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Industrial Engineering Oil & Gas

Why Sonic Rig Drilling Works?

If you have a relevant background in the oil exploration and drilling industry, you’d understand why you must be familiar with the many different kinds of drilling techniques. Like for instance, you need to know what makes sonic rig drilling work that major industry players prefer to use it over other available drilling methods. 

Sonic drilling is a qualified technique to penetrate the soil. This ground penetration technique is sought out by companies when they need to drill into the ground for various purposes due to its friction-reducing quality that occurs both on the drill string and the drill bit due to inertia effects, liquefaction, as well as the temporary soil porosity reduction. The combination of all these factors makes it possible to have seamless penetration for many different kinds of soil quality. 

drilling method

Besides, this technique also makes the penetration rate in the vast majority of bedrock types faster.  

Generating Sonic Vibration with the Drill Head

Drill heads normally house the oscillator, which is highly responsible for the generation of resonant, high-frequency energy. Usually, this is directed into the drill string. While drilling is in progress, the rotational movement is combined with resonant energy. By this measure, there is an even distribution of the energy and this will leave an impact on the drill string and drill bit of tooling. 

Drill operators have full control over the intensity of sonic vibration that the drill head will generate. This will significantly help in matching up the required force needed in penetrating bedrock and soil formations.  

Sonic Rig Mechanics

If you will try to engage a powerful drill head, you’re taking the entire drill string to a vibration frequency reaching as high as 150 Hz. This will induce the drill string and bit to lose hold of its structure. And with this, it will also reduce soil friction and drill cuttings so they become extremely loose to the point of assuming a liquified form. Thus, it can be flushed or removed easily from the borehole.  

The drill bit vibrations will render the soil to significantly lose its porosity and density, and eventually its structure. By this measure, the soil and cuttings will get moved in the sample barrel as well as up the drill string, helping your tooling to freely advance on its own.  

The inertia effects and liquefaction allows for the collection of continuous and long samples. And because of the presence of the high-frequency vertical movement, the odds are high that the drill string will be staying extremely straight yet with very little possibility of deflection.  

Less power, fewer problems

Due to the reduced amount of friction that will likely occur on the drill string length, sonic rig drilling will require lesser amounts of power to achieve the exact or same drilling power as what can be witnessed from other traditional drilling methods. This is one attribute that is solely unique to sonic drilling and will help in keeping torsional forces to begin appearing on the drill string. 

Another major benefit that can be enjoyed from applying sonic high frequency is how easy and seamless is the process of retrieving the drill string, even when working on quick expanding clays, boulders, and other similar but difficult or challenging conditions. All drilling rods, toolings, and casings can be pulled easier and way faster.  

Sonic Drilling Means Clean Drilling 

There are a handful of situations where you want to shy away from using air, drilling mud, or even water while drilling work is in progress. In a sonic type of drilling, they are not necessary. Hence, this is the reason why it is the most preferred geo-construction, environmental and geotechnical applications. 

Environmental projects will also enjoy significant savings on their costs if they will take advantage of the sonic type of drilling method. These kinds of drilling projects necessitate a good amount of time and money so that project managers will be able to properly dispose of their investigation derived drilling waste.  

Also, in every mining project, there is a leach pad. If you add air or water it is going to be a disturbance and may influence the soil’s mechanical properties. Under extreme cases, doing so may bring about the possibility of erosion which can pave the way for failure of drilling operations such as a partial landslide.  

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Industrial Engineering

Why is Hydraulic Maintenance Essential?

It is essential to check and service your hydraulic equipment on a regular basis. This helps ensure that any minor issue will not become a fault. Any fault, regardless how small or minor, good becomes an awfully expensive breakdown. Some people who own hydraulic equipment think that hydraulics can keep on running indefinitely, or with some annual safety checks. However, this is not the case. Regular inspection and training of the equipment is a must, and this is because of the following factors.

The Importance of Hydraulic Maintenance

Safety

First off, safety is of great importance in any workplace. The company needs to make sure that the equipment being used is safe for everyone. Also, it should be maintained regularly, making sure that it is in its safe condition and inspected to ensure that any problems are corrected. All employers need to make sure that their equipment is regularly checked and are safe to use.

For instance, if a pressurized hydraulic fluid suddenly escapes it can be dangerous as it can reach the so-called explosive velocity.

Obviously, this can cause major harm to anyone who is in the vicinity. It is also important to note that hydraulic parts are usually sharp and heavy that any anticipated movement that is caused by a fault could injure the workers and even the passersby. Therefore, it is important to keep the equipment well maintained to guarantee their safety for everyone who interacts with it.

 Cost factor

A lot of faults in hydraulic equipment are caused by dirt. Such faults can easily escalate to a need for costly repairs. Large expenses can be avoided by simply keeping the equipment clean and making sure that the correct protocols are being followed when replacing any parts so that dirt would not be able to find its way to the system.

In a hydraulic system, there are a lot of parts that may need replacement due to wear and tear. Immediately replacing them before they can completely break is a wise move. On the other hand, waiting until they break, can potentially damage the other working parts and can be considered as an expensive mistake.

machine repair

Oil is an essential element in any hydraulic system that could be expensive to change, however inexpensive to maintain. What is worse than the price of changing oil is the cost of running dirty oil through the system. Such can cause irreparable damage to the other working parts. Thus, maintaining the oil by making sure that it is in its good condition can help prolong the life of pumps, filters, valves, and cylinders. This means that these would need less frequent replacement.

Downtime

Checking and cleaning the equipment could take a few minutes. Replacing a part that is worn out could take a few hours. Repairing any major breakdown would often take days or weeks. During this time, the company loses big amounts of productivity, thus risking added cost in loss of earnings and potentially missing out deadlines

Maintenance log

There are a lot of computer programs that are available to be utilized to schedule various types of maintenance for the parts of the equipment. It is important to make sure that your staff are aware of the program and they complete a log so that the other members are also aware of what has been done on the equipment or what needs to be done. It is a great idea to work through the hydraulic maintenance plan with hydraulic equipment engineers.

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Industrial Engineering Safety Equipment Technology

Practical Applications of CNC Cutting Machine

CNC cutting machines belong to the most ubiquitous pieces of equipment today because they can be found in almost all industries. You see them practically being used even by small scale manufacturing firms up to major players in the industry. Food manufacturing, agricultural products, textile industry, electronic parts, and equipment, all these sectors are taking good advantage of the CNC profile cutter in their production teams. 

As we see it, there is no aspect of modern manufacturing that is not benefiting from the use of a CNC machining center. Anyone who is planning to embark on a business venture in the manufacturing industry ought to know and understand exactly how CNC machines can be of help to your company and how you can utilize it to advance your business interest. 

The extensive use of CNC machines in many industries has brought about increased demand for professional CNC programmers. To meet this growing demand for CNC programmers, many technical schools in the country are now offering educational programs that will help interested students learn everything about CNC machines, including CNC programming itself.  

Below are some of the many industries that are enjoying the benefits of CNC machining.  

Industries for removing metal

This line of business is involved in taking away metal from raw material and this would include the automotive industries. They use plasmacam Australia technology to make gears, shafts, and several other important parts.

The task of removing metal is usually carried out by different machine tools such as a milling machine, lathe, boring machine, reamer, shaping machine, and many others. These machines are normally handled by operators, but there are now CNC versions for these types of machines are used extensively.  

Electrical Discharge Machining (EDM) Industry

The EDM machines can take away the metal component of an object and does this efficiently by making sparks intended to burn the metal. EDM machines come in two types with the CNC automation — the Wire EDM and the Vertical EDM. 

In Vertical EDM, you need to have the cavity size that you are supposed to make in the job. You also need to have an electrode of the shape, whereas the purpose of the Wire EDM is to make the punch and the dies set combinations. They are being utilized in industries were fabrication is performed.  

Other Industries where CNC machines are used

Did you know that the popular CNC cutting machine is also practically and extensively used even in the woodworking space? It is used to carry out several operations such as routing and drilling. 

CNC cutting technology has also made its way to engraving and lettering systems. Even the electrical industry is taking advantage of CNC machining with their CNC terminal location, CNC coil winders, and soldering machines.  

Regardless of the industry, you will try to involve yourself in, you’d certainly find many other types of CNC machines in action. Industry experts and insiders both agree in saying that milestones in the manufacturing were only made possible due to the advancements we have in the CNC technology.

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Industrial Engineering Technology

What Does the Future Hold for Water Jet Machine Manufacturers?

According to water jet machine manufacturers, the early generation of waterjets can cut through soft materials very easily. However, they are not as effective when working on harder materials, and that includes metals. Water jet cutting machines started having this capability only after the idea of adding abrasive material to the cutting nozzle was thought of.

The technology of adding abrasive material to the waterjet cutting machine nozzle was pioneered by Leslie Tirrell and Elmo Smith in the 1930s. Back then, the service life of an abrasive waterjet nozzle was too short. Hence, they were obviously not viable back then. For that reason, mass producing it was not a practical idea and was thus shelved for quite some time.

The plan for mass production was only relaunched only after several material innovations came to surface by virtue of mixing tubes. The production of the commercially acceptable nozzle was initiated by Boride Corporation.

By fusing high-pressure pump and abrasive waterjet nozzle, water jet cutting machines are now made better than ever. They can now handle cutting through a wide spectrum of materials, including titanium, glass, stone and even hardened tool steel.

Nowadays, water jet cutting is considered by industry experts and insiders as among the leading cutting technologies we have in this modern time and age. The acceptance and level of popularity of the waterjet manufacturers and business sectors for this method of cutting have finally qualified it as the go-to choice for many.

While this technology has undergone several innovations and improvements in the past, the silver lining question here is where is it leading us to?

Faster

Compared to how it was back then when waterjet cutting machines were first introduced to the world, it has become a lot faster. This was after it was made to deliver higher water pressure via the machine’s cutting head.

Water pressure through the cutting head can reach up to 87, 00 PSI. This is water delivered to at least 4 times the sound speed. Over time, it is anticipated that this speed we now have will still go further and faster.

Nonetheless, it should be noted that speed gains may not happen through water pressure anymore. Instead, further improvements will focus more on design and software upgrades.

Thicker

Right this very moment, water jet cutting is already leading the way. It is capable of cutting through depths 10 times more than what a laser cutter does.

By virtue of increased water pressure, it would still be possible for it to cut deeper still. In a few years, perhaps we can make a seamless cut on metal that is half a meter’s depth.

Cutting Complex Parts

By far this can be considered as the biggest milestone in recent years. Water jets can now cut parts beyond the basic 2-dimensional cut we see.

XD cutting is now made possible through water jet cutters. It is a cutting head, capable of moving on multiple axes. This also signifies that it can cut complex 3-dimensional parts and that it can be carried in just one, singular strike. It is contrary to what you do in secondary cuts, which are time-consuming and costly, too.

The XD cutting technology is usually employed by the likes of formula one teams and Boeing. These industries require complex metal parts for their machinery, and they need to be done in the most accurate way possible.

There is more coming to this area, and it is anticipated that it will grow even further. Water jet cutting machines that are made capable of cutting more complex parts, more detailed and at a quicker pace.

Besides, industry experts are agreeing with each other that there will be a greater level of awareness about this technology. Business organizations will see this technology can save them both time and money on their metal cutting requirements.

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Industrial Engineering

What are the Common Telltale Symptoms of Fuel Contamination in Silvan Tanks?

Much like any other containment system for high-value liquids, silvan tanks, without proper care and maintenance, are prone to fuel contamination, too. Liquid fuel contamination — we define this as a presence of foreign matter that should not be there. 

This issue accounts for a wide array of the fuel-related concerns we have today. If this occurs, fuel quality is likely to degrade soon enough and produce inappropriate things, for example asphaltenes. Under pretty normal conditions, they are not supposed to be there but are now contaminating your liquid fuel.  

With the burgeoning of wrong information hounding this issue on contamination of liquid fuel, we figured that it might be a good idea to come up with a “down and dirty” compilation of the most common symptoms that can pave the way for it.

In resolving any kind of fuel-related problem, the first two critical steps would be to recognize what the problem really is and to correctly identify its underlying causes. After this, the drafting of a proper solution can be carried out and eventually implemented.  

While these “symptoms” may well indicate the presence of something inappropriate in your high-value liquid, when it is about knowing exactly the underlying reasons behind a particular symptom, there may be possible multiple root causes.  

White, Black or Blue Smoke 

Smoke is usually comprised of petroleum particles that have remained uncombusted. Smoke is not likely to become a byproduct of a properly-functioning engine that can efficiently and completely burn liquid fuel. 

Take smoke as a good indicator. Its presence may well indicate that your fuel may contain something that is not supposed to be there, provided of course that your engine is in proper working order. 

To identify exactly what that is may necessitate you to do more than just a little detective work. But the usual culprits are the heavier petroleum compounds. They may be fuel heavy ends, asphaltenes, sludge or even lube oil — normally they don’t burn easily and cleanly the way fresh fuel will.  

Off-Color Appearance or “Smelly” Fuel in your Silvan Tanks

You know that you have fresh gasoline or diesel by their sheer appearance, clear and bright. Another thing is that they also have this characteristic “solvent” smell in them. If the fuel is harboring entrained water, it is likely going to give it a cloudy appearance. 

The darkened appearance of your liquid fuel indicates that it is likely unstable already. Take it as a clue that it might be in the process of producing heavy ends and asphaltenes. Or if your liquid fuel is giving off an odd smell, it is an indication of microbes in the liquid fuel. This usually occurs when the tank does have in it significant amounts of water. 

fuel tanks contaminant

Engine Shuts Down or Runs Rough 

If your engine would eventually shut down on its own, without any apparent reason behind it, or would run rough like it never did before, take it as an indication that there might be some kind of foreign matter in your tank. 

Since we are dealing here with contaminants, we are going to preclude an issue such as the diesel fuel’s inadequate cetane rating. But in terms of contaminants, you would not want to take water or heavy end substances out of the equation, most especially in a marine or gas engine. 

It is also a good practice to keep an eye on your filter because there is a good chance that contaminants have found their way in there and is restricting the flow of your filter. If that happens, your engine’s performance will get compromised because it will not run properly. 

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Industrial Engineering

How to Properly Maintain Your CNC Plasma Kits Australia Machines?

One may think or qualify maintenance of CNC plasma kits Australia as some kind of a boring chore when compared to the aspects of running and keeping a successful machine fabrication shop. Proper maintenance or the upkeep for these machines is of prime importance not only because of the repair costs but more importantly due to the possibility of losing great amounts of profit if their equipment will be shut for some needed some repairs.

Preventive Maintenance Plan

If you want your CNC plasma kits Australian tools running smoothly and will help in keeping your business raking in more profits, it is paramount to have a preventive maintenance plan in place. This will be comprised of routine check-ups for your pieces of equipment to help in boosting up their efficiencies. It will also help increase their uptimes and in doing so will significantly enhance your expectable profit margins.

Are you not convinced yet? Here is something worth pondering on. CNC cutting machines, in the sheer absence of a good maintenance plan, are likely to experience unplanned breakdowns and this occurring may cost you 5 times more compared to annual PMPs. Between the wasted, unproductive hours and expedited part shipment, a solid PMP program in place will win for your business affordable machine maintenance.

Daily Care Routine for Your CNC Cutting Machines

  • Set a convenient time to inspect your hydraulic pressure and see to it that it is set at 4.5 MPa. 
  • Verify that your machine’s hydraulic fluids are on the right operating level. 
  • Verify if your chuck pressure is set to the right operating pressure as per manufacturer instruction.
  • See to it that your lube level is at the correct operating level and to replenish it as necessary.  
  • CNC cutting machines equipped with its cooling system must be set at the right operating level all the time.  
  • Make it a habit to clear the chips from the chip pan. 
  • Make it sure that you clean your machine’s window door and light, this way you can see what is inside.

Every week or right after the lapse of 40 hours or so, make it sure to take off your CNC control cabinet. Regular cleaning of this area is paramount to have proper ventilation and ease out cooling.  

Every 3 Months

After every 500 hours of use, make sure that you check out the chip conveyor chain and grease it as necessary. Also, don’t skimp on checking and cleaning out the filters on the coolant tank.

Every 6 Months

After every six months, doing the math we’ll see this is equivalent to 1000 hours, after the lapse of this period you may need to reach out to your local distributor and have them perform the following preventive maintenance measures on your CNC cutting machines:

  • Clean the coolant tank and clear it from chips, sludge, and oil. 
  • Dismantle the chuck and jaws from your CNC cutting tool to have it cleaned. 
  • Drain the hydraulic tank and change your hydraulic oil with a new one. 
  • Clean the radiator and see to it that your machine radiator fins are straight. 
  • Drain and clean your lubrication unit before you put on fresh lube to it. 
  • Have your machine leveling checked and make proper adjustments as necessary.  
  • Check also your wipers and inspect for any damage, replacing them as necessary.  
Plasmacam Australia

Once a Year

After every 2,000 hours of usage of CNC plasmacam Australia machines, which is roughly after a year, once every year reach out to your local distributor and have him inspect the following:

  • Check out the headstock and look for any tapers
  • Check out your machine spindles and inspect for radial or end play.
  • Inspect your chuck cylinder and check it for run out. 
  • Check your tailstock for any taper presence.
  • Have your machine’s inclination and turret parallelism inspected. 

Then finally, make it sure that your distributor will perform a backlash program. By this measure, they’d be able to see if the backlash in the X and Z axis are in proper order. Otherwise, make proper adjustments as necessary.

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Industrial Engineering Technology

How is a Water Jet Cutting Machine Different from Laser Cutting?

It is surprising to know that many people today are still unaware of how efficient water jet cutting machines are. The working idea behind this popular material cutting method was inspired by how a waterfall wears away rock formations at the bottom of a deep ravine. Only that it is done in warp speeds, and executed with greater emphasis on precision.

The Power of Water Jet Cutting Machine

To further intensify the cutting power of a waterjet cutter, the pressurized water used for these cutting machines can be mixed with abrasive particles. Typically used for this purpose are aluminum oxide and garnets.

As for the cutting force of water jet cutting machine, it can reach a maximum power of 60,000 psi. This explains the reason why this material cutting method is most recommended and preferred for projects that involve cutting of thicker material objects where the use of laser cutting method may not be very feasible at all, or would just run the risk of giving poor quality cut.

Some of the most common reasons why a significant number of metal fabrication centers in the country are shifting or patronizing the use of waterjet machines are due to the following: 

It can be used when working on thicker materials, including patterns that come with large tolerances.

They are trying to veer away from heat interference due to laser transferring its heat to the materials being cut. At high risk here are patterns that are so close to each other.

Waterjet cutting allows your metals to lay flat throughout the entire cutting process. In the laser cutting method, there are instances that you need to know how to put them at the right level.

Their team is involved or deals with an array of different materials. Waterjets earned a good reputation in cutting through stone, ceramic, steel, reflective metals, and many others.  

Laser Cutting

Laser cutting machines are in high demand these days, even from the very first day they were introduced to the market and we attribute this to their high level of precision. They also gained wide acceptance among various industries because they cut your materials fast.

But if there is one major setback you can complain about this method of cutting, it is the fact that you are limited to cutting only ⅝ of thickness. Beyond this level of thickness, it is hard to maintain an exceptional quality of cut.

Today’s software applications allow you to send a CAD file to the laser computer. After which you can begin cutting materials for your project within seconds. Many fabrication shops in the country are employing this method to help address their prototyping needs.

Laser cutting machines come with a stackable material tower which makes them ideal for big production runs. Many companies execute long, overnight cutting runs. They also leave these cutting machines unattended. 

Major Differences of Water Jet Cutting Machine and Laser Cutter Devices

Laser Cutting VS Water Jet

Infrared Light and gas laserEnergy and SourceWater and high-pressure pump
8 x (4 -20’) x 6.5’Standard Table Size8 x (4-13’) x 6.5’
Sheet MetalCommon Cut MaterialsStone, ceramics, thick metal
0.31” to 0.4”0.06”Economical ThicknessMinimum Hole Size0.250” to 2”0.02”
0.002”Tolerance0.008