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Performance and Maintenance

Maintenance of fabric expansion joint : what to know

When we speak about plant maintenance, the companies immediately think about activities that take a lot of time and money, without realizing that skipping the periodic maintenance can lead to serious problems.

In fact there is a risk of several problems that may result in sudden plant shutdown.

Can you imagine the damage to production, delays in delivery and customers waiting ?

Therefore, maintenance is NOT a waste of time.

If we talk about fabric expansion joints, the scheduled maintenance must be understood as an integral part of a correct production management.

In fact, the break of a fabric expansion joint can lead to interruption of production, or accident at the workplace.

In order to prevent these events, it is enough to plan periodic checks to find out any problems and intervene before they cause damage.

How to carry out maintenance?

First of all, we must keep in mind that fabric expansion joints are subject to wear, especially if they are subjected to extreme working conditions.

The first signs of wear should be repaired, if possible, or replaced.

After this fundamental premise, let’s see how to carry out the maintenance, step-by-step.

1. Drawing up a preventive maintenance plan

For expansion joints, as well as for other equipment, it is necessary to draw up an annual maintenance plant, taking into account also the type of expansion joint and the condition of the plant.

2. Identifying the maintenance personnel

Depending on the type of plant, a manager must be identified within the company and sufficiently trained to assess the state of the expansion joints.

3. Be in touch with the manufacturer

This point is fundamental and at New Componit we’ll never stop repeating it: the maintenance manager of the company must communicate with the manufacturer of expansion joints or with the company to which it was decided to entrust the controls.

The timing and the type of analysis to be performed, must be defined by expert technicians, depending on the needs of the plant and the working conditions to which the expansion joint is subjected.

4. Draw up a maintenance data sheet

All control and maintenance activities must be recorded in a special tab so that you can easily and quickly access this information.

5. Pay attention to the supplier

Usually companies that produce fabric expansion joints sell their products with a guarantee of several years, but do not take care of their maintenance.

It is therefore essential to buy the fabric expansion joints from a supplier who, in addition to the warranty, is able to support you throughout the life of his product.

We at New Componit not only provide you with the product but we offer a repair and maintenance service, that prevents problems or production interruptions due to a worn joint.

For this reason, we have designed the Efficiency Box® that allows us to respond to every type of customer need, in order to make production systems more efficient and safe.

Efficiency Box® includes:

  • Monitoring of the plant, carried out directly by our skilled staff;
  • Design and supply of the required interventions, with simple but technologically advanced solutions;
  • Installation by New Componit personnel or assembly supervision;
  • Direct assistance and immediate response with a dedicated toll-free number.

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Safefon horns: the efficiency of sound cleaning systems

Safefon horns: the efficiency of sound cleaning systems

When visiting industrial plants, you can come across many situations and unforeseen difficulties, like finding sediments on walls.

Usually, sediments on walls are the result of residual unburned powders or stored powders which, if not promptly and adequately removed, tend to solidify and damage the relative equipment or structure.

To our customers who have reported this problem, we have recently started to offer the Safefon® sound cleaning system, which is a horn powered by compressed air, whose terminal diffuser, placed inside the structure to be cleaned, is able to remove the dust sediment from walls, through the emission of a sound wave.

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The cleaning of industrial plants from granular materials: a problem to be solved

In an industrial plant, whatever the sector it belongs to, several problems can arise; some of them are common and therefore easily solved. In other cases, however, may occur problems which are more complex to solve.

This is the case of granular materials: we are talking about that dust, which is formed during the industrial process and which can damage the equipment.

As it often happens, in these situations we tend to postpone a problem that doesn’t seem imminent or whose consequences are not immediately visible.

But it is exactly in these cases that, over time, develop encrustation which risk to compromise the proper working of industrial boilers, silos, furnaces, bag filters, heat exchangers, industrial fans, scrubbers, ducts and bag filter housing.

The industrial fields involved are the most different, just think about:

  • Dust from ceramic industry;
  • Steel dust from foundries or steelworks;
  • Gypsum from cement industry;
  • Dusty substances from food, chemical, or pharmaceutical sector;
  • Combustion ashes from power plants;

The incrustations that form are the result of the presence of unburned powders or stored powders which, if not correctly removed, tend to solidify, risking damaging the machinery or jeopardizing its functioning.

Let’s see some examples together:

  • in industrial fans, the accumulation of deposits on the blades can unbalance the rotor and cause dangerous vibrations.
  • ash deposits in boilers and heat exchangers can clog the pipes;
  • in silos the materials risk depositing and creating blockage.

In all these cases, we erroneously think that the dust removal entails expensive, bulky, solutions, also difficult to install/remove or even worse, that interrupts the production cycle.

New Componit has developed SAFEFON® horns, a sound cleaning system, which, unlike more traditional systems, such hammers, air blowers and mechanical retractors, it is versatile and efficient in removing dust.

The low-frequency and high-intensity sound waves create some internal vibrations, that affect the residual deposits and have a fluidifying effect.

The sound impulses are emitted by a pneumatic generator, their frequency is then modulated by a diffuser which can have different shapes and sizes depending on the application requirements and installation needs.

The Safefon® sound cleaning system:

  • doesn’t cause secondary effects to structures
  • is easy to install;
  • works in a fully automated way;
  • has no unwanted stops;
  • guarantees a reduction in operating and maintenance costs.

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Industrial fans: how to make them more performing

Industrial fans: how to make them more performing

How many different needs and opportunities are there in the world of industrial fans and in air and flue gas vacuum systems?

Always more frequently, those who produce expansion joints, or like us who design and produce fabric solutions for heat and noise control, are contacted by manufacturers of industrial fans, in order to solve problems, that until a few years ago were neglected.

Soundproof expansion joints, resistant to acids, perhaps made with antistatic materials, thermal or thermo-acoustic jackets, are all accessories required as original part of a fan.

For obvious reasons, the producers of fans, are increasingly involved in the search of the most suitable product for their needs and this pushes us to study more and more innovative solutions.

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How to be sure of the performance of products you buy?

How to be sure of the performance of products you buy?

Since the development of our company is based on a process of continuous research, which has allowed us a constant improvement over the years, we often ask ourselves: “How can we guarantee our customers that our products really meet their needs?”

“How can we be sure to satisfy the technical characteristics required by customers or by a tender specification?”

The data reported on technical data sheets are a starting point, but sometimes they are not enough, in particular if we are talking about highly technological or custom-made solutions.

It is exactly in these cases that the possibility to test the products becomes essential to understand what happens, during the working steps, to the different materials, subjected to extreme and stressful conditions.

Tests, reports, videos e analysis can describe the behavior of materials used under particular stress conditions; this kind of information is important to overcome any doubts about the performance of the product

Furthermore, offering this type of service allows the company to differentiate itself from other competitors.

Obviously, it is necessary to assemble a team specialized in “research and development”, which can work in laboratory and test room, equipped with special software for simulating the working conditions.

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Quality and safety at the service of business progress

Quality and safety at the service of business progress

Innovation has meant for NEW COMPONIT to focus on quality since the beginning of its history.

In 1992, after a long and hard preparation work, NEW COMPONIT was one of the first small companies in Italy to be certified ISO 9001, accrediting itself with Certificate no. 160, received by CERTIQUALITY.

The preparation was the introduction to a first experience of renewal of the whole business process and the certification opened the way for the qualification at important multinational companies such as General Electric and ENEL in Italy.

NEW COMPONIT helped ENEL to eliminate completely the use of asbestos as insulation material and adopt MIL standard for the choice of alternative material, as already done by US Navy.

Since then, the turbines of thermoelectric plants (steam and gas) have been insulated by means of prefabricated jackets, which perfectly suit the turbine shape and dimension.

These jackets were and still are, made of fiberglass fabrics and felts, that New Componit, faithful to its original mission “textile solutions for heat control”, has hardly looked for all over the world, focusing on products that present lower intrinsic risks and that are classified as non-hazardous to health and with a very low environmental impact.

The commitment for quality has gone in step with the one for safety.

The materials suitable to be used for applications at high temperatures are mainly made of silico-aluminous fibers and require a particular attention and caution to be handled.

NEW COMPONIT has planned its production process of insulation jackets and fabric expansion joints, including particular attention to prevention and protection of the working environment, as well as the use of all necessary defenses to reduce the impact on the workers, who manipulate these materials.

The whole company is equipped with fiber vacuum and air disinfection systems, that ensure a healthy environment.

NEW COMPONIT textile solutions for heat control are always allies in the battle for the defense of environment and the fight against pollution.

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