Beruflich Dokumente
Kultur Dokumente
TOdAy
PROviding SOluTiOnS fOR ThE WORldWidE PumP induSTRy
OCTOBER 2014
Matching PuMPs
to the Right
aPPlication
electRonic WateR
tReatMent in
action
PuMPtuRbo and
WeFtec RecaP
COnTEnTS
4
10
OCTOBER 2014
Industry news
trade show ProfIle
Case studIes
Modern Technology
Low-Profile Chambers Solve Athletic Field Site Constraints
20
A basic primer on how food and beverage plants can reuse water effectively and efficiently
Part 3 in a 3-Part Series
MaIntenanCe solutIons
The Southern Hemisphere's largest entertainment complex reduces maintenance and treatment costs
Part 2 in a 2-Part Series
26
Why and where to use the Pulsarlube automatic single point lubricator
PuMP solutIons
dewaterIng solutIons
Motor solutIons
38
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Power generatIon
solutIons
@ModPumpMag
ProCessIng solutIons
sealIng solutIons
54
PuMPIng trends
www.highlandspublications.com
Atlas Copco's Jlio Tom on the growing market for reliable, portable power sources
Consulting Engineer,
Process Machinery Consulting
Robert G. Havrin
Director of Technology,
Centrisys Corporation
Michael Mancini
John M. Roach
Engineering Manager
for New Product Development,
Trebor International, Inc.:
A Unit of IDEX
laRRY daughetY
Vice President
dennis daughetY
Vice President
Lisa Riles
Greg Towsley
INDUSTRy news
KSB RECOGNIZED IN 2014 CITATION OF EXCELLENCE
KSB, the world's most experienced supplier of pumps and
mixers, was awarded by WEF the Best Design in the 2014
Citation of Excellence in Advertising Awards. KSB was
formally recognized at WEFTEC on September 30, 2014 at
the New Orleans Convention Center. Advertisements up
for consideration were judged by a committee comprised
of members of the Water Environment Federation (WEF)
Manufacturers and Representatives Committee and publishers
in the field.
The winning advertisement promotes KSB's end-to-end
water management solutions, which address all stages of the
water cycle from water extraction to sewage treatment. The
message resonated with the WEF, a not-for-profit technical
organization that brings together scientists, engineers,
academics, and other professionals with the mission of
leveraging knowledge to support clean and safe water
worldwide. Additionally, the advertisement highlights how
KSB's know-how and extensive product range enable users to
meet water supply and treatment requirements.
The design of the advertisement reflects KSB's mission:
applying over a century of experience in water management
to create simple solutions that ensure top performance,
longest wear life, and reduced total cost of ownership for any
water application.
4 | OCTOBER 2014
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INDUSTRy news
The Greenville, South Carolina, seminar is November 12
and the Durham, North Carolina, seminar is November 13.
Those interested in attending should call 864.284.0111 or
919.286.0774.
6 | OCTOBER 2014
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INDUSTRy news
perform satisfactorily before they are installed on site. Unlike
other manufacturers, Netzsch has a dedicated consulting
team, technical team, and spare-parts team that make sure
the best customized solution is built and delivered on time
for each application. In addition, Netzschs service and
maintenance contracts are proactive, rather than reactive.
Netzsch has global presence with an extensive distributor
network in all of the major regions. This enables Netzsch to
provide around-the-clock services and ensure that downtime
is minimized. Netzschs technicians document every aspect
regarding its customers and the products to make sure
the products are serviced on time. This shows Netzschs
commitment to reliability and quality.
Frost & Sullivan notes that NETZSCH has continuously
developed innovative technologies that aid end users with
their current challenges. This close look at the customers
requirements and the benefits that really count for their
application has made and kept NETZSCH the world market
leader for progressing cavity pumps over the years. Together
with joint venture partner Heishin in Japan, they hold 28
percent of the global market share.
8 | OCTOBER 2014
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A Look Back at
PumpTurbo and WEFTEC
From increased efficiency standards to wastewater repurposing, innovation pushes the pump industry
or industrial pump
manufacturers and their
related markets, the past
few years have represented a
shift from old ways of thinking
and an embrace of new
technologies, applications,
and designs. The downturn in
the domestic and international
economies during the first
part of the decade provided
an incentive for pump users
to seek out more efficient
operating standardsand
brought with them a rise in
after-market and maintenance
services.
However, as the economy
improves, risk is no longer a
four-letter word among those
working in the industrial pump
and rotary equipment markets.
Nowhere is this commitment
to forward-thinking and
innovative solutions better
on display than the recent
Pump and Turbo Symposia and
WEFTEC events from this past
fall.
WASTEWATER WONT
GO TO WASTE
A similar emphasis on
innovation continued into
the annual WEFTEC trade
show, held this year in New
Orleans. Not only is there a
shared quest for improved
efficiency standards, but
todays water and wastewater
industry is currently creating
Experienced pump users shared insights with tomorrows professionals at Texas
opportunities for itself
A&Ms Pump and Turbo Symposia.
in power generation and
chemical processing as well.
One wastewater expert in
attendance noted that, using
current industry standards,
the potential contribution to
the domestic power grid via
gas extraction from industrial
PUMP USERS LOOK
wastewater is three to four
times the cost to filter and
TO THE FUTURE
remove it. Furthermore,
The recently concluded 43rd
many experts project that
Turbomachinery and 30th
the majority of industrial
Pump Symposia welcomed the
most attendees in its history
wastewater processing plants
will be energy neutralor
over 6000and provided
even energy positivewithin
pump professionals with
the next five years.
hours of in-depth, field-tested
The expansive WEFTEC
solutions that can leave the
lecture hall in Houston and
exhibit floor featured new
WEFTEC 2014 showcased the industrys push toward innovative solutions as plants
products highlighting the
make a difference in plants
move from water treatment to reuse and repurpose.
around the world. Outside of
industrys urgent demand
the seminars and on the exhibit
for innovationfrom both
floor, attendees benefitted from the Symposias traditionally
large and smaller manufacturers. In the next decade, water
welcoming environment as lecturers and students mixed with
reuse and water repurpose will be the norm for wastewater
OEM representatives to share ideas and experiences.
processing rather than the exception, which means OEMs and
A common topic of discussion was the implementation of
equipment users will be working together to implement new
the Environmental Protection Agencys (EPA) Tier 4 emission
designs and new treatment processes that make the most of
standards and how manufacturers and operators will be
these opportunities.
10 | OCTOBER 2014
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CASE Studies
Figure 1: Service calls and the MTBSC for the ten-year period under analysis.
12 | OCTOBER 2014
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OCTOBER 2014 | 13
CASE Studies
However, 27 of
these 70 pumps
experienced two or
more service calls.
These repeat calls
accounted for 71
of the 127 calls or
56-percent of the
calls.
The root causes
of these calls
were traced to the
following and were
quickly corrected.
Many were attributed
to excessive disposal
of cooking grease
into the wastewater
stream by several
homeowners and
root penetration and
obstruction of the
inlet line between
homes and grinder
pump stations.
A spike in
service calls was
experienced in 2011
due to a prolonged
power outage.
14 | OCTOBER 2014
Figure 2: Annual maintenance cost per pump for the ten-year period under analysis.
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A LOOK AHEAD:
OCTOBER 2014 | 15
CASE Studies
16 | OCTOBER 2014
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OCTOBER 2014 | 17
CASE Studies
construction that was $665 lower than
Flygts conforming offer. This gives a
good baseline for the cost difference
between traditional design and newer
materials along with the more modern
approach to controls.
Upon review of the project with Jim
Rankin of JB Rankin Engineering, the
citys engineer for this project, it was
18 | OCTOBER 2014
SW Alder pump
station used to
be considered a
moderate to high
maintenance
station with ageing
infrastructure,
reliability issues
and peak loading
concerns. It is now
a model of what
can be achieved
by utilizing a
modern approach
to refurbishment.
The city can
effectively redirect
almost $13,000
(compared to an
estimated $4450
using traditional
materials and
designs) annually
towards other asset
management requirements as well as enjoy greater reliability
in operation, which will further reduce additional overtime
expenditures. In addition, with significant reduction
in electrical power used, the city is able to meet the
communitys current energy consumption and environmental
impact expectations.
Dont surrender
to wipes!
The buildup of wipes and other debris in sewage is the enemy.
Fight back with a powerful and energy-efficient Muffin Monster
grinder in your pump station. With over 40,000 installations and
over 200 different grinders and fine screens, JWC will help you
eliminate clogging and finally win the war on wipes.
New Monsters. New Solutions. No More Wipes.
Sign-up for Wipes Alert Newsletter at NoMoreWipes.com
Muffin Monster
& Channel Monster
sewage grinders
www.modernpumpingtoday.com
OCTOBER 2014 | 19
CASE Studies
Low-Profile Chambers
Solve Athletic Field
Site Constraints
20 | OCTOBER 2014
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A HEAVY-DUTY SOLUTION
HOW IT WORKS
OCTOBER 2014 | 21
Recycling Earths
Rapidly Shrinking
Resource
A basic primer on how food and beverage plants
can reuse water effectively and efficiently
Part 3 in a 3-Part series
By nate maguire, greg Claffey, and Keel Robinson, Xylem
22 | OCTOBER 2014
www.modernpumpingtoday.com
1
2
Static head: The height of a column of water that would be produced at a given pressure. The calculation
represents the internal energy of a fluid due to the pressure exerted on it from the pump.
Friction loss: The loss of energy (reduction of static head) that occurs in the pipe due to viscous effects
generated by size and surface of it. Narrow pipes, corners and valves that impede flow create friction loss.
3
4
SUSTAINABILITY
THE TAKEAWAY
24 | OCTOBER 2014
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Electronic
Water
Treatment
An alternative solution
to removing beerstone
and limescale
By Jan de Baat doelman,
Scalewatcher north America inc.
BEERSTONE
LIMESCALE
26 | OCTOBER 2014
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is estimated that 40
percent more energy is
needed to heat water in
a system fouled with
inch (6.35 millimeters)
of limescale. This leads
to more power being
consumed or to the
installation of heavier
duty, more expensive
heat exchangers to
compensate.
Although beerstone is
primarily derived from
calcium oxalate and
limescale from calcium
carbonate, both are
caused through precipitation and scaling
which are mostly caused through the
heating of water solutions. Within
this environment Electronic water
conditioners, such as Scalewatcher,
are the ideal solution for removing and
preventing the RO membranes being
clogged with scale. As Electronic water
treatment (EWT) changes the shape of
the molecules from rough to smooth,
they do not form a matted structure and
are washed away thereby preventing the
membranes from being clogged which in
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pH EFFECT ON
SCALE FORMATION
SUPER SATURATION
OCTOBER 2014 | 27
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INTErAcTIvE
DIGITAL EDITION
LOOk
fOr ThE
PLAY
VIDEO
buttOns
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28 | OCTOBER 2014
ELECTRONIC WATER
CONDITIONING
MAINTENANCE solutions
Part 2 of 2
CENTRIFUGAL SAND
SEPARATORS
30 | OCTOBER 2014
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www.est-aegis.com
PISTON OPERATED
SELF-CLEANING
SCREEN FILTER
SUMMARY
MAINTENANCE solutions
1. Cover
2. Body
3. Coarse Screen
4. Fine Screen
5. Collector
6. Suction Nozzle
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MAINTENANCE solutions
The Evolution of
Lubrication Technology
Why and where to use the Pulsarlube automatic single point lubricator
By Bill Zavala, Pulsarlube uSA, inc.
hen it comes
to bearings,
grease is often
the lubricant of choice.
However, over or undergreasing can cause
overheating, lubricant
deterioration, and eventual
bearing wear or failure.
To help ensure proper
lubrication, the Pulsarlube
automatic lubricant
dispensing system can be
used to manage a precise
amount of grease applied
to specific lubrication
points.
FOUR HISTORICAL
LUBRICATION
METHODS
34 | OCTOBER 2014
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BENEFITS OF AN
AUTOMATIC LUBRICATOR
The Pulsarlube M unit delivers a powerful 280
psi average operating pressure, but is capable of
delivering 1160 psi if necessary, through the use
of its vertical positive displacement pump, motor/
gear set, and microprocessor control system. This
is one of the key reasons why the Pulsarlube M
unit can lubricate up to 8 points, thereby offering
our customers tremendous savings, compared to
lubricators that can only lubricate a single point.
Immediate and Exact Lubrication: Exact,
Reliable, lubrication through Microprocessor
chip controlled technology.
LCD Display: You can obtain all info. at a
glance on LCD about the status of your lube
point i.e. Low battery, too much back pressure,
# of days before empty, how many days on
empty etc.
Lock Out Mode: Only lubricator in the world
with automatic digital lock out mode to prevent
accidental or unauthorized keyed entry.
Cost Efficiency: Can lubricate up to 8 points
(20 feet per point).
Increased Uptime and Profitability: Less
downtime and loss of production. According
to studies done by renowned lubrication
experts around the world, the Pulsarlube M
unit reduces bearing failure by more than 85
percent compared to manual lubrication.
www.est-aegis.com
2. Oil bath and splash, which is either the submergence
of all system gears and bearings in an oil sump or
the splashing of components with rotating gears. This
enclosed system is cost effective in the short term.
However, contaminants that may get trapped inside the
system will decrease the life of the oil and ultimately
cause increased maintenance costs.
3. Central lubrication systems, which store lubricant in
a reservoir and then continuously pump it to critical
equipment components through a complicated system.
Although these systems are important for some particular
manufacturing purposes, they are not effective for
most applications. Central lubrication systems are also
expensive to assemble and install.
4. Single point automatic lubricators, like those
manufactured by Pulsarlube, which are designed to
dispense lubricant consistently and precisely through a
powerful positive displacement pump for up to one to
two years depending on the application. It also has the
capacity to lubricate up to 8 lube points at a maximum
of 20 feet (6.1 meters) per point, this in turn allows for
the lubrication of hard to reach/hazardous areas. The
Pulsarlube product is a simple, accurate, and costeffective method for most applications.
Originally, automatic lubricators simply enabled a facility
to operate machinery and lubricate bearings simultaneously.
Today, single point automatic lubricators are widely accepted
in the modern manufacturing world and have an expanded
www.modernpumpingtoday.com
OCTOBER 2014 | 35
MAINTENANCE solutions
role to improve overall
maintenance practices,
reduce costs, increase
efficiency, and promote
plant safety.
RESISTANCE TO
CHANGE
36 | OCTOBER 2014
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www.est-aegis.com
RELIABILITY IN CRITICAL
APPLICATIONS
SUMMARY
OCTOBER 2014 | 37
PUMP solutions
PLANNING IS CRITICAL
We dont yet live in a world of course where pumps never break down,
but any well-run abattoir will be acutely aware of the sometimes dire
consequences of wastewater backing upand will have already have a
preventative maintenance program in place, says Landias Paul Davies.
With some larger abattoirs running lines at a rate of almost 200 birds
per minute, or well over 10,000 per hour, downtime can be disastrous,
Davies adds. In too many places the production line is being pushed
to absolute breaking point in order to meet the deadlines of their
supermarket customers, but all the same, a decent sturdy chopper pump
that doesnt allow solids to clog it up, backed by a regular servicing, can
make a world of difference.
At one factory, The Guardian discovered offal piled up during a pump system failure, with
breakdowns leading to high-risk materialfeathers, guts, and offalpiling up for hours.
Another breakdown led to the water in scald tanks at the same site not being cleaned
for three days, so that around 250,000 birds passed through dirty water after slaughter.
During The Guardians five-month investigation, workers also witnessed a breakdown
(which they said are repeated events) where it was the pump feeding the flume of water
that is supposed to carry feathers away from the plucking machines.
The evidence prompted Tesco, Sainsburys, and Marks & Spencerthree of the United
Kingdoms largest supermarket chainsto launch emergency investigations into their
chicken suppliers.
The concern centers on the campylobacter bacteria, which at the last count was present
in two-thirds of British fresh chicken sold in the United Kingdom. Although the bug is
killed by thorough cooking, around 280,000 people in the United Kingdom are currently
made ill each year by it and 100 people are thought to die. Contamination rates are
known to have increased in the past decade.
38 | OCTOBER 2014
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POSITIVE RESULTS
FROM PROPER MAINTENANCE
OCTOBER 2014 | 39
DEWATERING solutions
Reliability Needed
in Treatment Facility
Self-priming filter backwash end suction pumps offer high efficiency solution
By Andy Wilson, hidrostal ltd.
A PERFECT FIT
LOOKING FOR AN
ANSWER
Original installation
PROJECT AT A GLANCE:
SELF-PRIMING FILTER BACKWASH PUMPS
Customer: Severn Trent Water
Value: 15,500.00 (~$24,700 US)
Type: Supply and Install
Equipment Installed: Two Pumps and Static Priming Tank
40 | OCTOBER 2014
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IMPROVED PERFORMANCE
AND SAFETY
LONG-TERM SOLUTIONS
OCTOBER 2014 | 41
MOTOR solutions
Maximum Results
fro
Mini Drive
42 | OCTOBER 2014
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FEATURE-RICH IN A SMALL
PACKAGE
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OCTOBER 2014 | 43
EFFECTIVE MONITORING
44 | OCTOBER 2014
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BENEFITS
The Model DO90 Trace DO2 Sensor offers a large measurement range, reliable and
effective monitoring, and easy installation.
QUICK INSTALL
PROCESSING solutions
ELIMINATING
VALVES, IMPROVING
PRECISION
46 | OCTOBER 2014
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TECHNICAL DATA
Controller:
Input 115 VAC, 1,
50/60 Hz.
Output: 230 VAC, 3,
50/60 Hz
Features:
Local keypad control
MAX FLOW
(mL/min)
MAX FLOW
(gph)
RH00
45
0.71
RH0
90
1.4
Q0
144
2.2
RH1
180
2.8
Q1
576
9.1
Q2
1296
20.4
Q3
2304
35.9
OCTOBER 2014 | 47
hydronic radiant
system consists
of warm or cool
water flowing through
flexible PEX tubing
embedded in the floor
or in radiant panels.
Radiant systems use
the structure and
surfaces of an area
to transfer energy.
In radiant heating
applications, the
energy moves away
from the heated surface
toward the cooler area;
for radiant cooling,
the energy moves
towards the cooled
surface from the
warmer area. Radiant
heating and cooling
applications are among
the most efficient and
technologically sound
atmospheric systems
used in commercial
structures todayas
well see with a closer
look at two new
components.
The new stainless-steel manifold from Uponor is available in 1 and 1- inch (25.4 to 31.75 millimeter) sizes and offers 2 through 8, 10, and 12
loop configurations for residential and commercial radiant heating and cooling applications.
48 | OCTOBER 2014
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PEX-a Pipe Support is a galvanized steel channel that provides continuous support of PEX in suspended piping
applications, enabling hanger spacing similar to that of copper or steel pipe.
OCTOBER 2014 | 49
SEALING solutions
How to Cost-justify
Bearing Housing PART
2 of 4
Protector Seals
Key factors for reliability-focused process pump users
By heinz P. Bloch, Process machinery Consulting
50 | OCTOBER 2014
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Figure 2: Three different generic versions of bearing housing seals. Styles with contact between O-ring and sharp edged grooves (2a) are vulnerable,
especially so if rotors incorporate low clamping forces. Some styles have high drag force between the rotor and the stationary component (2b). Advanced
styles with dynamic O-rings (2c) make contact with a large and contoured surface (2c). They exert low pressure and have optimally low drag forces.
AREA OF CONTACT
AND NEED FOR LIFT-OFF
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OCTOBER 2014 | 51
SEALING solutions
fluid provides sufficient
lubrication between O-ring
periphery and cylinder
bore, reasonably long life is
usually attained.
In some rotating labyrinth
seal designsthe ones
similar to figure 3the
O-ring is expected to lift
off radially when the shaft
is rotating. But, the same
O-ring is also expected to
seal the small gap between
rotating and stationary
component whenever the
shaft stops turning. Will it do
that?
Figure 3: O-rings in contact with sharp edges are prone to wear excessively. Sometimes, slivers of the elastomer get into a bearing housing.
QUESTIONS OF
INTEREST
52 | OCTOBER 2014
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Water Spray/Moisture
Shaft
Housing
2nd Outlet
1st Outlet
Figure 5: Multi-tiered arrangement, tortuous path and expulsion orifices of modern, field-repairable rotating labyrinth seal
(source: AESSEAL, Inc., Rotherham, UK, and Rockford, TN).
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OCTOBER 2014 | 53
SJE-RhOmBuS
CE Approved Electromechanical
Control Panels Series Emd
SJE-Rhombuss CE approved Electromechanical Control Panels series EMD designed for
international applications control one or two submersible single phase or three phase
electric pumps in water and wastewater applications. The panels are provided with a
thermal overload protection relay incorporated in an IP 55 weatherproof cabinet. The
EMD control panels operate pumps based on signals provided from liquid level floats
or pressure switches. Four models are available; EMD1S, EMD1T, EMD2S, EMD2T
and accommodate single phase voltage (240VAC) or three phase (400VAC) voltage
50Hz or 60Hz applications. For more information, email sje@sjerhombus.com, call
218.847.1317, or visit www.sjerhombus.com.
AumA
A new electronic position transmitter designed to simplify end position adjustments for actuators
has been developed by AUMA. The EWG is compatible with its predecessor, the RWG, which
ensures rapid replacements and retrofits. Advantages provided by the EWG include continuous
recording of the valves current position, and transmission as an analogue 0 20 mA or 4 20 mA
signal to the control system. Inverse operation is also possible. End position adjustment is simple
and straightforward, as tools are not required. Valve position detection is contactless and avoids
wear. Should a power failure occur, the EWG reliably recognises the current valve position, even if
the device has been operated via the handwheel during the outage period. Once power supply is
restored, a position signal is issued immediately, without the need for renewed setting or reference
operation, and battery back-up is not required. For more information, visit www.auma.com.
54 | OCTOBER 2014
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Armstrong Fluid Technology has announced the expansion of its Astro wet-rotor circulator
offering with the introduction of the Astro 2 Series. Featuring four new sizes, the Astro 2 Series
now offers flange-to-flange and bolt-to-bolt compatibility with 100 percent of competing
models in terms of performance. Designed for fast and convenient installation and years of
trouble-free operation, the new models also address a broader range of applications. Key
features include: three field-selectable operating speeds, double the head and triple the
flow, a plug-in terminal strip to save time on installation, e-coating on the inside of the cast
iron volutes to provide enhanced corrosion protection, pre-installed high-flow check valve
and availability in cast iron, stainless steel and lead-free bronze. For more information, visit
www.armstrongfluidtechnology.com.
KB ElECTROniCS, inC.
AC digital drive KBWK-23d
AZTEC BOlTing
SERviCES inC.
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XylEm
OCTOBER 2014 | 55
PUMPING trends