Escolar Documentos
Profissional Documentos
Cultura Documentos
Mechanical Seal
Energy Audits
How to Save a Dying
Septic System
Modern Pumping Today
www.modernpumpingtoday.com
CONTENTS
14 28
MPT
Modern Pumping Today
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266
@ModPumpMag
32 J. CAMPBELL Editor
jay@modernpumpingtoday.com
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
OCTOBER 2015
INDUSTRY NEWS 6
SINCE 1958
Get me a Check-All.
Manufactured in
West Des Moines, Iowa USA
515-224-2301 sales@checkall.com www.checkall.com
POWER-GEN
INTERNATIONAL 2015
The industry comes together to charge into the future
P
ower-Gen THE PLACE TO BE
International is With a record-setting
the world's largest POWER-GEN 2015 AT A GLANCE expected attendance of
power generation event Where: Las Vegas Convention Center, more than 22,000 power
focusing on the industry's Las Vegas, Nevada professionals from more
latest innovations, than ninety countries and
When: December 810, 2015
technical trends, and a show floor comprised of
business strategies. Website: www.power-gen.com more than 1,400 exhibiting
Presenting a broad companies, there's no other
range of qualified power place to be for education,
professionals with the power to purchase, Power-Gen networking, and new business development that the 2015
International is the place not only to assess the direction meeting of Power-Gen International. Attendees will hear
of the industrys future but also to get business done from more than 200 of the industrys top speakers and
today! Throughout its history, Power-Gen International have access to more than fifty educational conference
has provided a global meeting space for the innovations, sessions.
ideas, and solutions that shape the industry now and in Events at Power-Gen International 2015 will also include
the future. multiple Competitive Power College courses, networking
WOMEN IN POWER
LUNCHEON
A luncheon hosted by the Women
in Power committee that features
the 2015 Woman of the Year and
finalists. The Power-Gen Women
in Power committee selects a
Woman of the Year each year to
serve as a role model to inspire
young women to pursue careers in
energy. Luncheon attendees will
have the opportunity to network
with women in the power industry
and learn about the career paths
of some of the most successful
women in the industry. The winner
of the Power-Gen 2015 Woman of
the Year Award will be announced
during the Awards Gala on
Monday, December 7 at 6:30 pm.
AN INDUSTRY UNITED:
POWER GENERATION WEEK
Covering every aspect of the
power generation industry, Power-
Gen International, Nuclear Power
International, Renewable Energy
World Conference and Expo
North America, Coal-Gen, and
GenForum converge in 2015 to
form Power Generation Week.
Benefit from five days packed
with pre-conference workshops,
technical tours, more than seventy
conference sessions, panel
discussions, three exhibition days
,and multiple networking events.
This unique collaboration provides
attendees with the chance to
access nearly every facet of the
marketall under one roof.
From Fresh to
Frozen Fast
Hidrostals F pump passes peas for Pinguin
By Lucy Ogden, Hidrostal Ltd.
P
inguin Foods is a leading, international processor of MOVING FROM FIELD TO FORK
harvest fresh vegetables priding itself on delivering At Pinguins site in Boston Lincolnshire, the company
fresh to frozen produce that are tasty, healthy, and utilizes a field to fork approach that encompasses the
of the highest quality. Pinguin is an independent division washing, de-stoning, separation, blanching, and freezing
of the major European Food Group, Greenyard Foods, of raw vegetables. Hidrostals F type pumps, ideally
which processes over 440,000 tons of product annually suited for food processing, are employed to transfer the
over eleven production field harvested peas
sites. However, moving directly with the use
food from fresh to frozen Hidrostals pumps have proved of recycled mains
requires solids handling water as the motive
that is reliable, efficient, extremely reliable with minimal media.
and fast. Hidrostal Ltd., Pea season
the UK distributor for maintenance required. They typically runs from
the major Swiss pump
manufacturer, has need to be reliable otherwise June until August
where the produce
provided an international
processor of fresh to
production stops. is being transferred
at a rate of up to
frozen vegetables with 11 tons per hour
the perfect pump for
Barry Cooper, per line during this
passing peas. Pinguin engineering stores manager period. The process
Pinguins food processing involves washing, de-stoning, separation, blanching, and Pea processing at Pinguin
freezing of raw vegetables.
Electrical Signature
Analysis
As performed on vertical turbine pump
motors in municipal application
By William Kruger, All-Test Pro, LLC,
and Alex Panattoni, City of Henderson Dept. of Utility Services Electrical Section
O
riginally put into operation in 1999, Pump
Station P-19A supplies drinking water to
the City of Henderson, which is the second
largest city in Nevada. Serving a population well
over 270,000 people, P-19A is one of the most
critical potable pump stations operated by the city.
The pump station originally utilized three pumps
when its operation began, but in 2006, two more
vertical pumps were installed in the pump station
(Pumps 1 and 5).
GPM 7400
# of Stages 5
RPM 1200
All-Test Pro 31 for initial tests Rotor Tested at 5-degree Intervals All-Test IV Pro for initial test
COMPREHENSIVE TESTING at different individual rotor positions. During the test, the
TO PREVENT MOTOR FAILURE rotor is positioned at exact intervals, as seen in the picture
The in-house maintenance team utilized their hand-held to the right.
All-Test Pro 31 and All-Test IV Pro. These high-tech The City of Henderson performed an extensive rotor
instruments, which are used for de-energized testing, are testtaking readings every 5 degrees of shaft rotation
designed to detect potential winding faults and provide using the All-Test IV Proonly then did indications show
indications of rotor problems. an issue with both Pump 1 and Pump 5.
First, they used both the All-Test Pro 31 and All-Test While the tests indicated the possibility of a rotor
IV Pro to perform winding tests and confirm that the problem, the results didnt show the problem definitively.
windings were in good condition. Technicians knew the current was modulating and put a
Then they used this equipment to conduct insulation time trace on it, but needed to do more extensive testing.
to ground tests to prove the insulation was not grounded. At the maintenance teams request, a third-party
Next, they performed a rotor inductance test, which specialist went to the pump station to perform vibration
measures the inductance of all three phases of a motor analysis. When the vibration analysis did not indicate
Severity Rating: 6 out of 7 7 out of 7 ALL-TEST PRO On-Line II Rotor bar breaks all occurred in the middle three rows
of laminations.
any electrical faults (pole pass very small change in motor load.
frequency sidebanding) in the The rotor was running considerably
associated vibration FFT signatures below name plate; after running
the decision was made to bring in about thirty minutes, the rotor
technical support from ALL-TEST speed was 1171 rpm. This was
Pro to perform additional testing. also confirmed by an independent
An All-Test Pro technician tach system provided by the third-
went to the pump station party who performed the vibration
in January to perform analysis. While the results of the
an Electrical Signature vibration analysis did not show any
Analysis. Electrical indications of rotor problems, the
Signature Analysis is a speed and the ESA data taken with
diagnostic technology the ATPOL II indicated that several
that uses the motors rotor bars were broken.
supply voltage and Rotor bars are solid continuous
operating current to bars that run through the rotors
identify existing and steel laminations, which are
developing faults in the spaced to allow air flow to cool
entire motor system. To the rotor. Once the maintenance
perform the Electrical team received the report from the
Signature Analysis, he Electrical Signature Analysis, which
brought with him the All- showed severe indications of rotor
Test Pro On-Line II. The bar issues (Pump 1 had a severity
ATPOL II is an energized rating of 6 out of 7 and Pump 5 had
motor testing tool which, a severity rating of 7 out of 7), they
when in ESA mode, pulled Motor 5 and found that 30
evaluates the condition of percent of the rotor bars were in fact
incoming power, the control broken.
circuit, the motor itself,
and the driven load. Kruger REBUILDING THE ROTOR WITH
requested that MVA data be DIFFERENT METALLURGY
taken simultaneously while the After discussing the issues with
Electrical Signature Analysis was the motor manufacturer and a third
being performed. party motor repair company, the
maintenance team chose to have
ELECTRICAL SIGNATURE both Motor 1 and Motor 5 rebuilt
ANALYSIS REVEALS BROKEN with copper rotor bars. Pumps 2,
ROTOR BARS 3, and 4 had copper rotor bars and
During the energized motor tests, did not have the same issues as
data was taken at different times; Pumps 1 and 5. The original rotor
first shortly after start-up, then bars in Pump 1 and Pump 5 had
again after the pump had been been made of aluminum. This was
running. Of significance was the believed to be the root cause of the
large change in rotor speed with a problem.
LESSONS LEARNED
Having a Predictive Maintenance
and proper diagnostic tools program
is important. It is essential to equip
your maintenance team with state-
of-the-art equipment to increase
the effectiveness of your Preventive
Maintenance program. Tools like
the ATPOL II exist so you can
perform higher level testing, such as
Electrical Signature Analysis, which
is proving to be a very effective
technology for detecting faults
before they lead to catastrophic
failure.
L
ocated within the greater Las Vegas metropolitan area, wastewater. Historically, the city of North Las Vegas relied on
North Las Vegas, Nevada, also sits in the majestic the city of Las Vegas to treat its wastewater, but in 2012, North
Mojave Desert, which means that how the city treats Las Vegas built its own plant using GE ZeeWeed membranes
and manages its water supply is of premium concern. The and MBR technology. The city then upgraded the facility with
upgraded water reclamation MBR facility, one of the largest LEAPmbr technology three years later to provide the same
in the United States, treats the municipal wastewater for more treatment capacity and highly treated water quality while
than 300,000 of North Las Vegass residents and processes up reducing energy and maintenance costs and increasing
to 25 million gallons of wastewater per day. productivity.
Optimized
Tank Design Increased
ZeeWeed
Productivity Lower Energy LEAPmbr
Aeration Technology
Reduced Blower Size
I
t only took a few generations and Around the dawn of World War I, Memorial Day to Labor Day period
several hundred dying septic vacation homes started to occupy the was aggravated by the arrival of full-
systems to age an idyllic vacation pristine shoreline of what pioneer time residents who were upgrading
spot like Peach Lake. Dutch farmers first named Peach once simple seasonal properties
Pond; later, Peach Lake. Inevitably, in lakeside communities like North
A CLOSER LOOK water quality deteriorated as the Salem and Southeast into pleasant
AT PEACH LAKE reservoir's spring intake was abodes with additional bathrooms,
Fed for millennia by fresh flowing supplemented by wastewater flushed washing machines and dishwashers.
springswith no creeks or rivers from these summer bungalows "Most of the people are here
for drainagea basin eventually and cabins, equipped with septic year-round but we do have the 20
matured into a 1.5-mile long and half- systems that only have a normal life to 30 percent that are there in the
mile wide aquatic paradise originally expectancy of ten to forty years. summer months," says Warren Lucas,
named Pechquenakonck by the By the 1990s, the problem of supervisor of the Town of North
Kitawonks, a Mohegan group. wastewatermostly during the peak Salem. "These communities grew
Peach Lake is a quiet, private lake located in Putnam and Westchester counties in New York, about a ninety minute commute from Grand Central Terminal. Single-family homes
surround the lake, consisting of both seasonal and full-time residents.
A LOOK AHEAD
Two sewer proposals were considered:
A gravity/low-pressure hybrid with
eight pump stations and a low-pressure
sewer system employing grinder
pumps at each home (or, where
housing is dense, a duplex pump
serving multiple dwellings). Next
month, well conclude this case study
by exploring Peach Lakes decision
and the benefits they discovered.
I
n last months introductory article, a true RCA is viewed as luxury not a our response time and accept that
we discussed some of the barriers necessity. Think about the objections the fires are a cost of doing business.
to selling not only the concept of we hear when we offer the idea of How much money is being accepted
Root Cause Analysis (RCA) but also gathering RCA teams. What follows as the cost of doing business? Hint,
the recommendations generated is a list of common objections to RCA how much is your maintenance
as a result of these analyses. We accompanied by rational justifications budget worth?
also laid the framework for making that any manager can employ.
better predictions by generating OBJECTION: WE DO NOT HAVE
and accessing better datanamely OBJECTION: WE DO NOT HAVE THE MONEY TO BACK A RCA
predicting our Mean Time between TIME TO DO RCA EFFORT
Failure (MTBF) and Mean Time to We do not have time to do RCA Maintenance budgets are primarily
Restore (MTTR) earlier and, therefore, because we are so busy firefighting developed to respond to failures that
implementing a fix faster. that we do not have time to analyze are expected to occur. Man-hours
Given this background, lets why the fires are occurring in the and materials are assigned and
explore how we can now justify first place or how to prevent their budgeted. Therefore, if it is in the
conducting a RCA and implementing recurrence. If this paradigm is budget, it is not a failure because we
the recommendations as a result of permitted to exist, then the conclusion have compensated for it. It is a cost
the analysis. By and far, conducting is that the best we can do is sharpen of doing business. This does not have
Reliability Starts
from the Ground Up
Outlining the benefits of polymer
concrete baseplates
By Scott Sapita, BaseTek, LLC
A
solid foundation is a proven way to increase the mean otherwise require an expensive alloy or corrode standard
time between planned maintenance for most types cast iron or steel. Polymer concrete systems eliminate the
of rotating equipment. Pump bases and foundations need for additional protective coatings or periodic upkeep
constructed of polymer concrete provide many benefits and maintenance activities.
over their cast and fabricated metal counterparts. Often
referred to as a poly, granite, or mineral cast baseplate, this FASTER INSTALLATION
material is a special combination of well-defined grain size Polymer concrete baseplates will not twist, bend, or
aggregates bound to a thermoset epoxy or vinyl ester resin. diaphragm like most metal designs. This eliminates the need
Manufactured in a controlled environment during a transfer for time-consuming field adjustment during installation. Most
molding process, these materials can be cast to precision designs also incorporate threaded leveling inserts along with
tolerances while offering the high mechanical properties a bottom surface ready for adhesion to grouting material
suitable for most industrial applications. without modification or special preparation. Bases can either
be stilt mounted or grouted in place like a conventional
VIBRATION DAMPING hollow design.
The polymeric matrix of the material provides damping
ratios 20-30 times greater per identical geometry than steel
or cast iron materials. Rotating equipment is often associated
with its stability under the influence of various disturbances
and polymer bases can effectively minimize vibrations
without the need to increase the mass size of the component.
PRECISION MOUNTING
Cast mounting surfaces are typically flat within 0.002 inches
per feet, which reduces soft-foot and speeds alignment.
Threaded insert holes are typically cast in place or
located with a CNC machine to insure precise location and
perpendicularity, which eliminates bolt bound conditions
often occurring with inexpensive metal bases. Difficult
to machine features can easily be cast in place. Thermal
expansion rates of most polymer concrete formulations are
considerably less than cast iron and maintain the consistent
alignment of equipment in a wider range of operating
conditions.
CORROSION RESISTANCE
Advanced resin systems along with inert natural aggregates
provide excellent protection from many fluids that would
PROVEN RELIABILITY
In addition, polymer concrete materials
offer low levels of heat conduction,
act as an excellent electrical insulator,
are non-magnetic, and resist water
absorption. Mechanical properties
are suitable for most indoor-outdoor
environments found in the process
industries.
The proven reliability of polymer
concrete baseplates for rotating
equipment is rapidly expanding as the
features above continue to add benefit
for applications of most every shape
and size. By combining a consistently
flat, vibration damping structure that is
easy to install and maintain, polymer
concrete baseplates will continue to
be the choice of Reliability Personnel
worldwide.
MPT
managing partner of BaseTek, LLC
?
in Middlefield, Ohio. Scott has over
twenty-eight years of experience WANT
in the rotating equipment market
including product design, product
TO
management and industrial sales. He READ
carries a BS in marketing from the
University of Dayton. Contact him at
MORE
scott@basetek.com. Modern Pumping Today
The Benefits of
Internal Gear
Pumps in Industrial
Operations
Enhancing the processing of dangerous chemicals
Part 1 of 2
By Chrishelle Rogers, Maag Industrial Pumps / PSG
I
t is no stretch to say that pumps production process. Whether handling oftentimes challenginghandling
make the world of industrial lube oils, paints and coatings, or characteristics. If a pump is the weak
manufacturing go round. Every working in applications from heat link in the production process, then the
day, thousands of industries around transfer to chemical processing, entire operation will be compromised,
the world rely on various pumping pumps must reliably, efficiently, and with the downtime required for
technologies to move raw materials safely transfer a dizzying array of repair or replacement eating away at
and end products through the fluids, all of which have uniqueand production quotas and the bottom line.
Chemical processors must deal with many fluids that are dangerous and difficult to handle. In order to fashion a handling and transfer operation that optimizes reliability, efficiency,
and safety in their operations, many are making the decision to install and rely on internal gear pumps.
SURVEYING THE OPTIONS among the most important. With manufacturing operations,
Industrial manufacturers have a wide manufacturing operations governed positive displacement internal
range of pump options to choose by operating budgets and expenses, gear pumps can offer the precise
from when outfitting their facilities. equipment acquisition costs and and consistent transfer of highly
There are also a number of factors subsequent maintenance are also demanding fluidsin this case,
that go into their choice of pumping primary concerns. dangerous chemicalsthat is
technology. Operational reliability This article will illustrate that while critical in creating a reliable,
and being able to meet very specific all pumping technologies can have efficient, cost-effective, and safe
fluid-handling requirements are their positive points in industrial- pumping system.
THE CHALLENGE OF intricate that there are several unit manufacturing process and stands out
CHEMICAL PROCESSING AND operations within the process, from above the others in its importance:
MANUFACTURE cracking, distillation and evaporation, fluid transfer. Often over-simplified
Chemical processing and manufacture to gas absorption, scrubbing and as transporting fluid from one point
is one of the most complex industrial solvent extraction, among others. to another, fluid transfer in chemical
operations in the world. In fact, the Within that family of unit operations, manufacturing is so much more.
chemical-manufacturing process is so one touches every stage of the Fluid transfer is a spectrum of
applications, with responsibilities
all along the chemical-production
chain. For example, thin or viscous
raw materials can be transferred
to storage tanks or blending and
mixing tanks. Final formulations can
be transferred to holding tanks, and
finished products can be loaded
into IBCs for delivery or consumer
packaging.
In many cases, chemical-
manufacturing processes require the
use of dangerous chemicals, such
as strong acids, caustics, solvents,
resins, and polymers. Despite their
inherent danger, these substances
are necessary for the manufacture
of thousands of consumer goods or
facilitate other industrial processes.
The challenge for users of these
dangerous chemicals is to construct,
handle, and transfer them in a
reliable way.
A LOOK AHEAD
Next month, well take a closer look
at the benefits positive displacement
internal gear pumps have continually
offered pump users seeking reliability
and cost-effectiveness when handling
raw materials and finished products
with a specific breakdown of Maags
own G Series Internal Gear Pumps.
Copper Mine
Quadruples Pump
Wear Life
GIW Enduraclad increases
operations from 450 hours to 2,000
By Ronnie Willis, GIW Industries
C
opper mining involves working with some of the When considering replacement parts, manpower, and
harshest materials in the world. As a result, mining revenue lost due to downtime, the costs the copper mine
companies must carefully monitor wear of their was facing on a regular basis were staggering. They
slurry pumps and schedule frequent shutdowns to replace desperately needed a solution for more efficient operations.
worn parts. The cost of this maintenance goes far beyond
just the price of parts; downtime and lost revenue can run FINDING A BETTER WAY
into hundreds of thousands of dollars. GIW offered the South American copper mine the answer.
An LSA centrifugal slurry pump was installed in a tailings
SEVERE WEAR RAISING COSTS booster application where GIW's exclusive Enduraclad
KSB's subsidiary, GIW Industries Inc., has produced material was applied to the new suction liner.
success at a South American copper mine.The GIW With the application of this new material, the mining
Minerals product solution quadrupled pump wear life and company has been able to extend wear life up to 2,000
created dramatic savings for the mine's tailing pumping hours and also improved wear life of other related pump
operations. The South American company had struggled parts. This success comes from years of hard work and
for years to reduce maintenance downtime in its tailings innovation from GIW's team of hydraulic and metallurgical
operations. engineers.
Tailingsthe material left over after the valuable metal
has been extractedconsist of very fine particles that are
highly abrasive in slurry. The material was wearing out
pumps more quickly than other equipment in the tailings
line, increasing the frequency of downtime. They were
having such severe wear that they were repairing the
tailings pumps every 400 to 450 hours.
SIDE-BY-SIDE COMPARISON
GETTING YOUR
MONEYS WORTH
Although Enduraclad-bonded parts
might be more expensive, they are
well worth the price. They will cost
more than uncoated parts, such as
suction liners, buy end-users save on
costs by using fewer parts, reducing
maintenance costs, and not suffering
the downtime revenue loss. To remove
and replace the parts on one of these
pumps requires two to four people
working with tools and lifting devices
for 6 to 8 hours. So the longer a
company can keep the pump running
with nobody touching it, the more
operational costs they will save.
Economy is just one of the things
GIW values and tries to deliver to
its customers. Users are seeking
partners concerned with their best
interest, who are not just developing
these really specialized materials and
processes and charging higher prices.
GIW is continually looking for ways to
reduce the cost of materials to provide
a product that serves customers'
needs and fits their budgets.
CONTINUOUS IMPROVEMENT
IS A MUST
GIW is constantly looking at new
Turning Away
from Tradition
NORD screw conveyor drive proves itself
compact, reliable, and cost-effective
By Alie Foy, NORD Gear Corporation
C
ompanies around the world reliable transmission of power to the dry to semi-fluid materials from
have come to rely on screw driven shaft. free-flowing to sluggish at very steep
conveyor drive systems for Depending on the type of conveyor, inclines and are totally enclosed for
reliable drive solutions to meet the different applications can see dust and vapor-tight requirements.
demands of transporting bulk material. significant benefits right away. For
For these critical applications, open, example, shaftless screw conveyors THE ALTERNATIVE TO
two-way communication between have proven ideal for handling sticky TRADITIONAL SCREW
OEMs and end-users is essential to and sluggish bulk materials and are CONVEYOR DRIVES
help drive customers with an accurate equally well-suited for material with The NORD Screw Conveyor Package
assessment of each individual high moisture content. offers a compact and cost effective
application. To understand the In addition, screw feeders and live alternative to traditional screw
demands of industry, a manufacturers bottom conveyors incorporate either conveyor drives. Closely stepped
goal should be to provide users with a a single or multiple gearbox design speed reduction ratios combined
drive assembly that will reliably serve and provide a means of moving a with a directly coupled gearmotor or
the needs of a plant for many years to wide variety of material from bins or NEMA C-face input design eliminates
come. hoppers at a constant and controlled the need for top motor mounts,
For example, NORDs screw rate of flow. This type of conveyor is pulleys, belts, or guards. Minimizing
conveyor packages, with their rugged one of the most accurate and efficient parts and eliminating the belted input
output seal and innovative CEMA to meter bulk materials. Lastly, vertical systems provides for easier system
drive-shaft, are designed for reliable screw conveyors are ideal for elevating maintenance, increased reliability,
performance in screw conveyor
applications. Some of the industries
that rely on screw conveyors include
agriculture; oil and gas; chemicals
processing and handling; stone, glass,
and concrete, food products, and
wastewater treatment.
Reliable Energy
Is Looking Up
Down Under
U.S. software integrator fuels
Australian utility automation
By Steven W. Schwabe, Woolpert
U
.S. software integrator Woolpert, with support from Denver, this team met challenging deadlines that enabled
enterprise consulting firm gViz, has implemented AAD to conduct improved customer service at a lower cost.
Cityworks, an asset and work management solution, With the client thirty hours away by plane, we
for ActewAGL Distribution (AAD). AAD, based in Canberra, worked both onsite during Australian business hours
provides power to more than 195,000 electric customers and domestically on opposite schedules, says Dave
and another 134,000 gas customers in the Australian Feuer, Woolperts director of information technology and
Capital Territory and New South Wales, and it is one the management consulting. We were essentially working
largest joint-utility companies in Australia. in shifts, each group furthering the project while another
Cityworks, developed by Azteca Systems, is the only group slept.
GIS-centric asset management software available. Feuer notes the pace of the project was equal to working
Woolpert, Cityworks first Diamond-level Implementation sixteen to twenty hours per day.
Partner and a Strategic Development Partner, has been For about nine months, it was all hands on deck, he
delivering enterprise asset management solutions built on says. We took the system live as we were still developing
Cityworks for over twenty years. some interfaces and continuing to roll out integrations and
other system enhancements.
ENHANCED SERVICE FOR ENHANCED FEATURES Woolperta national architecture, engineering and
The implementation of this solution went live with the core geospatial firmalso is among the domestic leaders in
Cityworks software in July 2014. Since then, Woolpert
has steadily supplied the AAD team with product
enhancements and integrations to the existing software,
such as Oracle Financials and Gentracks Velocity Billing
solution.
These have delivered improved AAD operational
management and efficiency within the utilitys electrical
division. This project enables AAD to route and track work
assignments more easily by automatically converting
customer calls into actionable work for the maintenance
and operations staff.
Minimizing Leaks
and Environmental
Hazards for Fluid
Transfer
ARO Station provides a safe solution
for processing needs
By Fausto Lotti, ARO Fluid Management
T
ransporting and securing its exposure. The risks with chemical 1 inch, 1- inch, or 2 inch Expert
hazardous material handling are a daily reality and the Series Pumps (EXP) ARO diaphragm
while also minimizing its ARO Station was designed to protect pump. With the capability to pump
exposure are the twin goals of any operators as well as the environment material from 1,320 to 7,900 gallons
processing engineer. Many of the during the transfer of these materials. per hour, the ARO Station can be
fluids transferred during chemical calibrated to pump the appropriate
processing can be corrosive to DIFFERENT PUMPING OPTIONS quantity for each application. Use of
equipment or dangerous to operating The ARO Station can accommodate the ARO Station increases the safety
staff. And although well-maintained three different size pumps, the of chemical installations during the
connections in the piping or pumping
system is a must, Ingersoll Rand
has introduced a product that thinks
outside the box by putting a pumping
system inside the box: the ARO
Station.
are a daily serviceability, enabling customers to achieve the best total cost of ownership. For eighty-
five years ARO has been helping customers solve their most complex fluid handling
challenges to keep their business moving. For more information, contact 800.495.0276 or
reality and the arohotline@irco.com.
IMPERVIOUS TO CORROSION
Made of high-density polyethylene,
the ARO Station is impervious
to corrosion, and features a drip
collection tray that can hold up to 52
gallons of fluid. The ARO Station can
be used as a free-standing pump
solution or it can be equipped with
wheels for mobility. Compact and
ready for use, the ARO Station is a
standardized skid size thus reducing
integration costs.
Managing Assets,
Saving Time
StruxureWare SCADA Expert ClearSCADA
software fills the markets need
By Brad Shaw, Schneider Electric
A
cross a range of industries and automation, Schneider Electric, Enhanced WebX user interface
connected to oil and gas has also announced the release of Process information is available
or water and wastewater, StruxureWare, an add-on to SCADA anytime, anywhere through any
companies are experiencing a Expert ClearSCADA that continues device with HTML5 cross-browser
worrisome trend. As a great number of to improve on the user experience support for trends, alarm lists,
long-time technical experts retire, they and provide functionality based event lists, and queries.
are not being replaced by an equal on customers needs. Template
number of younger skill workers. expressions save engineers time Extended integration of telemetry
However, companies requirements during implementation; alarm hardwareEnhanced integration
to manage assets dispersed over summaries help pinpoint maintenance with the Realflo software, a flow
large areas has not diminished, and issues faster, and the seamless measurement application, now
Schneider Electric has recognized integration with a tier-2 historian including support for Realflo
the growing need for integrated and facilitates data accessibility across the Liquids 6.91, plus native support
automated control systems that todays entire enterprise. for well-known third-party flow
workforce can operate reliably and computers via a new oil and gas
efficiently. EXPANSIVE FUNCTIONALITY, EFM Driver suite.
REDUCED OPERATING COSTS
SAVING ENGINEERS TIME These functionalities are part of a Increased system securityA
Schneider Electrics new open and software platform that is designed substantial increase in security
scalable software for telemetry and to lower the overall operating costs features includes enhanced
remote SCADA applications, SCADA of remote assets while providing a user account security, auditing
Expert ClearSCADA, controls budgets complete, comprehensive overview of of the system security through
throughout each project, captures site operations. Other features include: a dedicated security event
relevant and reliable data from remote list and dedicated security
and challenging locations, logging queries.
and also minimizes
system security risks. By providing remote
This software improves configuration capabilities
the user experience and collecting data from
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Mechanical Seal
Energy Audits
and Their Value
Part 1 of 4
By Tom Grove and Heinz Bloch
E
nergy Management is critical Energy Czar. The International vast majority of mechanical seals
to operational efficiency. Standards Organization recognizes the are deployed in process pumps at
Reviewing energy use in each importance of energy management refineries, petrochemical plants,
link of the supply chain of a business in the ISO-50001 Standard for Energy pulp and paper plants and a host of
can produce significant benefits. Management Systems. other industries. With the exception
Increasingly, industrial companies Mechanical seals are energy of gas-injecting seals (available on
are making a commitment to energy consumers. They are components very few pumping services), all other
control by staffing energy management which prevent fluid leakage from mechanical require a flush liquid in
positions. These positions may even the shaft region of process pumps the seal cavity. This flush liquid can
be referred to as the Corporate and other rotating equipment. The be supplied in different quantity and
KEY DELIVERABLES
Investment Profile to Return-On-
Piping Plan Energy Cost
Scope of Savings Priorities Deploy Corrective Upgrade Investment Summary
Savings Range
Strategy - Estimated Expectation
Heat exchanger
Cooling
water in
Pumping
ring
Temperature indicator
The audit replicated in this four-part series of articles pumps. Figure 1 shows a jacketed cooling (or heating)
assumes that the plant started out with API Seal Flush Plans cavity for occasional applications favoring controlled seal
02, 11, 23 and 32. The audit explains alternatives such as chamber temperatures.
Plans 53A and 54. In Plan 11 (figure 2) product is recirculated from the
Figure 1 shows API Plan 02, a dead-ended seal chamber discharge of the pump to the seal through a flow control
with no flush fluid being injected into the process. There is orifice. This arrangement is selected to increase the
no auxiliary piping connected to the mechanical seal cavity pressure at the seal to the full discharge pressure of
(shown) or the stuffing box, in case braided packing is the pump. The plan maintains pressure above vapor
used. This plan is suitable for sealing cool clean fluids with pressure; the product is less likely to vaporize at elevated
high specific heat, such as water, in relatively low speed pressures.
s
Flow
n
tio
nn ova Improve
Wh
ere
I
Reliabilityand
Versatility
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illustrates, a control valve and flow meter control the Pressure gauge
volume of water injected. These controls are frequently External nitrogen
pressure source
removed because of clogging if the seal water quality (normally open)
Pressure
has particulates. switch low
Plan 53A as shown here is the conventional layout
found in the API specification. Plan 53 applications
Liquid filling
are an adaptation from this traditional plan. Plan 53 connection Level
switch high
(normally closed)
is a pressurized barrier fluid circulation system for a (optional)
Wastewater
Accessories
Controls Controls
3. Customized solutions
4. Quick ship products
A LOOK AHEAD
A comprehensive audit may include a seal water sample
analysis performed by an independent laboratory. Such
From sampling and analysis is occasionally requested by the plant,
external
pressure but would incur an optional charge. Contaminated barrier
source
fluid systems limit the reliability of the sealing system in
a Plan 54 arrangement. Part 2 of this series will highlight
the energy impact of using API Plans at one particular pulp
mill.
Barrier in
Figure 6: API Plan 54 Tom Grove is an executive vice president at AESSEAL Inc.,
one of the world's leading specialists in the design and
manufacture of mechanical seals and support systems. He
water to drain system or it may be a closed loop system for a can be reached at tom.grove@aesseal.com. Heinz P. Bloch,
single or multiple applications. P.E., is one of the worlds most recognized experts in machine
reliability and is a Life Fellow of the ASME, in addition to
WATER-TO-DRAIN ARRANGEMENT having maintained his registration as a Professional Engineer
in both New Jersey and Texas for several straight decades. As
Illustration A depicts a water-to-drain arrangement. A a consultant, Mr. Bloch is world-renowned and value-adding.
common header is fed by a seal water pump. Supply lines He can be contacted at heinzpbloch@gmail.com.
from the header connect to the pump seal inlet port and go
to a drain through the seal outlet. Flow is not recovered or
re-used.
Pressure is not consistently applied to each pump due to
piping friction losses and flow diversion.
If the primary supply pump to the seal water system is
lost, multiple seal failures could occur. The seal pressure
at each seal can be reduced, if needed. Such pressure
reductions are needed in installations where the header
labeled Alternative Flow must also satisfy higher pressure
requirements, such as wash-down water.
Featured Product
GRIFFCO VALVE
Y-Strainers for Chemical-Feed Systems
Griffco Valve, Inc. introduces its new line of
Y-Strainers designed to enhance the performance
of chemical feed systems. The addition of a Griffco
Y-Strainer to the suction (inlet) side of a chemical
feed pump will prevent debris from entering the
pump and clogging the check valves or damaging
the interior of the pump head.
GORMAN-RUPP
6500 Series Standard Horizontal End Suction Centrifugal Pumps
The new 6500 Series line offers solids and water handling end suction centrifugal
pumps based on the proven technology of the Prime Aire and Prime Aire Plus
models. Featuring model sizes from 3 inches (75 millimeters) to 16 inches (400
millimeters), flows to 15000 gallons per minute (946.4 liters per second), total
dynamic head to 530 feet (161.5 meters), and solids handling capabilities up to 4
inches (101.6 millimeters), these pumps will provide a high level of performance
and efficiency for applications in wastewater treatment plants, industrial facilities,
construction, mining, and agricultural uses. For more information, contact Cyndi
Hoffner at 419.755.1207 or choffner@gormanrupp.com.
ALL-TEST PRO
AT5 Electric Motor Circuit Analysis Instrument
ALL-TEST Pros hand-held electric motor circuit analysis instrument, the AT5,
performs a comprehensive assessment of a motors health for troubleshooting,
predictive maintenance, and quality control of in-service, stored, and incoming
motors. Intuitive on-screen, menu-driven prompts guide users through testing
process. Perform tests directly at motor terminals or, for hard-to-reach motors (such
as submersible pumps), from distances to 1000 feet. Ideal for low-, medium-, and
high-voltage AC motors and DC motors, as well as generators and transformers. For
more information, visit www.alltestpro.com or call 860.399.4222.
BLACKMER
HD943 and HDL943 Oil-Free Reciprocating Gas Compressors
Blackmer, part of PSG, a Dover company and a global leader in positive displacement
and centrifugal pump and reciprocating compressor technologies, is pleased to
announce the release of its new triple-seal HD943 and HDL943 oil-free reciprocating
gas compressor line. Featuring a double-distance piece design with three individual
sets of packing to maintain product purity and prevent oil migration, Blackmer HD943
and HDL943 compressors have been specifically designed for applications that require
maximum leakage control. For more information, contact Thomas L. Stone, PSG director
of marketing, at 616.248.9252 or tom.stone@psgdover.com.
ENOVATION CONTROLS
Murphy PowerCore MPC-10
Enovation Controls introduces its newest controller: the Murphy PowerCore
MPC-10. This general, all-purpose manual/auto start and manual/auto throttling
engine controller is designed with rental applications in mind. Purposed
primarily for applications where a wide array of inputs and outputs are not
required, the MPC-10 is a powerful, rugged controller that supports J1939 CAN
protocols for electronically governed engines as well as I/O for mechanical
engines for fault and safety shutdowns. The MPC-10 follows a standard operating
sequence of twenty-two machine states that happen in a predetermined order.
Machine states can be set to zero if not needed or adjusted to fit the application.
The menu structure is incredibly versatile with the ability to change many
parameters and settings from the face without the need of a PC. For more
information, call 918.317.4100 or visit www.fwmurphy.com.
WIELAND ELECTRIC
ASD-NIB Non-Incendive Barrier
Wieland Electric Inc., a leading global manufacturer of innovative electrical
interconnect technology, has developed a single non-incendive barrier module for
virtually any type of signal, enabling engineers to eliminate the explosion-proof
enclosures and conduit in Class 1, Division 2 environments. The non-incendive barrier
also offers significant cost and space savings compared to traditional intrinsically-safe
(IS) barriers. The ASD-NIB non-incendive barrier minimizes the risk of ignition on the
load side of the module by providing an electrical barrier between control devices
and equipment installed in hazardous environments. This enables standard wiring
practices to be used to connect to end devices in the field, eliminating the need to
install expensive explosion-proof enclosures and conduit. For more information, visit
www.wielandinc.com or call 800.WIELAND (800.943.5263).
ONSET
HOBO MX2001 Water Level Logger
Onset, a world leader in data loggers, introduces the HOBO
MX2001, the industrys first water level data logger designed
for convenient wireless setup and download from mobile
devices via Bluetooth Low Energy. The MX2001 dramatically
simplifies and lowers the cost of field data collection by providing
wireless access to high-accuracy water level and temperature
measurements right from a mobile phone or tablet. Researchers
no longer need to take a laptop computer out to the field or pull
data loggers out of a well to download data. For more information,
visit www.onsetcomp.com/mx2001.
TIMKEN
Revolvo Split Roller Bearing Housed Unit
The Timken Company introduces its full Revolvo split cylindrical roller
bearing housed unit line to the North American marketplace. Timken added
the Revolvo line, which is well-known across Europe, to its bearing and
power transmission product line-up when it acquired the assets of Revolvo
Ltd. late last year. Revolvo split cylindrical roller bearing housed units are
widely used by mining, power generation, food and beverage, pulp and
paper, metals, cement, marine, and wastewater end users. The units and
components are fully interchangeable with most split cylindrical bearing
configurations in the market today. For more information, contact Matt Evans,
communications manager, at 234.262.3381 or matt.evans@timken.com.
The Growth
of Big Green
NuTerras Aaron Zahn on environmentally
responsible and economically viable technology
A
aron Zahn is president material handling more difficult. That knowledge base
and CEO of NuTerra, allows NuTerra to deliver exactly what we say we willor
which is leading the better.
transformation of the wastewater
and organic waste industry to MPT: Government regulations, resource pollution, and
mitigate the global water crisis. increasing energy costs are the three top factors facing
He recently spoke with Modern many municipalities as well as handling and treatment
Pumping Today to explain how facilities. What options can NuTerra provide for cost-
NuTerra has quickly become effective and environmentally sound waste management?
a preeminent developer and
operator of public and private Aaron Zahn: With the resources NuTerra brings to our
organics waste recycling facilities. For more information, clients, the options are practically limitless. We can come
visit www.nuterra.green. into a facility, bring in our technology, and take on that
risk from the private entity or alleviate that risk from the
MPT: What are some of the advantages NuTerra brings public. Typically, we structure our transactions in the form
to projects for managing and implementing biosolid and of public-private partnerships where what we bring to
other material handling solutions? the public sector is our capability and understanding how
technologies can be interconnected to create a successful
Aaron Zahn: The number one advantage is 100 percent project and then maintaining that project over its lifecycle.
success on a lifecycle basis. When youre looking at the The key to success is creating predictable costs. Its
track record of solids handlingbe it biosolids or food unpredictable costs that cause infrastructure difficulty.
waste or most processes with a material handling element When the public sector is unprepared for these costs,
to themthe industry as a whole is proliferated with thats when they have to go back to their rate base for
failures. Often time this is due to working with a waste more revenue.
stream that is regulated like water but managed like
solid waste. Unfortunately, theres never been an industry MPT: Municipalities are frequently caught with
leader or a professional organization that emphasizes underperforming and out-of-date infrastructure. What are
how to operate within the confines of the regulations but some of NuTerras options for these operators?
also engineer systems that take into account the material
handling element. Aaron Zahn: Theres a great deal of innovation in our
About six years ago, we started by aggregating industrywhether it be in energy conservation, energy
wastewater facilities into a database. Were now able to production, resource reutilizationyet at a state level
model exactly their unit cost and how they operate, which regulations are getting more and more stringent. What
then allows us to forecast model of any of our prospective NuTerra can provide is a series of design solutions
clients. When we forecast for a client, we can show them that adapt over a ten- to twenty-year framework. For
where theyre going to spend their money as well as example, many of our designed facilities in Florida are
what to do and what not to do when addressing the solid now providing 100 percent reuse on their water and 100
handling elements of organic waste. For example, we percent reuse on their solids. Were a big believer that
could advise a client not to design an auger system in using less energy is better than producing more, and
excess of 20 feet to avoid replasticizing and making their energy efficiency is at the core of our design solutions.