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THE INTERNATIONAL MAGAZINE FOR PUMP USERS Number 586 December 2015

Mining:
Reliability and availability in
high altitude environments

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• HVAC
• Oil & gas
• Construction

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Editorial 1

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16 Company focus:
Desmi

8 Product news

30 Water & wastewater

Contents Company focus


Desmi lifts green ship business case 16
Maritime pumping solution manufacturer DESMI’s energy optimisation approach
• Business news 4 generates positive cash flow for ship owners struggling to comply with new
regulations.

• Product news 8
Oil & gas
• Company focus: Desmi 16 Safe conveyance of sour crude oil
To convert sour crude oil into valuable and refined fuel the impurities need to be
19

• Applications 19 removed. However, sour crude oil is toxic, hazardous and extremely corrosive which
makes its transportation to the preparation system challenging.

• Features 32 Water & wastewater


• Frequently Asked Questions 42 Identifying and documenting hidden utilities 20
Finding utilities buried in the ground so they can be avoided is normally 'job one'
before any construction project begins. In this article we look at how the use of
• Product Finder 44 ground penetrating radar is helping to save time and money in construction.

• Diary dates 48 HVAC


Cutting costs with responsible waste management 24
When producing reliable, longest-lasting products, you come to expect the
World Pumps December 2015 edition. Cover image equipment used in your manufacturing processes will have the same reliability.
courtesy of Ammit Jack/Shutterstock. In this article we look at how the new Wilden air distribution system is helping to
cut costs.

www.worldpumps.com
Contents 3

19 Oil & gas 28 Construction

24 HVAC 32 Mining

Construction Mining
Quality synthetic stone slabs with vacuum technology 28 Axial thrust in vertical turbines 32
Diresco specialises in synthetic stone slabs and tiles. Quartz granules are used to Every year thousands of old worn pumps are thrown away as scrap material
create materials deceptively similar in appearance to stone surfaces in a number of becoming a huge headache for mining companies around the world. Petar Ostojic
finishes. Busch vacuum technology to produce slabs completely free of gas from Neptuno Pumps shows how some companies are transforming this into a
inclusions and cavities. Vacuum is supplied to the material presses of both global opportunity by replacing the old linear economy – produce, use and throw
production lines, ensuring top quality appearance and optimal structural integrity. away – with circular economy.

Water & wastewater General processing


Making waves in the correct way 30 Electric actuation gearbox progress 36
Today it is no longer necessary to go to the beach to experience the thrill of surfing Ongoing advances in actuator gearboxes are improving load capacities and
with sheet wave surfing attractions in theme parks. Flowrider simulations from increasing lifetime. Here, AUMA explores these developments, from new joining
Aquatic Development Group allows people of all ages and sills to surf the boar technologies to significant advances in the lubricant sector – as well as efficiencies
every day. However, to make a successful wave needs a successful pump – such as in self-locking worm gearboxes. AUMA also looks at safety requirements and
the KSB Amacan P Series. considerations to make when combining actuators with valve gearboxes.

Dates to remember
• 8 – 10 December 2015 • 25 – 27 January 2016
Las Vegas, Nevada USA, POWER-GEN, www.power-gen.com Florida, USA, 2016 AHR EXPO, www.ahrexpo.com

• 15 – 17 December 2015 • 26 – 28 January 2016


Dubai, UAE, PVPC Expo Middle East 2015, www.pvpcexpo.ae Abu Dhabi, 10th SPE/IADC, www.spe.org/events/medt/2015

www.worldpumps.com
4 Business news
WORLD PUMPS December 2015

Roper Technologies divests ITT brands partner to


Abel Pumps in €95mn deal serve Mexican market
Roper Technologies Inc has sold Equipment Group and Batesville. ITT Corp’s C’treat and Bombas nation systems, while Goulds
Abel Pumps LP to diversified indus- Process Equipment businesses Goulds de Mexico (BGM) brands Pumps’ BGM manufacturing plant
trial company Hillenbrand Inc for design, develop, manufacture and have formed an alliance to near Mexico City supplies API
€95 million in cash. service engineered industrial equip- deliver large-scale seawater, pumping systems to markets in
ment, while Batesville operates in potable water and high-purity Latin America.
Based in Buchen, Germany, Abel the North American death care water solutions to the offshore
specialises in diaphragm and piston industry. energy industry in Mexico. “This strategic ITT alliance
pumps primarily for the power demonstrates our growing
generation, wastewater treatment, Abel will become part of Hillen- Under the alliance, BGM is now commitment to supporting the
mining, general industry, oil and brand’s Process Equipment Group. an authorised sales representa- world oil and gas market and the
gas and marine markets. The tive of C’treat products and offshore industry, in particular,”
company was founded in 1947 “This acquisition advances Hillen- services with exclusive territory said Aris Chicles, president of
and was acquired by Roper in 2000. brand’s growth strategy and rights in the offshore market in ITT’s Industrial Process business.
provides our company with entry Mexico. “The Mexican offshore market is
For the trailing 12-month period into the flow control market,” said growing rapidly and this alliance
ended 31 July 2015, Abel had Joe Raver, Hillenbrand’s president BGM and C’treat also plan to will allow us to enhance our
revenue of €30 million and earn- and CEO. “We look forward to open an office in Cuidad del presence and bring our
ings before interest, taxes, deprecia- working with Abel’s team to Carmen in Campeche, Mexico to customers additional support and
tion and amortization of around leverage our combined strengths provide customer project sales services through a one-stop solu-
€8 million. and continue to grow the business.” support, aftermarket parts and tion for offshore platforms.”
offshore-qualified service.
Hillenbrand, which is listed on the www.abelpumps.com www.itt.com
New York Stock Exchange, has two www.ropertech.com C’treat specialises in offshore www.ctreat.com
business segments: the Process www.hillenbrand.com reverse osmosis seawater desali- www.gouldspumps.com

Energy Recovery signs VorTeq licencing deal with


Schlumberger
Energy Recovery Inc has entered royalties for the duration of the
into a 15-year agreement with licence agreement.
oilfield services company Schlum-
berger Technology Corp VorTeq is a hydraulic fracturing
providing exclusive rights to its manifold built to isolate hydraulic
VorTeq hydraulic pumping fracturing pumps from abrasive
system. proppants that cause pump failure.

Under the terms of the agree- Energy Recovery’s president and


ment, Schlumberger will pay a CEO Joel Gay said: “We believe this
US$75 million exclusivity fee technology offers Schlumberger
immediately. the immediate benefit of reducing
wear and tear on its pumps, as
Schlumberger will also make two well as reducing downtime. In the
separate US$25 million milestone medium-term, we believe it
payments subject to the provides Schlumberger additional
company satisfying certain key savings associated with eliminating
performance indicators expected redundant equipment onsite.” Energy Recovery’s VorTeq system is a hydraulic fracturing manifold built to
to occur in 2016. The agreement re-route abrasive proppants that cause pump failure. Image courtesy of
also includes continuing annual www.energyrecovery.com Energy Recovery Inc.

For more business news,


read Pump Industry Analyst every month.
Download a sample copy at www.pumpindustryanalyst.com

www.worldpumps.com
6 Business news
WORLD PUMPS December 2015

GIW Industries invests in new Grovetown foundry


Centrifugal slurry pump manufac- bution centre, additional heat-
turer GIW Industries Inc has offi- treat and casting cleaning
cially opened its new foundry in facilities, CNC machines and an
Grovetown, Georgia, USA. assembly centre. These new facili-
ties will more than triple GIW’s
The new foundry, which features current manufacturing capability.
72-foot ceilings and is about the
size of an American football The expansion is the biggest
field, will help GIW to better project ever undertaken by GIW,
handle the sizeable castings a subsidiary of KSB.
needed by its customers. It will
also allow GIW to keep up with Work on the new distribution
current market demand and to centre is currently underway and
quickly adapt to support future is set to be completed in mid
growth. 2016. The building will initially be
59 000 sq ft, but is designed to
The foundry is part of a major allow for future expansion.
expansion of the Grovetown
facility that includes a new distri- www.giwindustries.com GIW's new foundry in Grovetown, Georgia, USA.

SPX spins off Flow business Amarinth pumps selected


SPX Corp has completed the
spin-off of SPX Flow Inc.
for Middle East project
beverage, power and energy and
industrial end markets. Key pump
brands include APV, Bran & Luebbe, Amarinth has received a US$1.5 The Amarinth order was facilitated
Both companies are now listed on ClydeUnion, Gerstenberg million order from Petrofac for 12 through Arabian Industries, an
the New York Stock Exchange, Schroeder, Hytec, Johnson Pump, API 610 OH2 super duplex pumps EPC based in Oman.
with SPX Flow Inc trading under Plenty, Power Team, SPX and with Plan 53B seal support
the symbol FLOW and SPX Corp Waukesha Cherry-Burrell. systems for a produced water The super duplex pumps,
using the ticker SPXC. treatment plant that will serve including bespoke baseplates,
SPX Corp, which is also based in the increased capacity of the will be supplied on a tight 25
Based in Charlotte, North Carolina, Charlotte, is now focused on ZADCO Upper Zakum oilfield off week delivery. Amarinth will
USA, SPX Flow Inc supplies pumps, HVAC products, detection and the coast of Abu Dhabi. deliver the pumps in two
valves, mixers, filters, air dryers, measurement technologies and batches, the first six pumps to
hydraulic tools, homogenizers, power equipment. The ZADCO Upper Zakum 750 the South Island and the second
separators and heat exchangers, as project is one of the largest six to the North Island.
well as related aftermarket parts www.spx.com offshore field developments in the
and services, to the food and www.spxflow.com Middle East. www.amarinth.com

KSB wins major contract


for Indian power plant
KSB Pumps Ltd India has secured pumps, baseplates, electric motors,
a substantial order to supply six hydraulic couplings, oil coolers,
boiler feed pumps for the new, gearboxes as well as noise enclo-
ultra-modern fossil-fuelled power sures and related instrumentation.
station in Tanda in the Indian state
of Uttar Pradesh. The pumps will be manufactured
at KSB’s plant in Chinchwad, India.
Two new 600 MW power plant units
are currently being built in Tanda. Delivery will begin in November
2016 and is expected to be
In addition to the high-pressure completed by May 2017.
boiler feed pumps, the KSB scope
KSB’s Chinchwad plant in India (© KSB AG, Frankenthal, Germany). of supply includes six booster www.ksb.com

www.worldpumps.com
Hydraulics Automation Materials 440 developers

Our research puts you in front


We want pumps and valves to save energy and run for years. So our engineers look far
beyond today. They anticipate trends and adapt technologies – in hydraulics, automation
and materials. The result is top technology and innovative products. Like our SALINO®
Pressure Center, which has revolutionised how the world gets drinking water from
the sea. www.ourtechnology.yoursuccess.ksb.com

You can also visit us at www.ksb.com/socialmedia

Our technology. Your success.


Pumps Q
Valves Q
Service
8 Product news
WORLD PUMPS December 2015

Oil cooled line for Productivity gains through


submersible solids automatic lubrication
handling pumps
Pentair Flow & Filtration Solutions series represents the first oil-
has expanded its hydromatic cooled line of submersible solids
premium efficiency (HPE) solids handling pumps on the market.
handling pump range to include According to the company, this is
320 and 360 motor frames up to designed to provide municipal
150HP. Pentair says that the HPE customers with a lower cost of
ownership, longer life and
reduced maintenance costs.

Pentair says that the Class-H oil


filled motors run up to 40°C
cooler than competitive premium
efficiency air cooled motors,
leading to longer motor life and The H1900 LubePro pump is designed to improve the productivity of plant
less downtime. Premium efficient maintenance staff by allowing remote filling.
motors are designed to provide
improved wire to water efficien- Graco Inc. has introduced a new According to the company, the
cies, resulting in estimated annual member of the LubePro™ range H1900 LubePro pump is most
energy savings of up to $6,000 of injector-based automatic lubri- commonly used to lubricate
when compared to a pump with cation pumps, the H1900 oil machines used in stamping, can
a standard motor. pump. The company says that the production, glass production,
H1900 LubePro pump is designed machine tool, tyre production and
The HPE Solids Handling Pumps to improve the productivity of automation machinery.
are also designed to help users plant maintenance staff by
reduce maintenance costs. Pentair allowing remote fill - eliminating The company claims that the
says that the hydromatic seal leak the need to fill pump oil reser- pump is easy to install, provides
probes provide early moisture voirs individually around the plant. high lube output and improves
detection warnings to help mini- the productivity of plant mainte-
mize unplanned maintenance Graco adds that the H1900 nance staff. Other features of the
costs. A shaft grounding ring LubePro pump is built from the H1900 LubePro pump are claimed
protects against variable same components as the A1900 to include higher lube output and
frequency drive induced currents pump, but instead of a refillable frequency, factory-installed low
to prevent premature bearing reservoir, it is designed to connect level detection, and maintenance
The HPE solid handling pump range shaft failure. to a permanent oil header line productivity.
now includes 320 and 360 motor and is filled from a remote
frames up to 150HP. www.pentair.com mounted lubrication fill station. www.gracolubepro.com

Comeo C is approved for drinking water


KSB Aktiengesellschaft has made The company adds that the (Comeo C) or grey cast iron piping forces and is suitable for
an addition to the Comeo type suction and discharge nozzles are JL1040 (Comeo G). Depending installation in confined spaces.
series. The company says the cast as a single piece with a on the required discharge pres-
pumps are compact and cost-ef- choice of stainless steel – 1.4308 sure, the pump sets are The pumps can be either oper-
fective and are designed for an equipped with two, four or six ated by 230V single-phase or
operating pressure of 10 bar. KSB stages. The close-coupled design 400V three-phase current for the
adds that they are designed for is claimed to absorb external close-coupled motors. The drive
water supply and treatment, rating ranges from 0.37-2.2kW. A
small pressure booster systems 60 Hertz version is also available
as well as in light industrial for countries outside Europe. The
applications. The stainless steel pumps handle ambient tempera-
variant Comeo C is ACS and The Comeo C from KSB has ACS tures of -15 C to +55°C.
WRAS approved for drinking and WRAS approval for drinking
water applications. water applications. www.ksb.com

www.worldpumps.com
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10 Product news
WORLD PUMPS December 2015

Installations designed for Explosion proof range for


fish farming applications sewage and wastewater
Bedford Pumps and Hidrostal Ltd turer of pumps for the Land Tsurumi America has introduced
have launched a new website to Drainage industry, it offers experi- new FM-approved explosion proof
promote pumps that are suitable ence in all aspects of Land pumps, which the company says
for fish farming applications. The Drainage, Flood Defence and will enable it to expand in new
company says that as a manufac- Pumping Station Design. The new markets that require the strictest
website is designed to address safety standards, such as municipal
the history of Land Drainage, sewage and sanitation. The X Series
developments within the industry pumps are designed to provide
and the latest in legislative explosion proof versions of Tsuru-
requirements such as ‘The Eel mi’s B, BZ, U and UZ series sewage
Regulations’. In addition, the and wastewater submersible
website draws on Hidrostal’s pumps. Available in BYX, BZYX,
experience in the fish farming and UYX, and UZYX series, the pumps
fish processing industry with over will expand Tsurumi’s product
50 years of continuous product offering for applications that Tsurumi America has added explo-
development and application require a FM-approved pump, such sion proof pumps for applications
knowledge. as municipal sewage lift stations, that require the strictest safety
landfills, and industrial and agricul- standards, such as municipal
The website is designed to offer tural wastewater treatment. The sewage and sanitation.
users information on Bedford and company adds that 87 models will
Hidrostal’s full range of ‘Fish be added to the line. freestanding, guide rail and dry pit
Friendly’ pumps, along with case applications. These submersible
studies of the latest pump Tsurumi adds that the explosion sewage and wastewater pumps are
installations. proof pumps are designed to designed to meet the Class 1, Div
Installation of pumps suitable for contain any spark that could ignite 1, Group C&D explosion proof
fish farming applications. www.fishfriendlypumps.co.uk methane or other flammable gas in specifications required for most
the ambient area surrounding the municipal bids.
pump. The first of the explosion
proof pumps will be available for www.tsurumiamerica.com
VSD automation energy
expertise at SPS 2015 Self-priming design is
WEG is to launch a new variable
speed drive (VSD) to boost energy
efficiency across a broad range of
environmentally friendly
applications at this year’s SPS IPC BBA is introducing a new design
Drives (Nuremberg, 24-26 to its B series self-priming pumps.
November, Stand 250, Hall 3). The design of the larger B pumps
(6 to 10 in) has been modified,
Designed to meet the European resulting in a higher pump effi-
market’s growing demand for ciency and a larger passage for
inverters, in line with the require- solids. For the smaller models like
ments of the latest ErP Directive the electrically driven B40 to B70, BBA’s B series in a new environmen-
on energy efficiency, the CFW300 The new CFW300 variable speed BBA has made enhancements to tally friendly design.
variable speed drive (VSD) is drive covers the motor power range the production process.
designed for applications from 0.18 to 4 kW in two frame sizes. will now be powder coated as
requiring low motor power such An example of which are the standard; the motor keeps the
as small centrifugal pumps, for industries such as food and changes being made in the factory colour of the supplier; all
mixers, extruders and fans. beverage. company’s spraying process. BBA new deliveries will have hot-dip
aims to reduce its ecological impact galvanized inspection covers; a
Among WEG’s latest additions to Other product launches include and the generation of waste mate- clever modification to the pack-
WEG’s automation offering is the the CFW100 mini drive with RFI rials by replacing spraying as far as aging material ensures that the
new CFW500 VSD in a larger filter and the MW500 decentral- possible with a more effective steel motor plate, previously used
frame size (E) – for rated power ised inverter in frame size C with powder coating process. to prevent transport damage is
18.5 to 22 kW. The company is rated power from 5.5 to 7.5 kW. no longer required.
also unveiling IP55 rated devices Environmentally friendly design for
to make its CFW701 VSDs suitable www.weg.net/uk the B40 to B70: the pump housing www.bbapumps.com

www.worldpumps.com
Product news 11
WORLD PUMPS December 2015

Nominations wanted for Solids and water


2016 UK Pump Industry handling for multiple
Awards industries
butions to the industry. In 2016 Flows are up to 15000 GPM
the categories will include: Tech- (946.4 l/s), with total dynamic
nical Innovation of the Year head to 530 feet (161.5 m) and
– Products and Projects; Environ- solids handling capabilities up to
mental Contribution of the Year; 4” (101.6mm). According to
Manufacturer of the Year; Distrib- Gorman-Rupp, the pumps will
utor of the Year; Supplier of the provide a high level of perform-
Year; Engineer of the Year; and ance and efficiency for applica-
Lifetime Achievement Award. tions in wastewater treatment
The winners of the 2015 UK Pump The 6500 Series of solids and water plants, industrial facilities,
Industry Awards. The Awards ceremony will be handling end suction centrifugal construction, mining and agricul-
on Thursday 10th March at the pumps from Gorman-Rupp. tural uses.
The British Pump Manufacturers Crowne Plaza, Heythrop Park in
Association is now seeking nomi- Oxfordshire. The venue is located US company Gorman-Rupp has The company adds that the new
nations for the 2016 UK Pump 12 miles from Oxford, making it introduced a new line of hori- 6500 Series pump line standard
Industry Awards. Since 2000, the easily accessible from both zontal end suction centrifugal features include oversized bear-
Pump Industry Awards have been London and Birmingham pumps. The company says that ings, atmospheric vent, side
recognizing the best performing directions. the 6500 Series™ offers solids and access inspection port (on solids-
companies and people for their water handling end suction handling models), indexable
achievements and positive contri- www.pumpindustryawards.com centrifugal pumps based on the Smart Scroll® discharge locator,
Prime Aire® and Prime Aire Plus® and a five-year factory warranty.
models. Model sizes range from
3” (75 mm) to 16” (400 mm). www.GRpumps.com
Swedish plant passes
production milestone ®

Xylem Inc. has produced its 4 pumping capacity of 500 litres per
millionth Flygt wastewater pump second at 66.9 metre head.
at its manufacturing facility in
Pera-Prinz®
Sweden. The company says that it According to Xylem, the world’s
Twin Screw Pumps – Single and Double End
is the first international pump first submersible drainage pump
Positive Displacement Pumps
manufacturer to have produced was produced by Flygt in 1947,
this quantity of wastewater with the first submersible sewage
pumps at the same factory. The pump being introduced in 1956.
pump will be used at the central The first clean water Flygt pump
pumping station at Azaibah, was launched in 1930. Flygt
Muscat, Oman which pumps pumps are now also produced at
wastewater across 8km to the Al manufacturing sites around the
Ansab treatment plant in the world including China, India, the
Middle Eastern state. The pump is United States and Argentina.
rated at 500 kW and is 2.85 m
high. It weighs 5,300 kg and has a www.xyleminc.com

Screw Pumps:
The 4 Rotating
Positive Displacement Pumps
millionth Externally and
Internally supported.
Flygt pump
produced in For Enquiries or Further
Emmaboda, Information please contact:
sales@3pprinz.com www.3pprinz.com
Sweden.

www.worldpumps.com
12 Product news
WORLD PUMPS December 2015

Shaft grounding provides Rotating Equipment


bearing protection Conference returns in 2016
Inpro/Seal has updated and The VDMA has issued a Call for technical exhibition. Fields of appli-
expanded its range of shaft Papers for the 3rd International cation will include: oil and gas;
grounding solutions in order to Rotating Equipment Conference – chemicals and pharmaceuticals;
meet the growing need for Pumps, Compressors and Vacuum water supply and treatment;
protection against electrical technology, which will be held building services; energy supply
discharge machining (EDM). The from 14-15 September 2016, at the and generation; heating and
company says that its Smart Shaft Congress Center in Düsseldorf, cooling; mining; energy storage
Grounding combines Current Germany. Established in 2004, the and renewable energy.
Diverter Ring® technology with event was last held in 2012. The
new features to increase reliability Smart Shaft Grounding from Inpro/ conference includes three forums www.introequipcon.com
and decrease maintenance costs. Seal is protecting against electrical in a single venue: The 11th Pumps
discharge machining. Users International Forum 2016;
According to Inpro/Seal, the use of The 4th Compressors Users Inter-
variable frequency drives (VFDs) The Smart Shaft Grounding national Forum 2016; and EFRC,
continues to expand due to their product range consists of the the 10th European Forum for
ability to reduce energy consump- Smart™ CDR®, Smart™ MGS® and Reciprocating Compressors 2016.
tion and generate significant cost Smart Ground Monitor™, which
savings, but VFDs also induce high are claimed to address key limita- The organizers say that the confer-
frequency voltages on the shaft tions of existing shaft grounding ence will attract experts in pumps,
that can damage bearings as they technologies. According to Inpro/ compressors, compressed air and
seek a path to ground. With the Seal, Smart Shaft Grounding vacuum technology from all over
Smart Shaft Grounding product provides permanent protection the world, including scientists, end-
range, Inpro/Seal says that it can from conduction-inhibiting shaft users, and manufacturers. Around
increase motor reliability by oxidation and offers continuous 850 participants regularly attend
providing voltages with a low monitoring and feedback of shaft the conference and there will be The VDMA’s 3rd International
impedance path to ground away grounding performance. around 120 technical lectures, Rotating Equipment Conference
from the bearings while monitoring along with around 85 companies will cover all aspects of pump,
grounding effectiveness. www.inpro-seal.com and universities taking part in a compressor and vacuum technology.

First API turbine KEPL High rate, high head


commissions in Indonesia sewage slicer series
Kirloskar Ebara Pumps Ltd (KEPL) The company says that this turbine Franklin Electric has introduced its 100 ft, the company is confident
has commissioned an API 611 is capable of variable speed/power FPS IGPH series of high head that these units can replace other
Steam Turbine ‘K-TUR’ at PT. Pemu- operation from 30-110% of the grinder pumps engineered for the grinders that fail to meet current
kasakti Manishindah in Indonesia. boiler load and has been designed demands of higher head condi- application needs.
KEPL says that it designed and in a way to provide the best opera- tions found in many low pressure
developed the API 611 compliant tional efficiency over its design life sewage transfer applications. Available in single phase or three
steam turbine to a power rating of of 20 years. In addition to No Load phase versions, these grinder
3000 kW. This first ‘K-TUR’ was Mechanical Run Testing (NLMRT) as Available in an automatic or pumps employ a 2 hp, 3,450 rpm
supplied through ISGEC Heavy specified by API 611, KEPL also manual version, the grinder pumps motor to handle the demands of
Engineering Limited, India with a tested the turbine on a part load utilize a cutter system with grinding domestic sewage. Other
rating of 380 kW. for the first time using a calibrated tight clearances for design features include corrosion-
pump to evaluate its operational grinding at 414,000 cuts resistant upper and lower brass
performance compared with the per minute. These impellers and built-in overload
design performance. units incorporate two protection to prevent over-cur-
non-clogging rent/over-temperature damage.
KEPL’s turbines are used in applica- impeller stages for
tions including hydrocarbon pumping of sewage www.franklinwater.com
processing, petrochemicals, ferti- slurries with a
lizer and chemical process indus- shut-off head of 200
tries, power plants and water ft. With only 16
The API 611 Steam Turbine ‘K-TUR’ treatment facilities. full-load amps at
at PT. Pemukasakti Manishindah in minimum head Franklin Electric’s FPS IGPH
Indonesia. www.kepl.in.net requirements of manual high head grinder.

www.worldpumps.com
14 Product news
WORLD PUMPS December 2015

Magnetic drives for Vibration-free operation


solids-laden and low for brewing applications
boiling liquids SAWA Pumpentechnik AG has
developed the ZAL series of stain-
Swiss manufacturer CP Pumpen less steel pumps for brewing,
AG has added the MKP beverage, wine and distilling
250-200-315 magnetic drive pump industry applications. The
to its MKP series, which can trans- company says that they provide
port up to 750 m3/h to meet vibration-free operation and
increasing demand for pumps with smooth running, and are designed
a large flow volume. for KZE flash pasteurization The ZAL series of stainless steel
systems. pumps provide vibration-free opera-
CP says that the new centre tion and smooth running in KZE
support remains form-stable up to According to SAWA, the self- flash pasteurization systems.
350°C. The company adds that it priming HD side channel pump is
has designed pump feet, which designed for yeast conveying. The leakage-free, reliable operation. All
ensure that the heat stays in the company also offers a solution for systems have been tested in
pump. This ensures reduced loss The MKP 250-200-315 magnetic wort with the LE series, which is accordance with the ATEX guide-
when heating the medium. A tita- drive pump is designed to meet claimed to be quiet and efficient. lines for explosion protection. They
nium shroud allows as low eddy- increasing demand for pumps with This pump can be equipped with are designed for applications in
current loss as possible, which a large flow volume. an inducer in order to avoid the distillation and slurry conveying in
results in a higher level of effi- risk of cavitation. For difficult distilleries. The pumps are
ciency. In addition, it is claimed for the high demands of the media such as citric acid, caustic produced in certified stainless
that the new pump does not need chemicals and associated indus- solution and nitric acid, as well as steel 1.4435/316 L and the elas-
any plain bearing pedestal and as tries. They have a single, centrally in areas where a high degree of tomers used have FDA approval.
a result can be evenly heated. This arranged impeller bearing safety is required, the magnetic
means that the MKP 250-200-315 assembly which is lubricated and driven pumps are claimed to offer www.sawa.ch
can be used to convey challenging cooled with the pumped liquid,
media, such as liquid sulphur. allowing solids-laden and low-
boiling liquids to be transported.
Improved machine
CP says that its seal-less magnetic
drive pumps have been developed www.cp-pumps.com
efficiency and lower
Drum and container range exhaust emissions Bosch Rexroth has introduced the
meets food standards A1VO, a variable pump for lower-
power range mobile equipment.
Lutz has introduced the The PURE series of drum and The company claims that the
PURE series of drum and container pumps are axial piston variable pump for
container pumps for designed for handling foods. hydraulic systems in the new size
handling foods. The 18 narrows the price gap to iden- The A1VO is a variable pump for
company says that they well as the mixing pump tically-sized gear pumps. lower-power range mobile
are in compliance with MP for mixing and According to Bosch Rexroth, equipment.
the European Directives pumping emulsions, manufacturers of mobile equip-
1935/2004/EC, as well as suspensions and disper- ment in the agricultural and With the use of variable pumps
US FDA regulations. Lutz sions. The company adds construction sectors can now previously restricted to machines in
pumps and flow meters that viscous and shear- implement the technology on the upper power ranges, lower-
are also available in explosion sensitive substances can be gently tractors and vehicles of 37 kW powered machines were designed
proof versions according to ATEX pumped with the eccentric screw and higher, and auxiliary drives with energy-intensive open-centre
Directive 94/9/EC, because a large pumps of series B70V PURE. Lutz on larger vehicles. systems using fixed pumps. The
number of foods, cosmetics and flow meters in PURE version with A1VO is claimed to offer a range of
pharmaceuticals contain alcoholic touch screen display and menu- The company adds that by control types – pressure, load-
ingredients, and pump cleaning navigation in plain text are enabling demand-controlled sensing and electronic control –
products are flammable. claimed to enable precise evalua- power generation, manufacturers providing a cost-friendly alternative
tion and safe control of the filling and operators can improve for many hydraulic systems that
The Lutz PURE series also includes process. machine efficiency by up to 16%, previously used fixed pumps.
the drum and container pump RE while simultaneously lowering
for complete drum drainage, as www.lutz-pumpen.de exhaust emissions. www.hytecgroup.co.za

www.worldpumps.com
Axially Split,
Horizontal SINCE 1954
Double Suction
Centrifugal Pump
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KENFLO PUMPS GROUP


GUANGDONG KENFLO PUMP CO., LTD.
Add: No.14 Hebin Road, Foshan City, Guangdong, P.R. China 528000
KWWSZZZNHQÀRFRP(PDLORYHUVHDV#NHQÀRFRP
16 Company focus
WORLD PUMPS December 2015

DESMI lifts green


ship business case
aritime pumping solution manufacturer DESMI’s energy-
M optimisation approach generates positive cash flow for
ship-owners struggling to comply with new regulations.

It’s hardly news that the shipping Vessel and equipment producers forward solid customer data to range to optimisation solutions
industry is mobilising to meet the have, of course, risen to the chal- prove its claims. such as DESMI OptiSave™ which
demands of wave after wave of lenge, devising tools and strategies can, for example, save up to 80
new environmental regulations. from new, energy-saving hull percent of power consumption for
From the IMO’s ballast water paints to higher-capacity container Auxiliary systems in engine rooms a vessel’s seawater pumping tasks.
management legislation to EEDI ships. But is there a way to make and their pump components are We have delivered many of these
(the Energy Efficiency Design Index the necessary investments to designed to cope with the worst solutions by now,” says Michael
for new ships) and SEEMP (Ship satisfy regulations and create possible foreseeable conditions. In Lassen. “And all have been shown
Energy Efficiency Management savings, too? reality, however, such systems can to provide 60-80 percent savings
Plan), ship-owners need to be be made to run at operating levels for ships travelling, for example,
ready to drastically cut energy that better correspond to the between ports in Europe and
consumption and emissions. Reducing energy using vessel’s actual load at any particular Asia.”
on-board equipment time. And according to DESMI’s
Pump solution manufacturer Michael Lassen, Segment Director Seawater pumping systems aren’t
DESMI, drawing upon its long for Marine & Offshore, this is an the only pumps in a vessel’s
track record in the develop- excellent strategy for ship-owners engine room. Other systems cool
ment and manufacture of keen to comply with the new down steam that hasn’t been
pump solutions for regulations. used in steam turbines, for
marine, industry, oil example, condensing vapour into
spill, defence and “A lot of on-board machinery liquid again before re-feeding it
energy industries, has constantly operates as though the into the boiler. When there is little
some of the answers vessel is under 100 percent load steam to be returned to the
to that question. and having to cope with air condenser, less seawater is
temperatures of up to 50 degrees required, enabling the speed of
The Danish-based Celsius and sea water the pump to be reduced to a
company is focused temperatures up to 32 degree necessary minimum.
on reducing energy Celsius. But those conditions
consumed by reflect perhaps only one percent Asnother area for potential savings
on-board equipment of a ship’s operating lifetime. The arises, for example, when the
in and around engine rest of the time, you might say, it’s vessel is sailing at lower speeds.
rooms. With solutions like running the heating in your Normally, 3-4 fans push
covering everything house at full blast with the compressed air into the engine
from seawater pumps to windows wide open. Making room to boost combustion effect.
ventilation systems, the control systems that closely match These systems usually run at full
company has found plenty of energy consumption to actual speed, regardless of load, even
ways to cut requirements is something we’ve when less air is required. DESMI’s
consump- been focusing on for a number of OptiSave controls these compo-
tion. Its years.” nents, too, reducing their speed to
solutions correspond to real needs.
have Saving on pumping
surpris- power DESMI also applies similar
ingly short As a starting point, DESMI’s own thinking to the sulphur-removing
payback times seawater pumps are designed to scrubber systems required for
– but often, the pull maximum efficiency out of vessels operating in Nordic SECA
most compelling aspect is today’s pumping technologies. But (Sulphur Emission Control Area)
the annual savings that follow. the company doesn’t stop there, zones. Such systems use a ‘rain
NSL Scrubber pump in stainless steel. And the company is putting extending its energy efficiency shower’ of water to clean the gas

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


18 Company focus
WORLD PUMPS December 2015

produced by heavy fuel oil, ness model. So once such a


removing sulphur and other system is installed, it’s quick to
undesirables before releasing the prove its worth. And with the
exhaust into the atmosphere. initial investment recouped, the
Highly resistant, stainless-steel ship-owner actually earns money
pumps provide the seawater for every single year until the vessel
this process and, with the is decommissioned, sold or
scrubber system placed at the scrapped.”
highest point on the vessel, they
typically consume considerable DESMI has plenty of data to
energy. prove its claims. The company’s
off-the-shelf optimisation systems
achieve a six-month payback
All-in-one optimisation time for new buildings, which is
A key advantage of DESMI’s blindingly fast for most engine
Optisave™ is the ability to install room additions. Turnkey systems,
just one piece of extra on-board such as those recently sold to
equipment to control the energy one of the world’s top three
for seawater, condenser and container lines, achieve their
engine room fans. With just one payback in around 18 months.
cabinet, ship designers can After that period, savings of EUR
easily incorporate new energy 35,000 annually per vessel are
savings without significantly achieved. These particular
adding to the deck space head- systems were retrofitted on
aches already caused by the vessels in operation, and DESMI
need to install additional was responsible for project Sulphur-removing scrubber systems required for vessels operating in Nordic SECA.
systems for environmental handling, installation and
compliance. commissioning, all for a fixed
price. out for interested ship-owners DESMI offers a wide range of ener-
and their vessel designers. But gy-saving products under the
Positive cash flow ”With annual gains like these, even according to Michael Lassen, Pump-for-free concept, including:
So why is all this on-board energy the current oil price slide isn’t there’s still more work that can be
saving a good deal for the already affecting the general business case done to squeeze further savings • Replacement of older low-
cramped budgets of today’s ship- – or our sales of new systems. And out of today’s auxiliary systems on efficiency pumps with DESMI’s
owners? Michael Lassen claims everybody knows that the oil price board vessels. highly energy-efficient pumps
that, apart from the benefits of will not stay this low forever,” says • Retrofitting of Energy Savings
sheer regulatory compliance and Michael Lassen. “The new energy efficiency index Systems, also known as
regulations are pushing us to OptiSaveTM for Sea Water
develop even higher-efficiency Cooling pumps
"Pump components are designed pumps. We are still trying to lift up • Retrofitting of Energy Savings
from 80 to 85 percent efficiency, Systems for fresh water cooling
to cope with the worst possible challenging ourselves to do better pumps

foreseeable conditions." because we know that these


pumps run around the clock – so
• Retrofitting of Energy Savings
Systems for engine room fans
even a five percent improvement
continued access to profitable Balancing the books can make a very worthwhile differ- “Many of our customers prefer to
sailing routes, the potential savings Energy-optimising systems also ence over time.“ take advantage of our turnkey
of on-board energy control systems help to make sure ship-owner solutions, where we take care of
have proven to be quite business models don’t suffer from everything from pre-inspection to
spectacular. the additional fuel consumption Pumps-for-free commissioning. Others like to
associated with ballast water treat- Among DESMI’s innovative install the solution themselves,
“While it may be tempting to let ment systems and other new, approaches is ‘Pumps-for-free’: a turning to DESMI to carry out
tight new build budgets dominate mandatory equipment. Here, opti- cash flow-neutral investment commissioning,” says Michael
on-board equipment specifications,
ship-owners can do themselves a
misation power-savings can
balance the fuel equation to main-
concept for energy-saving solu-
tions. It’s a unique financing
Lassen. •
favour by focusing on the medium tain vessel profitability. package, enabling ship-owners to
and longer term numbers behind energy-optimise their vessels
high-end pumps combined with The strongest argument for while repaying the investment Contact:
energy-optimising systems like DESMI’s green ship solutions is to through savings, typically in 14 to Michael Lassen,
Segment Director Marine & Offshore
OptiSave™.” be found in the data it has made 18 months. The financing
mla@desmi.com
publicly available at www.optisave. schedule is linked to the ROI/ +45 96 32 81 72 or +45 23 63 17 55
“Fuel is the most expensive info - and in the specific calcula- payback period, with quarterly www.desmi.com
component of the maritime busi- tions its energy experts can carry payments.

www.worldpumps.com
Applications 19
WORLD PUMPS December 2015

Oil & gas

Safe conveyance
of sour crude oil
o convert sour crude oil into valuable and refined fuel
T the impurities need to be removed. However, sour
crude oil is toxic, hazardous and extremely corrosive
which makes its transportation to the preparation
system challenging.

Critical applications of conveying mixtures diaphragm pump heads made of super- (NPSHr). When pure hydrocarbons are
of acidic hydrocarbon/water to the duplex stainless steel. The diaphragm conveyed on hot summer days, their
washing system have always been a chal- itself, due to the eroding effect of the vapour pressure rises and the risk of cavi-
lenge for any pump manufacturer. This was particles in the corrosive liquid, is made of tation increases. Various options were
also the case in one recent project Lewa wear-resistant PTFE. Special suction valves analysed with the customer to tackle this
handled in the Emirate of Abu Dhabi. ensure a low NPSHr value. issue. Lewa offered integrated special
Lewa have designed and supplied 16 suction valves to keep the suction pres-
pumps to a major construction company While designing the pumps, it was also sure requirements low and satisfy all
in Abu Dhabi specifically designed to necessary to take into consideration that process conditions.
handle this critical application. the mixing ratio of water to hydrocarbons
in the liquid phase varies significantly and According to the customer, since commis-
On the project Lewa was asked to provide that the pressure can vary between 20 sioning, the installed Lewa pumps have
a solution to pump liquid hydrocarbons and 45 bar. "So we designed the pumps been running smoothly and with high
from the flare knock-out drum or the to handle a flow rate between 0.5 and reliability – fulfilling the expectation of the
blow-down drum respectively and convey about 15 m³/h of the acidic mixture," says maintenance and operating personnel.
the acidic hydrocarbon/water mixture back Sriram Iyer, who works for Lewa in Dubai. The on-call time agreement that permits
into the oil line to the washing system. To ensure that the pumps work reliably uninterrupted work at the plant even
Since the differences in these processes despite the changing flow rate, the net when one of the pumps needs mainte-
are only minor, it was possible to supply
16 mechanically identical pumps of the
positive suction head of the system
(NPSHa) also had to be kept higher than
nance is also working seamlessly. •
Lewa Ecoflow series, driven by 55 kW elec- that required at the pump suction www.lewa.com
tric motors, measuring 2.7 x 1.9 m, 1.9 m
high, and weighing 4200 kg.

To ensure high reliability in operating the


system, despite the project's difficult
conditions, the customer defined a series
of strict selection criteria. The critical fluid
characteristics that had been taken into
consideration while designing the pumps
are: high content of sulphur of about five
percent, high chlorine content, high
temperatures and highly humid condi-
tions under which even stainless steel
corrodes. Since the medium conveyed is
In all, 16 mechanically identical Ecoflow pumps were delivered by Lewa to the customer. There, they
very volatile and extremely hazardous, work under difficult process conditions to convey a highly volatile mixture of hydrocarbons and
Lewa selected hermetically tight hydrogen sulphide conveying water back into the oil line to the washing system.

www.worldpumps.com
20 Applications
WORLD PUMPS December 2015

Water & wastewater

Identifying and
documenting
hidden utilities
inding utilities buried in the ground so they can be
F avoided is normally 'job one' before any construction
project begins. In this article we look at how the use of
ground penetrating radar is helping to save time and
money in construction.

Unfortunately, nine times out of ten, util- of the country, utilities are more than buried utility will be hit, it is by no
ities and contractors are faced with the 100 years old, and many utilities have means fool proof. The information is
fact that there is no reliable paper record been added or abandoned without rarely backed up with adequate
of what has been buried. In some parts being recorded. records and employees use a very
limited amount of technology to locate
Damaging utilities can be costly, leading utilities. So contractors, utility owners,
to cost overruns and project delays. In and others responsible for digging are
response, many are adopting subsurface left holding the bag if something goes
utility engineering (SUE) practices that wrong. If an accident happens the bill
encourage utility locating. One inter- can be extremely high, leading to
esting example is the San José-Santa unacceptable project losses.
Clara Regional Wastewater Facility, a
large utility in the South San Francisco In addition to project expenses, a few
Bay, which developed a toolbox of other factors are behind a growing
methods to identify and document interest in determining where utilities
buried utilities. The program has already are really buried by using systems –
resulted in huge savings on several and even more importantly, modes of
major capital improvement projects and thinking – that improve utility
brought them in on time and within locating. One is the expansion of gas
budget. and oil drilling in the Midwest, where
an increase in buried fuel pipelines
has led to a greater potential for
Changing regulations conflicts.
Most states have quasi-regulatory
organisations that serve as a clearing- Another factor is the new PAS
house to notify utility owners of (Publicly Available Specification) 128
upcoming construction projects. These on underground utility detection, veri-
organisations, like Dig Safe in the fication and location. The PAS,
Northeast or Underground Service produced by the UK National Stand-
Alert in California, then send out ards Body, BSI, is intended to promote
someone to identify and stake where the use and drive the advancement of
Figure 1. An example of the myriad of pipes and utilities utilities are buried. While this service underground utility records during the
(current and abandoned) the utility encountered. makes it somewhat less likely that a planning, design, construction, and

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


Applications 21
WORLD PUMPS December 2015

operation of underground utility infra-


structure. It has resulted in a global
interest among engineers and project
managers in utilities and concrete to
do a better job of locating before
digging.

One agency that has decided to


respond proactively to these trends is
the San José-Santa Clara Regional
Wastewater Facility (RWF), located in
the South San Francisco Bay. Built in
1956, RWF cleans an average of 110
million gallons of wastewater per day,
serving eight cities with 1.4 million
residents and 17,000 main sewer
connections. The facility is the largest
advanced wastewater treatment facility
in the western United States. The 2,600
acre site includes a 175 acre waste-
water operations area, a 750 acre
sludge drying area, and an 850 acre Figure 2. Two ruggedized GPRs, manufactured by GSSI, are used.
former salt production pond.

on veteran staff, those who had worked Furthermore, Hayes explains that the
Improvements at the RWF for several decades or more, utility did not have a documents
According to Tim Hayes, Geosystems to tell them “what is buried where” even management system, with as-built draw-
Manager, knowing what is buried to a when there was no written documenta- ings scattered or in huge racks of
high degree of accuracy is absolutely tion in the files. However, in recent years, hundreds of drawings, which makes it
critical to any of the many improvement many of these veterans have retired and difficult and very time consuming to
and repair projects being done on the current staff has little or no knowledge access.
site. In the past, the utility could depend of the location of buried utilities.

Kerscheckstrasse 41
8076 Vasoldsberg/Graz
Austria
Tel.: +43 (0)316 873 8079

P
n Extra-occupational distance learning study programme En rogr
g a
n ”Certified Energy Consultant for Pumps and Pump Systems” Ge lish mme
rm in
an Ma start
n Open to all engineers and professionals working with pumps
n Developed by professors from leading European technical in rch s
universities and internationally renowned experts J uly 201
n Practical on the spot training by highly qualified pump specialists 20 6
1 6
In cooperation with institutes of:

www.worldpumps.com
22 Applications
WORLD PUMPS December 2015

“Given that it is difficult or impossible when you need to locate a buried utility, Two ruggedized GPRs, manufactured by
to pinpoint specific buried utility or a multitude of buried utilities. Each tool GSSI, are used. Hayes calls the use of
locations when viewing most of our or technology has its limitations. Says GPR a game-changer. “Despite the fact
as-built drawings, and the cost-overruns Hayes, “We found in our situation that the that we are located on the edge of San
associated with poorly or undocumented most effective strategy is to use a variety Francisco Bay Estuary with a high water
buried utilities, we decided we needed of tools and technologies and develop an table and clay soils, our GPR is able to
a different approach to managing them. approach where they can all work function in approximately 70% of our
We were convinced such a system would together. The core of our strategy is the service area. In some locations we can
save time, money, and increase safety in GIS, and all buried utilities information is see anything up to six feet deep, while
the long run,” says Hayes. stored in this GIS database.” in other locations we can only see utili-
ties less than one foot deep. Despite
However, achieving this goal would take a these limitations, the use of GPR is abso-
non-traditional way of thinking – being Cross checking data lutely critical to the success of our SUE
more concerned with the utility’s future The utility soon learned it could not program.”
needs, rather than the more common depend simply on its GPS; verification
“getting your project done and out the and cross checking of data with a GPR The team has been in many situations
door and moving onto the next project” and the EM locator was necessary, since where their only choice was to use an
approach. about 60% of utilities shown on the inductive EM locater, which has a high
drawings were either incorrect or degree of inaccuracy, or use the GPR. In
not there. This is quite a common this situation they typically use GPR
A look inside the toolbox situation at many industrial plants, like because it usually allows them to see
In response, RWF implemented subsurface oil, wastewater or water facilities, where what is buried. Without GPR, he says, “We
utilities engineering (SUE) practices, estab- a maintenance group typically installs would just be literally throwing our
lishing its own Subsurface Utilities pipes, which are then buried. A separate hands in the air and saying we cannot
Management Program. Their goal was to capital improvement program deals help.”
document at least 90% of the utilities on with engineering design and drawings.
the entire site to avoid problems for their The plant maintenance side typically
large capital improvement program. They does not document all the many small SUE saves
set out to document the utilities both on pipes and conduit installed over many The SUE program has been successful in
drawings and in a Geographic Information years. reducing construction costs and avoiding
System (GIS) database. construction delays. For example, before
The utility found that GPR was the tool the implementation of the Buried Utilities
As part of the new program, RWF most likely to identify a utility that is not Management Toolbox Strategy, a new
adopted the American Society of Civil in the GIS. The location and findings of headworks facility was constructed at a
Engineers (ASCE) ASCE C-I 38-02, the new information are input directly total cost of about $90 million. RWF had
Standard Guidelines for the Collection into the GPS while in the field, and later to spend $1 million locating poorly docu-
and Depiction of Existing Subsurface uploaded to the GIS. mented or undocumented buried utilities,
Utility Data, which helped them quan- mostly by potholing at hundreds of
tify how good the locational/positional The GIS is dynamic, and is updated daily locations.
accuracy of each of its buried utilities is. as the utility identifies additional infor-
The goal of the standards is to “allow mation about each of its buried utilities. Potholing, actually digging holes to
the project owner, engineer, and It now contains more accurate buried locate utilities, is the most accurate way
constructor to develop strategies to utilities information than the utility’s to identify buried utilities, but is by far
reduce risk, or at minimum, to allocate as-built drawings. “When we go into the the costliest method. On average, a
risk due to existing subsurface utilities field to locate a utility, we upload the single pothole can cost from $2,000 to
in a defined manner.” Each utility in the GIS data for the area into our GPS, which $5,000. In addition to the high cost of
GIS is assigned a Quality Level is connected real-time via cell phone to potholing, the poorly or undocumented
according to ASCE 38-02. our GPS Basestation,” explains Hayes. “This buried utilities resulted in a six-month
allows us to collect data and navigate to project delay.
The SUE practices included the imple- any buried utility in our GIS to within
mentation of a specific “Buried Utilities four inches.” Based on a post-project analysis, if the
Management Toolbox Strategy” for better toolbox strategy had been in place for
locating utilities. The toolbox includes a In addition, anytime a hole is opened in this project, estimated savings would
central GIS system; use of multiple utility the ground, and a utility is exposed, they have been approximately $400,000, and
designating technologies in addition to take a photo of it, obtain the location of there would have been less than three
available drawings; ground penetrating each utility with the GPS, and upload the weeks of project delays resulting from
radar (GPR); electromagnetic (EM) loca- information into the GIS back at the office. poorly documented or undocumented
tors; magnetic locators; and a laser When they get a USA Ticket and arrive buried utilities.
rangefinder. at a location, they usually know what
to expect, what is buried where, and This project was completed millions of
The approach is based on the under- what it looks like based on photos. This dollars over budget and more than a
standing that you cannot depend on any saves time – and time is money in the year late. It was this experience that led
single piece of equipment or data source construction business. directly to the development of the

www.worldpumps.com
Applications 23
WORLD PUMPS December 2015

Subsurface Utilities Management tion. About 15% of utilities have not yet “I have witnessed first-hand what a
Program, of which the Buried Utilities been documented, primarily the pipes headache it is for everyone in every way
Management Toolbox Strategy is a crit- used in the irrigation system for lawns when an undocumented utility or one
ical component. and landscaping, which was installed that was shown incorrectly on the
more than 50 years ago. Originally they as-built drawings is encountered,” says
After the implementation of the toolbox focused on other utilities, which if hit Hayes. “With the use of GPR and other
strategy, a fire main replacement project would have shut down plant operations tools in our toolbox we can accurately
was conducted, in which 10,000 feet of new – hitting irrigation pipes would just identify buried utilities that would
pipeline was installed at a total cost of $1.5 make a mess of the project. After conflict with our projects and complete
million. About $175,000 was saved by using having made such excellent progress any necessary redesign before construc-
the toolbox approach to verify buried utili- with all the other utilities, they are tion is started, helping us to complete
ties before construction began. There were
less than three days of project delays
currently in the process of mapping this
last system, using GPR along with other
projects on time and on budget.” •
resulting from poorly documented or tools. www.geophysical.com
undocumented buried utilities, and the
project was completed on time and on
budget.

Toolbox approach
A final example was a new electrical
duct bank installation project, in which
25,000 ft of new duct bank was
installed at a total cost of $10 million.
Approximately $150,000 was saved by
using the toolbox approach to verify
buried utilities before construction
began, with fewer than five days of
project delays resulting from poorly
documented or undocumented buried
utilities. The project was completed on
time and on budget.

As a result of the program success,


potholing is now done not to verify
buried utility locations, but to verify
utility depth and whether there is suffi-
cient underground space to accommo-
date the new planned buried utility.
RWF frequently encounters heavy buried
utility congestion (they estimate there
are 80 miles of buried utilities located
on just 150 acres), so it is critical they
have the ability to direct exactly where
potholing should be done, what they
can expect to find when they pothole,
and how many potholes should be
done for a project. Before the toolbox
strategy was implemented, potholing
was conducted based on pure
guesswork.

Exact location
Hayes estimates that the utility has docu-
mented about 85% of what is buried,
including abandoned pipes. They have
more than 7,000 geo-tagged digital
photos showing exposed buried utilities
with their identification and depths. The
utility has the ability to use its GPS to
navigate to the exact location of each
photo and tell what is buried at the loca-

www.worldpumps.com
24 Applications
WORLD PUMPS December 2015

HVAC

Cutting costs with


responsible waste
management
hen producing reliable, longest-lasting products,
W you come to expect the equipment used in your
manufacturing processes will have the same reliability.
In this article we look at how the new Wilden air
distribution system is helping to cut costs.

At the West Warwick, Rhode Island, USA, caused by 30-year-old air distribution reduced waste processing operating
manufacturing facility of AMTROL, the system (ADS) technology. By replacing costs by 60% and improved pump
efficiency of waste processing through the older ADS technology with new productivity by 40%.
newly installed filter presses had pumps equipped with the Pro-Flo®
become adversely affected by poor reli- SHIFT ADS from Wilden®, Amtrol not Founded in 1946 and headquartered
ability of their existing air-operated only eliminated reliability issues, but since then in West Warwick, Amtrol is
double-diaphragm (AODD) pumps also decreased pump maintenance, the market leader in thermal expansion
tanks, well tanks, indirect water heaters,
refrigerant and chemical cylinders,
propane tanks, and plumbing and HVAC
accessories for use by the residential,
commercial and industrial markets.

At the West Warwick Amtrol


manufacturing facility, nine production
lines produce metal tanks for plumbing,
heating, Freon, propane and water
storage on a seven-acre site. Tank
production involves punch forming, hole
punching, welding, grooving, assembling,
testing, buffing, etching, painting and
packaging.

Responsible waste
management
As in all manufacturing processes of this
type, various kinds of waste products are
generated in each step that must be
collected and disposed of properly.
Amtrol’s West Warwick, RI, USA, manufacturing facility produces metal tanks for plumbing, heating,
Freon, propane and water storage generating metal particulate waste that requires safe, efficient, At the West Warwick facility, the largest
economical disposal. quantity of waste generated is metal

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


Applications 25
WORLD PUMPS December 2015

particulates containing primarily iron


hydroxide, along with carbon steel,
copper, brass, zinc, caustic acid and
alkaline chemicals.

Processing of this waste begins by


collecting the particulates and chemicals
in slurry tanks for pre-treatment to sepa-
rate oils and neutralise caustic compo-
nents. Wilden, a leading brand of AODD
pumps from PSG, a Dover company,
based in Oakbrook Terrace, IL, USA, then
transfer the resulting sludge to holding
tanks in a laboratory for final processing
by three large recently installed filter
presses to separate the sludge into solids
and water for proper disposal. Each filter
press has eight two-inch wide chambers,
and each chamber is equipped with two
24 in by 24 in membrane plates.

To facilitate the process, three Wilden


AODD pumps are used to pump the
waste-laden sludge into the filter press
chambers. Amtrol utilises Wilden AODD
pumps exclusively for all fluid-transfer
applications at its manufacturing facili-
ties, including filter presses because of The largest quantity of waste generated during their manufacturing process is metal particulates containing
their proven effectiveness in a variety of primarily iron hydroxide, along with carbon steel, copper, brass, zinc, caustic acid and alkaline chemicals.
demanding applications.

www.worldpumps.com
26 Applications
WORLD PUMPS December 2015

The treated sludge containing water and


metal particulate waste is pumped into
the chambers until they become full with
solid “sludge cakes” formed from the
concentrated waste. During the process,
water in the sludge is separated from the
waste materials as it is filtered through
the filter press membranes. Upon exiting
the membranes, the now-clean water is
disposed of in the municipal sewer
system while “sludge cakes” drop into a
bin to be carried away for disposal.

Overall, the facility’s filter presses process


up to 9,600 gallons (36,340 litres) of
waste sludge per day and produce more
than 100 tonnes of “sludge cakes” a year.

Optimising process
improvement
While Amtrol’s 30-year-old Wilden M8
AODD pumps had been faithful work-
horses over the years, their older tech-
nology was a limiting factor in utilising Amtrol’s filter presses receive sludge containing water and metal particulate waste pumped by
the new filter press’ full potential. Wilden AODD pumps for separation into solid “sludge cakes” and water for safe, convenient disposal.

A crucial part of an AODD pump is the


ADS. This component directs pressurised disassembly, repair, reassembly and Perrotti discussed this issue with Dave
air to the diaphragms that convert it into restarting. While the Wilden AODD pumps Buckless, Account Manager at the F.W.
mechanical motion that push and retract were the best technology for the filter Webb Commercial and Industrial Pump
the pump’s diaphragms, causing it to press, a newer solution for ADS reliability Division, Amtrol’s pump supplier. “Relia-
pump fluid. Amtrol was using 30-year-old was needed. bility is key for their operation,” said Buck-
Wilden M8 AODD pumps equipped with less. “Unfortunately, 30-year-old ADS
ADS technology also dating back more Amtrol didn’t need to look far for a solu- technology has limitations in an extremely
than three decades. The poor reliability of tion. By replacing the 30-year-old ADS demanding application like a filter press,
these older pumps and ADS units under technology with the revolutionary new and that’s what was causing their issues.”
the demanding conditions of the filter patent-pending Wilden Pro-Flo Shift ADS,
presses resulted in periodic waste they were able to reduce the downtime As a solution, Buckless suggested that
processing halts and downtime for pump of their AODD pumps, streamline the Amtrol compare the operation of
waste-management process, conserve Wilden AODD pumps utilising the new
energy, save money and reduce the total Wilden Pro-Flo Shift ADS with the
cost of ownership, all at the same time. existing pump/ADS equipment. “I

"This incredible leap in ADS technology


solved several major issues."
“Pump stalling was a problem,” said Amtrol recommended pumps with the Pro-Flo
Environmental and Production Manager Bob Shift ADS because their cutting-edge
Perrotti. “Because the new filter presses were technology provides extremely reliable,
automated, they operated mostly unat- efficient operation and they could be
tended. As a result, if a pump stalled, it may easily piped into their existing installa-
not be discovered for a long period of time tion,” he said.
during which no waste was processed.
“This provided an opportunity to evaluate
“While our existing Wilden pumps had the Pro-Flo Shift side-by-side with their
provided us with great performance current ADS technology.”
Wilden AODD pumps with Pro-Flo Shift Air throughout the plant over the past 30 years,
Distribution Systems meet the heavy demands
of forcing waste-laden sludge into the filter press their older ADS technology was clearly the Amtrol installed new Wilden PS8 50 mm
chambers for water/waste separation. weak link in the new filter press process.” (2 in) Original Series clamped AODD

www.worldpumps.com
Applications 27
WORLD PUMPS December 2015

pumps equipped with the Pro-Flo Shift The secret to the Wilden Pro-Flo Shift’s
ADS and immediately noticed improved revolutionary operation is a unique air
pump reliability. control spool that automatically meters
the air and prevents overfilling without
“The results were astounding,” said reducing performance. By limiting the air
Perrotti. “The Pro-Flo Shift eliminated all used to the amount needed to maintain
mid-process stalling. Now, when a pump the pumping process, air consumption is
is not running, we know that the filter lowered by up to 60%. The result is more
press’ chambers are full. This incredible product yield per standard cubic foot per
leap in ADS technology solved several minute of air consumption for maximum
major issues. The additional unexpected operational efficiency and energy
benefit was decreased maintenance. savings. The Pro-Flo Shift technology also
Because the Shift doesn’t need oil, the increases pump reliability for added
bothersome maintenance tasks of moni- maintenance savings. In addition, the
toring ADS-unit oil levels and adding it Wilden Pro-Flo Shift can be retrofitted to
when they run low has been eliminated. existing Wilden AODD pumps to improve
In addition, we’ve cut maintenance costs performance while retaining the original
considerably since we no longer need to pump investment.
disassemble the pumps in order to
restart them every time they stall.”
Conclusion The facility’s three filter presses process up to 9,600
Amtrol Paint and Environmental As operations at Amtrol’s West gallons (36,340 litres) of waste sludge per day and
produce more than 100 tonnes of ‘sludge cakes’ p.a.
Supervisor Josh Hytinen commented, Warwick facility continue to expand,
“The Pro-Flo Shift also increased our effi- the enhanced reliability and processing
ciency. Our cycle time has been reduced capacity of its filter presses will be key in reliability and efficiency in high-demand
by nearly 40%, so we can expand our
waste-processing capacity without addi-
handling the increasing volume of waste
products efficiently, cost effectively and on
operations such as filter presses. •
tional equipment. The Shift has been a schedule. For Amtrol, the Wilden Pro-Flo Pro-Flo® and Wilden® are registered
major benefit in improving our waste- Shift ADS will play a key role in assuring trademarks
processing capabilities without major optimum filter-press operation with its www.wildenpump.com
capital investments.” ability to deliver the required power, www.psgdover.com

RUN DRY, AND


KEEP ON RUNNING.
Pumps fitted with GRAPHALLOY®
wear parts survive upsets.
GRAPHALLOY® bushings
and case rings:
• Run hot, cold, wet or dry
• Reduce maintenance
• New pumps or retrofits
• Non-galling
• Self-lubricating
• -400°F to 1,000°F
-240°C to 535°C+
GRAPHITE METALLIZING
• Corrosion resistant
CORPORATION
Yonkers, NY 10703 U.S.A.
ISO 9001:2000
PWR9b

TEL. 914.968.8400 • WWW.GRAPHALLOY.COM

www.worldpumps.com
28 Applications
WORLD PUMPS December 2015

Construction

Quality synthetic
stone slabs with
vacuum technology
iresco uses Busch vacuum technology to produce slabs
D completely free of gas inclusions and cavities. Vacuum
is supplied to the material presses of both production
lines, ensuring top quality appearance and optimal
structural integrity.

Diresco markets its products to well-


known kitchen and furniture manufac-
turers and interior decorators
throughout Europe and in Canada, USA
and New Zealand.

All Diresco Stone products are manufac-


tured at the main site in Opglabbeek in
Belgium. 65 employees work with
highly automated equipment in a three-
shift system producing synthetic stone
slabs with a dimension of 3.2 to 1.4
metres each.

After the mixing of various quartz gran-


ules and blending with synthetic resin,
the material is fed automatically into a
mechanical press. To create an abso-
lutely perfect surface vacuum is applied
to the pressing process. Even the
smallest indentations and cavities can
become visible after processing – the
Vibrating press in a “Diresco Stone” production line with Busch vacuum unit installed above the press. reduced pressure ensures that they
cannot form.

Diresco was founded in 2003, and and “Anticato”. In comparison to real The individual slabs are then hardened
specialises in synthetic stone slabs and stone, synthetic stone has the advan- in an oven at 100 to 125°C.
tiles. Quartz granules are used to tage of reproducible appearance – the
create materials deceptively similar in surface texture is always the same. After cooling they are stored for at least
appearance to stone surfaces. Other Synthetic stone is resistant to water, 24 hours before further processing.
surface textures can also be supplied. food acids and food colourings. It is Every slab is subjected to extensive
Diresco products are available in a also scratchproof, non-fading, long- quality control examinations before
number of finishes, from gloss to matt lasting and easy to clean. leaving the factory.

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


Applications 29
WORLD PUMPS December 2015

In order to meet increasing product


demand, the pressing process was
further accelerated by the addition
of a Panda vacuum booster before
the parallel arrangement of rotary
vane vacuum pumps.

Diresco was extremely satisfied


with this solution, and when a new
production line was introduced in
2009 an identical Busch vacuum
system was installed.

Maintenance work is carried out by


Rotary vane vacuum pump R 5 01600 A: two of these vacuum pumps with a Panda vacuum booster Busch under a service contract. There
each form the vacuum system for one vibrating press. are only two services per year, although
at times the vacuum pumps are in oper-
Vacuum technology plays a major part pumping speed of 1600 m³/h each ation 24 hours a day. Servicing is
in the manufacture of high-quality were installed, substantially increasing confined to inspection, oil change and
products, as even the smallest air or product quality and reducing the filter replacement. All the smaller R 5
gas inclusions cannot be tolerated. The duration of the pressing process. Busch rotary vane vacuum pumps used in
liquid ring vacuum pumps originally R 5 rotary vane vacuum pumps achieve numerous production handling units
used for the vibrating press were
unable to prevent the formation of all
an ultimate pressure of 0.1 mbar, which
corresponds to a vacuum level of
are inspected at the same time. •
air, steam and styrene vapour inclu- 99.99%. www.busch.co.uk
sions. As a result, in 2006 the Diresco
management decided to use Busch
rotary vane technology. Two Busch R 5
rotary vane vacuum pumps with a

"There are only two services


per year, although at times
the vacuum pumps are in
operation 24 hours a day."

“Diresco Stone” products in a Diresco showroom.

www.worldpumps.com
30 Applications
WORLD PUMPS December 2015

Water & wastewater

Making waves of
the right order
oday it is no longer necessary to go to the beach
T to experience the thrill of surfing with sheet wave
surfing attractions in theme parks. However, to make a
successful wave needs a successful pump - such as
the KSB Amacan P Series.

In recent years water parks and holiday How it works submersible horizontally positioned
resorts around the world have started to FlowRider is a sheet wave surfing attrac- pumps are located. The discharge of the
invest in a new and hugely popular tion with the sheet wave being created pumps is attached to a FlowRider nozzle
water attraction, namely sheet wave by pumping very high volumes of low assembly which takes the discharge flow
surfing attractions. Leading the market in pressure water up a suspended flexible and curves upwards and spreads the
the development of the technology for membrane ride surface installed in a flow wide onto the ride surface approxi-
producing surf waves is the White-Water shape that mimics the form of a wave. mately 5 ft above the bottom of the
West Industries and USA Licensee Pumping the water up and over the ride tank in which the pumps are installed. It
Aquatic Development Group (ADG), with surface provides a 1.5 to 3 in continuous is a thin sheet of water that is shot out
their FlowRider wave simulators. The flow of water which can be used for across the entire surface of the ride
FlowRider allows people of all ages and surfing using a flow board or body membrane and then falls back into the
skills to surf and body board every day board. The actual height of the wave pump chamber. In this way a continuous
of the year as they can be constructed form is about 5ft from top to bottom wave is provided.
inside buildings. Such is the popularity and the entire surface which is between
of the wave pool, it is now becoming 20 and 30 ft wide.
the must-have attraction for resorts, New installations
hotels, theme parks, sports centres and Below this ride surface is a concrete Clearly the continuous operation of
even cruise ships. containment tank, in which two FlowRider relies on superior pump

Marshall Myrman of White-Water West


says that their business is dedicated to
providing people with fun and one of
the most popular rides at their parks
around the world is the FlowRider surf
wave simulator. ““We are fun brokers”,
says Marshall, “and the FlowRider is an
exhilarating ride that is hugely popular.
It is a combination of skate boarding,
snowboarding, wake boarding, skim
boarding and surfing. It is a great
product for water parks and it is a prime
attraction particularly for visitors who like
to see it as a sport and this aspect is
developing. The greatest flow-boarders
in the world today come from skate-
boarding backgrounds and are doing the
moves and tricks that they have devel-
oped on sheet waves.” Boca Raton Resort and Club, Waldorf Astoria Resort. Image courtesy of White-Water West Industries.

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


Applications 31
WORLD PUMPS December 2015

success they are becoming more


commonly specified.” We have used
these pumps in about 12 installations
and the pumps have been outstanding,
with zero operational problems,”
continues David Keim. “The Amacan P
submersible pump is an excellent choice
for the FlowRider and other water park
applications where efficiency, reliability,
and safety are of the highest concern.”

Meeting client expectations


Azir Khan says that the Amacan P has
delivered many years of trouble-free
operation in installations all over the
world. “The mechanical seal in tandem
arrangement protects against fibrous
Planet Hollywood Resort and Casino, Las Vegas. Image courtesy of White-Water West Industries. material. Trouble-free operation is down
to the liquid reservoir and high-quality
technology and therefore White-Water’s inlet ribs and optimised bellmouth for wear-resistant seal face materials. Relia-
North American Licensee ADG has been vortex-free inflow. bility is assured through bearing temper-
specifying KSB’s Amacan P Series ature monitoring, thermal motor
submersible pump for its FlowRider protection, leakage sensors in the motor/
attractions. The most recent parks to take Reliability and performance connection space and leakage moni-
delivery of FlowRiders equipped with this With FlowRider being seen by operators toring of the mechanical seal system.
pump are at Six Flags in Gurnee, IL and as a valuable source of revenue, main- And we must not overlook the fact that
Camel Beach, Tannersville, PA. “Both these taining operation at all times is a major the slim motor minimises discharge tube
installations have the FlowRider Double issue, so pump reliability is high on flow losses, so making it highly efficient.”
and each one incorporates two of our White-Water’s list of priorities. “The attrac-
pumps,” reports KSB Regional Manager tion itself is the FlowRider Double, which “The operational demands of the Flow-
Azir Khan. “The decision to use our is our bread and butter and is typically Rider Double system are unique,”
pumps for two more installations was around 2000sq.ft,” says Marshall Myrman. continues Azir Khan, “because the system
based on the proven history and “We want our customers to have a requires a high-flow pump capable of
performance of the Amacan P.” hassle free experience with FlowRider, moving over 20,000 gallons per minute
which is a tough demand on the pumps with frequent starts and stops. After
The Amacan P submersible pump is a as they have to move a lot of water over several years in service in the FlowRider
proven pump that is used in a wide a vinyl fabric in the safest manner attractions, the KSB pumps have proven
variety of demanding storm water, possible.” to be reliable in these demanding
municipal and other water transport situations.”
applications around the globe. Most When reviewing its roster of pump
importantly for the FlowRider, where suppliers some time back, White-Water www.ksb.com
large volumes of water are used, the and ADG contacted KSB Inc. as they
pump has a flow rate capable of wanted a fresh look at the technology
exceeding 108,000 gallons per minute. available and the resources that it could
offer. “We contacted KSB because there
Unlike some other submersible pumps, are very few manufacturers of this type
the Amacan P can be mounted horizon- of pump which have a global presence,”
tally in the water containment tank comments ADG Vice-President David
below the ride surface. Furthermore, it Keim. “Because our products are used all
can withstand environments with a high over the world, it was essential that any
chemical concentration, such as a chlo- new supplier had a global presence in
rinated pool. For ADG, this pump offers a terms of engineering, technical and
number of key benefits when it comes spare parts support. We set out our
to the installation and operation. It is specific requirements and customised
easy to install, with the pump’s own items for the pumps and it was the KSB
weight ensuring self-centring seating in product that featured all our require-
the discharge tube, and an O-ring seals ments as standard. It was a pretty easy
it in. Because there are no anchoring or decision to go with them as an addi-
anti-rotation elements it is quick to tional supplier.”
install or remove. The pump is also
hydraulically optimised providing The first KSB pumps were supplied
low-vibration hydraulic system with around three years ago and due to their Amacan P submersible pump.

www.worldpumps.com
32 Feature
WORLD PUMPS December 2015

Mining

Axial thrust in
vertical turbines
eliability and availability are crucial for the mining
R industry, where pump systems are located at isolated
and high altitude locations with limited access to
machinery and workforce. Petar Ostojic from Neptuno
Pumps discusses how incorporating engineered axial
thrust bearing assemblies can improve vertical turbine
pumps reliability while reducing their life cycle cost.

Figure 1. Neptuno Pumps VTPX™ for high-pressure applications.

Vertical turbine pumps (VTP) are requiring Total Dynamic Head (TDH) of multiple pump stations installed in series.
currently among the most used equip- up to 300 m so they can be immediately This increases a project’s CAPEX and
ment in the mining industry worldwide. connected to a booster pumping station sometimes this alternative may not even
Their multiple benefits, such as high effi- –generally equipped with a tank and a be feasible, as in cases where geograph-
ciency performance, reliability, modular set of horizontal pumps- that will finally ical or regulatory conditions do not
design and minimum space require- provide the required high pressure. allow the installation of several pump
ments, make them one of the favourite stations. That is why some manufacturers
pumps when designing a new industrial Nowadays, as mine sites get bigger and are pushing the limits of this pump
process or project. Historically, these metal ore grades decreases, the mining model, designing engineered vertical
pumps have been widely used for fluid industry requires total dynamic heads so turbine pumps within a limited range
intake or transfer applications, generally large that pumping must be done in of specific speeds (30 < nq < 50), for

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


Feature 33
WORLD PUMPS December 2015

neered axial thrust bearing assembly is


required, especially when operating with
powers over 700 HP, such as in the case
of the mining industry located at the
Andes Mountains in Latin America.

In thrust we trust
Axial thrust bearing assemblies are
commonly used in vertical turbine
pumps, especially when using vertical
solid shafts that cannot withstand high
loads of axial thrusts. A standard motor,
with a power ranging from 1000 to 3000
HP, can usually withstand from 25 to 50
kN. However, when facing high-head
applications, an engineered vertical
turbine pump, even with thrust-balanced
impellers, can reach loads of up to 200
kN, leaving most standard vertical solid
Figure 2. Typical water-cooled axial thrust bearing assembly. shaft motors out of the game.

high-head per stage, reaching Total using a vertical hollow shaft motor (VHS) These bearing assemblies are usually
Dynamic Heads (TDH) of up to 700 (m) or a vertical solid shaft motors (VSS). installed on top of the pump discharge
or 2,297 feet. head, over a separate fabricated driver
stand and immediately before the flex-
VHS vs VSS ible coupling. This component with-
High head vertical turbine For many years pump users have stands both the total hydraulic axial
pumps debated between which are the advan- thrust and the total rotor weight.
As said before, due to high geographical tages or limitations of using a vertical However, as shown in Figure 2, most
altitudes and long distances, mining hollow shaft (VHS) or vertical solid shaft vertical turbine pump’s axial thrust
companies are requiring pumps that can (VSS) motors. The most common differ- bearing assemblies, for applications
offer higher heads. Neptuno Pumps has ences are that vertical hollow shaft above 1000 HP, are water-cooled,
taking the lead in the design and manu- motors have no external shaft extension requiring a continuous flow of fresh
facturing of a complete line of high- and that the couple to the pump shaft is water, with flows of up to 1 gpm and
head Vertical Turbine Pumps, known as located at the top of the motor. On the pressures of 35 psi, which is quite diffi-
the Neptuno Pumps VTPX, as shown in other hand, vertical solid shaft motors cult to get in a mining operation located
Figure 1, which resulted finalist in the are connected to the pump through a in the isolated mountains at 4,500
category Innovation of the Year – Prod- rigid or flexible coupling and they are metres above sea level. Others are
ucts at the 2015 Pump Industry Awards. coupled to the pump shaft at the lower designed to use water directly from the
end of the motor. pump’s discharge head, however, when
One key parameter for the right selec- using vertical turbine pumps with high
tion of this type of pump is thrust. This Over the years, many pump users have total dynamic heads, pressures are
load is generated due to unbalanced preferred vertical hollow shaft motors extremely high, reaching up to 850 psi,
internal pressure, weight and fluid direc- because they have fewer parts and less thus requiring different methods for
tion change, which acts parallel to the chance of vibration issues, being easier
pump shaft and is divided in two direc- to inspect without disassembly of the
tions, downthrust and upthrust. Since motor. However this 'high thrust' motors
downthrust is the predominant hydraulic can withstand forces of just 50 kN
force in the case of vertical turbine becoming a limitation for some vertical
pumps, reaching up to 90 kN per pump turbine pump applications that require
stage, some rigorous design aspects higher pressures, not taking advantage
must be considered in order to guar- of the full potential that this type of
antee a reliable, continuous and stable pump can offer.
operation without sacrificing neither
energy efficiency nor pump availability. Vertical solid shaft motors, on the other
hand, have their own set of benefits,
Furthermore, the definition of these being up to 20% cheaper than VHS
criteria in an early design state of any drivers, offering a more accessible adjust-
project is of the utmost importance ment and fewer problems with eccen-
because it will be critical in defining tricity. However in order to exploit its
which type of vertical motor will be economic and technical benefits to the
selected for each application, whether fullest, the incorporation of an engi- Figure 3. CFD Simulation of the ATAC™ Bearing Assembly.

www.worldpumps.com
34 Feature
WORLD PUMPS December 2015

of the oil inside the bearing assembly


was analysed in order to confirm that a
good temperature distribution is
obtained that would allow a long life
cycle of the bearing. At the same time a
complete structural analysis of the
bearing assembly ad fan is done in order
to select the right geometries and
materials.

This highly engineered air-cooled


bearing assembly, shown in Figure 4, can
withstand up to 270 kN of axial thrust,
enabling the use of lower-cost, standard
Figure 4. Neptuno Pumps Axial Thrust Air-Cooled (ATAC) Bearing Assembly. vertical solid shaft motors without
requiring a special independent fresh
lowering its inlet pressure, such as injected to the pump’s bearing water refrigeration system, allowing to
special valves, that usually fail at very assembly. be used even for heavy-duty applications
short time due to the heavy-duty condi- that transport highly corrosive fluids,
tions, frequently becoming a variable for such as in the case of solvent extraction/
premature failure for vertical turbine Air-cooled bearing assembly electro-winning (SX/EW) plants.
pumps, decreasing its mean time In order to solve this issue, Neptuno
between failure. Pumps designed its Axial Thrust Air-
Cooled (ATAC) Bearing Assembly. This Success story
Furthermore, the mining industry char- engineered component, which is filled Compañía Minera Lomas Bayas is located
acterises for pumping water with high with oil, transfers heat through a in the Atacama Desert, 120 km east of
solid concentrations, particularly in specially designed fan that forces ventila- the city of Antofagasta in northern Chile.
applications where pumping reclaim tion through the vanes. The shape of the As one of the world’s lowest-grade
water which generally contains more fan’s blade was developed using a NACA copper operations, with average grades
than 10% solid concentration. At the 4 digit airfoil from the National Advisory of 0.27% soluble copper, this open pit
same time, today more and more Committee for Aeronautics (US). copper mine is heavily intensive in the
Solvent Extraction/Electro Winning (SX/ use of hydrometallurgy processes, such
EW) plants are using high head vertical As shown in Figure 3, a complete as solvent extraction/electro-winning
turbine pumps, transporting acid fluids Computational Fluid Dynamics (CFD) and (SX/EW), which allows them to, effi-
with high-chloride concentrations of up Finite Element Analysis (FEA) were devel- ciently and economically, process lower-
to 70 (g/l), which naturally cannot be oped in order to predict its behaviour grade ores with lower water
used for a cooling purpose, thus imper- when summited to the required axial consumption (for more information on
atively requiring fresh water to be thrust and thermal conditions. The flow the SX/EW process please read our

Figure 5. Compañía Minera Lomas Bayas pumping station in northern Chile.

www.worldpumps.com
Feature 35
WORLD PUMPS December 2015

Figure 6. Remanufactured pump incorporating the Neptuno Pumps Axial Thrust Air-Cooled (ATAC™) Bearing Assembly.

previous article “Water management for millimetres per second, a critical condi- pump, representing a total investment
copper mining”, World Pumps, Number tion that damaged the pumps and, as for both pump stations of US$1,600,000,
579, July/August 2012). said before, was practically destroying its offering a payback period for this project
mechanical seals, requiring a continuous of just 4,2 months.
In the SX/EW process the ore is leached replacement of this component almost
with sulphuric acid, and then the copper each week. This translated in a mean
is extracted from the acid leach with a time between failures (MTBF) of just Conclusion
solvent which flows to the leach pad three months or 2160 hours. Under As described above, vertical turbine
where it is collected and directed to flow these operational conditions, and at an pumps are gaining terrain over other
into the leach ponds, where pumps average price of US$140,000 for the pump models in the mining industry
transfer it to the SX plant and the repair and maintenance of each of these due to its versatility, reliability and highly
copper is subsequently electrolytically pumps, the company was paying US$ efficient operation. However, the concep-
refined. This means that there is a limited 4,480,000 a year. tion that these pumps can offer low to
supply of fresh water and at the same medium total dynamic head operations
time it is not possible to use the same The solution consisted in repairing the has limited its full performance potential.
pumped fluid to cool down their vertical entire pump under new dimensions and By using an Axial Thrust Air-Cooled
turbine pumps’ bearing assemblies. tolerances which would guarantee a reli- Bearing Assembly, vertical turbine pumps
able performance, by manufacturing can be taken to the next level, reaching
The company was operating two pump new bushings and wear rings, rebal- total dynamic heads of up to 700 m,
stations, as shown in Figure 5, each ancing the impellers under the ISO using lower-cost and standard vertical
consisting of four vertical turbine pumps, 1940/1 norm, welding and re-machining solid shaft motors, reducing the number
with all wetted parts manufactured in the discharge heads and columns. It also of required pumps for some projects, as
Super Duplex 2507 stainless steel (UNS required the manufacturing of a new well as the payback periods to as little as
S32750). Station 1 was equipped with longer discharge shaft in order to install one year, while cutting the total cost of
four, two-stage pumps powered by 600
HP vertical solid shaft motors, while
the new ATAC bearing assembly. ownership up to 50%. •
Station 2 had four, five-stage pumps This engineered solution, as shown in VTPX and ATAC are trade marks.
with 1500 HP VSS motors. Figure 6, has allowed the company to
operate continuously 7,200 hours with
When operating, these motors presented vibrations of just 1.5 (mm/s). Under
an axial displacement of three millime- these performance conditions there is Contact:
tres when starting which immediately no need of taking the pumps out before Petar Ostojic
Mechanical Engineer, M.Sc.
damaged the mechanical seals. Impellers 10,000 hours of continuous operation for Project & Product Manager
on both pump stations were unbalanced preventive maintenance. This solution, Neptuno Pumps
and bushings where out of dimension consisting of repairing the old pump Av. Circunvalación 64B, Iquique-Chile
Tel: + 56 57 2424685
by 250%. These substandard mechanical plus incorporating the Neptuno Pumps
projects@neptunopumps.com
conditions had the pumps operating ATAC bearing assembly represented a www.neptunopumps.com
with high vibration values of up to ten cost for the customer of US$200,000 per

www.worldpumps.com
36 Feature
WORLD PUMPS December 2015

General processing

Electric actuation
gearbox progress
ew and improved manufacturing processes and materials
N are continually considered for product management.
When taking a closer look, this evolutionary process
can be observed for gearbox ranges with an
established industry track record.

Power supply has a crucial impact on


the actuator design and development.
The basic principle for electric actuators
is the electrical motor with integral
gear unit.

Selection of suitable gearing is decisive


for factors like self-locking or self-braking.
In this context, following an operation
command by the DCS, the actuator Figure 1: Actuator-gearbox combination in a water filter system.
operates the valve to a standstill at the
desired position and holds it, irrespective
of any external forces on the valve.
Heavy gate valve plates under the effects
of gravity are an ideal example of this
automation task. The same applies to
manually operated valves. This self-
locking issue will be dealt with in more
detail below.

Electric actuators cover a large torque


range. Part-turn actuators automating
gate and ball valves cover the torque
range of just a few Newton metres up to
approx. 2,500 Newton metres. For elec-
tric multi-turn actuators with their typical
gate automation, this range goes up to
32,000 Newton metres.

Actuators are implemented in combina-


tion with valve gearboxes when going Figure 2: Automation of butterfly valves - on the left with direct mounted actuator, on the right with
beyond these torque requirements. For an actuator-gearbox combination.
multi-turn actuator combinations, solu-
tions for up to 120,000 Newton metres valves stays below these values. As a Worm gearboxes provide
are currently available on the market. For matter of fact, valve gearboxes in combi- self-locking
part-turn applications, they can reach up nation with appropriate reduction are Actuators are self-locking if the valve
to 675,000 Newton metres. In turn, the capable of achieving an output torque position cannot be changed from stand-
torque range for manually operated of up to 70,000 Newton metres. still while torque acts upon the valve.

www.worldpumps.com 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved


Feature 37
WORLD PUMPS December 2015

actuator is added, and for rising required. Depending on the stroke


stems, the stem nut further contrib- required this could amount to several
utes to this effect. The consequence thousand revolutions. Consequently, the
is flexibility when sizing components. basic conditions can be very differernt in
In-depth knowledge is required spite of the identical design principle.
for using this benefit. The Whereas bearing bushes for the worm
wheel are sufficient and adapted solu-
tions for part-turn gearboxes, multi-turn
gearboxes require anti-friction bearings
to avoid critical heating up and
to withstand inevitable radial
forces. Gearboxes designed as
part-turn gearboxes are there-
fore only suited for multi-turn
applications to a very limited
degree. Appropriate multi-turn gearboxes
can be of considerably smaller sizes
provided that the generated heat can be
sector of civil engineering construction easily dissipated. This is the reason why
for water applications is the perfect bronze worm wheels should be used for
example to express the crucial impor- multi-turn gearboxes since they have
tance of these calculations. Precise superior sliding properties and increased
dimensioning of actuator/gearbox thermal conductivity compared to sphe-
combinations for lifting, lowering, roidal cast iron wheels.
braking and supporting large weir
penstocks is the core competence within Gate valves typically automated by
the field of self-locking and self-braking. multi-turn actuators or multi-turn
Figure 3: Sectional view of a part-turn gearbox. gearboxes dispose of internal end
position limitations. End positions can be
Gearing efficiency is the foundation for Significant distinctions: precisely approached even for manual
the simple and reliable self-locking Multi-turn gearboxes versus operation, in case of emergency for
effect. This is the main reason why the part-turn gearboxes example. Frequently this does not apply
worm gearbox design principle is so The worm wheel within the gearbox to part-turn valves. For multi-turn gate
crucial for valve gearboxes in part-turn performs less than a complete revolution and ball valves, end positions OPEN and
applications. Large reduction levels to cover the complete travel of a part- CLOSED may only be set by means of
required can be achieved at one stage turn valve. In compliance with EN ISO the end stops within the gearbox. This is
with only two movable parts while 5211, this is the definition for a part-turn the reason why part-turn gearboxes are
fulfilling simultaneously the desired effi- movement. When dealing with gate and equipped with end stops, unlike multi-
ciency of less than 0.5. Here, worm gear- ball valve automation, the typical part- turn gearboxes.
boxes are considered as statically turn movement amounts to 90°.
self-locking. Efficiency is controlled via
reduction which in turn depends on the This is different for multi-turn gearboxes. Design principle of end stops
number of worm wheel teeth in combi- When driving a gate valve by means of a There are two design options to imple-
nation with the pitch of the worm shaft. rising non-rotating stem from one end ment end stops for part-turn gearboxes.
The higher the reduction, the higher the position to the opposite end position, For one option, the worm wheel is
self-locking effect. Defined material several worm wheel revolutions are equipped with an upturn driving against
combinations for worm wheel and worm
shaft, surface quality of force transmit-
ting components and the selection of
the lubricant can further have an impact
on self-locking.

For valves with rising stems, the force is


transmitted to the valve stem by means
of a stem nut (output drive type A). The
generated friction also contributes to the
self-locking effect.

The result is the combination of all


intervening components. For manual
operation, this could be just a gearbox,
for motor driven valves, self-locking of an Figure 4: End stop design: 1: End stops, 2: Travelling nut, 3: Safety wedge discs.

www.worldpumps.com
38 Feature
WORLD PUMPS December 2015

ranges are often maintained over


decades. Within the framework of
product revisions, they benefit from new
technologies. These include multi-layer
powder coating of individual housing
parts for example, which has virtually
substituted the final wet painting of
completely assembled devices. This
coating is more resistant against UV radi-
ation and mechanical stress than tradi-
tional painting procedures. And most
importantly, when opening the device
for maintenance purpose for example,
the entire coating remains undamaged.
Figure 5: Bronze sprocket wheel soldered to cast iron support wheel.
This leads to a significant improvement
of corrosion protection complying with
the requirements of corrosion protection
category C5 according to EN ISO
12944-2. Gearboxes can be subjected to
continuous immersion without additional
coating and are suitable for buried
service.

New joining technologies allow the


combination in one component of
different materials combining desired
properties. For example, soldering
methods melting bronze and spheroidal
cast iron are currently in use.

Significant advances have been made in


the lubricant sector. On the basis of
close cooperation between AUMA as
actuator and gearbox manufacturer and
their lubricant suppliers, a product with
Figure 6: Worm wheel with adhesive lubrication. significantly superior properties was
developed fulfilling the special valve
a stop within the housing. In many excessive load causes end stop bursting, operation requirements.
cases, worm wheel segments are used the gearbox housing remains undam-
instead of complete worm wheels. The aged and gearbox function is not The new lubricant preserves its lubri-
drawback for this option is that the impaired. The gearbox can be operated cating properties within a temperature
output torque is applied to the gearbox at any desired swing angle, if a complete range between – 60 °C and + 140 °C at
housing when approaching an end stop. worm wheel is fitted. high loads thus fully complying with the
During commissioning, in particular prior gearbox application requirements around
to setting end stop seating of mounted The travelling nut design bears the risk the globe. A further objective for this
actuators, accidental end stop that the gearbox seizes in the end stop project was to reduce lubricant quantity
approaches might occur. position and that the unseating torque without concessions to the housing to
required is difficult to generate. Inserting be completely filled with lubricant.
The actuator stall torque multiplied by safety wedge discs ahead of every end
the gearbox reduction ratio is applied to stop prevents this risk. Thanks to the For modern and top quality gearboxes,
the gearbox housing which increases the safety wedge disc pair, the unseating adhesive lubricants are totally sufficient –
risk of housing damage. torque required amounts to just 60% of these are applied using an automated
the torque previously applied to spraying procedure resulting in gearbox
The second option is the travelling nut approach the end stop. This ensures that weight reduction, simplifying mainte-
design principle, whereby the drawbacks the unseating torque required is always nance work and preserving resources
described above are avoided. The end of available. This leads to the conclusion and environment. Compared to the oil
the worm shaft is threaded so that the that the travelling nut solution presents lubrication typical for this sector, the
travelling nut can move between two higher design safety. advantage of adhesive lubrication is that
end stops. Only the comparatively low there will be no lubricant loss even in
input torques act on the end stops, not Advances the event of a leakage. A tightness
the high output torques. Thus, the In valve automation, mechanical product scheme enhanced during product devel-
gearbox housing remains load-free. If life cycles are lengthy. Gearbox type opment with the use of new sealing

www.worldpumps.com
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40 Feature
WORLD PUMPS December 2015

Duty class 1
Gearbox size GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3 GS 160.3 GS 200.3 GS 250.3
Number of cycles
according to duty class 1 10,000 5,000 2,500 1,200
(EN 15714-2)
Max. torque [Nm] 500 1,000 2,000 4,000 8,000 14,000 28,000 56,000

Duty class 2
Gearbox size GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3 GS 160.3 GS 200.3 GS 250.3
Number of cycles
1,000
according to duty class 2
Max. torque [Nm] 625 1,250 2,200 5,000 10,000 17,500 35,000 70,000

elements significantly contributes to gearbox sector, there is no just reason to


considerable minimisation of the proba- comply with the superior requirements
bility of lubricant loss in case of a leak. of this standard.

Finally, the improved options for surface In this instance, definition of various load
treatment deserve particular mention. profiles is more pragmatic. Manually
The parts within the power drive have operated gearboxes are less frequently
hardened and achieve the required operated than motor driven gearboxes.
surface properties to withstand wear, Lengthy experience led to the following
temperatures and significant impact of classification:
forces.
• Duty class 1: motor operation in
New technologies have supported the compliance with EN 15714-2 Figure 7: Test cycle complying with standard
improvement of these properties in • Duty class 2: motor operation if rarely fulfilling increased requirements.
recent years. QPQ (quench polish operated
quench) adopted from the automotive • Duty class 3: manual operation. impair the lifetime. Type tests and the
engineering sector plays a significant resulting lifetime indications performed
role contributing to increased corrosion Lifetime for actuators and actuator on the basis of the load profile described
resistance thanks to the resulting oxide gearboxes is specified by the minimum in EN 15714-2 increase reliability. Manu-
layer. This is particularly important for the number of operation cycles to be facturers focussing on service safety and
gearbox input shaft showing best corro- achieved. One cycle comprises operation reliability make use of EN 15714-2 as
sion properties throughout the sector. from CLOSED to OPEN and back. Taking minimum requirements or even exceed
the example of selected part-turn gear- these demands.
All these measures support lifetime boxes, the tables above indicate the
improvement. Is this really required? At correlation between the number of
AUMA, a manufacturer with active cycles to be achieved and the maximum Conclusion
market presence for over five decades, admissible torque. The permissible Continual revision of products will
no incident of gearbox damage has torque for duty class 2 is 25 percent improve mechanical properties as well
been observed caused by material wear. above duty class 1. In many cases, as load capacities, leading to lifetime
Life-time is closely linked to the load smaller and more economic gearboxes increases. With the introduction of the
applied. Therefore, observations are can be applied. In combination with the duty classes, the strict standard is no
made that this benefit should not be duty class definition, dimensioning flexi- longer the only guideline for sizing and
used to stretch lifetime but to increase bility is increased by expanding available selecting gearboxes and higher
permissible torques. As a result the verifi- sizes of valve attachment flanges. economic efficiency can often be
cation of technical data makes sense. achieved. However, one issue remains
unchanged: valve gearboxes are imple-
The type test load profile mented in applications with superior
Lifetime requirements for The actuator standard EN 15714-2 speci- requirements on service safety. A disad-
valve gearboxes fies a load profile for operation cycle vantage is the lack of binding standards
Standards give no clear indication to life- achievement (refer to figure 7). Basically, related to lifetime and load profile for
time requirements for valve gearboxes. the application of this load profile is valve gearboxes. This makes it difficult
Actuator manufacturers with valve gear- optional since this standard does not to compare the technical data of
boxes as part of their product portfolio apply to valve gearboxes. However, devices made by different manufac-
are well advised to comply with the falling short of fulfilling the standard turers. To be on the safe side, the basis
standard EN 15714-2 applicable for actu- requirements could turn out to be a for data calculation must be questioned.
ators. A quite reasonable approach, since mistake. Users have no means to If the answer is: “on the basis of EN
gearboxes are frequently combined with
actuators, and not many manufacturers
compare application loads with manu-
facturer-specific load profiles. This can be
15714-2”, you are on safe ground.

act this way. For manufacturers in the an issue since small torque peaks might www.auma.com

www.worldpumps.com
2nd International Conference on
Desalination and Environment
23–26 January 2016 • Sheraton Doha
Resort & Convention Hotel, Doha, Qatar

Conference Chair
Nidal Hilal, Editor-in-Chief of Desalination,
Swansea University (UK) and
Qatar Environment and Energy Research Institute (Qatar)

Early Bird Registration Deadline: 13th November 2015

The Qatar Environment and Energy Research Institute and Elsevier


would like to invite you to join us at the 2nd International Conference on
Desalination and Environment: A Water Conference. It will be hosted by
the beautiful city of Doha in Qatar.

This conference represents a unique opportunity for academics and


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of desalination and water treatment.

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institutes actively involved in desalination and water sciences research.

The scope of the conference will be quite broad covering the below-
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Topics covered include:


• Thermal processes
• Membrane processes
• Hybrid processes
• Harmful Algal Blooms (HAB)
• Environmental and related technologies

To submit your abstract and to register, please visit:


www.icodeconference.com
42 Pump FAQs
WORLD PUMPS December 2015

Pump FAQs
Q. What are some differ- momentum or slow slightly at off BEP flows. The double runaway speed. If the head,
ences between single through the spiral to the volute design (see Figure under which such operation
volute and double volute discharge at the design point. 1.3.3.2) is typically used to may occur, is equal to or
casings for rotodynamic reduce shaft deflections and greater than that developed
centrifugal pumps? Radial thrust on the impeller bearing loads to permit use by the pump at its best effi-
varies with pump rate of of a smaller shaft and bearing ciency point during normal
A. The function of a flow, being lowest near the sizes or to prolong the life of operation, then the runaway
discharge casing is to collect best efficiency point (BEP), the pump. The casing speed may exceed that
output from the rotating and higher at reduced or complexity is greater than corresponding to normal
impeller, decrease the increased flow rates. The that for the single volute type pump operation. This excess
velocity momentum of liquid thrust at off BEP can be very due to the inaccessibility of speed may impose high
leaving the impeller before it high for large-diameter the outside chamber. mechanical stresses on the
reaches the next stage impellers producing high rotating parts both of the
impeller or pump discharge, head. Radial thrust also varies For more information about pump and the prime mover
and to transform increased with impeller diameter, casings for rotodynamic and, therefore, knowledge of
kinetic energy of liquid at the impeller width, and total pumps, see ANSI/HI 1.3 Roto- this speed is essential to
impeller outlet into pressure. head. Shaft deflection, dynamic Centrifugal Pumps for safeguard the equipment
combined maximum stress Design and Application. from possible damage.
The single volute is the most and bearing loads must be
common casing style due to kept within acceptable limits Q. What is reverse It has been found practical
relative ease of manufacture by various means for best runaway speed and what to express the runaway
and accessibility for inspec- operation. affects can it have on roto- speed as a percentage of
tion. An impeller discharges dynamic centrifugal that during normal opera-
into a single spiral-shaped With the double volute pumps? tion. The head consistent
passage with one cutwater casing, an impeller discharges with the runaway speed in
(tongue) that directs the into two spiral passages with A. A sudden power and this case is assumed to be
liquid into the system or into two cutwaters (tongues). The check valve failure during equal to that developed by
the next stage of a multi- pumped fluid then discharges pump operation against a the pump at the best effi-
stage pump. The volute has a via these two passages into a static head will result in ciency point.
constantly increasing area system or into the next stage reverse pump rotation.
cross section from the of a multistage pump. The The ratio of runaway speed
tongue, around the casing, to cutwaters are usually diamet- If the pump is driven by a (nro) to normal speed (nno)
the discharge nozzle. The rically opposed in the casing. prime mover offering little for single and double suction
typical design criterion (see Care must be taken in the resistance while running pumps varies with specific
Figure 1.3.3.1) is for the liquid design to minimize the loss of backwards, the reverse speed speed. This relationship is
exiting the impeller to main- pump efficiency. With prop- may approach its maximum shown in Figure A.9. The
tain either a constant mean erly designed passages, radial consistent with zero torque. data shown should be used
velocity, constant velocity thrust is minimized, especially This speed is called reverse as a guide, because it is
recognized that variations
can exist with individual
designs.

Transient conditions during


which runaway speed may
take place often result in
considerable head variations
due to surging in the pres-
sure line. Because most
pumping units have rela-
tively little inertia, surging
Figure 1.3.3.1 Single volute casing Figure 1.3.3.2 Double dual volute casing can cause rapid speed fluc-

www.worldpumps.com
Pump FAQs 43
WORLD PUMPS December 2015

tuations. The runaway speed


may, in such a case, be
consistent with the highest
head resulting from surging.
Therefore, knowledge of the
surging characteristic of the
pipeline is essential for deter-
mining the runaway speed,
and this is particularly impor-
tant in case of long lines.

For more information


regarding reverse runaway
speed with rotodynamic
centrifugal pumps, see ANSI/
HI 1.4 Rotodynamic Centrifugal
Pumps for Manuals Describing
Installation, Operation, and
Figure A.9 Reverse runaway speed versus specific speed when head equals pump head at BEP Maintenance.

Hydraulic Institute’s Year-End Sale


Is Happening Now!

Save on all pump engineering standards and guidebooks before prices


increase in 2016. Use coupon code YESALE15 during checkout.

includes both electronic


PDFs and hardcopy format visit eStore.Pumps.org and save!

www.worldpumps.com
44 Product finder
WORLD PUMPS December 2015

product
finder
Germany Germany
PUMP TYPES Tel. +49 65 94 100
MULTI-STAGE
Tel: +49 4821 77101
Fax +49 65941640 SINGLE ENTRY Fax: +49 4821 771274
BORE & WELL Email: info@feluwa.de Caprari S.p.A Email: sales@sterlingsihi.de
Website: www.feluwa.com Website: www.sterlingsihi.com
ABEL GmbH & Co KG Via Emilia Ovest 900
Abel Twiete 1 41123 Modena,
21514 Buchen, ELECTRICAL Italy SLURRY
Germany MOTORS, Tel: +39 059 897611
ABEL GmbH & Co KG
Tel: +49 4155 818-0 Fax: +39 059 897897
Fax: +49 4155 818-499
SUBMERSIBLE Website: www.caprari.com
Abel Twiete 1
21514 Buchen,
Email: mail@abel.de Caprari S.p.A Sterling SIHI GmbH Germany
Website: www.abel.de Via Emilia Ovest 900, Tel: +49 4155 818-0
Lindenstrasse 170
Caprari S.p.A 41123 Modena, Italy D-25524 Itzehoe, Fax: +49 4155 818-499
Tel: +39 059 897611 Germany Email: mail@abel.de
Via Emilia Ovest 900,
Fax: +39 059 897897 Tel: +49 4821 77101 Website: www.abel.de
41123 Modena, Italy
Tel: +39 059 897611 Website: www.caprari.com Fax: +49 4821 771274
FELUWA Pumpen GmbH
Fax: +39 059 897897 Email: sales@sterlingsihi.de
Lubi Industries LLP Beulertweg
Website: www.caprari.com Website: www.sterlingsihi.com
Near Kalyan Mills, Naroda Road 54570 Muerlenbach,
Ahmedabad, 380025
CENTRIFUGAL POSITIVE Germany
India Tel. +49 65 94 100
Tel: +91 79 30610100/166 DISPLACEMENT Fax +49 65941640
Caprari S.p.A
Fax: +91 79 30610300 FELUWA Pumpen GmbH Email: info@feluwa.de
Via Emilia Ovest 900,
41123 Modena, Italy Email: expsales@lubipumps.com Beulertweg Website: www.feluwa.com
Tel: +39 059 897611 Website: www.lubipumps.com 54570 Muerlenbach,
Fax: +39 059 897897 Tormac Pumps Germany SUBMERSIBLE
Website: www.caprari.com Tel. +49 65 94 100 BOREHOLE
M/s. Naargo Industries Private
Fax +49 65941640
Sterling SIHI GmbH Limited, 2 Gem Garden,
Caprari S.p.A
Email: info@feluwa.de
Ganapathy, Coimbatore,
ADVERTISERS Lindenstrasse 170
India 641 006
Website: www.feluwa.com Via Emilia Ovest 900
D-25524 Itzehoe,
GUIDE TO Germany Tel: +91 422 6522622
41123 Modena,

PRODUCT Fax: +91 422 2531956


PROCESS Italy
Tel: +49 4821 77101 Tel: +39 059 897611
FINDER Fax: +49 4821 771274 Email: (MEMBRANES)
Fax: +39 059 897897
Email: sales@sterlingsihi.de tormac@tormacpumps.com Sterling SIHI GmbH Website: www.caprari.com
Promote your company s Website: www.sterlingsihi.com Website:
Lindenstrasse 170
products and services in www.tormacpumps.com Lubi Industries LLP
Tormac Pumps D-25524 Itzehoe,
product finder and allow Germany Near Kalyan Mills, Naroda Road
M/s. Naargo Industries Private
our readers involved in
Limited, 2 Gem Garden,
GLANDLESS Tel: +49 4821 77101 Ahmedabad, 380025
purchasing, specifying or Fax: +49 4821 771274 India
Ganapathy, Coimbatore, Sterling SIHI GmbH
simply using pumps to Email: sales@sterlingsihi.de Tel: +91 79 30610100/166
India 641 006 Lindenstrasse 170
make direct contact with Website: www.sterlingsihi.com Fax: +91 79 30610300
Tel: +91 422 6522622
your sales force. D-25524 Itzehoe, Email: expsales@lubipumps.com
Fax: +91 422 2531956 Germany Website: www.lubipumps.com
If your products do Email:
Tel: +49 4821 77101
ROTARY, POSITIVE
not fall into any of the tormac@tormacpumps.com
Fax: +49 4821 771274 DISPLACEMENT SUBMERSIBLE
Website:
categories listed, we Email: sales@sterlingsihi.de
will create a new one www.tormacpumps.com
Website: www.sterlingsihi.com
Sterling SIHI GmbH CONTRACTOR
Lindenstrasse 170
specifically for you. Tsurumi (Europe) GmbH, HOMA Pumpenfabrik GmbH
D-25524 Itzehoe,
Heltorfer HOLLOW DISK Germany Industriestrasse 1
Str. 14 . 40472 Düsseldorf, Neunkirchen - Seelscheid,
IF YOU WOULD LIKE TO
PUMPS Tel: +49 4821 77101
Germany Fax: +49 4821 771274 53819,
FEATURE IN PRODUCT FINDER Tel: +49 211 4179373. 3P Prinz srl Email: sales@sterlingsihi.de Germany
PLEASE CONTACT: Fax: +49 211 4791429 Tel: 0049 2247 7020
Via Enrico Mattei 283/R, 55100 Website: www.sterlingsihi.com
UK, EUROPE & ROW Email sales@tsurumi.eu Mugnano, Lucca, Fax: 0049 2247 70244
RACHEL DI SANTO Website: www.tsurumi.eu Italy SCREW Email: info@homa-pumpen.de
T: +44-(0) 01625-876622 Tel: +39 0583 491183 Website: www.homa-pumpen.de
E: RACHEL.DISANTO@ CHEMICAL PROCESS Fax: +39 0583 954659 LEISTRITZ PUMPEN GMBH
HUSONMEDIA.COM Markgrafenstrasse 29-39 SUBMERSIBLE PUMP
Email: sales@3pprinz.com
GERMANY, SWITZERLAND Sterling SIHI GmbH D-90459 Nuremberg,
& AUSTRIA Lindenstrasse 170
Website: www.3pprinz.com & MOTOR
Germany
CHRISTIAN HOELSCHER D-25524 Itzehoe, Tel: +49(0)911/4306 0 Zhejiang Fengyuan Pump
T: +49-(0) 89-95002778 Germany HYGIENIC PUMPS Fax: +49 (0)911/4306 490 Industry
E: CHRISTIAN.HOELSCHER@ Tel: +49 4821 77101 3P Prinz srl Email: pumpen@leistritz.com Taihu Industry Zone, Daxi Town,
HUSONMEDIA.COM Fax: +49 4821 771274 Website: www.leistritz.com
Via Enrico Mattei 283/R, 55100 Wenling Zhejiang,
USA Email: sales@sterlingsihi.de
Mugnano, Lucca, China
DAN FETZNER Website: www.sterlingsihi.com SELF-PRIMING
Italy Tel: 86-576-8632d0776
T: +1 212-268-3344 Fax: 86-576-86320733
Tel: +39 0583 491183 Sterling SIHI GmbH
E: DAN.FETZNER@ DIAPHRAGM, Email: tzfy@fyupumps.com
HUSONMEDIA.COM Fax: +39 0583 954659
Lindenstrasse 170
DOUBLE/ Email: sales@3pprinz.com D-25524 Itzehoe,
Website:www.fypumps.com
MICHAEL MITCHELL SINGLE ACTING Website: www.3pprinz.com Germany
T: +1 631 673 0072 SUBMERSIBLE
Tel: +49 4821 77101
E: MJM@4M-MEDIA.COM ABEL GmbH & Co KG SEWAGE
LIQUID RING Fax: +49 4821 771274
Abel Twiete 1
VACUUM Email: sales@sterlingsihi.de Caprari S.p.A
CHARLOTTE ALEXANDER 21514 Buchen, Germany
Website: www.sterlingsihi.com
T: +1 631 673 0072 Tel: +49 4155 818-0 Via Emilia Ovest 900
Sterling SIHI GmbH
E: CHARLOTTE@ Fax: +49 4155 818-499 41123 Modena,
4M-MEDIA.COM Email: mail@abel.de
Lindenstrasse 170 SINGLE-STAGE Italy
D-25524 Itzehoe,
Website: www.abel.de PROCESS Tel: +39 059 897611
THE COST PER CATEGORY IS Germany
Fax: +39 059 897897
€460/$480/ 305 FELUWA Pumpen GmbH Tel: +49 4821 77101 Sterling SIHI GmbH
Website: www.caprari.com
FOR 12 MONTHS Beulertweg E-mail: sales@sterlingsihi.de Lindenstrasse 170
54570 Muerlenbach, Website: www.sterlingsihi.com D-25524 Itzehoe, HOMA Pumpenfabrik

www.worldpumps.com
Product finder 45
WORLD PUMPS December 2015

GmbH VACUUM Tsurumi, Tsurumi-ku, Website: www.caprari.com Email: info@feluwa.de


Industriestrasse 1 Osaka 538-8585, Website: www.feluwa.com
EXTRACTION Japan IRRIGATION
Neunkirchen - Seelscheid,
Sterling SIHI GmbH Tel: +81-6-6911-7271
53819,
Germany Lindenstrasse 170
Fax: +81-6-6911-0100
Caprari S.p.A
Via Emilia Ovest 900
DRIVES
Tel: 0049 2247 7020 E-mail:
D-25524 Itzehoe,
Fax: 0049 2247 70244 Germany
intsales@tsurumipump.co.jp 41123 Modena, ELECTRIC MOTORS
Website: Italy
Email: info@homa-pumpen.de Tel: +49 4821 77101 Tel: +39 059 897611
SUBMERSIBLE
www.tsurumi-global.com
Website: www.homa-pumpen.de Fax: +49 4821 771274 Fax: +39 059 897897 Caprari S.p.A
Email: sales@sterlingsihi.de Website: www.caprari.com
Lubi Industries LLP Via Emilia Ovest 900
Website: www.sterlingsihi.com EFFLUENT 41123 Modena,
Near Kalyan Mills, Naroda Road
Ahmedabad, 380025 Caprari S.p.A MINE DEWATERING & Italy
India
VERTICAL TURBINE DEWATERING Tel: +39 059 897611
Via Emilia Ovest 900
Tel: +91 79 30610100/166 Caprari S.p.A 41123 Modena, Fax: +39 059 897897
Fax: +91 79 30610300 ABEL GmbH & Co KG Website: www.caprari.com
Via Emilia Ovest 900 Italy
Email: expsales@lubipumps.com Tel: +39 059 897611 Abel Twiete 1
41123 Modena,
Website: www.lubipumps.com Fax: +39 059 897897 21514 Buchen,
Italy
Website: www.caprari.com Germany
Tormac Pumps Tel: +39 059 897611
Tel: +49 4155 818-0
Fax: +39 059 897897
M/s. Naargo Industries Private MBH Pumps (Guj.) Pvt. Ltd. Fax: +49 4155 818-499
Website: www.caprari.com
Limited, 2 Gem Garden, (Clean & Waste Water Pump) Email: mail@abel.de
Ganapathy, Coimbatore, 14 GIDC Naroda Website: www.abel.de
India 641 006
Tel: +91 422 6522622
PUMP Ahmedabad,
India
MBH Pumps (Guj.) Pvt. Ltd.
Fax: +91 422 2531956 APPLICATIONS 382 330
(Clean & Waste Water Pump)
Email: Tel: +91 79 2282 1018 & 3066 14 GIDC Naroda, Ahmedabad,
tormac@tormacpumps.com ASH HANDLING Fax +91 79 2282 1511 India
Website: Email: 382 330
www.tormacpumps.com ABEL GmbH & Co KG Tel: +91 79 2282 1018 & 3066
exports@mbhpumps.com
Abel Twiete 1 Fax +91 79 2282 1511
website: www.mbhpumps.com
TWIN SCREWS TYPE 21514 Buchen, Email: exports@mbhpumps.com
Germany website: www.mbhpumps.com
3P Prinz srl Tel: +49 4155 818-0 END SUCTION/BACK
Via Enrico Mattei 283/R Fax: +49 4155 818-499 PULL OUT MINING
55100, Mugnano, Lucca, Email: mail@abel.de
Italy Website: www.abel.de
Sterling SIHI GmbH (PUMPS MARKET)
Tel: +39 0583 491183 Lindenstrasse 170
FELUWA Pumpen GmbH ABEL GmbH & Co KG
Fax: +39 0583 954659 D-25524 Itzehoe,
Beulertweg Germany Abel Twiete 1
Email: sales@3pprinz.com 21514 Buchen,
54570 Muerlenbach, Tel: +49 4821 77101
Website: www.3pprinz.com Germany
Germany Fax: +49 4821 771274
Tel. +49 65 94 100 Email: sales@sterlingsihi.de Tel: +49 4155 818-0
VACUUM Fax +49 65941640 Website: www.sterlingsihi.com Fax: +49 4155 818-499
Sterling SIHI GmbH Email: info@feluwa.de Email: mail@abel.de
Website: www.feluwa.com GROUND WATER Website: www.abel.de
Lindenstrasse 170
D-25524 Itzehoe, Caprari S.p.A FELUWA Pumpen GmbH
Germany Construction & Mining Via Emilia Ovest 900 Beulertweg
Tel: +49 4821 77101 54570 Muerlenbach,
Tsurumi Manufacturing 41123 Modena,
Fax: +49 4821 771274 Germany
Co Ltd Italy
Email: sales@sterlingsihi.de Tel. +49 65 94 100
Tel: +39 059 897611
Website: www.sterlingsihi.com 16-40, 4-chome Fax +49 65941640
Fax: +39 059 897897

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THE INTERNATIONAL MAGAZINE FOR PUMP USERS Number 529 October 2010 THE INTERNATIONAL MAGAZINE FOR PUMP USERS Number 530 November 2010 THE INTERNATIONAL MAGAZINE FOR PUMP USERS Number 534 March 2011

Alpine rescue:
Growing the Oiling the gears: Dewatering glaciers under
market: Mont Blanc
Underlying Pumps streamline
trends in biofuel production
Eastern
Europe

Also:
   
Also: Also:   
,%%&$(&'"!& t E-learning from the BPMA 
  
overview of the last 10 years
t Dry-start vertical pumps
,""&' #'"
with PTFE bearings
new building regulations
t Avoiding contamination in
, "*%)&'!&!
food & drink and pharma
can improve efficiency
in liaison with in liaison with in liaison with

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Advertisers' index 47
WORLD PUMPS December 2015

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December 2015

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Complimentary. Fluxys/Pumpro 17

Gratis.
Gorman-rupp OBC
Graphite Metalizing 27
Guangdong Foshan Pump Factory Co Ltd 15
Hung Pump Industrial Co Ltd 25
Hydraulic Institute 43
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up-to-date with the Pump Indsutry Awards 39
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Vesco Plastics 48

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www.worldpumps.com Wuxi Trumy Transmission Engineering Co ltd 29

europump information
Europump is a pan-European organisation composed of national pump EUROPUMP Officials
manufacturer associations in 18 countries. In total the organisation comprises President
more than 450 member companies – manufacturers and distributors. Carlo Banfi, Diamant Building, 80 Boulevard Reyers, 5th Floor, 1030‚ Brussels, Belgium.
The Executive Council is the board of Europump. Its members – company Tel: +32 2 706 82 30; Fax: +32 2 706 82 50
presidents, managing directors or CEOs – are elected representatives of their
national associations. The Europump President is the head of the Council. The General Secretary
Council’s work is administered by the General Secretary and his staff. Guy van Doorslaer, Diamant Building, 80 Boulevard Reyers, 5th Floor, 1030‚
Brussels, Belgium. Tel: +32 2 706 82 30; Fax: +32 2 706 82 50

EUROPUMP Member Associations PROFLUID Association française des pompes, des compresseurs et de
la robinetterie, Maison de la Mécanique, 45 rue Louis Blanc, F - 92400
A FMMI, Wiedner Haupstrasse 63, Postfach 430, AT - 1045 Wien, Austria
Tel: + 43 5 90 900 3468, Fax: + 43 (0)1 505 10 20
Courbevoie, France Tel: + 33 1 47 17 62 98, Fax: + 33 1 47 17 63 00, Eml:
profluid@profluid.org

B Agoria, Diamant Building, Blvd A.Reyers 80, B - 1030 Brussels, Belgium


Tel: + 32 2 706 79 73, Fax: + 32 2 706 79 66
Union of Greek Metal Industries, Loudovikou Street 1, EVEP Building,
GR - 18531 Piraeus, Greece Tel: + 30 141 78412, Fax: + 30 141 73974 Eml:
mdamigos@dppumps.gr
CH SWISSMEM, Kirchenweg 4, CH - 8032 Zürich, Switzerland Tel: +41 44 384 41
11, Fax: +41 44 384 42 42 ASSOPOMPE, c/o ANIMA, via Scarsellini 13, IT - 20161 Milano Tel: +39 02 45
418 531 Fax: + 39 02 45 418 713 Eml: pasquini@anima-it.com
RU Russian Pump Manufacturers' Association - RPMA, 1 Sokolnichesky Val, hall 4,
of.6, CIS - 107113 Moscow, Russia Tel: + 7 499 269 3396, Fax: + 7 499 269 3396 Holland Pomp Groep, c/o Vereniging FME-CWM, Boerhaavelaan 40, Postbus
190, NL - 2700 AD Zoetermeer, The Netherlands Tel: + 31 79 353 12 63, Fax: +
CZ Czech Pump Manufacturers' Association - CPMA, Jana Sigmunda 79 - CZ -
783 50 Lutin, Czech Republic Tel: + 420 585 652 423, Fax: +420 585 652 400
31 79 353 13 65, Eml:hsl@fme.nl

Polish Pump Manufacturers Association - ul. Lelewela 15 - PL - 53-505


DE VDMA Fachverband Pumpen + Systeme, Lyoner Strasse, 18, D - 60528
Frankfurt a.M, Postfach 71 08 64 D - 60498 Frankfurt a.M., Germany Tel: + 49
Wroclaw Tel: +48 71 783 61 52, Fax: +48 71 783 61 52, Eml: ppma@p-s.com.pl

69 66 03 12 82 Fax: + 49 69 66 03 22 81 APPR - str Ziduri Mosi nr 25 - RO - Bucuresti cod 021203, sector 2


Tel: +40 724 463 578, Fax: +40 311 043 272
Association of Danish Pump Manufacturers, c/o Steen Stensler Sørensen,
DK Ørnevej 11, DK 9230 Svenstrup J. Denmark Tel: + 45 25 77 66 77, Eml: sss@
dkpumps.dk, web: www.dkpumps.dk
SWEPUMP, PO Box 5510, SE - 11 485 Stockholm, Sweden Tel: + 46 8 782 08
00, Fax: + 46 8 660 33 78, Eml: swepump@teknikforetagen.se

ES Asociacion Espanola de Fabricantes de Bombas para Fluidos, Principe de


Vergara 74 - 3a, ES - 28006 Madrid, Spain Tel: + 34 91 411 1881 / + 34 91 563
POMSAD, Istanbul Karayolu 16, Km No 153 P.K. 3, TR - 06790 Etimesgut,
Ankara, Turkey Tel: + 90 312 255 1073, Fax: + 90 312 255 1074
1721, Fax: + 34 91 411 1881, Eml : aefbombas@terra.es
BPMA, The National Metalforming Centre, 47 Birmingham Road, West
FI Technology Industries of Finland, Eteläranta 10, FI - 00130 HELSINKI, Finland
Tel: + 358 9 19231, Fax: + 358 96 24462
Bromwich B70 6PY, United Kingdom. Tel: + 44 121 601 6350, Fax: + 44 121
601 6373, Eml: enquiry@bpma.org.uk

www.worldpumps.com
48 Diary dates
WORLD PUMPS December 2015

2015 Diary Dates


November 30 November – 2 December 26 Jan – 28 Jan
Abu Dhabi, UAE
Riyadh, UAE
17 – 19 November MCE SAUDI 10th SPE/IADC Middle East
New York, USA www.mcexpocomfort-saudi.com/ Drilling Technology
2015 Chem Show Conference and Exhibition
www.chemshow.com December www.spe.org/events/medt/2015/

17 – 20 November 8 – 10 December February 2016


Paris, France Las Vegas, Nevada
MIDEST 2015 POWER-GEN International 17 – 20 February
www.midest.com www.power-gen.com Indianapolis, USA
Water & Wastewater
18 – 20 November 15 – 17 December Equipment, Treatment &
Beijing, China Dubai, UAE Transport Show
Water Expo China 2015 PVPC Expo Middle East 2015 http://wwettshow.com/
www.water-expo-china.hk. www.pvpcexpo.ae
messefrankfurt.com

24 – 25 November
January 2016
Sydney, Australia 23 – 26 January More diary dates are listed in our events
Boilers Pumps & Pipes Doha, Qatar page on the World Pumps website:
Conference 2nd International Conference http://www.worldpumps.com/events/
www.idc-online.com/view-conferences on Desalination and All events are subject to change and/or
Environment cancellations. World Pumps accepts no
23 – 25 November www.icodeconference.com/ responsibility for any changes. Further
Dammam, Saudi Arabia information can be obtained only by
contacting
SAOGE 2015 25 – 27 January the relevant parties.
www.saoge.org Florida, USA
2016 AHR EXPO To list your event in our next issue and
website, please send the information to
www.ahrexpo.com a.burrows@elsevier.com

All contributions, whether articles, news items, or letters, should be addressed to the Editor, World Pumps Magazine, PO Box 150, Kidlington, Oxford OX5 1AS, UK.
Tel: +44 1865 843686; Fax: +44 1865 843973; E-mail: a.burrows@elsevier.com

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