World Pumps 20121201.pdf

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www.worldpumps.com

THE INTERNATIONAL MAGAZINE FOR PUMP USERS

in liaison with

Number 553 December 2012

Also:

Oil & gasConstructionChemical handling

Water & wastewater:

Lifecycle cost saving benefits

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A member of Reed Elsevier plc

Contents

Business news 2

Product news 4Applications 10

Construction

General processing

Water & wastewater

Food & drink

2012 Elsevier Ltd. All rights reserved.This journal and the individual contributions contained in it areprotected under copyright by Elsevier Ltd, and the following termsand conditions apply to their use:

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e-mail: [email protected]. You may also contact Rights& Permissions directly through Elseviers home page (http://www.elsevier.com), selecting first Customer Support, then GeneralInformation, then Permissions Query Form.

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Derivative WorksSubscribers may reproduce tables of contents or prepare lists ofarticles including abstracts for internal circulation within their institutions.Permission of the publisher is required for resale or distribution outsidethe institution. Permission of the publisher is required for all otherderivative works, including compilations and translations.

Electronic Storage or UsagePermission of the publisher is required to store or use electronicallyany material contained in this journal, including any article or part ofan article. Contact the publisher at the address indicated. Exceptas outlined above, no part of this publication may be reproduced,stored in a retrieval system or transmitted in any form or by any means,electronic, mechanical, photocopying, recording or otherwise, withoutprior written permission of the publ isher.

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NoticeNo responsibility is assumed by the Publisher for any injury and/or damage to persons or property a s a matter of products liability,negligence or otherwise, or from any use or operation of anymethods, products, instructions or ideas contained in the materialherein. Because of rapid advances in the medical sciences, inparticular, independent verification of diagnoses and drug dosagesshould be made. Although all advertising material is expected toconform to ethical (medical) standards, inclusion in this publicationdoes not constitute a guarantee or endorsement of the quality or

value of such product or of the claims made of it by its manufacturer.

Annual subscription and PaymentsAn annual subscription to World Pumps includes 11 printed issuesand costs: 424.00 for all European countries & Iran.US$476 for all countries except Europe and Japan.

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Avenel, NJ 07001.

Editorial

Editor: Alan BurrowsTel: +44 (0) 1865 843686

E-mail: [email protected]

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Marketing and circulation manager:

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Tel: +44 (0) 1865 843190


Advertising

BeneluxRodric Leerling, Sales Director

E-mail:

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Tel: +31 229 841882

Fax: +31 847 488240

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and Switzerland) & Rest of World

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Email: Christian.hoelscher@

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Editorial and advertising offices

Elsevier Ltd, The Boulevard,

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OX5 1GB, UK.

Editorial and advertising fax:

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Marketing fax: +44 (0) 1865 843987

WORLDPUMPS

our environmental policy

We are committed to reducing our environmental

impact wherever possible, by limiting resource use

and efficiently employing sustainable materials and

technologies. This magazine is printed on a type of

paper known as Apollo Gloss, which is manufactured

from ECF pulp (bleached without using elemental

chlorine) produced from renewable forest resources.

The cover is produced using a water-based laminate.

for further information about our environmental

policies, please visit www.reedelsevier.com

EUROPUMP INFORMATION

Europump, the Association Europenne des Constructeurs des Pompes, counts more than

300 pump companies as its members. Eighteen national associations of pump manufacturers

are represented. Within the EU alone, its members have a collective annual turnover of more

than E5 billion. Among Europumps objectives, are the intention to be acknowledged as the

principal body representing the European pump industry, and to become the recognized

European source for, and forum for, the exchange of pump industry related information.

Lifecycle cost saving benefits 24Lifecycle cost calculations in wastewater installations can realise huge savings overtime for the wastewater company. The lifecycle costs summarise the total cost of a

wastewater installation and in this regard the pump system plays a major role.

Smarter systems, tougher slurries 28Recent advances in pump hardware and accompanying software help plants

across many industries to achieve the trifecta of lower energy costs, higher

equipment reliability and improved process efficiency. Variable-frequency

drives are the centerpiece of most smart pumping solutions.

Peristalics prove their compatability 32Dangerous chemicals, which are classified as being highly corrosive, toxic or

potentially explosive, require cautious and vigilant handling. The sheer volume of

chemicals that need to be produced in order to meet global demand also requiresa production process that can reliably and consistently meet production quotas.

Handling abrasive, corrosive liquids 35When it comes to handling abrasive chemicals, the demands on pumps are more

critical than ever as it is vital that this equipment keeps fluid contained, matches chemical

compatibility and adheres to the increasingly strict health and safety standards.

Torsional analysis of complex trains 38For a simple pump train, the torsional vibration modes and their consequences

are well known. However, this is not the case for modern, complex pump

trains. Comprehensive torsional analysis is therefore essential during the design

phase in order to avoid damaging problems during later use, as Amin Almasi

explains.

Contents

contact: ELSEVIER LTD PO Box 150, Kidlington, Oxford OX5 1AS, UK. Fax: +44 (0)1865 843973. www.worldpumps.com

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WORLDPUMPS December 2012

www.worldpumps.com

Business news2

For more business news,read Pump Industry Analyst every month.

Download a sample copy at www.pumpindustryanalyst.com

Wilo invests in newBeijing plant

Xylem expands indewatering pumps

Wilo SE has invested more than

24 million in a new productionfacility in Beijing, China.

With the new plant, Wilos

Chinese subsidiary in Beijing has

increased is floorspace to 20 000

sq m. Wilo intends to build on its

market position in China through

the new facility, and offer a faster

delivery service to its customers

in Asia.

The Asia-Pacific region is currently

the most dynamic economic regionin the world, said Wilo Group CEO

Oliver Hermes. This explains why

Asia, and China in particular, plays

an important role in our growth

strategy. With this new, highly

modern production facility in

Beijing, Wilo is taking account of

the current economic situation.

www.wilo.com

Xylem Inc has bought privately held

Heartland Pump Rental & Sales Incfor approximately US$29 million.

Heartland Pump, headquartered in

Carterville, Illinois, has been a

Godwin business partner in dewa-

tering pump rental, services and

systems design since 1995.

Weve identified dewatering as a

strategic growth market for us,

building on our existing capabili-

ties in emergency water removal,

bypass, drainage and industrial

applications, said Gretchen

McClain, president and CEO ofXylem. This acquisition supports

our strategy by expanding our

footprint in an important region of

the United States.

Heartland Pump employs approxi-

mately 100 people, with branches

in Evansville, Indiana; Horn Lake,

Mississippi; and Nashville,

Tennessee.

www.xyleminc.com

www.heartlandpump.com

Taco buys Hydroo

Gorman-Rupp acquiresSouth African distributor

Taco Inc has acquired Fairview,

Tennessee-headquartered Hydroflo

Pumps, a manufacturer of vertical

and submersible turbine driven

pumps.

Hydroflos pumps, which come

with investment cast steel impel-lers and ductile iron discharge

heads, are used in agricultural irri-

gation, mining operations, munic-

ipal water systems and HVAC.

The pump company has a manu-

facturing plant in Fairview, and

assembly and distribution facilities

in Culver, Indiana; Marion,

Arkansas; Grand Island, Nebraska;

Brownfield, Texas; and Fresno, Cali-

fornia. Hydroflo also has a sales

and distribution facility in Panama

to serve its Latin American

customers.

Hydroflo is a privately owned and

operated company which was

started by Brian Daschner in 1998.

Daschner will remain CEO of the

business under Taco ownership.

www.taco-hvac.com

www.hydroflopumps.com

Gorman-Rupp Africa Proprietary

Ltd (G-R Africa) has purchased

South African pump distributor

Pumptron.

A Gorman-Rupp distributor for

more than 25 years, Pumptron

provides water-related pumping

solutions mainly for the construc-tion, mining, agricultural and

municipal markets in South Africa

and in other sub-Saharan African

countries.

Pumptron is headquartered in

Johannesburg with operating loca-

tions in Cape Town and Durban

and had approximately US$10

million in revenue in fiscal 2012.

Jeffrey Gorman, Gorman-Rupp

president and CEO, said: The

acquisition of Pumptron will accel-

erate Gorman-Rupps presence in

South Africa and serve as a plat-

form for future growth in therapidly-evolving sub-Saharan Africa

region where the needs for water,

wastewater, agriculture and

construction infrastructure present

excellent opportunities for growth

in key markets we serve.

www.gormanrupp.com

November 2012 marked the

centenary of Japans Ebara Corp.

We are committed to the

continued challenge of further

growth by taking full advantage of

our technology, creativity and

ingenuity. In the coming 100 years

as well, we are determined to

remain a company that makes an

extensive contribution to society

by providing superior technologies

and services," said Ebara president

Natsunosuke Yago.

www.ebara.co.jp

Kirloskar Brothers Ltd (KBL) has

opened its first Authorised Refur-

bishment Centre (ARC) at Vado-

dara in India.

The ARC is a state of the art facility

designed to service, repair and

improve the effi ciency of all small,

medium and large pumps manu-

factured by KBL.

KBL is planning to set up four

more similar refurbishment centres

in different cities in India.

www.kirloskarpumps.com

Ebara celebrates100th anniversary

Kirloskar opens Indianrefurbishment facility

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Water To live To work Together

exclusive on: www.caprari.com

+ RESISTANCE+ PERFORMANCE

+ ENERGY SAVING

Submersible, radial and mixed flow electric pumps completely made of microcast

stainless steel. Designed to provide top-level performance, maximum efficiency and

reliability even in harsh environments thanks to Capraris advanced technologies.

DEFENDERCAPRARI INTERNATIONAL PATENT

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Product news4

Purpose-built testingfacilities in new depot

Following a 12 month planning

and investment process, HVAC and

pump hire specialist Andrews

Sykes Group, has offi cially openedits newly refurbished premises and

depot this week in South London,

UK.

The new 22,5002 ft facility

contains a built-in testing facility

and has almost double the

capacity of the previous

premises. This increased space

gives Andrews Sykes the capability

to expand the fleet size to meet

customer demand and has other

effi ciencies such as the amalgama-tion of the air conditioning team

under one roof.

Although less than half a mile

away from the previous site at

Gallions Road in Charlton, South

London, the move to Peninsular

Park is part of the companys

expansion plans.

The Andrew Sykes Groups new 22,5002ft facility contains a built-in testing facility

Having been the offi cial supplier

of air conditioning to the Olympic

and Paralympic Games and as the

shirt sponsor for Charlton AthleticFootball Club, Andrews Sykes offi -

cial opening was attended by UK

Olympic silver medal winner

Gemma Gibbons and also Chris

Powell, manager of last seasons

League One winning Charlton

Athletic side.

Paul Wood, Managing Director at

Andrews Sykes said: Every effort

has been made to build in the

latest facilities to meet the current

and future needs of the business,whilst having regard to our envi-

ronmental impact. Were all excited

about the new depot but equally

pleased that the move is only just

down the road - Charlton has been

the home of one or more parts of

our business for over 80 years.

www.andrews-sykes.com.

Self-priming designwithout corrosionVanton Pump and Equipment

Corporation is promoting its port-able, non-metallic Flex-I-Liner

rotary peristaltic pump. The

company is keen to highlight that

the pump evacuates drums and

totes containing acids, caustics,

salts, chlorides and reagent grade

chemicals, without corrosion of the

pump or contamination of the fluid.

Vanton Pump says that the self-

priming design has no seals to

leak or valves to clog, and can run

dry for extended periods withoutdamage. Compact in size with

integral handle, the pump fits on

drum lids without protruding, and

has suffi cient lift characteristics to

operate from the floor, skid, or stand.

Only two non-metallic parts

contact fluid: a thermoplastic body

block, and an elastomeric flexible

liner that can be replaced in the

field without special tools. The

rigid body block is of solid poly-

propylene, UHMW polyethylene, orPTFE, and the molded flexible liner

of natural rubber, Neoprene,

Buna-N, Hypalon, Viton,or

Nordelelastomers, eliminating

corrosion or contamination associ-

ated with metal pumps. Vanton

Pumps says that the range of ther-

moplastics and elastomers used

during manufactured permits the

pumps use over the full pH range

and for an extensive list of corro-sive, volatile and viscous fluids.

A rotor mounted on an eccentric

shaft oscillates within the flexible

liner, imparting a progressive

squeegee action on the fluid

trapped in the channel between

the liner and the body block.

Flanges on the flexible liner are

pressed to the side of the body

block by concentric grooves on

the bracket assembly and the

cover plate, isolating the fluid tothe channel.

The pump is suitable for flows from

1.25 to 151 l/h and pressures to

310 kPa at temperatures to 121C.

www.vanton.com

AA-0989 drum pump evacuates drums

containing abrasives without corrosion or

fluid contamination.

VDMA enjoys success with 2012 conferenceFor the second time VDMA Pumps

+ Systems and VDMA Compres-

sors, Compressed Air and Vacuum

Technology Association as well as

the EFRC (European Forum for

Reciprocating Compressors) joined

their three forums, the 10thPump

Users International Forum, the

third Compressor Users Interna-

tional Forum and the eighth EFRC

Conference. The conference was

held from 27-28 September 2012

in Dsseldorf, Germany.

A very successful event - even

more user-oriented and more

international than in 2008, said

Christoph Singrn, managing

director VDMA Pumps + Systems

as well as VDMA Compressors,

Compressed Air and Vacuum

Technology.

The three forums attracted around

850 participants from 42 countries

or five continents. A considerable

part of participants, about 30%

were users.

Apart from Technical Papers about

current topics around pumps,

compressor and compressed air/

gas systems, this time for the first

time vacuum technology also was

an offi cial par t with two sessions

with three papers each.

Moreover there were panel

discussions about the optimal

compressed air supply in indus-

trial processes and about the

extended product approach

within the frame of the European

Ecodesign directive. The session

entitled Young ProfessionaIs led

to initial informal contacts

between the graduates and

potential future employers.

During the two days an

accompanying technical exhibi-

tion took place. More than 70

companies presented the whole

range of pump, compressor

and vacuum technology on

around 70 m2.

Meeting points integrated in the

exhibition area allowed partici-

pants to continue discussing the

technical papers and informing

themselves of product

innovations.

www.introequipcon.com

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Our role within the process industry is vital.

In bringing together our services and expertise

in uid dynamics with our range of uid handling

equipment and systems and matching it all with

what you want from your processes, we create

winning solutions.

Its what we call

Using the right pumps

for your process?

Or just the ones that

youve always used?

What really

makes the best

pump for the job?

Is pump maintenance

taking too long?

What does it cost if

your process stops?

Whats keeping yourprocesses running?

ramp

isa

registeredtrademarkoftheAxFlowGroup

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Product news8

Salino pressure center forRO seawater desalination

In early 2013, KSB will launch itsnew compact unit for reverse

osmosis seawater desalination: the

SALINO Pressure Center. The unit

consists of an axial piston pump

and an axial piston motor, arranged

on a common shaft. Driven by the

diaphragm return flow, the axial

piston motor transfers its power

directly to the pump shaft. Three

functions are fulfilled by the same

unit: creating high pressure,

compensating pressure losses and

recovering energy. There is no needfor a separate booster pump. The

entire system runs on a single elec-

tric motor and frequency inverter.

Compared to conventional energy

recovery systems with pressure

exchangers or Pelton turbines, KSB

believe that this design can save

up to 50% in energy costs. The

Salino Pressure Center is designed

for RO systems (reverse osmosis

systems) with a capacity of up to

480 m3per day.

Fluctuating salt contents in the

seawater to be processed can be

responded to by the integrated

control system. In tests the new

compact unit desalinated one cubic

metre of seawater with a salt content

of 35,000 ppmat a power input of

approximately 2 kW per hour.

www.ksb.com

The SALINO Pressure Center a new system

for use in reverse osmosis desalination.

(KSB Aktiengesellschaft, Frankenthal,

Germany)

Dedicated test facilityverifies performanceHydra-Cell metering pumps meet

API 675 performance standards, in

terms of repeatability, linearity and

steady state accuracy. However,

Wanner International has invested

in a dedicated test facility that

enables customers to verify

performance of individual pumps.

Independent witnessed and non-

witnessed testing is available,

followed by performance

certification.

A more accurate knowledge of

pump performance can often be a

critical element in process optimi-

zation and the reduction of oper-

ating costs.

API 675 is the specification for

controlled volume, positivePump testing underway verifying pump

performance.

Measuring instrumentsaimed at food industryThe Baumer Group manufactures

and develops sensors, encoders,measuring instruments and

components for automated image-

processing.

The first two models in Baumers

new B series, the CombiPress pres-

sure transmitter and the CombiTemp

temperature gauge can be

combined with the new CombiView

display generation. The models have

a newly developed stainless steel

hygienic housing making them

suitable for the food industry.

The CombiView displays visual mode

allows the user to choose from

several different types: analog,digital

or illustration. The large display mean

that the measured values even from

increased distances. The background

color of the display works like a

traffi c light system (red/green),

depending on whether the meas-

urement results have reached a

critical value that requires inter-

vention. A touch-screen displayallows the setting to be changes

when the process is running.

With its protection class IP 69 K

and entirely stainless steel design,Baumer claims that the hygienic

version can withstand even the

toughest conditions. In addition,

its ability to pivot around two axes

is designed to give installation

flexibility.

Measurements are provided by the

CombiPress pressure transmitter

between -1 and 400 bar and by

the CombiTemp temperature

gauge between -50 and +400

degrees Celsius.

http://www.mymepax.com/

Baumers CombiTemp (li.) and CombiPress

with new CombiView display are designed to

provide safety and user friendliness in process

instrumentation.

displacement pumps for use in

service in the petroleum, chemical,

and gas industries but is increas-

ingly being adopted as the

general industry specification for

metering and dosing pumps.

www.hydra-cell.eu

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Applications10WORLDPUMPS December 2012

www.worldpumps.com

Swedish supplier takeson tunnel project

Construction

construction method to connect the under-

water and under bedrock tunnel sections. At

a depth of 20 m these excavated channels,

which have retaining walls held in place by

1.5 m wide piles, are the deepest ever used

in northern Europe.

The six LH23.0 W pumps from Tsurumi are

being used for dewatering during thecomplicated installation of submerged

tunnel sections at the project. The pumps

were selected for their reliability and powerful

Global pump manufacturer Tsurumi has

supplied six of its LH series high head

dewatering pumps to the Sderstrm

tunnel project in Sweden. The pumps are

positioned 28 m underwater in drilled holes

just 200 mm wide and are a vital part of the

ambitious project.

The 300 m long submerged section of theSderstrm tunnel is being built using

immersed tunnel sections. These are

supported on four grouped piles that have

been drilled into the bedrock. This means the

tunnel is resting on an underwater bridge.

The submerged tunnel consists of three

100 m long prefabricated sections. The

sections contain two tubes that will each

carry a 12 m wide railway track and a 5 m

wide access tunnel for service and rescue.

Deep channels have been excavated on both

sides of the Sderstrm bay. In these chan-

nels the contractor is using the cut and cover

Tsurumi pumps are working at a 1.7 billion inner city tunnel project in Stockholm, Sweden.

The pumps were added to the underground project to replace another manufacturers

pumps after the project experienced delays. Because of their compact design, reliability

and power, the six LH23.0 W pumps from Tsurumi are being used for dewatering during thecomplicated installation of submerged tunnel sections at the project.

At 20 m deep, the channels are the deepest of their kind in Europe.

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vacon

intelligent process control

VACON 100 FLOW is a product dedicated to two keyingredients in our everyday lives air and water. Thepumps, fans and compressors that control the flow ofthese elements affect everyone and yet so often slipunder the radar.

With VACON 100 FLOW, weve handpicked all thefunctions that are best suited for regulating air- andwaterflow: features like Multipump systems, long-life

DC link technology and StartUp Wizards open up newpossibilities for controlling pumps and fans. It comeswith a power range of 0.55 kW/0 .75 HP to 160 kW/250HP, and a voltage range of 230 V to 500 V. VACON100 FLOW is available in a IP21/UL Type 1 or IP54/ULType 12-certified enclosure, ensuring it can operate inchallenging environments. For additional details, visitwww.vacon.com

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www.worldpumps.com

High pressure mistingsystem for mobile res

General processing

John Dennis Coachbuilders (JDC) has

introduced a new fire-fighting system

designed and constructed around Cat

Pumps high pressure triplex plunger pump

technology. Designed to provide effective

control of brush and grass fires, as well as

incidents in industrial premises, the vehicle-

mounted JDC Wildfire Attack System uses Cat

Pumps 5CP Series for generating a fine mistfoam and water fire suppressant.

This wildfire attack system gives fire and

rescue and emergency services greater

accessibility to locations where fires breakout

but cannot be easily accessed by large

tenders. It is comprised of a Cat Pumps 5CP

piston pump coupled to a 13HP petrol

engine, an adjustable foam concentrate

proportioning system, pressure relief valves,

foam dispensing guns and a foam concen-

trate tank. The foam proportioning system is

exclusive to Cat Pumps and provides opera-

tors with the ability to control precisely the

volume of foam used between 0% and 6%

without interrupting the flow at the gun

nozzle. This device results in faster knock-

downs and laying down foam blankets, whilst

optimising the foam concentrate.

Following the construction of a 4 x 4 demon-

stration vehicle, Guilford-based JDC have

received an order for 17 rural response vehi-

cles from the Mid and West Wales Fire Service.

The demonstration vehicle is equipped with

a 250 litre water tank and carries a 60 m high

pressure 3/8 inch hose, Cat Pumps twin foam

gun, a variable stream gun, a jet spray lance

and Cat Pumps 5CP pump which delivers 19

litres/min at 100 bar.

A new vehicle-mounted wildfire attack system gives firefighters and emergency rescue services

greater accessibilty in hard to reach locations where fire breakouts cannot be easily manipulated

by larger tenders. The high pressure triplex plunger pump system, which generates a fine mist

foam and water fire suppressant, is designed to provide effective control of brush and grass fires,as well as incidents in industrial premises.

The JDC Wildfire Attack System and Cat Pumps 5CP piston pump assembled in an off-road 4 x 4 vehicle.

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Applications 15WORLDPUMPS December 2012

www.worldpumps.com

The high pressure pump is central to the

effectiveness of the complete system, so

when we started out on our development

programme we recognised that we could

not compromise on quality and perform-

ance, said Nick Uwins, JDCs sales and engi-

neering director. With the guidance of CatPumps, we opted for its 5CP series, not just

because it is a very high quality and reliable

pump, but because it has been used exten-

sively on similar systems throughout the U.S.

We also specified Cat Pumps twin foam guns

as these have been developed specifically for

fire-fighting duties. These can deliver a foam

spray in excess of 12 m, depending on the

spray configuration, which can be selected

either as a jet stream or a fine mist stream.

Cat Pumps foam fire-fighting systems

combine its high pressure triplex pumps withfoam induction technology. The compact

5CP high-pressure, low-flow pump delivers a

precise metered water/foam solution for

quick fire suppression and provides increased

time at the fire line, even with a limited supply

of water. The pump and integral speed-

reducing gearbox are suitable for mounting

directly onto a petrol or diesel engine with an

SAE parallel shaft and flange, providing a

compact, reliable and effi cient installation.

Furthermore, the operating pressure can be

preset before start-up and the engine speedcan be controlled independently of the lance

or foam gun power. In this way, operators

have complete control of the speed and pres-

sure of foam delivery to the fire.

The high-pressure triplex pump breaks water

droplets down to under 5% of a standard low

pressure system droplet. This increases the

surface area covered, extinguishing the

flames more efficiently without wasting

water and expensive chemicals. In addition,

the high-pressure spray penetrates deep intoroots for effective fire breaks and increased

protection against rekindling.

The JDC Wildfire Attack System comes pre-

assembled in a skid frame for connection to

a water tank and is suitable for mounting on

a wide range of pick-ups, transits and off-road

4 x 4 vehicles.

www.catpumps.co.uk

Cat Pumps 5CP piston pump

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A recent climate change forum held in South

Africas city of Cape Town warned of even

worse devastation on water sources and

towers should governments in the region fail

to take measures to reduce both carbon

emissions and the style of environmental

management.

Changes in water level

After the Zambezi River water levels dropped,there was reduction in pressure from the

intake point forcing the pumps to pull in

unwanted material from the river. The water

level in the river is low, so the pump is pulling

in all sorts of materials which are damaging

the pump mechanically, Erdtelt said.

The fall in the water level would have resulted

in reduced weight of the water above the

pumps inlets hence leaving the atmosphere

as the only force to push down the water into

the pump.

NamWater said water from the Zambezi River

is pumped directly to the five pressure sand

filters at a reservoir where any suspended

matter is removed from the water. The water

is then disinfected by adding a chlorine gas/

water mixture as it flows from the filters to an

underground reservoir.

"From the reservoir the water is pumped to

supply Katima and its suburbs, Mafuta, the

army base at Mpacha and Chinchimane-

Linyanti pipeline. Chlorine disinfection again

takes place before the water is pumped to

the consumers," Namwater explains.

NamWater further said the raw-water

entering the Katima Mulilo water treatment

plant is already fairly clean, and the plant

(Katima Mulilo) employs only two treatment

steps filtration and disinfection. Adding of

flocculants and settling of suspended parti-

cles is thus not necessary on this plant.

This process has been disrupted on several

occasions because of the frequent reduction

in water volumes at the Zambezi River and

the resulting water pumping complications.

How effective and suitable is a vertical

multistage in-line centrifugal pump in a

situation where water levels cannot be

regulated and there is a possibility of the

pump pulling in destructive materials from a

water source?

Although both NamWater and Katima Mulilo

Town Council could not respond to queries

on the suitability of this type of pump in the

prevailing situation at the Zambezi River,

various manufacturers attest to the fact that

properly installed, and all parameters

remaining correct (including average water

levels at a water source like a river,) the

pumping solution is one of the best in the

water pump segment.

According to Feeling Pumps (Shanghai), a

maker of vertical multi-stage in line pumps,

but which has no connection with the supply

and installation of the failed water pumps at

Katima Mulilo, this water pumping solution

is preferred by many water supply service

providers across the globe. This is because of

its small volume, lightweight, low noise and

easy maintenance.

Those who have chosen this kind of pump

have been attracted to it by its vertical and

The company said the two water pumps

complement each other but at times, like it

happened during the water shortage period,

both pumping solutions can be faulty

plunging the town and its environs into a

water supply crisis.

NamWater blamed an electrical fault and

failure of the internal parts of the pumps on

their break down. "We have two pumps and

we use one water pump at a time. It wasunfortunate that when we switched to the

other, it also had a problem," NamWater said

in a statement.

NamWater spokesperson Tommy Numbala

said the public water utility was also consid-

ering importing new water pumps as a long

term solution to the perennial breakdown of

the two solutions already installed. However,

by late April 2012, the procurement process

was yet to kick off in earnest.

It is after the tendering process has been

kick-started that it would be possible to know

where the pumps will be imported from and

who will do the installation. NamWater has

in the past relied on its own engineers for the

installation and maintenance of the water

pumps at all its pumping sites.

Back to the climate change and perform-

ance of these two pumps. Michael Erdtelt ,

a technical engineer at Katima Mulilo Town

Council, said the damage caused to the

pumps arose from the falling water levels of

Zambezi River. The drop in the rivers water

level is a common phenomenon in Southern

Africa where ravages of drought have

affected even the largest water bodies in

the region.

The fluctuating water levels at the mighty Zambezi River have lead to low pressure and the subsequent pulling in of material impurities by the pumps which have been blamedfor their malfunctioning.

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compact structure, Feeling said. Its inlet and

outlet flanges are located at the same

central line, small area occupation and

installation.|

Its assembly mechanical seal makes its installa-

tion and maintenance safer and more conven-ient, and guarantees the reliability of the

mechanical seal, the Shangai-based pump

maker said on its website.

Long term ideas

A long-term solution to the water crisis in

Katima Mulilo, which residents say has been

recurring over the past three years, lies in

improving the towns water supply network

in addition to installing a new water pump.

Although there is currently an ongoingprogramme to upgrade the water supply

systems at Katima Mulilo, there have been

proposals for more and bigger water reser-

voirs that can outlast the prolonged drought

periods experienced in the region.

The planned upgrade of water systems in

Katima Mulilo follows completion of feasi-

bility study by Lund Consulting Engineers

(LCE), experts in water, civil and structural

engineering as well as project managers.

LCE said the project study commissioned bythe Department of Water Affairs in the

Ministry of Agriculture, Water Affairs and

Forestry, entailed a physical assessment of

the water supply infrastructure (mostly single

borehole installations) between Katima

Mulilo and Kongola in the Caprivi Region and

the preparation of proposals and cost esti-

mates for an upgraded water supply infra-

structure to this area.

Several water supply options have been

explored including upgraded boreholes to tap

the currently used shallow aquifer, new bore-holes to tap the deep aquifer recently discov-

ered, and the combination of a supply of

piped water from Katima Mulilo (from the

Zambezi River) and from the Kwando River

near Kongola. The options are being explored

in search of a long term solution to water

shortages in the area.

The Namibian government has allocated

$4.2 million for the Katima water supply

upgrading project spread over four years

since 2009. The upgrading and expansion is

likely to create additional water storage

capacities and drawing points to cater for

lean periods when the Zambezi Rivers flow

is low or when the water pumping system

fails.

A number of institutions in Katima Mulilo have

suffered the brunt of the perennial water

pumping disruption over the past two years

with some reporting reduced business and

disruption of operations as the crisis persisted.

Residents have also been forced to draw waterdirectly from the Zambezi River, a practice

which has exposed them to water-borne

diseases like cholera and the frequent crocodile

attacks.

At the height of any water shortage crisis in

Katima Mulilo, food outlets are among the most

affected businesses while most public toilets in

the town were shut for lack of water. Residents

had to walk several kilometers to fetch water

from Zambezi River for cleaning and flushing

toilets.

The other large rivers relied on by Namibia for

water including Orange River in the South as

well as the Okavango Rivers in the North.

However, the residents are not only paying the

price of a malfunctioning water pumping

system, they have also to pay for the cost of

abstracting water from the Zambezi River. This

has been considered one of the most prohibi-

tive factors in expanding water supply to the

nearest local councils including Katima Mulilo.

Local councils, including Katima Mulilo, usemore than 70 million m3 of water out of the

estimated 300 million m3 consumed in

Namibia. Namibia tops sub Saharan African

countries in providing water through municipal

councils. The councils buy the water from

NamWater for distribution to consumers.

The country, which is the fourth-largest exporter

of nonfuel minerals in Africa and the world's

fifth-largest producer of uranium, spends an

average of 3% of its gross domestic product in

the operations of water utilities, the largest

amount in sub Saharan Africa.

Despite the hiccups in water supply in Katima

Mulilo, the UN listed Namibia as one of the

leading sub Saharan countries to have improved

its water supply situation. Last year, the UN did

an evaluation of Namibia's water supply and

commended access levels compared to the

situation at independence in 1990.

"A large part of the population cannot, however,

make use of these resources due to the prohibi-

tively high consumption cost and the long

distance between residences and water points

in rural areas," another report on the country's

water and sanitation said.

www.namwater.com

The Namibia Water Corporation Ltd (NamWater) looks forward to

import centrifugal pumps, similar to this one by Yongjia Haihe Pumps

Factory China, to alleviate water shortages in Katima Mulilo town.

(PHOTOS COURTESY: Ministry of Information and Communication

Technology and Yongjia Haihe Pumps China.)

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UKs largest slurrytank gets customized

Food & drink

Simplicity and reliability were among

the key requirements for the custom

control system developed and

supplied by Ralspeed for use on the U.K.s

largest slurry tank. The tank which, was

designed, manufactured and installed by

slurry handling specialist Storth, is 40 m in

diameter, almost 6 m high and is capable

of holding more than 7 million litres ofslurry.

Slurry which is essentially farm animal

excrement mixed with water is stored in

the tank at certain times of year as an envi-

ronmental protection measure, and then

used on farmland at other times of year,

where it acts as a valuable natural fertiliser

that is rich in nitrates. Pumps are used to

control the flow of slurry into and out of the

tank, which is also equipped with motorised

Ralspeed was recently charged with designing a simple and reliable control system for use on

the U.K.s largest slurry tank. The tank which, was designed, manufactured and installed by slurry

handling specialist Storth, is 40 m in diameter, almost 6 m high and is capable of holding more

than 7 million litres of slurry. To meet these special requirements, Ralspeed designed and built afully customised control panel.

The slurry tank is almost 6 metres high with a diameter of 40 metres The UK's largest slurry tank holds 7 million litres of slurry

agitators to stir the slurry periodically during

storage.

To provide the control system for the pump

and agitator motors, Storth approached

Ralspeed. For the new slurry tank, the design

of the control system had to take into

account the limited capacity of the mains

supply at the tank installation site. Thismeant arrangements had to be made to

limit the inrush current when starting the

pumps and agitators. It also had to ensure

that no more than two agitators could run

at the same time, and that the agitators

could not run when the pumps are

running.

Storth also wanted to be sure that the

agitators had approximately equal usage,

in order to equalise wear and tear, thereby

maximising their operating lives. Further

requirements were that the control system

should be as simple as possible to facilitate

maintenance, and that the user controls

should be straightforward and intuitive.

To meet these spe cial req uir eme nts,

Ralspeed designed and built a fully custom-

ised control panel. The company used 18.5kW Torq-master soft starters from its own

range to control the motors. These units

provide excellent control over the motor

starting current, ensuring that the capacity

of the supply is never exceeded, and also

ensure that the agitators and pumps start

and stop smoothly.

Because no more than two of the motors on

the tank could ever be running simultane-

ously, the Ralspeed engineers realised that

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Local isolation facilities for the agitatorsThe main control panel with duty selector switches

substantial cost savings could be achieved

by using only two soft starters, and

connecting them, via main contactors, to

the appropriate motors as needed to meet

operational requirements.

Ralspeed was able to provide a single

selector switch to configure the operation

of the system. This switch allows the user to

rotate the duty of the agitators, and also to

select operation of the pumps instead of the

agitators when necessary. With careful

design, it proved possible to implement this

straightforward and effective form of control

without needing to use a PLC or smart relay,

thereby satisfying the end users request for

simplicity.

Throughout the project, Ralspeed was

helpful and responsive, said John Hird of

Storth. Even when we had a very late

change in requirements after the panel had

been delivered and installed, the company

came to the site and made the necessary

modifications quickly and effi ciently. And,

now that the control panel is in regular use,

the end user is very satisfied both with its

performance and its reliability.

www.ralspeed.com

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New SAF range isproven sh friendly

Water & wastewater

Bedford Pumps has been awarded an

excellent rating for its new SAF range

of fish-friendly pumps. The creden-

tial was granted by independent research

In 2007, legislation was brought into effect to tackle the rapid decline in global populations

of the European eel. Trials show that Bedford Pumps new SAF range of pumps are fish and eel

friendly with no direct mortality observed from exposure to the pump. Bedford Pumps has just

installed its first fish friendly pump at a new pumping station in Kempsey, the first station in theUK to comply fully with the new EU regulations.

Fish completely unscathed after the test.

consultants, VisAdvies BV (specialists in

the field of water management, focusing

on the environment of fish in all types of

inland waterways), following extensive

and stringent trials. The results prove

that Bedford Pumps new SAF range of

pumps are fish and eel friendly with no

direct mortality observed from exposure

to the pump.

EU legislation was brought into effect in

2007 to tackle the rapid decline in global

populations of the European eel. Eels are amigratory species and in order to breed

must return to their spawning grounds of

the Sargasso Sea - a distance of approxi-

mately 6500 km. Obstructions which

impede their journey, such as pumping

stations, may be a contributing factor in

their fall in numbers.

The EU legis lation EU Eel Regulations

proclaims that each member state shall

implement appropriate measures to

reduce eel mortality. In 2009, UK legisla-

tion empowered the Environment Agency

to undertake activity to satisfy EU regula-

tions. To this effect the Environment

Agency can serve notice where the safe

passage of eels is impeded and enforce a

resolution to preserve the life of eels. This

legislation is specific to the eel population

but it is generally accepted by all

concerned that protecting fish stocks is an

added bonus of utilising this type of

pump.

Eel and fish friendly pumping solutions will

shortly become a requirement at the

majority of pumping station and water

abstraction points where eel populations

have been identified.

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Bedford Pumps Axial Flow fish friendly

pump underwent rigorous tests in a dry

dock in Hellevoetsluis, Holland. VisAdvies

BV performed the evaluation by means of

forced exposure of the fish to the pump.

Three representative groups of fish were

used, in two size classes, 0-15cm and 16cm

plus. The pump was tested at a duty of

1300 l/s at 1.5m head, running at speeds

of 330, 425 and 518rpm consecutively.

The pump achieved 100% survival of eels

passing through the pump. The most

severe damage that occurred was some

scale loss on the coarse fish. This was not

caused by the pump impeller, but by the

impact of the fish hitting the water after

passing through the pump. In an actual

land drainage application, the discharge

point would be below the water level.

Bedford Pumps SAF Range of fish friendly

pumps cover from 400 to 7,000 l/s at 2 to 6 m

head and are ideally suited for land drainage,

flood defence and fish farm applications.

Larger capacity pumps can also be designed

to meet specific requirements.

In addition to protecting the fish, the new

design demonstrates a significant

improvement in hydraulic efficiency

resulting in an 8% reduction in power

absorbed. Consequently the new range will

satisfy objectives of eel protection and

carbon reduction.

Bedford Pumps have just installed its first fish

friendly pump at a new pumping station in

Kempsey for the Environment Agency. The

pumps will discharge water from Hatfield

Brook, a waterway which has caused flooding

to the village 23 times in the past 30 years.

Hatfield Brook is home to an eel population,

so the new pumping station will be the first

station in the UK to comply fully with the

new EU regulations.

www.bedfordpumps.co.ukBedford Pumps fish-friendly pump undergoing trial.

Fish-friendly pump on site at Kempsey.

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The pump system may not be the

largest single investment in the

wastewater installation, but over the

time from cradle to grave it is the key

element to ensure long-term cost effec-

tiveness of the wastewater installation.

of these costs are rather insignificant parts

of the lifecycle costs of a wastewater

installation; only three of these factors

have significance. This article focuses only

on the pump system, since this will

normally have the highest impact on the

total cradle-to-grave, lifetime cost of the

wastewater installation.

In the pump system, the three main

issues that need to be considered are,

depending on the pump brand selected

and in no particular order:

Investment

Energy costs

Maintenance costs

Investment

The initial procurement cost is often seen

by municipalities and contractors as the

parameter to ensure low cost. Meeting

investment budgets means keeping in mind

that the cost of operation, maintenance and

disposal could be five to 20 times higher

than the initial investment. This is why

municipalities and contractors increasingly

consider the requirements for perform-

ance, reliability and energy consumption

when purchasing a pump system.

Choosing the right pump is a key issue

which needs to be handled carefully

not by looking only at the initial procure-

ment costs but by looking at the total

Total lifetime costs normally include costs

such as planning, design, purchasing,

installation, commissioning, energy,

maintenance and operation, downtime

costs, environmental costs and costs for

disposal at the end of the lifetime. Most

Lifecycle cost calculations in wastewater installations can realise

huge savings over time for the wastewater company. The lifecycle

costs summarise the total cost of a wastewater installation andin this regard the pump system plays a major role. This article

looks at the many variables that make selection a success.

Lifecycle costsaving benets

Water & wastewater

0262 1762/12 2012 Elsevier Ltd. All rights reserved

Figure 1. Unless lifecycle costing practices are implemented at the beginning of a project, it could be

money down the drain.

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Leakage flow Q

Conventional pump with metal-to-metaldischarge connection

t D

lifecycle cost. A service maintenance engi-

neer and designer should be involved in

the decision of the pump purchase to

ensure pump system reliability.

Energy costs

Decision makers might think that the

energy cost of the pump is an easy thing

to work out. Simply take a pump cata-

logue, find the correct pump for the

wastewater installation, look at the curve

and determine the energy consumption

in the specified duty point. Then multiply

with the estimated running hours, price

per kW and the expected lifetime of the

pump the total energy cost of the pump

over the lifetime.

However, many things must be consid-ered when determining the energy cost

of a pump. For example:

a. Wear

b. Variable load

c. Installation

d. Clogging

WearA wastewater pump has probably one of

the toughest pump jobs in the world.

These pumps are pumping media

containing sand, stones, rags, robes, beer

cans, diapers, and much more. The media

content leads to wear and costly break-

down of the pump. The wear of the

pump leads to lower effi ciency. I t has

been demonstrated that wear can easily

lower the effi ciency with 3-5% every year

if nothing is done to maintain the pump.

Most pump brands make it possible to

restore some of the effi ciency loss by

different means. Some have a replaceablewear ring; others have built in trimming,

where restoration of the effi ciency is done

by adjustment of the impeller clearance

using outside bolts. Even though some of

the effi ciency can be restored, full restora-

tion of the effi ciency is not possible, since

the wear affects non-replaceable parts of

the pump.

Considering this, the design of the pump

impeller is a key issue, since a simple

design with large free passage, no inserts

and moving parts will wear less than theopposite, thus ensuring a high effi ciency

over the pump lifetime.

Variable load

The second issue regarding energy

consumption is the duty point at which

the pump is operating. It is seldom

constant and varies depending on the

time of the day, year and during the

pump lifetime. Choosing a pump with a

high effi ciency in one point might make

good business sense at the time ofselection, but might be totally wrong

later on. Always ask for flat effi ciency

curves this ensures high effi ciency

over a wide duty range and also if the

pump is running with variable speed drive.

If the pump is running with variable

speed, a pump with a duty point

relatively to the right of the curve shouldbe selected so that when adjusting the

speed downwards, the pumps duty point

moves to a part of the curve with higher

effi ciency.

The energy saved when operating with a

variable speed drive is also very

dependant on the system curve. If the

static head is small compared to the fric-

tion losses, the energy-saving potential is

relatively small; whereas in a system with

large friction losses compared to the

static head, the savings potential is quitelarge.

A variable speed drive can also heavily

influence the clogging frequency of the

pump, as the water velocity might fall

below the self-cleaning velocities in the

system, as discussed below.

Installation

The third issue of energy cost is the

installation. It is important to avoid leak-

ages in the system and it is recom-

mended to have seals or gaskets at all

joints. If the connection between the

pump and the installation equipment is

metal to metal, leakages can occur, espe-

cially when the system gets older. The

more leakages there are, the greater the

loss of energy.

A too small diameter in the rising main

leads to increased head requirements and

increased energy consumption, since the

pipe friction losses of the installation is

amplified in small pipes. A small rising

main also increases the leakage flow.

To avoid high losses, the water velocity

through the pipes should be kept low.

Figure 2. Maintenance and disposal could be five to 20 times higher

than the initial investment.

Figure 3. Conventional pump with metal-to-metal discharge connection.

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s

ss

Semi-open Closed, radial clearance Closes, axial clearance

will be able to determine the cost of the

repair, taking into account:

maintenance to be performed on thepump

time taken to do the activity

number of staff involved

spare parts cost for the activity

Conclusion

As can be seen, LCC can be an excellent

tool for selecting the optimum pump,

ensuring minimum cost of pump opera-tion over the pumps lifetime. But many

things need to be taken into account to

make the selection a success, such as:

Ensure that all aspects of the pump

evaluation are done before the pump

purchase and that pumps with high

effi ciency, non-clogging capabilities and

large free passage impeller are

preferred.

The selected pump should have flat

effi ciency curves, a seal between the

pump and installation equipment and

be extremely service friendly with built-

in sensors to minimise unplanned

expensive service visits.

The pump system should be chosen

with the full system perspective in

mind.

Maintenance costs

Maintenance costs are often diffi cult to

estimate. Historical data for existing

pumps might help determine this.Normally, the maintenance cost will be

divided in two:

a. Planned maintenance costs

b. Unplanned maintenance costs, for

example with the sump and grates at

the intake.

Planned maintenance costs

Obviously, the planned maintenance costs

will vary depending on many differentfactors. For example:

value of pump

cost of maintenance on pump

operational experience

consequence of pump failure

probability of pump failure

system design

If you have small inexpensive pumps or

pumps which are diffi cult to maintain due

to their placement, planned maintenance

activities might be kept to a minimum,

whereas large expensive, critical pumps

might get the full range of planned and

predictive maintenance.

Unplanned maintenance

An experienced operator will normally

know or be able to estimate the

unplanned maintenance cost as well. He

will know what typically breaks down on

the particularly pump brand and knowing

the service friendliness of the pump he

The exact maximum velocity depends on

the length and roughness of the pipes,

but as a rule of thumb the velocity

should not exceed 3 m/sec. It is howeveralso crucial to avoid velocities that are too

low, as this will result in sedimentation

and deposits in the pipes, increasing

friction losses and energy consumption. A

low velocity will also contribute to the

maintenance costs, as manual pipe

cleaning might become necessary.

For horizontal rising mains, a minimum of

0.7 m/s is recommended, whereas a

vertical rising main should be dimen-

sioned for a velocity of no less than 1 m/s.

This is especially important in pumpsystems with variable operation. The

water velocity is of course also heavily

influenced by the use of variable speed

drives and care should be taken that the

pump is not at all times running at a low

speed, as the self-cleaning velocity in the

pipes might otherwise not be achieved.

Clogging

Clogging in the installation is not

connected directly to the energy cost.

However the impeller design is and the

improved non-clogging capability of an

impeller has normally been achieved by

using semi-open impeller designs. By

using a semi-open impeller, you might

gain better non-clogging capabilities, but

at the expense of effi ciency loss.

New developments with closed channel

impellers now combine the best of both

worlds by having non-clogging, high

effi ciency impellers with large free

passage, no inserts and no moving parts.

So you get non clogging and high

effi ciency without compromising either of

them, especially when taking into account

the ever-changing dry matter content of

modern wastewater.

ContactLars Bo Andersen,

Global Product Manager

Poul Due Jensens Vej 7

DK-8850 Bjerringbro, Denmark

www.grundfos.com

Figure 4. Wear of impeller clearances with different impeller designs.

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The oil and gas industry in Latin

America is on an upward but uncer-

tain growth trend. Earlier this year,

experts at Fitch Ratings stated that Latin

American oil and gas companies have

strong cash holdings and are helped by

higher oil prices. [Oil and gas] companies

are positioned favorably to withstand diffi -cult market conditions over the next 12

months, it said. However, Fitch analysts

added, Rising fixed costs including escala-

tion in labor and energy costs will cause a

rise in production expenses.

Reports like these highlight the pressure

in natural-resource industries to lower

production costs in order to achieve

growth potential. In oil and gas refining,

along with mining operations, managers

are faced with a twofold challenge: Trim

production costs while improving the

control of the process. Advancements in

full speed, with flows adjusted by manual

valve throttling that lowers pump and

process reliability.

Recent advances in pump hardware and

accompanying software commonly

known as smart pumping help plants

across many industries to achieve thetrifecta of lower energy costs, higher

equipment reliability and improved

process effi ciency. Variable-frequency

drives, which adjust the pumps motor

speed to meet the flow needs of the

process, are the centerpiece of most

smart pumping solutions.

However, the oil and gas industry has not

been as quick to embrace VFDs as some

other industries. This isnt because energy

effi ciency is less important to energy

producers. More likely, its because early

VFD designs did not work well in typical

oil and gas applications. Most refineries

are sprawling, outdoor plants in remote

locations where temperatures can be

extreme, and access to specialized equip-

ment and personnel can be costly if

things go wrong. In addition, the need for

smarter pumping was less evident,

because of the general effi ciency and reli-

ability benefits of API standards.

Changing perceptionsRecently, however, we have seen

increased adoption of VFD technology in

oil refining and gas processing operations

worldwide. At the Volpak fuel terminal in

traditional as well as digital pumping

technologies can help, by improving

energy effi ciency and equipment

reliability at the same time.

Its important to understand that these

goals are closely linked, because any

excess energy in a pump converts to heator vibration that reduces reliability. Thats

a simple fact of physics, but the direct

relationship between energy effi ciency

and reliability of a pump with the

associated potential for double cost

savings is not well understood.

Reducing energy waste in pumps can also

boost process control, which is especially

valuable for the pump-intensive processes

that refine natural resources into usable

products.

Smarter pumping at reneries

To their credit, companies in the oil and

gas industry were early adopters of auto-

mated process control systems that

monitor production processes and opti-

mize effi ciency. In addition, the evolution

of API standards has helped to ensure

that process pumps are properly sized

and designed. These and other trends

have helped oil and gas producers to

continually improve production, produc-

tivity and profitability.

At most refining operations, however,

hundreds or thousands of pumps work

outside the automated process control

system operating around the clock at

Recent advances in pump hardware and accompanying

software help plants across many industries to achieve the

'trifecta' of lower energy costs, higher equipment reliability andimproved process efficiency. Variable-frequency drives are the

centerpiece of most smart pumping solutions.

Smarter systems,tougher slurries

Oil & gas


ITT Goulds Pumps 3600 API pumps propel seawater 145 km (90 miles)

from the Pacific Ocean to a copper mine in Chile.

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stuffi ng box and gland for easier packing

maintenance. Operators can choose their

packing arrangement with dedicated seal

water ports, and the stuffi ng box is

designed to accommodate most mechan-

ical seals by simply removing the split

stuffi ng box.

Onboard condition monitoring. To help

identify problems, XHD pumps are

outfitted with i-ALERT monitors that

measure vibration and temperature a

standard feature on process pumps from

ITT Goulds Pumps. When an i ALERT

monitor detects that pre-set limits have

ContactMiguel Otarola, Regional Director,ITT Industrial Process in Latin America

Buddy Morris, Global Product ManagerITT Goulds Pumpswww.gouldspumps.com

PumpSmart is ITT's award winning intelligent

flow system that works with any pump.

been exceeded, it signals users with a

blinking red LED. The light is easy to spot,

especially in mining applications where

direct access to pumps can be a challenge.

It allows the pump operator to make

changes to the process or the pump

before a catastrophic failure occurs.

Heavy duty bearing cartridge. Mounted

on fully protected machined rails that

provide positive alignment and are easy to

re-establish fit should wear occur, unlike

saddle mounted bearing cartridges. Also,

the wet end cartridge design enables the

bearing cartridge to be removed and

serviced without disturbing the suction,

discharge piping or wet end of the pump.

Large-diameter shaft. The shaft on the

XHD pump is manufactured for lowdeflection and longer seal life. Pump wear

also is improved through heavy-duty

bearings, standard oil lubrication (a grease

option is available) and Inpro bearing

isolators.

Dual impeller adjustment. A patented

dual adjustment on the power end

provides easy access for operators who

perform impeller corrections. As operators

see a drop in effi ciency, they can adjust

the impeller and/or seal ring, or replace

the parts.

In the same way that improved extraction

and crushing methods have boosted

mine output over the years, these

advancements in slurry pumping can

help mines to improve productivity at

costs that can be quickly recovered.

Conclusion

Demand for natural resources will

continue to grow, almost indefinitely, as

developing economies advance and the

worlds population increases. But that

does not make life easy for the managers

in charge of mining operations or oil andgas production facilities. In the global

economy, managers in every industry face

intense pressure to lower production

costs while improving productivity.

Because the basic look of pump exteriors

hasnt changed much over the years, its

easy to overlook the technology advance-

ments in pumps that can help to achieve

these goals. Pumps are especially critical to

the industries that process natural resources,

and therefore can play an especially impor-

tant role in controlling costs. Smart pumpingsolutions, which improve the operating effi -

ciency of a specific piece of equipment, can

deliver a trifecta benefit to the operation as

a whole lower energy costs, higher relia-

bility and improved process effi ciency. In

mining operations, advancements in the

design of slurry pumps can also improve

reliability and reduce downtime.

Wise investments in these technologies

can deliver improved productivity and

cost savings that go directly to the

bottom line.

This ITT Goulds Pumps model 3600 (API BB3) is shown with

a gas turbine at an oil & gas separation plant in Australia.

The new Goulds XHD Heavy Duty Slurry Pump enables customers in mining and related industries to move slurries

with improved reliability and at lower operating cost.

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When handling potentially

dangerous chemicals, one must

take extra care. Keeping up with

global demand can sometimes prove to

be a challenge. This means identifying

and incorporating a pumping technology

that not only is compatible with the

myriad types of chemicals, dangerous ornot, that are being manufactured and

used at one time, but also one that can

meet the unwavering demands of

product flow and volumetric consistency.

Positive displacement peristaltic (hose)

pumps can rise to the challenges inherent

in the manufacture, transfer, transport and

containment of many of the worlds

unique chemical configurations.

The challenge

The design and operational characteristics

of peristaltic (hose) pump technology

hose at a constant rate of displacement.

The hose restitution after the squeeze

produces an almost full vacuum that

draws the product into the hose from

the intake piping.

The pump casing is lubricated to cool

the pump and lengthen the service lifeof the shoes and hose. Since the product

only contacts the hose and not the

internal pump components, this

pumping technology is very suitable for

abrasive and corrosive applications.

This pump style also maintains excellent

volumetric consistency, making it ideal for

the strict dosing applications that can be

found in chemical processing. The pumps

seal-free design makes it dry-run,

self-priming and low-slip capable, and

eliminates any potential leak or

contamination points while providing

make it a wise choice in a wide range of

chemical-handling applications from

moving viscous and/or abrasive slurries to

the transfer of water-thin, non-lubricating

fluids and shear-sensitive materials. These

characteristics make peristaltic (hose)

pumps ideal for the full array of diverse

operations within the chemical-processingindustry.

Peristaltic (hose) pumps satisfy the

requirements of such a wide range of

chemical applications because their

operation is based on the alternating

contraction and relaxation of the hose,

forcing the contents to move through

the pump and into the discharge piping.

A smooth-wall, flexible hose is fitted in

the pump casing and is squeezed

between shoes on the rotor and the

inside of the pump casing. This rotating

action moves the product through the

Dangerous chemicals, which are classified as being highly

corrosive, toxic or potentially explosive, require cautious and vigilant

handling. The sheer volume of chemicals that need to be produced

in order to meet global demand also requires a production process

that can reliably and consistently meet production quotas.

Peristalics provetheir compatability

Chemical handling


The sheer volume of chemicals that need to be produced to satisfy global demand in many industries requires the use of reliable, effi cient and safe pumping technology, such as

that offered by Abaque peristaltic (hose) pumps (inset).

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suction lift. Finally, peristaltic (hose) pumps

are easy to operate and easy to maintain.

The pumps reversible operation also allowsfor pumping in both directions.

However, while peristaltic (hose) pumps

can be a workhorse in chemical-handling,

concerns regarding the pump hoses

chemical compatibility are ever-present.

For example, these are just some of the

chemicals that a peristaltic (hose) pump

may encounter during its operational life:

Sodium hydroxide

Sodium hypochlorite

Cyanide solutions

Calcium hydroxideSulfuric acid

Catalytic agents

Plating solutions

Solvents

Resins

In order to successfully handle this

gamut of fluids, the pumps hose

which, because of its seal-less design, is

the only component to actually come in

contact with the pumped medium

needs to achieve the highest level of

chemical compatibility, while also beingable to reliably deliver the millions of

pumping cycles that are required during

its lifetime.

Another consideration when selecting a

hose material is its fatigue resistance.

This trait defines how resistant to failure

the hose material is as it runs through its

millions of pumping cycles.

A hose material that is susceptible to

developing cracks and holes relatively

early in its operational life is not as desir-able as a material that can reliably

handle the demands of the repeated

contraction and relaxation of the hose.

The reinforcement construct ion of the

Abaque hose and its use of rubber

compositions that have been specially

designed for the stresses within the peri-

staltic hose allow for the optimum life

cycle and performance.

The solution

While peristaltic (hose) pumps can be a reli-able component in the optimization of

chemical manufacturing and handling oper-

ations, one specific pump brand has risen

above the competition to be a top choice

among chemical processors Abaque series

peristaltic (hose) pumps from Dover Corpo-

rations Pump Solutions Group (PSG).

Abaque series pumps feature a seal-free

design that eliminates leaks and product

contamination, which enables them to

handle everything from abrasive andaggressive fluids to shear-sensitive and

viscous materials. The pumps, which can

run in either forward or reverse, are self-

priming and offer suction-lift capabilities

to 9 m (25.5 ft), as well as the ability to

run dry continuously without adversely

affecting the pumps performance.The design of peristaltic (hose) pumps allows them tohandle a wide array of product-transfer applications

within the production of chemical compounds.

Maintaining strict dosing rates in chemical production

is a constant concern and the operation of Abaque

peristaltic (hose) pumps delivers the volumetric

consistency that is required.

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Conclusion

The chemical universe is one of the most

diverse in the global economy and is

also one of the most dynamic. This diver-sity means that the pumps used in their

manufacture, transport, handling and

containment must be nimble and versa-

tile enough to cope with fluids with

many different levels of viscosity, temper-

ature, corrosiveness, toxicity and abra-

siveness, to name a few.

These varying product characteristics

must also be successfully handled while

adhering to strict production quotas.

For more than 80 years, peristaltic

(hose) pump technology has been aleading choice for chemical producers

and processors who know the value

of highly reliable, environmentally

friendly, maintenance-free pump

operation.

Abaque pumps are available in 10

different sizes and 19 total models with

flow rates ranging from 1.7 to 1,249 L/min

(0.46 to 330 gpm). They have beendesigned to handle products with

water-like viscosities to those as high as

70,000 cSt (352,000 SSU), solid particle

sizes from 1.5 mm to 18 mm (0.06 ins to

0.71 inches) and soft particle sizes from

1.5 mm to 31 mm (0.06 ins to 1.22 ins).

All Abaque pumps can handle product

temperatures ranging from 0C to 80C

(32F to 176F) with models featuring an

EPDM hose capable of handling

maximum temperatures to 90C (194F).

Optional equipment includes hose-failure

detectors, vacuum kits and non-metallic

inserts.

Ductile-iron and steel construction lets

the pump produce discharge pressures

as high as 16 bar (232 psi).

The Abaque pumps hoses are available in

three materials of construction, all of

which have been chosen because of their

high levels of chemical compatibility and

fatigue resistance:

Natural rubber highly resilient with

excellent abrasion resistance and

strength; ideal for use with diluted

acids and alcohols

EPDM high chemical resistance, espe-

cially when handling concentrated

acids, and alcohols.

Buna-N highly wear resistant to oily

products

The simple design of the Abaque series peristaltic (hose) pumps features a seal-free design that eliminates leaks and product contamination, which enables them to handle the

chemical industrys toughest pumping applications.

ContactJohannes Meijer

Global Product Manager Peristaltic Pumps for PSG

Tel: +49 151 6283 5979


Website: www.psgdover.com

"Pumps used in chemical manufacture,transport, handling and containment mustbe nimble and versatile enough to cope

with fluids with different levels of viscosity,temperature, corrosiveness, and more."

The Abaque pumps hose restitution after the squeeze produces an almost full vacuum that draws the product into the hose from the intake piping.

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process, the suction stroke takes place

simultaneously in the other chamber.

This results in effi cient, reliable, cost-

effective, repeatable operation when

handling any number of abrasive liquids

or chemicals.

John Roach, senior mechanical engineer

for Trebor Pumps, sites an example of a

problem he recently faced when pumps

were having shorter life spans on the

diaphragms because of the chemicals that

were being used in the line and how they

were being used.

We have our pumps all over the world

in different fabs, but in one fab we were

seeing another pump having issues

within an ammonia and TMAH line,

Roach said. They had high pressure andhigher temperatures. We developed a

diffuser head technology on our Maxim

50 pump, which is our workhorse pump.

This took the air pressure in the head

and dissipated the air delivery over the

entire diaphragm rather than single

delivery.

With AODD pumps diaphragm life is

vitally important. This small change

allowed the end-user to get longer

diaphragm life in aggressive chemical

situations.

Another issue manufacturers are

constantly facing is that everybody has a

different recipe for their process. One

might use ammonia and TMAH,

another might use sulfuric with ozone

infused.

It is very different across the board and

the aggressiveness of the chemicals isbecoming more important in our

development of products, Morgan said.

Over the years, Trebor has created a very

durable pump that can withstand any

chemical that is used.

Sodium hypochlorite

Sodium hypochlorite is known as

liquid bleach, and it creates a challenge

for the people charged with producing,

transporting and metering the chemical

in a wide range of industrial applications.

Finished sodium hypochlorite is a clear,

slightly yellowish solution with a charac-

teristic odor. In its commonly used

liquid-bleach form, it has 5% sodium

hypochlorite with a pH of around 11,

which makes it irritating to the skin.

However, in more concentrated doses,

such as 10%-15% sodium hypochlorite,

its pH level rises to 13, which means it

will burn and be corrosive to many

substances.

Tom ODonnell, Neptune Chemical Pump

Co.s product manager with Pump Solu-

tions Group, explains that the powerful

disinfection and oxidation properties of

sodium hypochlorite allow it to be used

in such operations as bleaching in the

paper and textile industries, disinfection of

drinking water, pre

Documents

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