The Importance of Combustion Control in an Industrial Setting

Combustion Control boiler all set up

Today, industrial facilities have to navigate a world of safety regulations, guidelines, and the need for efficiency and performance. We work with all components used in industrial settings from boiler repair to welding to mechanical repair or pressure piping. We understand the difficulty many industries face. In previous posts, we’ve discussed the history of combustion and the combustion engine before and how it plays a role in various industrial applications. In an industrial setting, combustion control is necessary to ensure optimal operation and safety, pollution control, and operation efficiency. 

Why Combustion Control is Necessary for Optimal Performance 

Newer industrial boilers are equipped with more sophisticated combustion control systems that allow for the regulation of carbon monoxide and nitrogen oxide emissions monitoring. The Department of Energy has energy goals when it comes to various sectors and industries and their use of energy and environmental impact. According to some government estimates, over 45,000 industrial and commercial boilers are larger than 10MMBtu with a total fuel input capacity of 2.7 million MMBtu/hr. And according to the Office of Energy Efficiency & Renewable Energy, boiler efficiency can be improved in three ways: 

  • Replacing with new boilers
  • Replacement of the burner 
  • Installing a combustion control system 

What Does a Newer Combustion Control System Do?

Burners are an essential component of many industrial applications. Gas and oil burners are responsible for powering package boilers, furnaces, and other heat processes. Newer combustion control systems and their respective gas sensors set the opening of fuel and air inlets. The system is constantly providing feedback and measurements of oxygen, carbon monoxide, and nitrogen oxide concentrations. 

Improving Efficiency for Industrial Boilers 

Effective combustion control and monitoring systems will improve the overall efficiency of an industrial boiler. The idea is that combustion efficiency is achieved through a burner’s ability to burn fuel, as measured by unburned fuel and excess oxygen in the exhaust. These systems tend to be digitally controlled and are capable of monitoring a boiler system’s efficiency. These systems will also monitor boiler performance, reduce greenhouse gas emissions, and improve fuel efficiency. 

As defined by the United States Department of Energy, Combustion efficiency is a measure of how effectively the heat content of a fuel is transferred into usable heat. Key indicators of combustion efficiency are the stack temperature and flue gas oxygen concentrations.

A Quick Example of Boiler Efficiency and Energy Usage 

As published by the U.S. Department of Energy, if a boiler operates for 8,000 hours per year and consumes about 500,000 million MMBtu of natural gas produces about 45,000 lb/hour of 150-PSIG steam. The stack gas measurements will be 44.9% with a flue gas air temperature of 400 degrees. From this equation, the combustion efficiency can be measured at 78.2%. Improving the efficiency that reduces the excess air even by 9.5% with a temperature of 300 degrees, the efficiency increases to 83.1% with annual fuel costs of about $235,856. The difference is substantial and why efficiency matters for energy use consumption.

The Stoichiometric Balance – Finding the Right Ratio 

Finding the right amount of air for the operation allows for the perfect balance that achieves optimal efficiency. A stoichiometric chemical equation is essentially balanced. The equation for combustion will usually involve Co2 and H2O from the reaction of another chemical and oxygen O2. Combustion conditions are never in perfect harmony, but any excess air must be used up to burn the fuel. This is called a stoichiometric amount of air. To ensure that the fuel will be used up, there is excess air. This air increases the amount of oxygen to the combustion. Stoichiometry involves using relationships between reactants or products in a chemical reaction to find precise results or data. 

The Benefits of Combustion Control Systems 

As combustion control systems become more commonplace and accessible, they are making it easier for industry levels to ensure that their systems are working at an optimal level. The main benefit of a combustion control system is the overall energy savings. The gain inefficiency is a result of a reduction of oxygen used. Other benefits include: 

  • Carbon monoxide monitoring checks for potentially unsafe or inefficient combustion does not happen 
  • Very low levels of oxygen in the exhaust flue gas improve efficiency 
  • Real-time data and boiler performance 
  • A control system that monitors gases and helps avoid accidents 
  • It prevents unsafe conditions from happening 

Get Combustion Control for Your Industrial Boiler or Application

When it comes to industrial boilers or equipment, Wyler Industrial has you covered. We offer combustion control services to help you achieve boiler efficiency and optimal performance. We ensure your equipment is working like it’s supposed to, not only for safety but for efficiency. 

Ready to see the efficiency potential of your boiler with combustion control? Call Wyler Industrial today and learn more. 

 

The Need for Pressure Vessel Inspection & Why They Matter 

Worker installs clamping ring on coated pipe

In any industrial setting, anything that is functioning or performing under high pressure is prone to cause serious damage if not working properly. Anything that is pressurized means that it is operating under very specific circumstances and requires every component to do its part. From industrial boilers to other pressure vessels, to your typical pressure washer or water tanks, the importance of maintaining and keeping these vessels secure is absolutely essential.  As certified inspectors of pressure vessels, we understand the necessity for quality upkeep and maintenance of these vessels. 

What is a Pressure Vessel?

To those that work in the industry, a pressure vessel is an everyday occurrence and necessity.  For others, it might sound very exotic but really it refers to any vessel that is operating under high pressures. Most pressure vessels are for industrial use like hot water storage tanks and dividing cylinders.  They can also be used to hold toxic and other non-toxic liquids. For this reason, these are carefully fabricated enclosed containers. They are primarily designed to hold gasses or liquids at high pressures or varying pressures.

These vessels serve a variety of purposes in industrial settings, factories, or installations. Because of the inherent dangers present in anything that involves contained and pressurized gas or liquids, there are stringent regulations and safety protocols that must be met. 

The most common shapes for pressure vessels include:

  • Spheres
  • Cones
  • Cylinders

How are Pressure Vessels Made? 

Because of the high pressure, they must withstand, these vessels will typically be fabricated out of different types of steel. Many will use carbon steel and stainless steel. When fabricating a cylindrical vessel, for example, different steel parts must be welded together to form the shape and ensure safety.

Subpar welding can lead to the compromise of quality, which means that precautions are necessary to ensure the parts are correct and properly installed. Only certain kinds of steel are appropriate for certain parts, as per regulations. Engineering standards require that only steel with high impact resistance should be used for pressure vessels. 

The bodies that establish these fabrication codes include ASME safety guidelines and the National Board of Boiler & Pressure Vessel Inspectors in the U.S. and the EU Pressure Equipment Directive in Europe. Other regulations around the fabrication of these vessels include the use of a load-bearing liner that helps withstand the pressure load. These will typically be composed of metal, ceramic, or polymer. 

What Happens When a Pressure Vessel Loses Integrity or is Cracked? 

If a vessel becomes cracked or damaged it can lead to rupture or leakage. None of these is good news. The potential health hazards that come with either of the above are serious and include poisonings, suffocations, fires, and even explosions. If the energy in the vessel expands and puts added pressure that the vessel is not able to withstand, it is a recipe for disaster.

What is an Industrial Pressure Vessel Inspection? 

Faulty pressure vessels lead to catastrophic consequences. This is why various governmental bodies have stepped in to ensure that there are frequent inspections that maintain the performance and integrity of these vessels. 

The inspection process will look at:

  • How well the vessels meet established industry standards
  • The vessel while empty and in operation
  • Several kinds of pressure tests will be conducted 

As mentioned above there are several ways that a pressure vessel can be inspected. The inspection must happen by someone that is certified through the Board. They might conduct a:

Internal inspection: This type of careful examination of the vessel happens when it is empty and not in operation. This inspection is used to identify internal damage, corrosion, worn-out components, etc. The welded seams will be looked at carefully, as well as other areas near welds and fittings. 

External inspection: This is a type of inspection that is done while the vessel is operational. External inspections are conducted on the outside of the vessel. These are important to catch malfunctioning external components like the piping, connections, and more. 

How Often are These Pressure Vessels Inspected? 

This might vary depending on the particular use for that vessel.  Pressure vessels that house toxic liquids, for example, will need more frequent inspections. Preventative maintenance is the best way to ensure successful inspections and avoid fines, loss time of operation, damage, and —most importantly— accidents and malfunctions. 

Get a Trusted Technician for Your Industrial Needs 

When it comes to industrial pressure vessels and other components, the consequences of malfunction or bad quality can be major. Here at Wyler Industrial, we have been providing quality services for generations. As a family-owned company, we have passed on our knowledge and understanding of the industry as we have grown and settled in the El Paso area. All of our technicians are certified and carefully trained. 

Need a pressure vessel inspection, maintenance, or service? Call Wyler Industrial today. 

The Role of the Machinist: From Aviation and War Efforts to Manufacturing 

CNC router machine

Machining is a broad topic and mostly refers to the process of converting raw materials into finished parts. Many times, it requires removing a piece of material in order to change its shape, size, and function and convert it into a part that will form part of a larger structure like an airplane, vehicle, machine, equipment, etc.  A person who performs this job is typically called a machinist. They are highly-skilled tradesmen that know how to operate machines with a high level of efficiency and they work in machine shops. Wyler Industrial provides machining services for many industries as well, so let’s look more closely at what that entails. 

The Role of the Modern Machinist

The role of the machinist has evolved over time. Today, a machinist operates CNC, or Computer Numerically Controlled, machine tools. These are used to create very specific parts for machines, instruments, aircraft, etc. 

A machinist’s job is very important in manufacturing, as the work that is done in a machine shop will determine the performance of the end-product. The parts that a machinist develops will take their rightful place as an important component of another structure. In order to operate CNC machines, the operator needs to be familiar with the codes, have a solid background in math, and a foundational understanding of the basic concepts of machining. 

In manufacturing and production, a machinist is called upon when a client needs a part to be cut. Machinists will be proficient in working with a variety of metal materials including aluminum, brass, copper, and various alloys. 

Machining can be broken down into three major categories or processes:

Turning

A machinist that specializes in turning is responsible for manufacturing parts in various sizes and working with modern machine tools. Turning requires defining machine data and making necessary corrections or fixes. Turning uses a cutting tool, as a tool bit.

Milling

The process of milling utilizes rotary cutters to remove material. The machinist advances the cutter through the material to cut the material piece. A milling machine looks like a complicated contraption from the early Industrial age, although its workings are far more sophisticated. 

Drilling

When it comes to drilling, a machinist is an expert workman operating heavy-duty drills and making precise drill holes in workpieces. Larger components require drilling to ensure holes are in the right place. 

Typical Machinist Tools:

Machinists use a wide array of tools. They are often used alone or in conjunction with other tools at various steps of the manufacturing process. The major tools include:

Boring tools

Boring is a holemaking operation in the machinist’s tool box, so to speak. Single-edged boring bars will have only one point of contact with the workpiece. 

Cutting tools

This category includes tools such as saws and shears. The cutting tools are used to cut pieces of material that are carefully measured and require a specific shape or size. 

Drilling tools

Any tool with a rotating axis used to penetrate material and create holes or for driving fasteners like screws into the material. 

Turning tools:

These include tools like lathes; they rotate workpieces on their axis. 

A Closer Look at CNC Machining

Computer numerical control machining is a technique used in conjunction with other techniques to precisely cut and produce parts from raw materials. Today’s CNC machines are highly sophisticated and can perform complicated cuts with little to no error margins. The machine is programmed and uses software that is very specific to the task at hand. The history of these machines goes all the way back to the dawn of industrialization. 

As computers and automation become more and more advanced, the technology improves the quality of the work. The earliest Numerical Control machines were built in the 1940s and 50s.  The early versions actually consisted of punching tape and feeding it into a basic machine. The machine was not fully automated and would often have large margins of error. 

Machinists will work for various industries including aviation, automotive, and manufacturing needs. An aircraft machinist is a necessary part of the industry and is not always given the credit they deserve. 

During World War II, machinists and what were called “machinist mates” were indispensable to the war effort. It was these people that ensured the construction of what was then rather experimental aircraft with many moving components and a need to be sturdy as heck. 

Many machinist mates positions were actually open to women during this time and many made their mark on the industry. As military operations became more and more dependent on airpower, the role of the machinist was central to the basic components of the machine. Modern machinists require a variety of skills including deep proficiency working with machine and machine parts, knowledge of CNC, and a deep understanding of hand tools. The job is also physically demanding and requires a lot of problem-solving. 

Make Wyler Industrial Your Go-To Machine Shop!

Wyler Industrial machine shop includes high-grade machining services. If your business operates in an industrial setting, you likely require quality parts made of metal. We are happy to service machines as well. Our trained machinists will help you get your issues sorted out. Connect with a machine shop and find quality industrial services in the southwest. 

History Of The Oil & Gas Industry

worker walking through a oil and gas refinery

Many film fans remember the drama unfolding in the film There Will Be Blood. Its portrayal of the deadlock arguments between families and neighbors when it came to ‘oil-rich’ land. The film showed many shocking moments—including the final bowling alley scene that leaves the viewer a bit shaken. These events are dramatized, as they are based on a satire novel by Upton Sinclair. Still, the oil and gas industry certainly has a unique history full of larger-than-life figures, incredible engineering, and innovation. The need for energy is an important driving force for much of this inventiveness and progress, as they endeavor to make use of the earth’s incredible resources continues.

There is a lot that goes into oil drilling. Here at Wyler Industrial, we love everything that has to do with heavy-duty equipment and machines used in the industrial and manufacturing sectors. So, why not explore some of these super cool tools that help provide one of the most needed resources.

The Steam Engine Changes Everything

Indeed it does. The steam engine brings the transformation from agrarian to an industrial economy. Still, it also spearheads significant changes to specific industries, including production, manufacturing, and the transportation of goods via the steam engine, trains, steamships, and other machines powered by coal. As the population from many coal-burning plants ensued, many women’s groups and others lobbied to take this into account and reduce the smoke-filled air quality that was lingering above many inner-city neighborhoods.

Throughout history, there had been several discoveries into several oil reserves. The most notable ones that kickstarted the move into petroleum as a new energy source began in the late 1900s and early 20th century. Also, one of these first often-cited oil discoveries is the one that happened in Oil Creek, Pennsylvania, in 1959. Native American populations had known about crude oil in the region.

Change Is Happening

It wasn’t until George Bissell and Edwin L. Drake used an oil rig successfully on a site near Oil Creek in Titusville, Pennsylvania. With the help of a clever professor, they tested the substance and surmised it proved useful for many different uses, including illuminating oil. Exactly five minutes until the first significant wave of investors and interested parties came rolling in, looking for ways to get more of this.

Not too far away, in the Appalachian Basin, seeping oil drew some attention and encouraged many to pursue these leads. As the Civil War happened, the oil-producing region spread over much of western Pennsylvania, through New York State, and into parts of Ohio and Kentucky.

Other states had their notable oil contributions in the early 20th century. These include states like Oklahoma in Glenn Pool and, a few decades later, the East Texas oil field. As other technologies developed, like the electric lightbulb,  and automobiles increased. The demand for more efficient production and energy sources rose. The immediate impact of oil was felt across the board. Overall, gasoline sales shot sky high. So, demand only kept growing as dependence and love for a mobile America grew bigger and bigger.

Then comes a major world conflict. The onset of World War I had a tremendous impact on the manufacturing and production of many goods across industrialized nations. The United States of America entered the war a few years late but still ramped up its military production.

The Fist Baron

We would be remiss without talking about the first major oil baron in the United States. John D. Rockefeller began his career in refining and formed the Standard Oil Company. By 1879, the company controlled 90% of the country’s reigning capacity, pipelines, and gathering systems. Many of these companies and major players’ history is another fascinating topic we’ll cover next time!

Just a Few Important Pieces of Equipment in the Industry

Wildcat drilling or exploratory drilling is the process of drilling for oil and natural gas.

Tank vessels: There two types used include storage tanks and gas condensers (pressure vessels). There are many different types of tank vessels used in the industry as well. Some of these can include

Heat exchangers: These types of vessels are known to transfer heat from one fluid to another. The type of heat exchanger used depends on the drilling system. Several different types exist, including shell and tube heat exchangers, plate heat exchangers, regenerative heat exchangers, and more.

Air coolers: These are important equipment in many industries, not just oil and gas. It absorbs heat from materials to be cooled and sent to where the materials need to go.

Evaporators: The evaporator is a device that turns a material that is liquid form into a gaseous state. There are several types as well, including natural/forced circulation evaporator, rising/falling film evaporator, and multiple-effect evaporator.

Here at Wyler Industrial, we work with several important industries. The oil and gas industry is just one of them. So, when it comes to serving and repairing industrial equipment, call a professional!

The Conveyor and How it Improved Industry and Efficiency 

Crossing of the roller conveyor, Production line conveyor roller transportation objects.The conveyor gets a bad rap. Popular culture has given a negative connotation to the conveyor belt and used it as a symbol of work automation and all the negative aspects of the Industrial Revolution. In reality, the conveyor belt has done a lot for important industries that we depend on every day. The production and assembly of important computers, automobiles, and more make use of the industrial-grade conveyor. The conveyor helps to decrease workload, improve efficiency, and carry heavy materials. This invention has actually come a long way and is used across many industries and industrial settings. As industrial technology and innovation improve, so does the technology for use in our factories, production lines, and industrial plants, and more. We thought we’d tour the history of the conveyor and the conveyor belt as an important part of our industrial services. 

Most people might not realize that a big percentage of materials they buy or consume that are constructed of metal, food, cosmetics, medical supplies, and plastics, make use of conveyors. Conveyors are mostly used to move large and bulk materials across distances. When it comes to the factory setting, conveyor belts are used to transport part of the material from one side of the factory to the other and to improve efficiency and decrease workload. Today, they are important in a variety of industries from quarrying, mining, and mineral processing. Conveyors come in all shapes and sizes and are used in different stages of production depending on the industry and the size of the plant. This aspect of the production assembly line has become integral and essential for many automated facilities and applications, particularly those that deal with heavy machinery or materials. 

The concept of the conveyor belt began way before the industrial revolution when it was used by farmers in the late 1700s to assist in moving large items across distances. This is why the invention of the conveyor is not exactly credited to one sole person or inventor. The concept was used by many across industries and before mass production. Henry Ford is often credited with the technology, as he implemented it in his early automobile plants, but Ford only took an existing idea and improved on it. In fact, it was Ransom Eli Olds, founder of Oldsmobile, that patented the design for a continuous assembly line, which is often credited to Ford as well. The early conveyor belts were more than likely used in agriculture and often made with a wooden framework with belts made of rubber or leather. 

Assisting with Continuous Production

The term continuous production is an industry term used especially in the 20th century to refer to a workplace setting defined when technology is used to define the sequence. Conveyor belts are simply part of a continuous production process that entails transporting materials from one production station to the next. In the Ford plants, for example, where early use of conveyor belts helped build the famous Model-Ts led to an extraordinary reduction of time that it took to build the models; the time went from 12 and a half hours down to one hour and 33 minutes. The conveyor belt has to be perfectly timed and coordinated in order to keep the production line in order, but once it was perfected, the efficiency and labor it saved were undeniable. 

Modern Conveyor Belts 

These aspects of factories began with a simple design and were used to transport sacks of grains or other heavy materials across distances simply to save labor. As the Industrial Revolution took hold in Great Britain, the implementation of the combustion engine and the steam engine continued to improve production. The conveyor was a part of this, as they no longer had to be hand-cranked and made the operation flow more easily. The first steam-operated conveyor was put into use by the British Navy. In fact, the British Navy used this incredibly powerful invention not to load important machinery or weapons or ship materials but to load up biscuits for sailors! These conveyor belts began appearing throughout all industries and would soon be part of the mining industries as well. 

With the invention of Vulcanized rubber, the materials for belts would be much more adaptable and sturdy, and once the underground conveyor belt was built, mining and quarrying would be completely revolutionized. Suddenly, much more material could be moved from the extraction point without that much labor. In 1908, the first roller conveyor came into the scene, and with the advent of automobiles and the demand slowly growing, conveyors became instrumental in the assembly of automobiles. 

The conveyor continued as an essential part of factory and production and became even more vital as the war broke out. Conveyor belts were used throughout America when producing essential war-time materials. The shortage of rubber also forced the invention of synthetic materials to be used for the belts and made the production that much more efficient. The booming economy after the war also led to mass production of many goods and the conveyor played a major role in being able to keep up with production demands. 

With advancements in robotics and computerization, the conveyor belt has taken on even more responsibility. They are essential to the mining and quarrying industries, as well as production for many goods we consume. 

Conveyor Maintenance and Repairs 

When your conveyor breaks or malfunctions, the entire operation can be put to a halt. This is why it is important to have conveyor repair you can trust to do the job quickly and efficiently. Here at Wyler Industrial, we know the stakes are high. Our mechanical repair includes repair for conveyors and other industrial operations. Call us today and keep your operation running. 

An Ode to Combustion and Why Combustion Control Matters

a close-up shot of an internal combustion engineOh where would we be without combustion? Well, life would surely have progressed differently. If you own a car that runs on gas or diesel, then the combustion engine has become part of your life. The engine is the heart of the vehicle, as it is what pumps the necessary fuel through the engine to get it up and going. Because it is now so ubiquitous, most people don’t think about the internal combustion engine even though it likely is responsible for their daily commute. And while most people know that the engine is vital, we might not understand just why this engine is the best type. This type of engine was really the beginning of a lot of key manufacturing processes, so we thought why not pay tribute to it. That’s because today many of our industrial boilers use this technological concept to produce steam or hot water for space heating or process heating. 

There are essentially two types of combustion engines: an internal and an external combustion engine. In the latter, the fuel source—usually coal— is burned outside the engine. Then, the burning fuel will give it the energy it needs to run. 

An internal combustion engine works a bit differently. Instead of heating the fuel on the outside, a mixture of fuel and oxygen is injected into the engine. From there, there is a spark that ignites the fuel that causes it to make tiny explosions. This is why, of course, spark plugs are quite important to the whole operation. 

Over 150 years, the design of the internal combustion engine has been worked on and perfected and is by far the most preferred way to power a vehicle. When it comes to vehicles, this brings an advantage in using petrol or diesel as its fuel source because it can last longer. 

The invention of this type of engine was almost reached by several people simultaneously. Like many great inventions in human history, it seems that several minds across the world often come to it around the same time. Ultimately it was a man named Jean Joseph Etienne Lenoir that patented the first combustion engine. Early iterations of the invention had only one cylinder. This often caused the engine to overheat, but it was able to power small vehicles. This was a huge milestone in the technology as there was an ability for it to run continuously. And then, thanks to several great scientific minds of the 19th and 20th century, the internal combustion engine was improved and became the most efficient engine. 

Combustion Systems in Boilers and Industrial Machinery 

After all, boilers use a lot of energy and take a lot of energy to run properly. They are made to produce hot water or steam through the combustion of a fuel. The combustion efficiency is important to consider for any business or commercial facility that utilizes these. There are more than 45,000 industrial and commercial boilers in the United States. These are boilers with a total fuel input capacity of 2.7 million MMBtu/hr. A combustion system for industrial boilers is a system designed to maintain a proper air/fuel mixture under varying load conditions and safe limits. 

Boilers can be categorized by water temperature and/or steam pressure. They can also be further classified by the type of metal they are constructed with. Typically, however, they will be built cast iron or welded steel. Boilers are rated in different ways and are measured with Btu/h or BTU per hour and MBtu/hr indicates the rate of input. 

 Many large commercial sites often wonder how they can increase the efficiency of their boiler function. There are essentially three ways to do this and they include replacing the boiler completely, replacement of the burner, or installation of a combustion control system. Having a combustion control system installed can help some facilities earn efficiency without having to spend the upfront costs of a full replacement. 

Combustion control systems work through continuous feedback from measurements of oxygen, carbon monoxide, and nitrogen oxide concentrations. This allows the combustion system to improve combustion efficiency while maintaining low carbon monoxide and nitrogen emissions. It also allows for continuous monitoring of boiler performance. 

A test conducted on the combustion control system in the Watervliet Arsenal in New York showed significant savings over the course of a year. The efficiency gain comes from various factors including the constant monitoring of carbon monoxide, which prevents inefficient and unsafe combustion to occur. 

Here at Wyler Industrial, we perform boiler maintenance and repair for small and large industrial or commercial facilities. If you’re looking to improve the efficiency of your boiler, call us today. We’re here for all your industrial needs. 

 

Dealing With Metal: Welding, Its History, and Importance

a man welding a pipelineWorking with metal is a craft in its own right. Oh, all the things metal will build! Since the dawn of time man has used the elements at his disposal to construct the world around him. And who would have thought, one hundred years ago, how metal would impact our lives on a daily basis. The history of welding goes back to the early 20th century and is today an effective method of fusing metal. One can trace the origins of the practice way back to the Bronze Age but the advancements and proficiency with which it is used today are entirely different. Here at Wyler Industrial, we offer welding services and know the importance of a job well done. An entire structure or infrastructure can depend on welding and this is a big responsibility we take very seriously. 

So when did it begin?

Well, no one can pinpoint the precise place in time where welding was born, but there is evidence of it as early as the ancient Egyptians, who may have learned how to weld iron together. After that, it was really various people and inventors throughout the following centuries that contributed, in their own way, to the advancement of the technique. 

During the 1800s, several advancements were made in countries like England. Edmund Davy of England is credited with the discovery of acetylene in 1836. The electric generator was invented in the 1900s, which gave way to some new technology to help the technique of welding. Around this time, Arc welding with the carbon arc and metal arc was developed and resistance welding became a practical joining process. Still, in the early 20th century, Stoghmenger introduced a coated metal electrode in Great Britain, and another engineer in Sweden invented a covered or coated electrode during the period of 1907 to 1914, as resistance welding techniques were also developed. 

The techniques since then have greatly improved and today we have things like robotic welding. This method uses computers to weld certain projects more effectively and precisely. This method is also incredibly safe and keeps workers out of hazardous situations. 

Important Industries Where Welding Is Used

How might the world be different if it weren’t for welding techniques? You might not see sturdy metal bridges, airplanes, or military tanks. There might be no room for large ships or cruise boats. So much of this is a result of the welding process that we thought we’d take a look at a few common industries where welding plays a key role. 

Aerospace

Remember that vacation you took last year with the family? It likely wouldn’t have been possible if it wasn’t for welding. This is because most commercial, military, and cargo aircraft use some kind of welding. So imagine the tremendous impact that aircraft has had on modern life and modern warfare. Without it, the world would look pretty different. During World War II, especially, the power of aircraft was truly tested, and welders and mechanics showed their grit and talent by repairing aircraft that would get damaged during routine flights and need to be ready again by the next day. Warfare today and many unmanned aircraft use welding to a similar degree and it is through the outstanding engineering and design that our planes have become as proficient as they are in their given task. 

Trains

The railroad industry was a key part of his country’s history. It was, after all, after railroads started being installed in major cities and through towns, that trade and commerce within the United States really increased. Railroads and trains are, of course, large made and produced with metal. Joining hundreds and hundreds of rail miles necessitated a lot of professional welding. America’s first diesel streamline train was made by the same firm that came up with shot welding. 

Automotive Industry

Cars are just another way that welding is used on a regular basis. There are currently about 279.1 million registered vehicles in the United States. That’s a whole lot of automobiles! And every one of those cars had to go through the assembly line and probably be subject to some kind of welding. 

Construction

Building anything this day and age will likely take some kind of welding to get the structure secure and the foundation set. In the construction industry, it is mostly steel that is used. A large percentage of the steel produced in the world is used for the construction industry.

Shipping

Let us not forget our friend out at sea. Of course, ships, including many military naval ships, require a lot of welding in order to produce strong and robust ships. 

Get Reliable Welding and Metal Services with Wyler Industrial

If you have any kind of industrial work area, you want to ensure that your facility and infrastructure is secure and well-made. That’s where we come in. Here at Wyler Industrial, we provide top-quality welding services for your business. Give us a call today. 

 

The History of Mechanical Engineering and How it Moves the World

Mechanical engineer working install chilled water pipe system. Engineer consult discussion with team work for install pipe.

Engineers are defined as people that make things. They are the ones that figured out how to make a car, how to fly a plane, how to go to the moon, and how to create intelligent software. Engineers are trained and skilled in the design, construction, and use of engines or machines. A mechanical engineer is involved in the design and construction of power-producing machines. Here at Wyler Industrial, we work for the industrial world and have mechanical engineers in our staff and have frequent contact with them and their machines and/or supplies. So we thought we’d take a look at this amazing profession that powers so much of the world around us.

Mechanical engineering is all about machines, how they function, how they can be improved, and how they can improve work capacity. It involves the principles of physics, engineering, mathematics, and material science to analyze, design, and manufacture mechanical systems.  The industry includes everything from machines, power systems, factory production lines, computers, boilers, and pressure vessels. 

Mechanical Engineering begins when the Industrial Revolution begins. Because as human beings began to depend and look to machines to increase the work output and make production more efficient and reliable, the world of mechanical engineering opened up to incredible possibilities. As we have mentioned in previous blogs, the invention of the steam engine was monumental for the industrial revolution. James Watt is often coined the father of mechanical engineering because it was that particular invention that gave way to many more important developments of the industrial revolution and beyond.  His invention was also central in the development of the profession of mechanical engineering. The steam engine gave way to modes of transportation that included steam locomotives and self-propelled boats. This led to the soon-to-be fast-growing network of railroad tracks, canals. Not long after, the invention of the automobile also created a big demand for mechanical engineers, especially as the auto industry was in its infancy and developing new technologies. 

Mechanical Engineers Join the War Effort

Both in World War I and World War II, mechanical engineers and engineers in general, were very important to the war effort and developing necessary machinery, aircraft, weapons, and more to help win the war. During World War II especially, mechanical engineers contributed to the design and improvement of fighter airplanes, tanks, vehicles, machines, and more. The first computers, developed around this time, were very much mechanical devices with electronics. A lot of these early mechanical computers were funded by military projects that were looking to get an edge on the enemy and figure out firing trajectories of artillery shells. During this time, mechanical engineers worked together to develop the jet engine and space rocket. 

Unforgettable Inventors and Inventions from Mechanical Engineers 

Throughout history, engineers working on developing power machines have had a tremendous impact on our society. Here are just a few notable names and inventions and discoveries in the field of mechanical engineering:

  • Nikola Tesla: Testa is well known for his contributions to the design of the modern alternating current electricity supply system. He also contributed to radio technologies and is often known as the father of radio. 
  • George Stephenson: This was a British inventor who created the first inner-city railway system. He is known as the father of railways. This, of course, reshaped the transportation industry. 
  • Aurel Stdola: Began the study of thermodynamics and was even a professor of Albert Einstein himself. He most notably invented the first heat pump and contributed to the beginning of steam and gas turbines. 

ASME and ASME Certified Industrial Suppliers 

Here at Wyler Industrial Works, we are an ASME certified Repair Team. What is ASME? It stands for the American Society of Mechanical Engineers and is a non-profit membership organization that enables collaboration and knowledge toward the goal of helping the global engineering community. ASME’s mission statement is to advance engineering for the benefit of humanity. When choosing a repair team for your industrial needs, look to Wyler Industrial who is ASME certified. 

ASME has been a leading resource for mechanical engineers for many decades. They publish codes, regulations, changes, and other relevant information for a variety of industries. Their informational publications always are written into state and federal regulations. They have the legendary Boiler & Pressure Vessel Code, where they issued their very detailed first code. 

Get the Right Repair Services With Wyler Industrial 

As an ASME certified repair service, Wyler Industrial will provide high-quality repairs and services for all of your industrial needs. We have been a full-service for the Southwest for over 100 years. After all, we started with a machinist in the 1880s, who owned a bicycle shop that would soon turn into a spare parts store and slowly grew and transformed into what it is today. 

A Deep Dive Into Combustion Control and How It Emerged

Still of a room of large combustion boilers.

For most people, the word combustion is likely associated with the beloved internal combustion engine. This type of engine, of course, provides incredible durability and drivability and is quite relevant to about 250 million highway transportation vehicles that use this type of engine. In addition to gasoline and diesel, they can use renewable or alternative fuel. If you deal with or are involved with commercial and industrial boilers, however, you also understand the importance of combustion control systems in the industry. 

The Heart of the Car — Combustion Engines 

Where would modern American life be without the vehicle. After all, one of the things that set this country apart from most others, is our incredible highway systems and the love of the open road. Americans love their cars and the truth is that on a day-to-day basis most Americans might not give a second thought to the process that allows them to get to work or get home or go to the movies. The heart of the vehicle is, of course, the combustion engine.  Since the year 1680, ideas and early designs of the internal combustion engine began to emerge. And from the year 1680, there were several engineers and inventors involved in the continuous attempt to develop, improve, and further advance this system. Up until the early 1900s, all of the previous attempts at internal combustion helped inspire the design of automobiles. 

A Word About the Famous Benz and Ford

These are likely two familiar names to anyone that has ever driven a car. Well, before it was Mercedes-Benz, German mechanical engineer, Karl Benz, built the first practical automobile to be powered by an internal combustion engine and received the first patent for a gas-fueled car. Henry Ford also played an important role in what would become the development of cars and internal combustion engines that are efficient and produced in mass. He was, after all, the first one to begin the assembly line manufacturing process which means some of the first Ford vehicles were assembled in about 93 minutes. 

Combustion Engines Continue

Combustion is burning; it’s the basic chemical process that happens when you mix fuel and air mixture. Sometimes this process can produce emissions that have been deemed undesirable for the environment. Over the last couple of decades, research and innovation have helped manufacturers reduce harmful emissions of pollutants such as nitrogen oxides and particulate matter by more than 99%.

Today there are two types of internal combustion engines. One is the compression ignition diesel engine and the spark ignition gasoline engine. Most of these engines are what we refer to as four-stroke cycle engines, which requires four pistons to fire off before one cycle is completed. 

The Boiler Combustion System — The Use of Fuel/Air Ratio

The boiler combustion control system is designed to maintain a proper air-fuel mixture under varying conditions. This is often called FAR in the industry— standing for fuel/air ratio.   These control systems in natural gas or oil-fired industrial boilers use the links in the machines between the fuel control valve and air damper to adjust. Good combustion control helps minimize the overall air pollution. The combustion control system (CSS) is an important component of modern industrial boilers. 

According to the U.S Department of energy, there are more than 45,000 industrial and commercial boilers larger than 10 MMbtu/hr in the U.S. The twenty-first century is largely concerned with energy efficiency and the improvement of emissions systems.  There are several ways that the efficiency of boilers can be improved:

A good combustion control system gets continuous feedback and measures oxygen, carbon monoxide, and nitrogen oxide concentrations and thus improves combustion efficiency while it maintains low carbon monoxide and nitrogen oxide emissions.  A good system continually monitors the boiler performance. 

Large industrial facilities or commercial facilities are looking for the ability to adjust the fuel-to-air mixture in order to maximize efficiency while controlling emissions in order to comply with regulatory requirements. The Department of Energy encourages systems that help facilities improve their energy efficiency while reducing the release of harmful emissions into the environment. 

Effective combustion control systems have the potential to increase fuel savings by several percentage points. This gain in efficiency is due to the reduction of oxygen in the flue gas. Most systems will have a monitoring and data logging device that provides real-time feedback on the boiler performance. This allows for consistent assessment and measurement of savings and efficiency. Energy savings can be achieved in most facilities when equipped with well functioning equipment and a trusted boiler combustion control system. 

If your facility uses an industrial boiler, you want to ensure that you have an effective system that is working properly and functioning at its highest capacity without wasting energy. 

Get Boiler Service and Combustion Control Systems from Wyler Industrial

 Here at Wyler Industrial, we are boiler experts. Whether you are looking to install a new boiler, repair an old one, maybe replace the burner, or to install a combustion control system, we are here to do the job right.

A Look Back at the Industrial Revolution and Industrial Services Today

We’ve come a long way since the days of the industrial revolution that profoundly altered United States history and world history. Innovation is a great force; it’s kind of like steam— you can’t really catch it in your arms but it’s in the air and it carries with it great energy. As we’ve reached the end of another successful year in the industrial sector, we thought we’d take a look at the period of U.S history that kickstarted so much change and has brought us— about a hundred years later— to an incredible time in a different type of technological advancement. 

Well, we would be remiss if we didn’t give credit where credit is due and the truth is that Great Britain, our sister country, got started with the industrial revolution before the United States. The movement really started across the pond in old King’s territory around the mid17th and early 18th centuries. Then, in the mid-1800s, this movement really spread to the United States, which completely transformed and positioned the nation for its imminent turn to a global superpower. 

As the industrial revolution took hold of Britain, there was the emergence of water, steam, and coal as abundant sources of power. In America, the changes really began to take hold as the nation regrouped and solidified after the devastation of the turmoil of the Civil War. Many American inventors were working in Britain, helping the movement there. And as the years advanced, new forms of transportation and the emergence of electricity would create changes to the way life and labor progressed. 

Noted Inventions of the Era and Beyond — Paving the Way For Faster Production and Expansion

Cotton Gin 

Before the official industrial revolution really took hold, some brilliant American minds were already at work and looking to make labor and power production more efficient. In 1794, Eli Whitney invented the cotton gin. This little invention shook its fair share of ground when it proved to be quite effective in the separation of cotton seeds from fiber. This could then improve and increase the speed of cloth manufacturing. 

Transportation & Communication

The westward expansion of the United States played a big role in increasing the demand and the need for faster and more efficient transportation. In the Midwest and other areas of the country, the steamboat was already making quite the splash (no pun intended) in helping people transport goods through the water. Railroads also played their role in people expanding further west and settling in towns along this trek. The first freight railroads emerged around the 1820s along the Erie Canal and other industrial centers. Regular passenger service on some of these railroads began as early as 1830. 

And as production grew, so did the middle class. Once this started to happen there was a little more leisure time available and it led to even more innovations and inventions, as people found time to explore new possibilities and avenues in which to increase production, improve efficiency, and make labor safer and more effective. The sewing machine, for example, was quite revolutionary around this time as well, as it completely transformed the clothing industry and allowed for mass production. 

The telegraph also emerged during this time, completely revolutionizing the way people communicated and could communicate. Today, we are so connected and have such easy access to everyone we know and love across the country and the globe, that we don’t often think how impactful the early communication devices were. 

Steam Engine

And who could forget our friend the steam engine? Thomas Newcomen designed the first prototype for the first steam engine in the 1700s in England.  Deemed the atmospheric steam engine, this invention was originally applied to power the machines used to pump water out of mine shafts. From this original idea, other inventors like James Watt and Matthew Boulton added modifications like a steam engine with a rotary motion, which spread the invention through a variety of industries including flour, paper, and cotton mills, ironworks, distilleries, waterworks, and canals. 

Today, we still use concepts of the steam engine in our industrial boilers when we use heat to produce power. The energy that is created within the boiler can then be turned into work or used for commercial or residential heating needs. An industrial boiler today works through using steam to power a turbine that is then converted into work. 

Use the Industrial Experts for Your Industrial Needs

Here at Wyler Industrial, we offer a variety of services for the industrial sector. Whether you need boiler repair, a boiler startup, pressure piping repair, combustion control, and more, we got you covered. All of our techs are highly experienced and specialize in a variety of areas. We offer all kinds of mechanical repair and services dealing with commercial gas lines.