where computerized systems for temperature-pressure corrections are not available. Usually, a competent operations man would measure fluid usage by indirect means, like measuring the tare-weight of containers or tare liquid level of tanks holding the gases or the water usage in the case of steam systems. These methods are far more reliable and accurate, than simply putting in the pipelines a non-correction capable meter.
Understandably, these appear crude to top management, but technically, it is more accurate. There is no sense in putting on line, a beautiful meter that will just create a confusion and a lot of inaccuracy and subsequent controversy. This explains, why you seldom see a metering device in a compressed air system, and a steam system output pipeline. If they are there, they are used more for short period experiments and tactical observation purposes, wherein temperature and pressures are monitored to be constant, but seldom used as an integrating system for a long period of measurement, unless corrective computational capability is also put in place. So, the next time you see a non-correction capable metering device in a gas or steam line, be cautious , be aware and knowledgeable of the limitations and manner of their usage or applications. An inaccurate device is no better than a seemingly crude method that provides accurate measurements.
Written by: Sanoy C. Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte
Tuesday, December 15, 2009
Bearings in Compressors!
A typical case of a Quick Failure of bearings!
In an installation that was encountered and observed, a compressor bearing failed so early (within less than four months in continuous operation) after a restoration procedure. Many failure propositions were advanced by different engineers in maintenance and by the jobber, which included the following:
1.Bearings were not original.
2.There was lack of lubrication.
3.The bearing alignment was not correct.
4.There was lack of skill in assembling the bearing.
5.The bearing was not the correct one for the service.
6.The clearance was not correct.
The bearings were again replaced, and again the replacement bearings failed for the second time in less than one day operation. Replacement of bearings were again made for the third time, and the same thing happened. Noteworthy to consider was the fact that the cost of the bearings were substantial, because these were about six (6) inch diameter roller and ball bearings, with some thrust capability. In the end, the jobber was asked to verify the original bearing casing center, and it was learned that the work was subcontracted to a shop that may not have been able to find the original centers, due to the need to rebuild the casing or bearing housings, which were damaged during the first failure. In this connection, all efforts were directed by the jobber’s new shop service provider, to the restoration of the bearing alignment and centering back to the original installation.
The procedure of the OEM may not have been replicated locally the first time, to the extent that the bearing subsequently improved in its performance only, but continued to give a noisy operation and a non-stable air gap performance between air lobes (screws). In this regard, it is deemed high-time to bring the matter to the OEM shop for trade-in and replacement of a new service unit. Some OEM machineries and skills are not totally replicable by less qualified local shops . Hence, to save further inconvenience and uneconomical operation, it is advised that the OEM should be brought in. When local efforts fail so dismally after the first service restoration process, and several times thereafter, the recourse to the OEM becomes obvious and much more logical. Further local efforts may find the solution, but only at the expense of long term operational potential losses.
Written by: Sanoy C. Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
In an installation that was encountered and observed, a compressor bearing failed so early (within less than four months in continuous operation) after a restoration procedure. Many failure propositions were advanced by different engineers in maintenance and by the jobber, which included the following:
1.Bearings were not original.
2.There was lack of lubrication.
3.The bearing alignment was not correct.
4.There was lack of skill in assembling the bearing.
5.The bearing was not the correct one for the service.
6.The clearance was not correct.
The bearings were again replaced, and again the replacement bearings failed for the second time in less than one day operation. Replacement of bearings were again made for the third time, and the same thing happened. Noteworthy to consider was the fact that the cost of the bearings were substantial, because these were about six (6) inch diameter roller and ball bearings, with some thrust capability. In the end, the jobber was asked to verify the original bearing casing center, and it was learned that the work was subcontracted to a shop that may not have been able to find the original centers, due to the need to rebuild the casing or bearing housings, which were damaged during the first failure. In this connection, all efforts were directed by the jobber’s new shop service provider, to the restoration of the bearing alignment and centering back to the original installation.
The procedure of the OEM may not have been replicated locally the first time, to the extent that the bearing subsequently improved in its performance only, but continued to give a noisy operation and a non-stable air gap performance between air lobes (screws). In this regard, it is deemed high-time to bring the matter to the OEM shop for trade-in and replacement of a new service unit. Some OEM machineries and skills are not totally replicable by less qualified local shops . Hence, to save further inconvenience and uneconomical operation, it is advised that the OEM should be brought in. When local efforts fail so dismally after the first service restoration process, and several times thereafter, the recourse to the OEM becomes obvious and much more logical. Further local efforts may find the solution, but only at the expense of long term operational potential losses.
Written by: Sanoy C. Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
Friday, December 11, 2009
Boiler Safety!
Boiler Safety Practices!
When a boiler runs very low in water inadvertently, because of some malfunctioning in the feed water control systems, it is necessary that the boiler fire be put to the minimum and the feed water be fed right away to bring the water level to safe minimum levels. It should be noted that feed water addition is done in such speed and rate, without taking the risk of chilling the boiler tubes and the boiler casing until the liquid level appears on the gage glass. Sudden introduction of cold water and abruptly bringing the boiler to cold can warp and damage the boiler tubes or the baffles installation structures or cause some imbalance in the stresses in the boiler. A first encounter of this in boiler operations, should be enough to trigger a repair and rehab of the control mechanisms that caused the failure, so that a major catastrophic failure and a long boiler shutdown is avoided.
Written by: Sanoy C. Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
When a boiler runs very low in water inadvertently, because of some malfunctioning in the feed water control systems, it is necessary that the boiler fire be put to the minimum and the feed water be fed right away to bring the water level to safe minimum levels. It should be noted that feed water addition is done in such speed and rate, without taking the risk of chilling the boiler tubes and the boiler casing until the liquid level appears on the gage glass. Sudden introduction of cold water and abruptly bringing the boiler to cold can warp and damage the boiler tubes or the baffles installation structures or cause some imbalance in the stresses in the boiler. A first encounter of this in boiler operations, should be enough to trigger a repair and rehab of the control mechanisms that caused the failure, so that a major catastrophic failure and a long boiler shutdown is avoided.
Written by: Sanoy C. Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
Wednesday, December 9, 2009
Energy Conservation!
Energy Conservation Audits!
How to conduct an effective energy audit is something that requires knowledge of the amount of energy usage distribution in a particular establishment. The areas with large energy consumption, are usually the areas where a large potential for conservation is present. It is important therefore to identify these areas, and to understand the processes in the system. Familiarity with the processes is another key. Knowing, what the critical aspects are of a particular process is important, as this provides a better understanding of what the constraining factors for an energy conservation opportunity are in existence. Then a general knowledge of alternative systems available in the industry is necessary, so that more efficient ways of attaining the same objective is introduced in a given process. The investment on equipment and new technology will usually be a part of the availing of the energy saving opportunities. Normally, however, one would not see this necessary without going into the examination of the practices and methods that are currently in use.
Written by: Sanoy Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte.
How to conduct an effective energy audit is something that requires knowledge of the amount of energy usage distribution in a particular establishment. The areas with large energy consumption, are usually the areas where a large potential for conservation is present. It is important therefore to identify these areas, and to understand the processes in the system. Familiarity with the processes is another key. Knowing, what the critical aspects are of a particular process is important, as this provides a better understanding of what the constraining factors for an energy conservation opportunity are in existence. Then a general knowledge of alternative systems available in the industry is necessary, so that more efficient ways of attaining the same objective is introduced in a given process. The investment on equipment and new technology will usually be a part of the availing of the energy saving opportunities. Normally, however, one would not see this necessary without going into the examination of the practices and methods that are currently in use.
Written by: Sanoy Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte.
Units of Measures!
Consistency of Units of Measures! Back to basics.
One of the common source of errors in the solution of a problem in engineering is the making of the model of the problem in a model space. A model is a simplified representation of the actual problem in real life situation. It is almost exact, but not necessarily always. That is why it is called a simplified representation of a confluence.
This involves the making of free body diagrams, and the proper indication of acting forces in such a diagram.
The next common source of problem solution errors, is the an oversight or failure to use consistent units of measure. One has to examine, whether or not units of measures are similarly indicated or not. In a stress-strain problem for example, the stress can be given in Mega Pascals, and the area in mm squared or inches squared, and the unit force being sought after in newtons. Not knowing that a Pascal is in newtons/meter squared and Mega Pascals in Million Pascals can stop dead a novice or even a long time practicing engineer on his tracks to finding the solution to an urgent problem. Important system of units in common use should be made handy for easy and convenient reference always.
I was once working with a student apprentice of mine in analyzing a problem, and I was so surprised to notice that even the basic geometric principle of “alternate angles” being equal and law of sines ,have already been forgotten so easily for so short a time. Basic elements of the practice, may be useful from time to time, so these should be kept handy for possible use in the day to day business of an engineer, an architect, or a technical man for that matter. Not appreciating enough the value of simple things may provide undue inconvenience in a fast paced business environment and career setting.
Written by: Sanoy Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte.
One of the common source of errors in the solution of a problem in engineering is the making of the model of the problem in a model space. A model is a simplified representation of the actual problem in real life situation. It is almost exact, but not necessarily always. That is why it is called a simplified representation of a confluence.
This involves the making of free body diagrams, and the proper indication of acting forces in such a diagram.
The next common source of problem solution errors, is the an oversight or failure to use consistent units of measure. One has to examine, whether or not units of measures are similarly indicated or not. In a stress-strain problem for example, the stress can be given in Mega Pascals, and the area in mm squared or inches squared, and the unit force being sought after in newtons. Not knowing that a Pascal is in newtons/meter squared and Mega Pascals in Million Pascals can stop dead a novice or even a long time practicing engineer on his tracks to finding the solution to an urgent problem. Important system of units in common use should be made handy for easy and convenient reference always.
I was once working with a student apprentice of mine in analyzing a problem, and I was so surprised to notice that even the basic geometric principle of “alternate angles” being equal and law of sines ,have already been forgotten so easily for so short a time. Basic elements of the practice, may be useful from time to time, so these should be kept handy for possible use in the day to day business of an engineer, an architect, or a technical man for that matter. Not appreciating enough the value of simple things may provide undue inconvenience in a fast paced business environment and career setting.
Written by: Sanoy Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte.
Upcoming book for publication in Amazon
GrowingUp the Leaders of Tomorrow:
Insights for everyday living and Leadership preparations in business management .
Author: Sanoy C. Suerte, RME/MBM
Vol.1, November 2009
This tract is written and dedicated to young people, ages 16-40 years old, who are paving their way to become leaders and managers of business today and in the not so distant future ahead of them. People, who may have the early encounter and inclination towards the call of business as a youngster, or student and college graduates/non-graduates alike, who have decided to explore the world of business and necessarily the principles of management that go right along with it. This mini-book is only one of a series to be written in several volumes, similar to an ongoing compilation of articles, written by an author for different fora to help build a new generation of well balanced, humane oriented management and business practitioners, highly aware of the needs of the common man and society in general for sustainable development, and sound business principles. Being more of a compilation of important thoughts and philosophies than a normal standard pedagogical textual material, the series is arranged more liberally as a loose compilation of wisdom, purposely deviating from the normal logic of the common text book type of organization. May the younger generation continue to build a better society than they have found it.
Http://www.linkedin.com/in/sannysuerte
Insights for everyday living and Leadership preparations in business management .
Author: Sanoy C. Suerte, RME/MBM
Vol.1, November 2009
This tract is written and dedicated to young people, ages 16-40 years old, who are paving their way to become leaders and managers of business today and in the not so distant future ahead of them. People, who may have the early encounter and inclination towards the call of business as a youngster, or student and college graduates/non-graduates alike, who have decided to explore the world of business and necessarily the principles of management that go right along with it. This mini-book is only one of a series to be written in several volumes, similar to an ongoing compilation of articles, written by an author for different fora to help build a new generation of well balanced, humane oriented management and business practitioners, highly aware of the needs of the common man and society in general for sustainable development, and sound business principles. Being more of a compilation of important thoughts and philosophies than a normal standard pedagogical textual material, the series is arranged more liberally as a loose compilation of wisdom, purposely deviating from the normal logic of the common text book type of organization. May the younger generation continue to build a better society than they have found it.
Http://www.linkedin.com/in/sannysuerte
Boiler Economics!
How do you justify the replaceability of a vintage boiler?
It shouldn’t be forgotten, that the cost of fuel running your boiler may have already changed in several folds after installation. It is likely so to have increased fuel cost bills at least 2-5 times, or even more, depending upon the span of time that had elapsed, since you first installed your boiler unit. An efficiency lost factor therefore of 5% must have multiplied also by the same number of folds, over the years in terms of energy cost, and if it’s a large consumer of fuel, then you better assess now and evaluate again those cost of operational inefficiencies, as it could certainly justify the investment of getting a more efficient boiler. A newer boiler could be specified to fit better the actual consumption for steam in your facility. It can also have better control systems and mechanisms to make air to fuel ratios more consistent. A very large boiler serving the needs of a small demand load is highly inefficient, in terms of start up cost, cycling cost, and heat losses by radiation due to large surface area exposure also. Try doing your pencil pushing in this regard. You may save your firm a fortune today and ride better, the tide of a fast changing business landscape. Ask outside help if you must. Just save energy and help your operational profitability improve your company bottom-line.
Written by: Sanoy Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
It shouldn’t be forgotten, that the cost of fuel running your boiler may have already changed in several folds after installation. It is likely so to have increased fuel cost bills at least 2-5 times, or even more, depending upon the span of time that had elapsed, since you first installed your boiler unit. An efficiency lost factor therefore of 5% must have multiplied also by the same number of folds, over the years in terms of energy cost, and if it’s a large consumer of fuel, then you better assess now and evaluate again those cost of operational inefficiencies, as it could certainly justify the investment of getting a more efficient boiler. A newer boiler could be specified to fit better the actual consumption for steam in your facility. It can also have better control systems and mechanisms to make air to fuel ratios more consistent. A very large boiler serving the needs of a small demand load is highly inefficient, in terms of start up cost, cycling cost, and heat losses by radiation due to large surface area exposure also. Try doing your pencil pushing in this regard. You may save your firm a fortune today and ride better, the tide of a fast changing business landscape. Ask outside help if you must. Just save energy and help your operational profitability improve your company bottom-line.
Written by: Sanoy Suerte, RME /MBM; http://www.linkedin.com/in/sannysuerte
Friday, December 4, 2009
Sanoy Suerte at Amazon Kindle!
When you visit amazon u can use search words “sanoy suerte” and discover what’s in promo!@ www.amazon.com at kindle.
Thursday, December 3, 2009
Process Systems and Time!
Time Constant and Process Systems!
Depending upon the kind of devices you use in your instrumentation system and process, there will always be a time constant. It is the time delay that is incurred by the system, because of the kind of components you use in the system. If the components are such that they are slow to sense the changes that happens, it is important for you to understand that, and must relate your expectations to such time constant.
Take for example, in heat transfer by radiation. The amount of heat absorbed by a substance by radiation is directly related to its emissivity, kind of material, temperature difference of heat transfer surfaces, mass of the material absorbing heat.etc. Reaching a temperature change therefore takes some time and the time constant is somewhat fixed, given the factors involved. Be aware of this, and you will always know, what kind of expectations to have for a particular set up in a given process. When you put therefore a material to heat up in a particular oven, you must know what to expect as the time length to heat it to a certain temperature. Establish the time constant of the oven, given a material mass and you will always be able to predict your process productivity.
Written by: Sanoy Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte
Depending upon the kind of devices you use in your instrumentation system and process, there will always be a time constant. It is the time delay that is incurred by the system, because of the kind of components you use in the system. If the components are such that they are slow to sense the changes that happens, it is important for you to understand that, and must relate your expectations to such time constant.
Take for example, in heat transfer by radiation. The amount of heat absorbed by a substance by radiation is directly related to its emissivity, kind of material, temperature difference of heat transfer surfaces, mass of the material absorbing heat.etc. Reaching a temperature change therefore takes some time and the time constant is somewhat fixed, given the factors involved. Be aware of this, and you will always know, what kind of expectations to have for a particular set up in a given process. When you put therefore a material to heat up in a particular oven, you must know what to expect as the time length to heat it to a certain temperature. Establish the time constant of the oven, given a material mass and you will always be able to predict your process productivity.
Written by: Sanoy Suerte, RME /MBM; Http://www.linkedin.com/in/sannysuerte
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