Unit Weight of Oil Products

 Dear Readers,

Oil products are measured both in kilograms (kg) and in Liters (L). Calculating weight from volume units of oil products are as follows.

1. LPG: 1 liter = 0.53 kilogram.

2. Naphtha: 1 liter = 0.75 kilogram.

3. Oil-aromatics: 1 liter = 0.75 kilogram.

4. Aviation fuel: 1 litre = 0.80 kilogram.

5. Motor fuel: 1 litre = 0.745 kilogram.

6. Other light oils: 1 litre = 0.75 kilogram.

7. Petroleum: 1 litre = 0.79 kilogram.

8. Gas, diesel, light fuel oil: 1 litre = 0.84 kilogram.

9. Heavy fuel oil: 1 litre = 0.96 kilogram.

10. Lubricants: 1 litre = 0.88 kilogram.

The standard unit of measurement for oil weight is API Gravity. This scale was created by the American Petroleum Institute to measure the density of oil.

 

It shall be summarized as follows.

The higher the API, the lighter the oil.

The lower the API, the heavier the oil.

Laminate Construction of FRP Pipe

 Dear Readers,

This is continuation of my previous post of “Introduction of FRP Pipe.”

Fiberglass reinforced plastic (FRP) laminates are manufactured with thermosetting polyester or Vinyl ester resins and various types of fibrous glass reinforcing. The fiberglass reinforcement is thoroughly saturated with catalysed resin to form a dense laminate with the required physical and chemical resistant properties.

In general, the glass reinforcing provides the strength to the laminate and the resin binder provides the shape and chemical resistance. To achieve optimum chemical and abrasion resistance, all laminates are composed of an Inner surface, an Interior layer, a Structural layer, and an Outer Surface layer.

The combination of inner surface and interior layer is often referred to as the Liner or Corrosion Barrier and is generally considered to contribute structural strength as well as corrosion resistance to the laminate.

Summary of Laminate Structure as follows.

Liner / CBL (Corrosion Barrier Layer or Chemical Barrier Layer)

Structural Layer

Top Layer or Surface Layer

Inner Surface - This surface is exposed to the cursive environment and is composed of resin reinforced glass veil or a synthetic veil.

Interior Layer - This portion of the laminate is composed of multiple layers of chopped strand fiberglass reinforcement.

Structural Layer - This layer is primary structural portion of the laminate and is designated to withstand the loads caused by pressure, wind, seismic and other conditions. It consists of alternating layers of chopped strand and Woven Roving to the required thickness.

Outer Surface Layer - This surface is a resin coating formulated to be non-air inhibited and fully cured. When exposed to the environment, this coating contains ultraviolet absorbers or pigments to minimise ultraviolet degradation.

Eddy Current Coating Thickness Gauges (ECT)

Dear Readers,

In continuation with my earlier post of DFT, let us know the ECT (Eddy Current Thickness)

As you may aware that Dry film thickness (DFT) or coating thickness is arguably the single most important measurement made during the application and inspection of protective coatings. Dry film thickness can be measured on either magnetic steel surfaces or non-magnetic metal surfaces such as stainless steel or aluminum using a digital coating thickness gauge.

The eddy current principle is used for non-conductive coatings on non-ferrous metals substrates. They can be divided into two types: contact and non-contact. The contact type measures coating thickness by the amplitude of eddy currents, while the non-contact type measures coating thickness by the phase difference in eddy currents

Eddy current dry film thickness gauges are used in eddy current testing (ECT), a non-destructive test (NDT) method that determines dry film thickness based on the strength or level of eddy currents induced in a metal by a probe containing a conducting wire coil. The distance between the probe and the substrate, which is equivalent to the coating thickness, inversely affects the eddy current strength level. So, the strength of the eddy current deceases as the coating thickness increases.

An eddy current dry film thickness gauge is a widely used non-destructive coating thickness measurement tool because of its high sensitivity and wide range of thickness capability.

For More Details about Dry Film Thickness (DFT) click Here

Welding Terms (A&B)

Dear Readers,

Following terms are commonly used in Welding works. 

Arc Blow – The deflection of an electric arc from its normal path because of magnetic forces.

Arc Cutting – A group of thermal cutting processes that severs or removes metal by melting with the heat of an arc between an electrode and the work piece.

Arc Force – The axial force developed by an arc plasma.

Arc Gouging – An arc cutting procedure used to form a bevel or groove.

Arc Length – The distance from the tip of the electrode or wire to the work piece.

Arc Time – The time during which an arc is maintained.

Arc Voltage – The voltage across the welding arc.

Arc Welding – A group of welding processes which produces coalescence of metals by heating them with an arc, with or without the application of pressure and with or without the use of filler metal.

Arc Welding Deposition Efficiency (%) – The ratio of the weight of filler metal deposited to the weight of filler metal melted.

Arc Welding Electrode – A part of the welding system through which current is conducted that ends at the arc.

Atomic Hydrogen Welding – An arc welding process which produces coalescence of metals by heating them with an electric arc maintained between two metal electrodes in an atmosphere of hydrogen.

Autogenous Weld – A fusion weld made without the addition of filler metal.

Automatic – The control of a process with equipment that requires little or no observation of the welding and no manual adjustment of the equipment controls.

Back Gouging – The removal of weld metal and base metal from the other side of a partially welded joint to assure complete penetration upon subsequent welding from that side.

Backfire – The momentary recession of the flame into the welding or cutting tip followed by reappearance or complete extinction of the flame.

Backhand Welding – A welding technique where the welding torch or gun is directed opposite to the direction of welding.

Backing – A material (base metal, weld metal, or granular material) placed at the root of a weld joint for the purpose of supporting molten weld metal.

Backup Strip — is a strip or section of steel butted up to an open gap between two pieces of steel.

Backing Gas – A shielding gas used on the underside of a weld bead to protect it from atmospheric contamination.

Back-Step Sequence – A longitudinal sequence in which the weld bead increments are deposited in the direction opposite to the progress of welding the joint.

Base Metal (material) – The metal (material) to be welded, brazed, soldered, or cut. See also substrate.

Bead - the deposited filler metal on and in the work surface when the wire or electrode is melted and fused into the steel. A stringer bead is a narrow bead with only a dragging motion or light oscillation, while a weave bead is wider with more oscillation.

Bend Radius – Radius of curvature on a bend specimen or bent area of a formed part. Measured on the inside of a bend.

Bevel – An angled edge preparation.

Blown-up - what you will be if you weld or cut on containers with fumes. NEVER weld or cut on any container unless it is new or you know it has been cleaned and safety certified! Containers can be toxic, flammable, or explosive.

Braze Welding – A method of welding by using a filler metal, having a liquidus above 840 °F (450 °C) and below the solidus of the base metals.

Brazing – A group of welding processes which produces coalescence of materials by heating them to a suitable temperature and by using a filler metal, having a liquidus above 840 °F (450 °C) and below the solidus of the base materials. The filler metal is distributed between the closely fitted surfaces of the joint by capillary attraction.

Burr – A rough ridge, edge, protuberance, or area left on metal after cutting, drilling, punching, or stamping.

Buttering – A form of surfacing in which one or more layers of weld metal are deposited (for example, a high alloy weld deposit on steel base metal which is to be welded to a dissimilar base metal). The buttering provides a suitable transition weld deposit for subsequent completion of the butt weld on the groove face of one member.

Butt Joint – A joint between two members lying in the same plane.

Busted Out - failing a weld test because of defects in the welds. "He busted out on his test plates and didn't get hired."

For More Details about Electrode Classification Click Here

For More Details of TIG Welding Click Here

For More Details of Stick Welding Click Here

For More Details of Welding Symbol Click Here

Introduction of FRP Pipe

Dear Readers,

The Expansion of FRP is fiberglass-reinforced plastic which is a composite material consisting of thermoset resin and fibre reinforcement. FRP is principally made up of thermoset resin and glass Fibers. Resins can be divided into two broad classes: thermosetting and thermoplastic. Thermosetting resins cure to produce an infusible solid material that does not melt when heated. They soften when heated above their glass transition temperature, but do not reach a liquid state. Thermosetting resins used for FRP are typically purchased in liquid form and are reacted to a solid with chemical additives.

FRP is a reliable material of construction for piping and equipment in acid and base chemical services, such as hydrochloric acid (HCI), sulfuric acid (H₂SO₄), Chlorine dioxide (ClO₂), sodium hypochlorite (NaOCI) and caustic (NaOH) solutions.

Compared to most metals, FRP is generally considered a non-ductile material. FRP has a long elastic zone and markedly lower modulus of elasticity as compared to carbon and stainless steel. It should be noted that since FRP is a composite material, its material properties are orthotropic in nature, meaning that the properties are different in the hoop and axial directions.

Pipes can be manufactured by contact moulding (Hand lay-up) or hand lay up in combination with filament winding.

Types of glass fibre reinforcements

1. Chopped Stand Mat (CSM)

2. Rovings

3. Woven glass fabrics

4. Surface Veil

They are manufactured from glass or synthetic fibres such as polyester.  

A wide range of process equipment is constructed from FRP to meet the service conditions including Chlorine dioxide generators and storage tanks, bleach towers, Effluent Piping, Process Piping, Sump, and trough linings. FRP piping system is available in a wide range of sizes starting from 1 inch to 144 inches.

FRP Pipes are light Weight and Non-Corrosive and easily constructed, it is up to 75% less than Steel weight but it is equally strong. Density of FRP composite is 1800 Kg/Cum, Where as Carbon Steel is 7860 Kg/Cum.

Moisture Separator

Moisture separators are devices used in air compressors to remove moisture from compressed air. Since, moisture in compressed air can cause several problems, such as corrosion of tools and equipment, freezing of pipes, and reduced efficiency of the compressor itself. They are employed by several industries, including automotive, food and beverage, pharmaceutical, and textiles. Moisture separators are typically used in systems where compressed air is stored in an air receiver.

They can also help to improve the efficiency of air compressors and other equipment by removing water from the compressed air. Moisture separators are available in various sizes and configurations to suit different applications.

Dehydration is the preservation technique that attempts to remove moisture. The prefix de refers to removing or eliminating, the root word hydra refers to water, and the suffix ion refers to a process, thus making dehydration the process of removing or eliminating moisture or water.

Separators work on the principle that the three components have different densities, which allows them to stratify when moving slowly with gas on top, water on the bottom and oil in the middle. Any solids such as sand will also settle in the bottom of the separator.

There are three types of Moisture separators:

1. Water Separator

2. Moisture Separator

3. Moisture Separator with Filter

First, they are highly effective at removing water vapor from compressed air. Second, they are relatively easy to install and maintain. Third, they are relatively inexpensive to operate. Finally, Moisture separators can be used in various climates and applications.

It is used to protect equipment that can be damaged by contact with moisture, such as pneumatic tools and cylinders, and to improve the equipment’s efficiency by removing unwanted water vapor.

What items should not be kept in AC room?

Dear Readers,

It is continuation of our previous article" How to use AC in this hot season." Apart from the usage in hot sessions, we should also know what the materials are should not kept inside the AC room, so that we can use the AC in better.

Large metal objects such as iron bureaus, iron beds, iron tables and iron chairs should not be placed in the room. If they are placed in an AC room, they will absorb the cold and cool down first when the air in the room is cooled by the AC operation.

Thus, AC is used for more time than required. Along with running, the AC machine wears out quickly due to wastage of power and long running time of the compressor.

Some offices install false ceilings with thermocol to reduce the height of the room. Due to this the area of ​​the room is reduced. The room will be cool enough if it runs for a short time.

But this is only suitable for offices where doors are opened and closed frequently.

If installed in homes, the room will soon be filled with carbon dioxide emitted by people sleeping in closed rooms! This is not healthy!

AC if the room has iron furniture. The life of the engine will decrease slightly! In a nutshell that AC room should not have more Furnitures.

Basic Guides for Hot Weather Concreting

 Dear Readers,

This article is in continuation with my previous posts of Hot Weather Concreting and Concrete Precautions. Following points are the simple basic guides for Hot Weather Concreting.

While hot weather conditions are commonly encountered in summer, combinations of high temperatures, winds and low humidity could result in conditions leading to problems with concrete placement and finishing at any time. Hot weather is any combination of:

High ambient temperature;

Low relative humidity;

High wind

AS 13791 places a 35°C limit on the maximum concrete temperature at the time of delivery. However, when the air temperature rises above 30°C, it is usually recommended that precautions be taken, particularly if there is also hot dry wind.

1.     Plan in advance. Have equipment and materials ready before the hot weather arrives during the pouring day.

2.       Keep the subgrade and forms moist so they do not absorb water from the mix.

3.       Keep sunshades and windbreaks available and use them whenever possible.

4.       Have everything prepared before the ready-mix truck arrives. Don’t make the truck wait for you.

5.     Keep in constant communication with the ready-mix concrete provider. Coordination between the contractor and the producer is key.

6.       Concrete should be placed, struck off and Darby immediately.

7.     Use evaporation retardants, fogging or misting with water, or cover with a vapor-proof sheet after screeding (Finishing works). This will help prevent rapid drying, crusting, plastic shrinkage and rubber sets.

8.     Temporary covers, like continuously moistened burlap, may be placed over the fresh concrete and removed in small sections immediately ahead of the finishers.

9.      Substituting a burlap drag or broom finish will eliminate other high-risk finishing practices, such as smooth trowel finish.

10.   Curing should take place when the surfaces are hard enough to resist marring.

11.   Seal with a good, quality sealer for a minimum of 30 days after placing and curing.

12.   Remember to protect the crew in high temperatures. Drink plenty of fluids and be careful with long exposure to the sun.

13.   Use PPE’s for workmen and rest shed (minimum 15% additional workforce)

14.   Ensure the machinery technicians at work location to attend minor repairs immediately.

15.       Have standby equipment and manpower for all stages

16.       Programme concreting for the cooler parts of the day, or even schedule night-time placement if possible.

17.       Plan the locations of construction joints ahead of time with hot weather contingencies in mind.

18.       Keep all equipment that touches the concrete cool (chutes, conveyors, pump lines, tremies, reinforcement and buggies). Protecting equipment from the direct sun will If it can’t be kept continuously cool, spray-cool it as necessary with water.

19.       Use a thermometer to monitor the temperature at which concrete is being delivered, and call for adjustments at the plant if necessary.

20.       Avoid delays at all stages. 

Wish You all the Best for Excellent Concreting during Hot Weather. Have a Nice Day!!! 

Employees' State Insurance Act (ESI Act)

 Dear Readers,

Wish You a Happy May Day - 2023

The Employees State Insurance Act, 1948 is beneficial and social legislation. Its main aim is to provide economic security to people who work in certain factories and establishments. 

The ESI scheme provides complete medical care to the employees registered with the ESIC during the period of his/her incapacity and working capacity. It also provides financial assistance to compensate for the loss of wages of the employee during the period of his/her abstention from work due to sickness, maternity and employment injury. The ESI scheme provides medical care to family members of the employee also. The Act contains several important definitions and provisions that regulate these workers.

At present, the ESI scheme is applicable to all factories and other establishments as defined in the Act with 10 or more persons employed in such establishment and the beneficiaries’ monthly wage does not exceed Rupees twenty-one thousand (Rs 21,000) are covered under the scheme. In future this limit may change subject to government policy.  Whether the employer has employed 10 or more employees, all employees employed by the employer, agnostic of the salary are reckoned. The applicability of the scheme is explained through a flow chart below:

Please take a note that Construction Industry does not cover under ESI if it is a green field project. For the similar benefits Construction Industry used to follows BOCW Cess Act. However, it may differ for brown field project hence follow the principle employer guidance.

Establishments that are covered under the ESI Scheme

The Central Government issued a notification that all factories where 10 or more persons are employed are covered under the ESI scheme mandatorily. The following establishments employing 10 or more persons are also mandatorily covered under the ESI scheme:

1). Shops.

2). Hotels or restaurants not having any manufacturing activity, but only engaged in ‘sales’.

3). Cinemas, including preview theatres.

4). Road motor transport establishments.

5). Newspaper establishments.

6). All private educational institutions and medical institutions.

Benefits of the ESI Scheme

Broadly, the benefits under this scheme are categorized under two categories:

Cash benefits (which includes sickness, maternity, disablement (temporary and permanent), funeral expenses, rehabilitation allowance, vocational rehabilitation and medical bonus) and,

Non-cash benefits through medical care.

Complete medical care and attention are provided by the scheme to the employee registered under the ESI Act, 1948 at the time of his incapacity, restoration of his health and working capacity.

During absenteeism from work due to illness, maternity or factories accidents which result in loss of wages complete financial assistance is provided to the employees to compensate for the wage loss.

The scheme provides medical care to family members also.

In case a worker under the Act dies during employment, the ESI Corporation pays some money to his dependents. According to the Act, dependents are certain relatives of a deceased worker. These include his widow, a son below 25 years of age, an unmarried daughter and his widowed mother. A son/daughter above 25 years can also be a dependent if he/she is wholly dependent on the worker.

Pregnancy which leads to the birth of a living child is called “confinement” under this Act. It can also mean the birth of a child (living or dead) after 26 weeks of pregnancy.

The ESI Act contains a few categories of disablements for which employees can claim compensation. These may be either permanent or temporary. Permanent disablements may further be either partial or total.

For More Details about BOCW Cess Click Here
For More Details about Rules and Regulations Click Here 
For More Details about Labour Law's of Construction Industry Click Here
For More Details about Labour Welfare Fund Click Here

How to use AC in this hot season?

 Correct use of AC:

With the start of hot summer season and regular use of air conditioners, let's follow the correct method.

Most people have a habit of running their ACs at 20-22 degrees and when they feel cold, they cover their bodies with blankets. This leads to a double loss. How???

Did you know that our body temperature is 35 degrees Celsius? The body can easily tolerate temperatures between 23 degrees and 39 degrees. This is called human body temperature tolerance.

When the room temperature is too low or too high, the body reacts by sneezing and shivering.

When you run the AC at 19-20-21 degrees, the room temperature is much lower than the normal body temperature and this starts a process called hypothermia in the body, which affects blood circulation, thereby causing insufficient blood supply to certain parts of the body. sees Long-term disabilities such as arthritis can result.

When the AC is on there is mostly no sweat, so the body's toxins cannot get out, and in the long run there is a risk of many diseases like skin allergies or itching, high blood pressure etc.

When you run the AC at such low temperature, it keeps the compressor running at full power, even if it is 5 star rated, more power is consumed & it wastes money from your pocket.

What is the best way to run AC?? Set temperatures at 26 degrees or higher.

First setting the AC temperature to 20 - 21 will not give you any benefit, then It is always better to run the AC at 26+ degrees and keep the fan on slow speed. 28 plus degrees is ideal.

It consumes less electricity, and your body temperature is also within range, and there is no harm to your health.

Another advantage of this is that the AC will consume less electricity, the blood pressure on the brain will also decrease and the savings will ultimately help reduce the effects of global warming. How??

Let's say you save 5 units per night by running AC in 10 lakh houses at 26+ degrees, then we save 5 million units of electricity per day.

At the regional level this saving could be crores of units per day.

Please consider the above and do not run your AC below 26 degrees. Keep your body and environment healthy.