Category Archives: Uncategorized

Hastelloy and Inconel Fabrication for Vessel Head Assembly

inconel to monel fabrication

High alloy fabrication is a requirement across the many unique industries that we serve. Our skilled tradesman manufacture equipment fabricated with a wide range of carbon and stainless steel alloys, including 304 and 316 stainless steel. In addition to standard alloys, we support manufacturing to customer specifications using a variety of exotic alloys including Inconel 600, Inconel 601, Inconel 602, Inconel 625, Hastelloy, 2205 and 2507 Duplex, Monel, Incoloy, AL6XN, Carpenter 20, and RA 253 MA.

For this particular project, we built an ASME Section VIII, Division 1 vessel head replacement system capable of passing test pressures at 150 PSIG over a 10’ diameter vessel head. The head is fabricated utilizing Inconel 600, manufactured to withstand high temperature (650oF) and corrosive environments of the customer specified chemical process.

Inside the vessel head, a network of piping provides processing flexibility to our customer. The integrated shower piping system is fabricated using the specialty alloy Hastelloy C276. The carbon steel flange around the outside of the vessel head was custom designed and forged to customer specifications. The flange then had a corrosion resistant overlay (CRO) applied to the service side to match the service requirements of the vessel. To complete fabrication on this vessel head, a number of unique weld processes were utilized in the creation of this vessel head.  A combination of GMAW-Pulse and GTAW welding procedures were used to join the alloy metals. The processes were chosen to ensure the performance of the part in service by decreasing heat input into the materials. Our fleet of power sources boast the most up to date technology which allows us to work very efficiently with these material types.

This project is currently in production and is expected to be completed in the summer of 2017. With all of the technical challenges associated with this project, we are proud to showcase the fabrication of this project, highlighting the Inconel 600 fabrication and the Inconel to Hastelloy welding capabilities of our employees.

If you have a project you would like to discuss, reach out to us.

 

A Look at the Project

 

R-V Builds: Pilot Project Cooker

food production processing equipment

One of R-V’s greatest assets is the ability to design and produce a product based on a customer’s desire, not a generic template. Recently, a nationwide food processing and production company approached R-V with a unique need. They requested a pilot system for cooking their product using a consistent cooking and agitation process. The vessel would need to be portable and efficient. While details of the project are confidential, some highlights are:

  • pilot cookerR-V’s team of engineers and designers created a design to suit the customer’s requirements and the piece was then manufactured on-site.
  • The rotating vessel included mixing features while maintaining heat and pressure during the cooking cycle.
  • The entire vessel was monitored using a PLC control system which is able to track recipes, save information, and configure cooking parameters.
  • All components of the vessel were manufactured according to ASME Code and NEC standards, while meeting all of the customer’s design and sizing requirements.
  • R-V provided factory and on-site training for the end users.

Our company embraces opportunities like this one which allow us to generate creative solutions for our customers’ needs. Innovation requires the ability to constantly anticipate ways to be more efficient and effective. We are happy to partner with our customers to help them accomplish these goals.


Download the PDF Version R-V Builds: Pilot Project Cooker

Fourdrinier Paper Machine: Project Profile

fourdrinier machine section

solidworks rendering of a fourdrinier sectionThis fourdrinier paper machine was supplied to a customer in Ohio, installed in their linerboard manufacturing facility. One of the key benefits of the new machine was the telescoping beam design, which replaced the roll-out framing design on the old fourdrinier section. One of the major problems in the service and maintenance of the old machine was significant wire change times. To facilitate efficient wire change out times, the breast roll and forming board were designed to pivot down. As a result, a wire change on the new fourdrinier machine was completed in under 1 hour!

A complete breakdown of the machine specifications and deliverables are listed below:

  • Telescoping Beams
  • Wire Tensioner
  • Powder Coating Finish
  • Stainless Steel Wire Return Rolls
  • U-RV and S-RV Doctors
  • Auto and Hand Guide Assemblies

 

fourdrinier machine telescoping beam

Fourdrinier Paper Machine: Telescoping Beam Demonstration

Guide to Getting a Custom Equipment Proposal

custom vessel drawings

Guiding You Through The Process

At R-V Industries, we strive to be your partner in the design and manufacturing stages of creating custom industrial process equipment. To help guide you through the initial Request for Proposal (RFP) process, we created this guide to make the process as straightforward and efficient as possible.


6 Important Steps

  1. Fill out the contact form with project overview information so we can match your needs with the right manufacturing partner. If we cannot fill your needs, we will point you in the right direction to find a suitable supplier.
  2. Upon receiving a reply from a member of the R-V Industries team, you can submit any necessary Non-Disclosure Agreements (NDA’s) for review and consideration by the R-V team.
  3. After an NDA contract is executed by both parties, you may submit any project related designs and drawings to R-V through the document submittal form found on the R-V website.
  4. Upon submitting documentation, let us know of any budgetary or RFP due date restrictions. We want to make sure we are able to serve you, and any specific information related to your custom project allows us to not waste your time waiting for our proposal if we are unable to meet your budgetary or due date restrictions.
  5. Following your receipt of the proposal, review all proposals to ensure they are including the same information in the project scope. You will not want to be surprised when certain aspects of your project were left out of the awarded scope when they were listed in another scope.
  6. Select Your Supplier and Thrive With Additional Processing Capacity!

Download the PDF Guide: Guide to Getting a Custom Equipment Proposal

Coming Soon: Electric Power 2017

electric power logo

In less than two weeks, R-V Industries will return to Chicago for the 19th Annual Electric Power Conference and Exhibition. This year’s exhibition will be held April 10th through the 12th, at the McCormick Place West Convention Center in the heart of downtown Chicago, showcasing some of the power generation industry’s top professionals and manufacturers.

Come visit us at Booth #219 for a chance to get some face time with the power generation experts at R-V. In case the opportunity for free food every afternoon is not enough, here are three reasons to swing by our booth:

  • virtual reality viewer

    Experience Virtual Reality!

    The patented Thermal Guard™ Series II Nozzle Tip Design, which protects nozzle tips from thermal distortion in extreme conditions and elevations.

  • An opportunity to brainstorm solutions to your firing system problems with our power team. We have extensive experience in diagnosing problem sources, designing solutions, and manufacturing equipment for firing high sulfur coal, coal-natural gas conversions, and co-firing systems.
  • For the first time at Electric Power, an opportunity to get a look inside of our manufacturing facility utilizing cutting edge Virtual Reality technology!

You will not want to miss out! To get your free exhibit hall pass, visit the Electric Power site to sign-up.

Rise of Industrial Processing Automation in the Food and Beverage Industry

automated food production

Online Shopping for Groceries?

The rise of online shopping is undeniable. As industry behemoths like Amazon and Wal-Mart, along with a host of other niche retailers, have established online shopping as a key tool in the purchasing habits of today’s consumers for clothing, sporting goods, electronics, and even automobiles. Online grocery shopping, on the other hand, has lagged behind in capturing the spending of contemporary consumers. But, just as many of the aforementioned industries continue to see growth in online spending, the online grocery shopping industry is expected to rise.

According to a CNBC report about the expected surge of the industry, online grocery shopping could grow from 4.3% of the total U.S. food and beverage sales to as much as 20% through the 2016-2025 timeframe. This growth would represent an increase in nearly $80 billion dollars.

 

SKU expansion

SKU Expansion Continues

The Expansion of Product Offerings

This change in purchasing habits could continue to increase the number of items available to the American grocery shopper. With retailers no longer restricted by shelf space in brick-and-mortar store footprints, the variety of products is expected to grow. The availability for product growth will be absorbed by contemporary consumer trends featuring non-GMO and reduced sugar foods.  The Association for Packaging and Processing Technologies (PMMI) notes in the 2017 Trends in Food Processing Operations Market Research Report that 4 of 5 companies surveyed have over 100 product SKUs, while more than 50% of companies expect to see SKU’s totals continue to increase.

 

What Does This Mean?

For industrial food processing companies, the expanding number of products requires a new level of production that ingredient supply and food and beverage processing companies simply are unequipped to handle. According to the PMMI report, the next wave of industrial processing equipment will need to have cleanability, flexibility, and operator safety at the center of the design and manufacturing development.

  • Flexibility: as illustrated earlier, the increasing SKU product counts of processing companies will require capital equipment investment that is able to change from one process to another with quick, reliable, and repeatable transformations.
  • Cleanability: as processing line changes are made, line cleaning must be done to reduce or eliminate cross-contamination of food and beverage ingredients to maintain the integrity of the taste and the production process. Furthermore, the cleanability of the processing equipment is paramount to protect consumers from food borne illnesses like Listeria, Salmonella, and E coli while limiting costly recalls for processing companies when outbreaks occur.
  • Operator Safety: as automation continues to grow in food and beverage processing and equipment line transformations, safeguarding operators against equipment malfunction is paramount to the safety of the operators.

 

How Can We Help?

R-V Industries, a global leader in the designing, engineering, and manufacturing of industrial process equipment has been serving the needs of industrial processors since our founding in 1974. With experience across a wide array of industries, we excel in manufacturing equipment to meet the flexible needs of food and beverage processing companies. Whether it’s the design, manufacture and assembly of an entire line of processing, or the addition/replacement of single equipment pieces such as mixing tanks and pressure cookers, R-V is ready to help you meet the growing list of demands for food and beverage companies.

To foster equipment flexibility, we integrate industry leading Allen-Bradley PLC control systems to facilitate process line changeovers quickly and efficiently.

To facilitate cleanability, we are capable of producing equipment with finish measurements as little as 3 Ra with electropolish processing.

To protect your operators, we design and implement important equipment safeguard features born from the same understanding of employee safety that has led us to be recognized through OSHA’s Safety and Health Achievement Recognition Program (S.H.A.R.P.) since 2007 for an outstanding record of workplace safety.

 

What’s So Cool About Manufacturing?

A Part of a Greater Effort to Shrink the Technical Skills Gap in Manufacturing

Manufacturing is cool. At least that is what R-V Industries, Inc. and “Dream it. DO IT. PA” set out to prove to local teenagers while breaking some of the traditional negative stereotypes associates with this industry.

R-V Industries, an industrial manufacturing company with facilities in Exton, Honey Brook and Morgantown, connected with “Dream it. DO IT. PA” to offer middle school students a chance to explore career opportunities in manufacturing.

“Dream it. DO IT. PA” works to instill interest in industry jobs by changing the perception about careers in manufacturing. The program coordinates activities for students and educators to participate together, including an annual video contest that pairs local middle schools and manufacturers. R-V Industries was excited to be a part of Dream it’s “What’s so Cool About Manufacturing” video contest which allowed a group of eighth graders from Octorara School District to explore the Beta Star Life Sciences division of R-V Industries. The students’ goal was to record their own short film meant to inspire and educate their peers about the manufacturing industry.

 

A Greater Effort: The Next Generation

R-V Industries is aware that ensuring the future of manufacturing in the United States is contingent upon developing the next generation of skilled trade and technical workers. R-V partners with several programs that provide opportunities to students who want to learn more about careers in manufacturing.

In addition, students from nearby institutions such as Drexel University, Rowan University, Penn State Berks, Pennsylvania College of Technology, and local high schools, have participated in internships and job shadows within several departments of R-V Industries. R-V Industries is also an active member of the Chester County Economic Development Council and the Twin Valley High School Advisory Council, as well as a member of the boards for Berks and Reading Muhlenberg Career and Technology Centers.

The landscape of education has been shifting slightly in recent years as more schools have embraced S.T.E.M. programs and technology. Investing in technology and education is also vital for organizations that are primarily focused in skilled trades. The partnerships R-V Industries has with local organizations helps promote the passion R-V has for manufacturing and the growth path technical education and jobs can provide students. The connection with “Dream it. DO IT. PA” is another conduit to achieve R-V’s mission of improving the quality of life for each individual they employ or hope to employ in the future.

 

A Greater Effort: The Current Generation

This focus on the value of education is not new to R-V Industries. The company is aware of how much of its success is driven by the skill of its manufacturing associates. Expanding their skills and knowledge base improves the overall performance of the organization, which led to the decision to invest in providing education for Tooling University, a skills based competency and training tool.

Individuals who are already with the company are able to expand their knowledge through tuition reimbursement along with the recently implemented certification program through Tooling U. This training offers participants the opportunity to expand their skill sets and learn new areas of expertise through online training and practical application.

 

Don’t Forget to Vote!

For more information about the What’s So Cool About Manufacturing video contest, and to vote on the R-V video in partnership with Octorara Middle School students, go to the “Dream it. DO IT. PA” voting page and look for our video! Voting takes place today, February 27th through 11:59 PM on March 1st.

R-V Industries, Inc. is proud to announce its purchase of a dual-cell robotic welding system, expanding their cutting-edge welding technology. The welding robot adds to R-V’s automated machining and welding capacities and improves customer lead times and manufacturing quality. For projects with repetitive welds, the robotic welder will be programmed to specific customer requirements while enhancing the speed of existing welding capabilities with efficient, high quality, and repeatable welds.

The dual headstock system accommodates a wide variety of modular tool lengths for different product and manufacturing applications. Offline programming and three-dimensional simulations also help maximize production uptime.

The system supports R-V’s team of world-class fitters and welders to bring new fabrication capabilities to its customers. This will also provide existing welding associates growth opportunities to participate in more complex custom welding projects that are not easy to automate. New positions were created and training provided to fill roles of Programmers, Operators, and Robot Maintenance.

“The investment into the robotic welding cell further proves to our customers that we invest in the safety of our employees, the quality of our products, and the productivity of our processes and technology that allows our customers to grow and become more successful,” said Pete Koegel, Weld Engineer at R-V Industries. The robotic welding system boasts a variety of featured benefits including:

  • Fully integrated safety rated devices (compliant with ANSI and RIA standards).
  • Latest in robotic welding software including: Coordinated motion, touch sensing, through-the-arc seam tracking, and live data cloud-based data monitoring.
  • Positioning capacity of 2,500 lbs per side.
  • Fume extraction system keeps operator and surrounding craftsmen safe.

The robotic welding system was installed in early February and production operations will begin on February 13th. Use your favorite social media network to view the video!

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LinkedIn Company Page

 

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Ok… for all the non-social media folks out there… here’s the video.

 

Investing In The Future With Robotic Welding from R-V Industries on Vimeo.

The Nuclear Manufacturing Industry Gets a Big Boost

nuclear power generation facility

Over last summer, the New York State Public Service Commission approved $7.6 billion to keep aging power plants in upstate New York running.  The subsidy is part of New York’s proposed Clean Energy Standard (CES).  Before the subsidy approval, nuclear power companies, including Exelon, stressed they could not keep the plants open without government assistance.  Exelon intended to close its Nine Mile Point and Ginna nuclear plants if the Commission failed to approve CES.

This was welcome news for both the nuclear energy and nuclear manufacturing industries.  Despite calls from federal and state governments for clean energy, U.S. nuclear power plants are losing money.  Nuclear power plants can’t compete with the much lower prices of their natural gas competitors.  Lack of demand for electricity is also hurting the industry.  Five plants across the country have shut down since 2013.  Many others are at risk of closing.  The Nuclear Energy Institute estimates that 15 to 20 of the United States’ nuclear reactors may close.  More could shut down if the economy takes a downturn.

NQA-1 manufacturing and custom manufacturing companies hope that New York’s CES will become a model other states adopt.  The Clean Energy Standard pushed by New York Governor Andrew Cuomo would require 50 percent of New York’s electricity to come from “clean and renewable energy sources” by 2030.  Under the plan, nuclear, solar and wind power utilities can earn zero-emission credits for generating electricity.  In turn, utilities can trade or sell a credit for each megawatt hour of electricity generated.  The credits could be worth an estimated $965 million in the first two years of the program.  The subsidy will be cut if power prices increase.

Opponents contend that the subsidies will increase power costs for consumers.  They point to the fact that subsidies will be funded by surcharges on electrical bills paid by residential and industrial customers over a 12-year period.  Critics are also upset that the Clean Energy Standard allocates twice as much money to nuclear than it does to wind and solar power.

Governor Cuomo pushed for the passage of CES after last year’s climate accord in Paris.  The United States joined both rich and poor countries at the accord and pledged to drastically cut carbon emissions.  Another reason Cuomo supported the CES passage was to save jobs at the plants in danger of shutting down.

Immediately following the decision, Exelon Corp. said it would invest $200 million in its Nine Mile Point and Ginna power plants and continue its negotiations to buy the FitzPatrick plant from Entergy.  “We’ll immediately invest hundreds of millions of dollars right back into the upstate economy, which will have a long-term positive impact across the state,” Exelon CEO Chris Crane said in a statement.

New York’s decision has given hope to the struggling nuclear manufacturing industry.  As Whitney Herndon from the Rhodium Group states: “You need to start somewhere with a state having a successful proposal so that other states can use that as an example.  Even if other states couldn’t apply this exact type of proposal, there’s enough information going around for them to take some lessons.”

 

Sources

R-V Industries Acquires Genesis Packaging Technologies

R-V Industries Acquires Genesis

R-V Industries, Inc. (RVII) announced the purchase of Genesis Packaging Technologies, Exton, PA. Genesis Packaging Technologies is a worldwide leader in the science and technology of parenteral vial sealing and residual seal force testing. RVII will retain the Genesis employees and continue operations at its existing Exton, PA location as the “Genesis Packaging Technologies” division of RVII.

“The Genesis acquisition provides a great opportunity to realize the synergies between our organizations,” said Kirk Putt, president of R-V Industries. “The Genesis team has established their products and services as best-in-class within the pharmaceutical and life science markets. Both organizations saw the opportunity to partner the process expertise of Genesis with the resources and custom manufacturing strengths of RVII. We offer customers a U.S. based supplier who provides integrated engineering, manufacturing, testing and field service. Together we will continue to provide the highest quality equipment while offering unmatched service and delivery.”

Bill Seiler, President of Genesis, sees the acquisition as an opportunity for significant market penetration and growth. He states, “I am very excited to share in the resources RVII can provide Genesis for continued growth and expansion of the products and services we offer our customers. RVII is an extremely innovative company that will bring a wealth of skill, knowledge and experience to Genesis, it’s operations, employees, and customers in the parenteral vial sealing industry.”

”The merger represents R-V’s continued investment in the pharmaceutical and life science industry, joining the Beta Star Life Science Equipment Division of R-V Industries in supplying equipment to this continually growing industrial and commercial sector,” added Dave Larson, marketing manager of R-V Industries. The Beta Star Division, which has been a part of R-V Industries since its acquisition in 2006, manufactures and services steam sterilization equipment for the biomedical, pharmaceutical, research, and life science industries.

Founded in 1996, following its acquisition of the West Company’s Machinery Systems Division, Genesis Packaging Technologies is a leader in the science and technology of pharmaceutical vial processing and handling. In addition to providing a line of vial capping and residual seal force equipment, Genesis provides parts and service for all their machines along with those supplied by the former Machinery Systems Division of the West Company.

Founded in 1974, R-V Industries, Inc. with annual revenue of $50 million is a privately owned company headquartered in Honey Brook, PA with an additional manufacturing plant in Morgantown, PA, employing over 250 people company-wide. R-V Industries offers complete turnkey industrial design and manufacturing services to the Chemical, Custom Fabrication, Food & Beverage, Life Science, Nuclear, Oil & Gas, Pharmaceutical, Pulp & Paper, and Power Generation industries.

R-V Industries Pledges To Help Keep American Jobs

manufacturing in america

As a proud American manufacturing company, R-V Industries pledges to continue making our products exclusively in the United States, which we have done since our inception in 1974. We believe in supporting our economy and providing our customers with the best services and products custom manufactured at our plants in Pennsylvania. We will continue to compete in the custom manufacturing marketplace by engaging American ingenuity and work ethic, not taking the easy way out by sourcing material from lowest cost countries.

Our larger competitors have begun sourcing both material and component fabrication from China. Several of our clients have unknowingly awarded orders to our competitors without this knowledge. This has resulted in receipt of counterfeit materials, suspect quality, and late deliveries.

Please join us, and other companies such as Ford and Carrier, to help keep American jobs by insisting your products are made here. Ask before you order: Is It Made Here?

 

buy american manufacturing

The Importance of Electropolishing

Protecting Your Food and Beverage Equipment and Industrial Process.

Just imagine: it is scheduled maintenance time in an industrial food production facility. Maintenance and cleaning teams scramble into action, checking off the maintenance needs while cleaning the conveyors, drying equipment, processing vessels, tanks, and toasting ovens inside the facility. As the equipment is being cleaned, tiny pieces of residue remain in between the tiny crevices of the equipment. To fully clean the equipment, it takes more and more time as residue builds and the equipment ages, increasing downtime expenses while risking contamination of the food production process. However, an electropolish finish can significantly improve equipment cleaning while reducing cleaning time.

food blending vessel

High Polish Food Blending Tank

Residue is trapped in the surface of the industrial equipment because of the microscopic peaks and valleys inherent in any surface. These peaks and valleys are measured in microinches, or 1/1,000,000 of an inch. The industrial equipment surface profile, measured by evaluating the average distance below and above the mean line of the microscopic peaks and valleys, establishes a standard for measuring the smoothness of a material surface. This average distance is referred to as Ra, or roughness average. Standard mechanical polishing brings equipment surfaces to 20 – 30 Ra depending on the material type. However, adding electropolishing into the industrial process equipment manufacturing process reduces the surface profile to 3 – 5 Ra. By reducing the height of the peaks and the depth of the valleys through electropolishing, the food production facility realizes a number of immediate and long-term benefits including:

  • Improved anti-cling characteristics
  • Improved sanitary characteristics
  • Improved resistance to corrosion characteristics
  • Improved equipment appearance with a “near-mirror” finish
  • Reduced residue build-up

All of these value-added benefits provide significant return on investment over the life time of the vessel, while reducing cleaning time. For more information about the type of custom food and beverage equipment we offer, visit the Food and Beverage Industry page or Contact Us today.

 

Attending AALAS? Visit Beta Star and Experience Virtual Reality!

sterilizer manufacturer vr tour

Visit Booth #1707 To Experience Virtual Reality and Enter To Win!

Are you considering attending the AALAS National Meeting in Charlotte on October 31st through November 2nd? Do it! Every fall, the American Association for Laboratory Animal Science (AALAS) puts on it’s National Meeting for members and non-members to attend lectures, poster sessions, and meet with vendors such as Beta Star. This year’s 67th Annual Meeting features nearly 300 educational sessions, 300 exhibiting companies, and more than 650 booths showcasing the latest research innovations and vendor products specifically tailored to vivarium laboratories.

sterilizer manufacturer vr tour

Experience Virtual Reality

To provide a sneak peek inside the world of sterilizer manufacturing, Beta Star Life Science Equipment, a division of R-V Industries, will be giving a virtual reality look inside the sterilizer production facility at Booth #1707. Check out the latest in Virtual Reality Technology while taking a look inside Beta Star’s manufacturing, assembly, and sterilizer testing facility. If that’s not enough, by stopping by the booth, taking a virtual tour and dropping off your business card, you will be entered to win your own Virtual Reality Viewer and iPod Touch to take the virtual reality experience home!

Here are some helpful links to make the best of the AALAS Meeting. We hope to see you there!

For more information about Beta Star and the autoclaves we manufacture for the sterilization industry, visit the Beta Star homepage.

 

ASME Pressure Vessel Jacket Types

Pressure Vessel Jacket Types

Across the chemical, oil, and gas processing industries, a variety of ASME Pressure Vessel Jacket Types provide unique benefits for specific processes. R-V provides three jacket types, which benefit the functionality of the vessel. These jackets include:

Conventional Vessel Jackets

Conventional Jackets are best used on small volume vessels (under 300 gallons) and high-pressure applications where internal pressure is double the jacket pressure. A conventional jacket is defined as an extra covering around all, or part, of a vessel. This jacket creates an inner and outer vessel wall, which provides greater insulation value with heat transfer being controlled using specified baffles.

asme jacketed pressure vessel

ASME Jacketed Pressure Vessel

Dimple Vessel Jackets

Dimple jackets allow for light-gauge metal construction that does not sacrifice strength and durability required to handle internal vessel pressure. As a result, the dimple jacket provides considerable cost savings over conventional, higher-gauge material options. This jacket style is approved by the National Board of Boiler and Pressure Vessel Inspectors to 300 psi.

Half Pipe Coil Vessel Jackets

Half Pipe Coil Jackets provide optimal strength, rated to 750 psig (depending on material thickness), while utilizing light-gauge metal for fabrication that saves on material expenses. In addition, half pipe jackets are recommended for high temperature industrial processes and all liquid head transfer applications.

 

For an ASME jacketed vessel summary, download our informational flyer here.

To go back to our hompepage, click here.

Co-Fired Generation

The challenges facing the coal power market are no secret. In November of 2015, a large gathering of political leaders from around the world gathered to discuss steps to reduce pollution levels to limit their effects on climate change. In the United States, strict EPA emissions restrictions have caused many older, inefficient coal plants to be retired or converted to natural gas, while newer coal plants have been forced to invest significantly in emission-reduction technologies.

While the proclamations of “the death of coal” are still a bit farfetched, the coal-fired power generation industry needs to adapt to the new political and economic landscape. As natural gas emerges as a cost-effective and pollution-reducing source of energy, many coal-fired facilities are evaluating co-fired generation utilizing coal and natural gas.

Co-fired generation ensures that plants have a reliable fuel supply at times of need. If a problem arises with the delivery of one of the fuels, the plant has the ability to fire the other fuel without skipping a beat. But, there’s more to co-fired generation than simply fuel supply. As the glut of domestic gas supplies has grown in the United States, thanks to significant investments and successes in hydraulic fracturing, the price has made it economically beneficial to power generation facilities with natural gas. However, the price could fluctuate significantly in future years as political pressures on hydraulic fracturing and investments in natural gas export facilities could drive the price of natural gas out of the “sweet spot” and closer to Europe’s natural gas price, which is currently 3 times higher per million BTUs than it is here in the United States.

Maintaining flexibility is paramount for the health of any industry, and the power generation industry is not different. If co-fired generation is something your facility would like to explore, give us a call today!

R-V Industries in PaperAge Magazine

R-V Industries delivers decades of experience in engineering and manufacturing to the paper industry, designing and fabricating a broad range of equipment and systems for use in paper mills nationwide and worldwide. Recently, R-V had the privilege of participating in a project for a Massillon, Ohio-based paper mill that entailed the replacement of the mill’s #1 paper machine. We are proud to have provided all of the design, engineering, and manufacturing services needed for this project, which included a fourdrinier, press, and drying section with a horizontal track reel.

Steam Dryer Project: That’s a Whole Lot of Weld Wire!

R-V Industries recently completed a multi-year, multi-million-dollar manufacturing project to supply multiple steam dryers that will be used at the nearby Peach Bottom Nuclear Power Plant in York County, Pennsylvania. Thanks to a long history of manufacturing excellence and NQA-1 certification with customer-acclaimed nuclear manufacturing experience, R-V was entrusted to build a complex and mission critical steam dryer for the plant.

This project was one of the most complex projects we have ever undertaken, right down to the delivery, which entailed a 7-car police escort and the delicate lifting of power lines and stop lights!. However, the most impressive part of the steam dryer project was the amount of manual welding and inspection that was required. The project required so much welding that we consumed over 2.5 tons of weld wire! But 2.5 tons is difficult to put into the context of everyday life. Take a look at the chart below, and prepare to be amazed (just as we were!).

 

Actual Reference Comparison
Weight 5,287 pounds 0.3282 pounds per foot* Weighs more than two (2) compact cars
Distance 16,103 feet 5,280 feet per mile About 3.05 miles, roughly the distance of a 5K Color Run

*Based on an average of weld wire requirements and data from WeldingDesign.com.

The Importance of Avoiding Carbon and Stainless Cross Contamination

The structural integrity of raw steel material is vital to the industrial manufacturing industry. A common and serious problem in stainless steel manufacturing is contamination stemming from carbon steel manufacturing in the same area of a facility.

In the manufacturing process, several different processes (including grinding and machining) generate carbon steel dust that can become ingrained in other material, such as stainless steel. In addition, simply moving raw stainless steel with tools and equipment that have also moved carbon steel can cause contamination.

Why is stainless steel contamination such a problem? In various chemical applications, specific stainless steel grades will provide better corrosion resistance to certain chemicals than other steel grades. In those applications, contamination from carbon steel can negatively affect the structural integrity of the tank or vessel, resulting in a shorter life expectancy for that tank or ASME vessel.

In 2009, as a way to address these concerns, R-V built a 26,000 square foot stainless and alloy-only fabrication and assembly facility at its company headquarters in Honey Brook. This facility gives us the capability to eliminate cross contamination of steel at our facility as part of our mission to provide our customers with a superior product.