Pump industry august 2014 digital edition by Monkey Media

ISSUE 8

AUGUST 2014

pumpindustry Export market update Pressure sewer pumps Vacuum packing food

Managing mine water

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PU MP I N DU STRY

President’s welcome Welcome to another high quality issue of Pump Industry magazine.

Pump Industry Australia Incorporated Kevin Wilson – Secretary PO Box 55, Stuarts Point NSW 2441 Australia Ph/Fax: (02) 6569 0160 pumpsaustralia@bigpond.com Ron Astall – President United Pumps Australia & Astech Consulting Services John Inkster – Vice President Brown Brothers Engineers Mike Bauer – Councillor Dynapumps Frankie Camilleri – Councillor John Crane Geoff Harvey – Councillor Davey Products Pty Ltd Tony Kersten – Councillor Grundfos Pumps Pty Ltd

In my last President’s welcome I encouraged you all to read my article Are your pumps running too slowly? which addressed the problem of pump purchase specifications that enforced inappropriate running speed requirements, all too often compromising the pump selection process for no good reason. As the concept of faster running pumps being more reliable than slow speed pumps is somewhat counterintuitive, I expected a certain amount of controversy. I was not disappointed. Chris Bland had posted this article in the Pump Engineers discussion group in LinkedIn and it certainly generated some comment. There is a follow-up article in this issue. Feel free to get involved and comment. We are trying to generate discussion on the pump selection process, particularly on selecting more efficient pumps. I am most interested in your feedback. At PIA we have an ongoing commitment to education and we were pleased to get involved in the recent ARBS mechanical services exhibition and seminar program, where Keith Sanders, Ken Kugler and I presented on pump

selection topics and developments in fire pump standards to a small but enthusiastic group. We also provided a similar technical briefing for the Air Conditioning and Mechanical Contractors Association at their headquarters in Burwood, Victoria in July. All of this is consistent with the PIA’s aim to develop a better educated industry. In November we are celebrating the 50th anniversary of PIA (previously APMA) with our AGM, a seminar and a dinner cruise on 11 and 12 November. We are very pleased to have as a special guest and keynote speaker, Steve Schofield from the British Pump Manufacturers' Association, who has an abundance of interesting topics and developments affecting the pump industry in Europe. I am personally looking forward to his presentations and encourage you to come along. More details to follow. Enjoy another great issue of Pump Industry magazine. Ron Astall President, Pump Industry Australia

Martin O’Connor – Councillor KSB Australia Alan Rowan – Councillor Life Member Keith Sanders – Councillor Australian Industrial Marketing & Life Member www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

ISSUE 8

AUGUST 2014

pumpindustry

PUMP I NDU STRY

Export market update Pressure sewer pumps Vacuum packing food

Managing mine water

Editor’s welcome

n Australia, considerations regarding water usage and management are never far from mind, and the pump industry has a huge role to play in managing our most precious natural resource. Mine dewatering and wastewater are two particular areas of water management where the pump industry has a vital role to play. In this edition of Pump Industry, we profile two mines – the McArthur River zinc mine, and the Mt Morgan gold mine – and bring you a detailed profile of the specific pumping systems that have been used in the process.

Published by

Monkey Media Enterprises ABN: 36 426 734 954 PO Box 3121 Ivanhoe North VIC 3079 P: (03) 9440 5721 F: (03) 8456 6720 monkeymedia.com.au info@monkeymedia.com.au pumpindustry.com.au magazine@pumpindustry.com.au Publisher and Editor: Chris Bland Managing Editor: Laura Harvey Editorial Assistant: Michelle Goldsmith Design: Sandy Noke

Managing and treating wastewater, while perhaps not the most glamorous aspect of the water industry, is a vital part of our national infrastructure. Integral to the functionality of wastewater treatment plants are the pumps that drive them, and in this issue you’ll find profiles on a number of wastewater treatment plants, both local and global, with a focus on the pumps that are being used to keep them operating at maximum efficiency. I mentioned in my last column that the 50th anniversary of Pump Industry Australia is rapidly approaching, a milestone we intend to commemorate in this magazine with the recognition it deserves. Over the past couple of months I’ve been in touch with a

number of members of our industry, as well as past members of the PIA board, to begin the process of putting our 50th anniversary feature for the November edition of Pump Industry together. If you have any photographs, historical documents or anecdotes you’d like to share with your fellow pump industry colleagues, please email me at chris.bland@monkeymedia.com.au. Our range of custom marketing services is continuing to grow and we are working with clients to deliver their own email newsletters, search-engine-optimised websites, blogs and other content, social media campaigns and more. We have a new brochure which outlines all of the services we can offer you, from writing editorial to publishing newsletters, which will help you achieve your business goals. Contact me for a copy. Finally, as many of you will know, we’re about to head into a busy program of conferences and social events across the sector. I’ll be attending WIOA in Bendigo from 3-4 September, and InterWater/All Energy Australia in Melbourne from 15-16 October. I look forward to seeing many of our readers there. Chris Bland Publisher and Editor

ISSN: 2201-0270

This magazine is published by Monkey Media in co-operation with the Pump Industry Australia Inc. (PIA). The views contained herein are not necessarily the views of either the publisher or the PIA. Neither the publisher nor the PIA takes responsibility for any claims made by advertisers. All communication should be directed to the publisher. The publisher welcomes contributions to the magazine. All contributions must comply with the publisher’s editorial policy which follows. By providing content to the publisher, you authorise the publisher to reproduce that content either in its original form, or edited, or combined with other content in any of its publications and in any format at the publisher's discretion.

pump industry | August 2014 | Issue 8

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pumpindustry

President’s welcome................................................ 1 Editor’s welcome...................................................... 2 News briefs............................................................... 6

C O N T E N T S

Contracts awarded................................................... 10 Index......................................................................... 68

MAIN FEATURES

14 MINE DEWATERING Legacy of a golden past: dewatering the Mount Morgan Mine......................................... 14

Dewatering an active zinc mine................................................. 18 Hosing in on efficient fracking.................................................... 24

26 Exports Global markets, local players..................................................... 26

30 Manufacturing Paint and ink manufacturers improve efficiency....................... 30

Shale

R&D on a large scale.................................................................. 32

36 WASTEWATER Bringing pressure sewer to small communities........................ 36

Efficient and cost-effective wastewater pumping...................... 39 Upgrading the Kincumber sewage treatment plant.................. 40 Serving the industry’s needs...................................................... 42

43 Drives Optimal drive............................................................................... 43

44 Compressors Optimisation of centrifugal compressor re-wheel design......... 44

48 Agriculture Solar powered pumping solution............................................... 48

pump industry | August 2014 | Issue 8

www.pumpindustry.com.au

IS SU E 8 | AU G U S T 2 0 1 4

50 FOOD Central vacuum supply for meat products............50

53 Balancing Basics of balancing.................................................53

54 Maintenance Pump rebuild shops: facts and considerations (Part 2)..........................54 Reducing sludge treatment costs..........................57 Making maintenance easier...................................58

59 Expert Ask an Expert..........................................................59

62 PUMP PIONEERS Alan Rowan..............................................................62

Pump school

How is the volume of pump sump pits determined.......................................................65

Understanding pump curves

Are your pumps running too slowly? Part 2.......................................................................66

PIA events..............................................................12 PIA news................................................................13 Product Showcase New products available

52 www.pumpindustry.com.au

through White International....................................60

pump industry | August 2014 | Issue 8

Pump Industry News Briefs Get all the latest news at www.pumpindustry.com.au

$11M upgrade for more reliable and efficient pump station A two-year upgrade project is underway in Queensland on the Glenmore Water Treatment Plant’s High Lift Water Pump Station (WPS) to significantly improve its pumping capacity and energy efficiency. Rockhampton City Council’s Water Committee Chair, Councillor Greg Belz, said that as the Glenmore WPS is instrumental to the supply of drinking water to the area, and currently the council asset that consumes the most energy, the $11 million upgrade was vital. “The upgrade to the WPS will significantly improve the capacity and reliability of the pumps, and will supply water for at least the next twenty to thirty years by using modern technology to help reduce energy consumption and pumping costs,” Councillor Belz said.

Chris Bland and Laura Harvey.

Key appointment at Monkey Media A recent appointment at Monkey Media has boosted the company’s editorial team and ability to provide niche marketing solutions to those in the pump industry. Laura Harvey joins the team as Pump Industry Managing Editor. Laura has more than ten years of experience as a journalist and editor in the infrastructure and energy industries. “When Pump Industry launched I was incredibly impressed with its concept, design and content. I’m delighted to now be a part of the team, and look forward to working with our industry stakeholders to continue to grow the magazine and its standing across the pump industry,” said Laura. Monkey Media Managing Director Chris Bland is thrilled to welcome Laura to the team. “Laura is integral to the growth of Pump Industry and Monkey Media. Having worked with Laura in various roles over the past ten years, I’m excited she has joined Monkey Media to produce the highest quality magazines and innovative marketing solutions for our clients,” said Chris. “Together we have 20+ years of infrastructure and industrial marketing experience to offer, and we look forward to sharing our expertise with our clients in the months and years to come.”

“This WPS currently has a maximum monthly energy usage of approximately 1,000,000kWh (just over $100,000 per month) of which Fitzroy River Water (FRW) noted significant potential to reduce its energy and power consumption,” he said. The tender for the project was awarded to local Aquatec Maxcon Pty Ltd on 11 July 2013 and Stage One works have recently commenced on site. Councillor Belz said works to date include demolition and removal of old transformers to allow space for construction of a new electrical switch room. “Stage One of the project has a contract value of approximately $4.5 million; $800,000 of which is being funded by the Queensland Government,” Councillor Belz said. “Improving the efficiency of our energy use via this project is one of the fastest and most cost-effective ways to reduce greenhouse gas emissions. In the long term, rate payers will benefit from this project through improved performance and reduced operating costs for FRW.”

Meter upgrades begin for Sunraysia Modernisation Project A rollout of approximately 3,700 water meters has begun in the Mildura, Red Cliffs and Merbein irrigation districts in Sunraysia, Victoria as part of the Sunraysia Modernisation Project. The $120 million project is a joint initiative between the Commonwealth and Victorian State Governments and Lower Murray Water (LMW) and involves upgrades to pump stations, irrigation systems and various other water infrastructure. As a part of SMP, approximately 2,500 Domestic and Stock meters and 1,200 6

irrigation meters will be upgraded and/or installed to: • Enable the National Metering Institute standards and objectives to be met; • Deliver consistent metering methods across all districts; • Enable improved operation of the irrigation system through the modernisation of the metering fleet; and • Provide the availability of real-time metering information for irrigation customers.

pump industry | August 2014 | Issue 8

The metering works will involve upgrading all irrigation meters to electromagnetic flow meters; the standardisation of meter sizes and outlet arrangements; the installation of irrigation meters prior to customers’ pump stations; replacing active Dethridge wheel outlets; metering any unmetered supplies; and the installation of telemetry to all irrigation outlets. The metering works are expected to be complete by the end of October 2015.

www.pumpindustry.com.au

Pump Industry News Briefs Get all the latest news at www.pumpindustry.com.au

Wastewater upgrade scheme makes progress Lithgow City Council, located in the Central West region of NSW, has reported progress on an upgrade of the wastewater delivery system from the town of Bowenfels to the Lithgow Sewage Treatment Plant (STP). The project involves the construction of two new pump stations, one at South Bowenfels and one at South Littleton, a new rising main to Endeavour Park and a new gravity main from Endeavour Park down Enfield Avenue, under Main Street, under Farmers Creek and into the Number 1 Pump Station at the Lithgow STP. The scheme will see a reduction on the load on the existing systems in the Littleton area and allow the wastewater system to cope with additional demands from the Bowenfels residential development area. The work is being undertaken on behalf of the council by contractors Precision Equipment Co Ltd and the estimated value of the work being carried out is approximately $3.5 million.

Pump upgrade to help mitigate drought impact Work has commenced on a water supply drought mitigation project at Wallabadah, NSW. This project involves equipping a bore, constructed during the 2007 drought, with a pump, and the construction of approximately 1,500 metres of rising main. It also includes significant alterations to the existing pipework for enhanced operation of the supply from this new water source. Mayor of Liverpool Plains Shire Council (LPSC), Councillor Ian Lobsey OAM, said the Council is undertaking the construction using its own workforce and plant. “LPSC liaised with affected landowners prior to commencement of the work and good progress has been made on pipe laying,” he said. “There is also good progress with the switchboards and controls utilising the standards designed by Council and its electrical contractor in-house during the Willow Tree pump station upgrade.

This enables a standardised board with operational protections, such as against lightning strikes, to be utilised, as well as the minimisation of electrical component stockpiles that would be required if different installations were used. Flexibilities in operational modes to control pump outputs used to manage varying water inflows and control redundancies are also built into the design,” he said. “This project is an important part of LPSC’s vision to drought-proof our communities. Work is currently proceeding on the design project for the Regional Water Supply Scheme to greatly enhance water security for Werris Creek, Quirindi and Willow Tree. The Wallabadah supply is a standalone one and currently it is unfeasible economically to include it in the wider concept. Previously, it has been prone to quick falls in level during prolonged, hot, dry spells and this project is the best way to overcome that problem,” Councillor Lobsey concluded.

Correction In the last edition of Pump Industry, we featured an article on Brown Brothers being the exclusive distributor for Sakuragawa Pump Manufacturing Company for Australia and New Zealand. In the article we stated that Sakuragawa was Singapore-based, however, we would like to confirm that Sakuragawa is in fact based in Japan.

Maryborough flood resilience project funded Flood defences in the Maryborough CBD will be bolstered through the Queensland Government’s record investment in flood and disaster mitigation projects to protect Queensland communities. Local Government, Community Recovery and Resilience Minister, David Crisafulli, said $6 million would be spent on a 1.8 metre portable flood barrier, a permanent pump station and upgrades to Adelaide Street, located in the city’s CBD. “Protecting the CBD is a priority, and mitigation projects like this will keep businesses open and keep the local economy moving when the floodwaters rise,” Mr Crisafulli said. “This government has a plan to create jobs in 8

the Wide Bay-Burnett and building critical infrastructure like this will make a huge difference to the region.

local councils to literally move heaven and earth to protect and prepare homes and livelihoods,” Mr Crisafulli said.

“Adelaide Street will be raised by 300mm and upgrades to stormwater drainage will be made to improve flood resilience to a gauge level of 11.4 metres.”

“Queenslanders have been pushed to the brink in the past few years, and we are doing everything we can to not only protect them but make them stronger.

The Maryborough CBD works are part of a major state-wide investment in projects such as levees, temporary flood barriers, road-raising, major drainage and stormwater upgrades, improvements to evacuation routes and the installation of rainfall and river height warning systems.

“The works will also provide a muchneeded financial boost to communities through jobs and lower insurance premiums.

“Our strong plan to protect Queensland communities means we are working with

pump industry | August 2014 | Issue 8

“Disasters can strike at any time but the Newman Government’s strong plan to protect communities for the long term will ensure a brighter future for all Queenslanders.”

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Works begin on Dial Blythe irrigation scheme

$250M of Pacific LNG contracts awarded

Construction has begun on the Dial Blythe Irrigation Scheme (DBIS) in north-west Tasmania.

Engineering group Monadelphous has been awarded three contracts with the Australia Pacific LNG Project (APLNG) for the construction of upstream gas processing and compression facilities associated with its coal seam gas to LNG project in Queensland.

Shaw Contracting Australia was awarded the two construction contracts for the scheme; for the 4,000 ML South Riana Dam and the distribution network, which consists of two pump stations, 40km of pipeline and over 40 outlets. Local Wynyard manufacturer Zezt Pty Ltd was awarded the pipe supply contract. The scheme commenced construction after securing $9.06M in Federal Government funding under the Tasmanian Jobs and Growth Plan and $1.96M in State Government funding from the Water Infrastructure Fund. A further $3.4M in private capital was raised by farmers purchasing water rights. The project is scheduled to be completed by February 2015 to deliver water in the latter part of the 2014/15 irrigation season. Water for the DBIS will be extracted from the Blythe River above the South Riana Road bridge during winter. It will be stored in a storage dam at South Riana of up to 4,000ML. Water will be distributed to the scheme over a 120-day summer irrigation period from December through March each year using 42km of pipelines and boost pumps.

The contracts have a combined value of approximately $250 million and the largest is for the construction of an upstream gas processing facility that will process gas from the project’s gathering network for delivery to its main pipeline. The other contracts comprise the installation of a pipeline compression facility and an interconnect facility, enabling the transfer and metering of gas between networks. Work will be completed in line with APLNG’s schedule to deliver first LNG in mid-2015. “We are extremely pleased to be working with Australia Pacific LNG on this significant coal seam gas project in Queensland,” Monadelphous Managing Director Rob Velletri said. “These contracts further strengthen our reputation in the delivery of major oil and gas projects in Australia and overseas.”

Two pump stations will be required, one at the dam site and one at the Blythe River. The pipes will traverse 92 private properties and various Crown land holdings.

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PIA E VENT S

PIA hits Perth T

he next meeting of the PIA will be held in Perth at the Mt Lawley Golf Club, with the meeting to be followed by an informal dinner in the golf club. The Mt Lawley Golf Club is one of Perth’s leading golf clubs. Located just ten minutes from Perth’s CBD, the convenient location also offers ample free car parking. The meeting will commence at 4.30pm, and will include a presentation from a guest speaker, as well as presentations

from West Australian members about their activities in the State. After the meeting’s conclusion, attendees will enjoy an informal dinner in the golf club. PIA members can register their attendance by contacting Kevin Wilson at pumpsaustralia@ bigpond.com. Following the Perth meeting, the final PIA meeting for the year will be held in Melbourne, with the AGM taking place on Tuesday 11 November 2014. ■

Next PIA meeting: Perth, Mt Lawley Golf Club, Walter Road, Inglewood WA 4.30 pm, Tuesday 12 August 2014

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pump industry | August 2014 | Issue 8

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PIA N E WS

PIA turns 50

With Pump Industry Australia, formerly the Australian Pump Manufacturers' Association marking its 50th anniversary in November this year, Pump Industry will be marking this milestone with a commemorative feature in the November edition of the magazine. The Australian Pump Manufacturers' Association was first considered in 1963 and then officially came into being in late 1964. Companies involved included Southern Cross, Thompsons, Kelly & Lewis, Ajax, IEL and Mono. Many of the current PIA Life Members were active in the early development of the APMA. Over the past 50 years, the organisation has consistently adjusted its activities to take into account the changing nature of the global pump market and its impact in Australia. In the 1990s, there was a significant rationalisation in Australia through mergers and acquisitions. This resulted in a change of name from APMA to Pump Industry Australia and

www.pumpindustry.com.au

now our membership ranges from multinational companies, who are ‘fullliners’ in the Industry, through to small independent businesses who specialise in providing products and services for niche markets. To commemorate the past 50 years of the APMA/PIA, Pump Industry will include a feature in the November edition of this magazine, which looks back at the achievements of both the industry’s association, and indeed the industry itself. We’ll delve back into the

history books to record some of the key moments in the development of the industry and its association, and profile some of the people who have helped to make the industry what it is today. ■

Do you have a story to tell, photos to share or historical documents that can help tell the story of APMA/PIA? We’d love to hear from you – contact Pump Industry Managing Editor Laura Harvey at laura.harvey@monkeymedia.com.au.

pump industry | August 2014 | Issue 8

MIN E DE WATE RI NG

Legacy of a golden past:

dewatering the Mount Morgan Mine The Mount Morgan Mine was once the largest gold mine in Queensland, yielding around 250 tonnes of gold and 360,000 tonnes of copper, and generating approximately 134 million tonnes of waste rock and tailings. While the mineâ&#x20AC;&#x2122;s mineral wealth has since been exhausted, the changes it wrought upon the surrounding environment live on. To prevent the negative impacts of uncontrolled pit water discharge into the nearby Dee River, a series of pumps work round the clock to dewater the mine.

ount Morgan is located 32 km south-west of Rockhampton in Central Queensland. It was founded in 1882 as a gold mining town and mining operations in the area continued until November 1990. In the early years of peak activity at the mine, mining activities were unregulated and as a result have left a legacy of impacts on the Dee River and the mine site. These include acid mineral drainage and seepage, caused when sulphide minerals (such as those found in abundance in the mineâ&#x20AC;&#x2122;s mineralised dumps and tailings dams) oxidise when exposed to air, forming sulphuric acid. The acid then leaches metals from the surrounding rock and, as a result, the water that seeps out of the dumps and into the nearby Dee River has a low pH, a high metal content and high sulphate levels. This results in a reduced number of species being able to survive in the contaminated areas of the river, and the water being unsuitable for drinking or 14

recreation and sometimes causing skin irritation upon exposure. The Dee River flows into the Don River and then into the Dawson River before reaching the Fitzroy River. However, the Dee River catchment represents just 0.63 per cent of the entire Fitzroy River catchment, and the effect of the low-quality water from the Mount Morgan mine site lessens as one gets further away from the mine site and it becomes more diluted. As a result of these impacts, in 1992 the Queensland Government took responsibility for the ongoing management of the site and has since undertaken a number of measures to manage the site and minimise its legacy issues. The main priority of the management program, part of the Abandoned Mine Lands Program (AMLP), is to minimise the amount of low-quality water leaving the site and discharging into the Dee River. One of the main ways this is achieved is by reducing the volume

pump industry | August 2014 | Issue 8

of water in the mine pit, which in turn reduces seepage into the surrounding environment.

Dewatering the pit

In January 2013, a once-in-2,000-year rain event caused acidic water from the abandoned Mount Morgan Mine site to flow into the Dee River from the open cut pit. As a result, the mine dewatering infrastructure was dramatically upgraded to prevent a reccurrence. Water is removed from the mine's open-cut pit via two methods: water treatment and evaporation. A lime dosing water treatment plant operates continuously, taking water from the pit, neutralising its pH and removing contaminants before releasing it into the Dee River. Additionally, three large evaporators and one smaller unit operate to supplement the water removal capacity of the water treatment plant. According to a spokesperson from the Queensland Department of www.pumpindustry.com.au

MI N E DE WATERI NG

One of the evaporators that assists with water removal from the mine. Natural Resources and Mines, these evaporators have increased the site’s daily water treatment and removal capacity from an average of 3.2 megalitres (ML) per day to approximately 4.7ML per day. By accelerating the lowering of water levels in the open cut pit in addition to the water treatment plant, the evaporators minimise the likelihood of an uncontrolled discharge of pit water into the Dee River and reduce site seepage. The evaporators consist of a pump, a ring of nozzles that produce a fine spray, and a high capacity air fan which pushes the evaporated water into the atmosphere. By maximising contact between air and the water droplets, evaporation is maximised. The evaporators operate automatically and are linked to a weather station that monitors wind direction and speed, as well as humidity. This means that they only operate when the winds are www.pumpindustry.com.au

blowing from behind, generally in a south-easterly direction, ensuring that the mist from the evaporators falls into the pit and will not reach the town or the department’s site equipment and staff. For maximum operational efficiency, the evaporators are also programmed to operate only when humidity is lower than 80 per cent. Water seepage from the site's tailings dams and waste rock dumps is also captured and pumped back to the old open-cut pit to reduce seepage to Dee River. This also enables rainfall flows to quickly leave the site, rather than pool and create more seepage. Water flows are also diverted to prevent them entering the pit. A new pumping system was designed and installed to increase the efficiency of this operation, using land-based centrifugal equipment to collect seepage and direct it back to the pit – as well as a submersible pump on a pontoon. The pumps are stainless

steel and the pipelines are poly pipe; all pumps and pipelines are acid-resistant and high metal-resistant. Pressure gauges are mounted on the pumps to check their efficiency. In designing these pump systems, the Department of Natural Resources and Mines calculated seepage rates and surveyed the pipeline route to determine head and suction requirements. Energy efficiency was also a priority for this project: electrical, diesel and solar-powered pumps were used. Some systems required several different sumps due to their remoteness from one another. Maintenance is also a vital aspect of the project. Pumps and pipelines are inspected daily, bearings and seals are regularly overhauled, and complete pumps kept on-site as back-ups. This means that repairs can be made and replacements installed quickly. A maintenance schedule has been established using →

pump industry | August 2014 | Issue 8

MINE DE WATERI NG

A new pumping system was designed and installed to increase the efficiency of this operation, using land-based centrifugal equipment to collect seepage and direct it back to the pit – as well as a submersible pump on a pontoon.

Pump specifics Pump type: Thompson Kelly & Lewis – Hydro Titan 125/100-315 Motor: Toshiba 110 kW 2970 rpm, 415 vHi Delivery pipeline: 900 metres of 200 mm PN8 poly Suction: 7 metres of 200 mm suction hose; 6 metres of 200 mm stainless pipe Pump rate: 40 L/sec

standard advice in pump and motor manuals along with site-specific observations such as factoring in preparations for the wet season.

Pump type: Thompson Kelly & Lewis – Hydro Titan 100/65-315

System functions are monitored by hour meters, flow meters, level controls, and undercurrent switches to prevent excessive running. Monitoring also includes surface and groundwater sampling.

Motor: Teco 55kW 1440rpm, 415v

Training staff in the maintenance schedule, comprehensive monitoring program and continual review of different types of pumps and motors have all been vital during the process. Staff are also well aware of the need to maintain their observations during normal operations and to ensure there are critical spares quickly available. The new pumping system was engineered for smooth installation and it has been an overwhelming success in helping the Department of Natural Resources and Mines to achieve its management goals for the site. ■

Delivery pipeline: 480 metres of 125 mm PN12.5 poly; 204 metres of 125 mm PN10 poly; 336 metres of 125 mm PN 6.3 poly; Suction: 5 metres of 160 mm stainless pipe Pump rate: 16 L/sec

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pump industry | August 2014 | Issue 8

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MI NE DE WATE RI NG

Dewatering an active zinc mine The McArthur River mine is currently the largest zinc resource in the world. It is located 45 km south west of the township of Borroloola in the Gulf Region of the Northern Territory, adjacent to the McArthur River. Maintaining the mine site requires extensive water management and dewatering, and a $28 million water management project for the site, awarded to Intech, is currently in its final stages.

nderground operations began at the McArthur River mine site in 1995 and McArthur River Mining Pty Ltd was formed to operate the mine on behalf of the joint venture partners, the GlencoreXstrata group. In 20072008 the mine transitioned to open pit development, and over 2011-2013 it underwent a $360 million development project to increase its capacity from 2.5 million tonnes of ore per annum to 5.5 million tonnes, and increase production from 360,000 dry metric tonnes to 800,000 dry metric tonnes per annum. 18

McArthur River Mining (MRM) is the world’s largest bulk producer of zinc in concentrate form, supplying 70 per cent of global demand for a high-grade bulk zinc-lead-silver concentrate. The mine’s production also represents approximately three per cent of the world’s total zinc resources used by all types of smelters each year.

Water management on site

Concentrate is transported from the mine to MRM’s Bing Bong loading facility by road. From there it is loaded onto a barge and transported to waiting ships at sea in the Gulf of Carpentaria.

• Underground mine dewatering

pump industry | August 2014 | Issue 8

Intech were awarded the engineering, procurement and construction management contract for the design and installation of a $28 million water management system project at the McArthur River mine. This project includes the following major elements: Dewatering infrastructure

• Shallow bore dewatering • Raw, dirty and contaminated ring mains. www.pumpindustry.com.au

MI N E DE WATERI NG

Water storage, transfer and discharge infrastructure

• Construction of reservoirs, including 1830 ML WMD Cell 3, 80ML Pond 2 and 120 ML Pete’s Pond • Transfer of dirty water between reservoirs • Contaminated water transfer to holding ponds. Four different models of pumps were used for dewatering at the site: • Mine dewatering pumps, also known as the evase pumps – three 670 kW 6 stage Schlumberger P2500-A C pumps were installed in a disused mine ventilation shaft. • Surface Pumps – five 315 kW Sulzer APP53-250 O pumps were installed at three different dams, to pump from one dam to another. • Bore Pumps – six Lowara model pumps ZN622 13-L6WN were installed at a depth of 100m to pump water from a shallow bore field system to a dam. • Seal water pumps – three Sulzer J15W were installed to wet the internal seal during the priming phase of the surface pumps. Each of these pumps came with a flotation device and strainer. www.pumpindustry.com.au

Choosing the right pumps for the job

The pumps selected for the project were chosen by evaluating a number of important criteria to suit their application at the site. Mine dewatering pumps

The three evase pumps were selected according to the requirement for a static head of 385m and a flow rate of 180l/s. The materials offered were judged to be of a superior quality and design and were more than suitable for the process fluid. The slim design of the motor diameter 7.38" (187.4 mm) gave these pumps an advantage over other pumps for this narrow borehole application. These pumps were also available with the shortest lead time.

Bore pumps

The nominal duty for the bore pumps was a flow rate of 5l/s at 150m head and the expected maximum flow rate was 8l/s. Having one model of pump had advantages; allowing spares to be kept to a minimum. The pumps operate with a desired DOL drive without a VSD. Surface pumps

The Sulzer surface pumps had a nominal duty of 828m3/hr with total dynamic head of 55m and maximum duty of 1224m3/h with total dynamic head of 60m. The ability of the pumps to draw down the level of the ponds to a nominal 6m below the maximum level was identified as an important performance requirement. →

pump industry | August 2014 | Issue 8

MINE DE WATERI NG

The pumps were specified by Sulzer to be self-priming units. This presented the advantage of having a built-in design, simplifying the design of the power supply and control system, and negating the need to install and maintain the priming units separately. Sulzer Pumps offered materials which were determined to be superior to those offered by the other vendors

due to a higher wear and corrosion resistance, hence a reduced maintenance requirement and longer operational life of the pumping systems.

The pumps at work

The bore pumps were installed into a vertical vent shaft and used to pump water from disused workings, which have been flooded since the end of

underground mining several years ago. The purpose of the system is to lower the water table in the pit. Water is pumped from the underground workings to a storage pond via HDPE ring main around the perimeter of the pit, where it is currently distributed and used at various locations including water sprays for evaporation, storage dam

→

High Quality Dewatering Pumps. Sakuragawa Pump Manufacturing Company was established in Osaka, Japan in 1953 and is now recognised as a renown manufacturer of submersible dewatering pumps with a world wide reputation for quality construction and robust design. With duties ranging from 100 l/min to 12,000 l/min and heads ranging from 8m to 120m Sakuragawa is ideally placed to meet the needs of the most difficult dewatering jobs. Applications include: • Mine dewatering • Drainage of pits and quarries • Storm water drainage • Transfer of liquids carrying sludge or sand • General dewatering duties on building and construction sites Call us today for a Sakuragawa brochure and to see how we can meet your pumping requirements.

03/14

Melbourne: (03) 9793 9999 Sydney: (02) 9671 3666 Brisbane: (07) 3200 6488 Email: info@brownbros.com.au Web: www.brownbros.com.au

DELIVERING PUMPING SOLUTIONS

pump industry | August 2014 | Issue 8

www.pumpindustry.com.au

The

experts in

dewatering

& pump hire

We are passionate about pumps, Vortex Hire was founded with the goal to provide pump hire equipment maintained to the highest standard available when you want it, where you want it.

CONTRACT MINE DEWATERING Vortex pride ourselves on our experience in mine dewatering in particular within the coal mines of the NSW Hunter Valley. Our staff have been providing solutions in mine dewatering for 16 years with the last 7 years clocking up an impressive 2,555 days incident and injury free onsite managing our clients water needs. We are acutely aware that down time is not an option with mine dewatering and our scheduled maintenance and daily onsite attendance and operation of assets is the key. As part of this turnkey approach we conduct scheduled diesel plant refuelling currently contracted capacity 2,400L/day. Contract surface water management (mine dewatering), scheduled servicing and maintenance inspections – pumps, lighting towers, generators, general plant, mechanical repairs.

PUMP PROJECT MANAGEMENT AND CONTRACTING: Vortex Hire offer solution based contracting focused on providing individually tailored approaches, utilising customer resources to achieve cost effective outcomes. Our staff are experienced in managing general over pumping “sump and pump” applications, sewer bypasses, pump station diversions, diversions for manhole cut ins and bypass during sewer relining. Our onsite mine maintenance services are testament to our pump project management ability.

PO Box 582, Belmont NSW 2280

Phone 0488 654 284

Fax 02 4945 5552

www.vortexhire.com.au

To request a copy of our Company Overview Call 0488 654 284

COMPANY

OVERVIEW

MINE DE WATERI NG

for dust suppression and at the processing plant. Pump speed and dewatering flow rates are controlled via VSD. System automation comprises local/remote flow control and leak detection. Additional infrastructure installed as part of the dewatering system upgrade included surface pump stations and pipelines for the transfer of water from the mine to the location of a future storage facility.

The project nears completion

The project is now wrapping up, with initial priming of the surface system and performance testing having taken place in June. The greatest challenge for construction was posed by the volatile environmental conditions that characterise the region, according to Intech Business

The three submersible pumps that are in an old underground vent shaft have been up and running for approximately three months and have more than doubled the mine’s dewatering capacity. The water level is now well under the bottom of the open pit. Development Manager David Nolan. However, persistence and flexibility saw the project through. “Our time at MRM has seen us through two wet seasons. Trying to do any amount of work in a place where you can experience up to 80mm of rain in a matter of hours is always going to be a challenge.

“This was heightened due to a lot of that work being civil based. Along with the rain, our design and construction methodologies have evolved over the past 18 months to adapt to some fairly major changes in the criteria of the system, including a whole new catchment dam and complete relocation of a pump station. Being a smaller

FIRE PUMP AND GENERATOR SPECIALISTS SINCE 2001 Maintenance • Installations • Testing Phone: 07 3883 3833

•

Fax: 07 3883 3933

•

Email: operations@ndhs.com.au •

pump industry | August 2014 | Issue 8

www.northerndiesel.com.au

www.pumpindustry.com.au

MI N E DE WATERI NG

company helps when it comes to having to be flexible. Continuous collaboration has allowed us to make design changes on the fly to deal with the roadblocks.” Overall Mr Nolan was extremely happy with the results. “The third pump station is currently in the final stages of construction, with completion expected mid-June. Our three submersible pumps that are in an old underground vent shaft have been up and running for approximately three months and have more than doubled the mine’s dewatering capacity. The water level is now well under the bottom of the open pit. “With the wet season having just passed, the new installation has already been put through its paces. This stage of the project is likely to come to an end by beginning of July. There will likely be a requirement to return in 12 to 18 months’ time for further commissioning and relocation of the submersible bore pumps to keep up with the expanding open pit.” ■

www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

Hosing in on efficient fracking PROJECTS

A unique layflat hose produced by Crusader Hose is being used to great effect on fracking projects across the US and Canada, offering the Australian oil, gas, shale and coal seam gas exploration industries a new tool that can make their fracking operations more efficient.

rusader has been developing their layflat hose to suit many applications for over 25 years. Wherever liquid needs to be transferred, Crusader Hose has the perfect layflat hose for the task. In recent years, the task has been fracking wells in the US and Canada, allowing oil and gas developers to maximise the resources that can be extracted from any given well.

By propping these small fissures open, the fluid mix allows more gas or oil to be released from the wellbore. By increasing the flow of oil and gas from individual wells, overall production per well on a major project is increased, reducing the total number of wells needed to develop resources. It also allows commercialisation of tight reservoirs in which oil and gas do not easily flow.

What the frac?

Industry estimates suggest that up to 90 per cent of new gas wells in the US are now fracked – and Crusader’s layflat hoses are playing an increasing role in this process.

A mixture of water, sand and chemicals (typically 99 per cent water and sand) is pumped in the borewell, which creates small cracks, or fissures, in the reservoir.

How it works

Fracking, also known as hydraulic fracturing, is an established technology which enhances oil and gas production in wells.

Before a well can be fracked, the developer or operator will need to get water to the site – which is where Crusader hoses play their part. The hoses are long enough to pump water from sources up to 15 km away – such as a dam or pond – to site. From a

Crusader’s hoses are being used to assist fracking projects around the world.

pump industry | August 2014 | Issue 8

www.pumpindustry.com.au

PROJ ECT S

Crusader’s lay flat hoses are compact and transportable. There is no need to construct infrastructure to get water to site – the layflat hose does this, and simply winds up and moves on to the next job when the current task is completed. logistics point of view, because the hoses lay flat they can easily be transported to the well site where water is needed. “Unlike poly pipe, Crusader’s layflat hoses are compact and transportable,” said Crusader Hose Managing Director Francois Steverlynck. “There is no need to construct infrastructure to get water to site – the layflat hose does this, and simply winds up and moves on to the next job when the current task is completed. There is no welding, no environmental damage and no infrastructure footprint.”

The layflat hose is easy to use, easy to pack up, and offers a large diameter, low cost solution to bringing the key element to any fracking project – water – to where it is needed. “Our layflat hoses facilitate the easy transfer of liquids over long distances without a huge logistical burden,” adds Mr Steverlynck. “The layflat hose is a low coil volume solution to storing metres of pipes. A rigid hose does not offer the same benefits, as it takes up a lot of space, making handling more difficult.”

Crusader’s layflat hoses also provide a convenient solution for mine dewatering projects. When the question of how to transport mine water from a site being dewatered arises, the layflat hose offers a simple, convenient and reusable solution. The layflat hose can transfer water away from site simply and safely. The reduced footprint offered by the layflat hose ultimately results in reduced costs for the mine operator. “We believe there are many opportunities in the Australian mining industry to utilise our technology. For example, our hoses can be used to move large volumes of water out of open-cut mines – which can lead to a quicker means of extracting ore,” said Mr Steverlynck. “We manufacture and supply a wide range of layflat hoses which are securely attached to couplings. These hoses have proven extremely popular in connecting into poly and steel pipelines.” ■

WATERLORD

MINE DEWATERING HOSE

Australia’s leading manufacturer of layflat hose

22 Industry Place Bayswater VIC 3153 Australia Telephone: +61 3 9720 1100 Email: sales@crusaderhose.com.au

www.crusaderhose.com.au www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

E X P O RTS

Global markets, local players In recent years, much has been made of the ability of Australian manufacturers of pumps and associated equipment to continue to export their equipment in the face of the rising Australian dollar and increasing competition from global manufacturers. Pump Industry met with some of the key players in the Australian market about their experience in exporting in the current economic climate. For the 2013/14 financial year, the value of exports from the Australian pump manufacturing industry was estimated at $415.3 million dollars. This is compared with the value of imports into the Australian market, which are forecast at $2 billion â&#x20AC;&#x201C; almost quadruple the value of the equipment being exported. According to IBIS World, 12.4 per cent of exports are to Indonesia; 12.1 per cent are to New Zealand; 10.9 per cent are to Papua New Guinea; and 8.4 per cent are to the United States. Thus we can see that almost half (43.8 per cent) of Australiaâ&#x20AC;&#x2122;s pump industry exports are to close neighbours in the Oceania region.

Australian exports up close

Pump Industry approached three companies operating in the pump industry for their take on the current state of play in the export market. Our three respondents are Weir Minerals Slurry Pump Product Manager Martin Naimo; Sterling Pumps Managing Director Anton Merry; and Crusader Hose Managing Director Francois Steverlynck. Our respondents are all exporting a wide variety of products. Sterling Pumps are exporting submersible and vertical turbine pumps, primarily for the oil and gas industries; while Crusader Hose 26

pump industry | August 2014 | Issue 8

www.pumpindustry.com.au

E XP O RT S

There are some notable trends as to where Australian manufactured pump equipment is being exported, with Asian markets being the most popular export locations from our respondents. exports layflat hoses in large diameters. For Weir Minerals, it’s a varying range of products including Warman centrifugal slurry pumps, Linatex rubber products, hose and screen media, mill lining solutions, Isogate and BDK slurry valves, Cavex cyclones, Enduron comminution equipment including screens and crushers, and Aspir centrifuges. There are some notable trends as to where Australian manufactured pump equipment is being exported, with Asian markets being the most popular export locations cited by our respondents. According to Weir Minerals’ Martin Naimo, “At Weir Minerals Australia we focus our exports across the Asia Pacific region, including: Japan, Korea, the Philippines, New Zealand, PNG, Fiji, New Caledonia, Indonesia, Laos, Vietnam and Mongolia. In addition to these countries, Weir Minerals Australia continually looks for opportunities in other emerging Asian markets where we currently do not have an installed base. Weir Minerals Australia also supply products manufactured in Australia to our sister companies throughout the world.”

For Sterling Pumps, Europe and the Middle East are also proving to be strong export markets for the company. Crusader Hose meanwhile is primarily exporting to the US, where they are seeing a large market for their layflat hoses in the fracking of oil and gas wells. In terms of future markets for these companies, most are expecting to continue to capitalise on the opportunities in the regions they are already exporting to; and all are expecting to increase their exports in the coming years. According to Mr Naimo, “With a wide presence throughout Asia, we are predicting an increase in exports as a result of our service and sales presence in the region, as well as upcoming projects in the mining and flue gas desulphurisation markets. We have recently opened new offices in Indonesia and the Philippines. Projects kicking off in Vietnam and Thailand are expected to result in an overall increase in exports to the region. In addition to the growing market demand, we are also expanding our product offering to include a wider range of mineral

processing equipment. We continue to offer these products based on our existing philosophy of high quality robust equipment aimed at lowering our customers' total ownership costs.” Anton Merry of Sterling Pumps notes that emerging oil and gas markets are expected to continue to drive export growth for Sterling Pumps; and for Francois Steverlynck at Crusader, the shale gas boom across the US is continuing to drive their growth. Mr Naimo believes that growing geological investment into the South East Asian region, and a more open stance on foreign involvement from governments in the region, will result in an upturn in opportunities over the coming decade. “Much of this is driven by the success of other countries in the region that have successfully developed mining industries that are both profitable for the companies involved and great for the continued development of those nations,” he added. "In terms of the challenges our exporters face, a major challenge is the remoteness of mining sites, and →

UNITED PUMPS AUSTRALIA

Repair, Re-Manufacture For ALL types of Centrifugal Pumps A U S T R A L I A

Efficiency Improvement Reconditioning Restore Clearances Re-Engineering

Inspection and trouble-shooting Case build up and re-machining Axial split case facing and reboring Axial thrust balancing Shaft and bearing upgrades Mechanical Seal upgrades to API 682 Custom Spare Parts Rotating Element balancing ASME & AS1210 qualified welding Hydrostatic Testing ISO 9001 CERTIFIED

AS2417 ISO9906 API 610 Hydraulic Institute Performance Testing 31 Western Avenue, Sunshine, Victoria 3020 Phone: +613 9312 6566 Fax: +613 9312 6371 Email: unitedpumps@unitedpumps.com.au http://www.unitedpumps.com.au/

www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

E XP O RT S

Product and service segmentation (2013-14)

Submersible pumps

Other pumps and compressors

12%

43%

Reciprocating pumps

Source: www.ibisworld.com.au

Centrifugal pumps

14%

Rotary pumps

16%

Air and gas compressors

Total $1.6bn

Major market segmentation (2013-14)

Power generation sector

22%

Water and wastewater sectors

Industrial sector

Other sector

11%

12%

Oil and gas sector

Total $1.6bn 28

pump industry | August 2014 | Issue 8

Mining sector

14%

Agriculture sector

Source: www.ibisworld.com.au

17%

Construction sector

www.pumpindustry.com.au

E XP O RT S the logistical barriers which need to be overcome to service these customers". Government policy and legislation can also pose challenges to our exporters. Mr Merry noted that “Australian autonomous sanctions can cause shipment delays of exotic materials, even if they are not bound for a sanctioned country. We need to be more in step with Europe and Asia.” However, most agreed that certain government export programs, such as Austrade, have helped to open up international markets to Australian manufacturers. Mr Steverlynck noted that these programs do help, with Austrade in particular supporting a wide range of industry sectors and products, and the export of intellectual property and know-how outside Australia. When it came to the question of why international companies choose to import Australian products, several key factors stood out for all of our respondents – quality, price, service and support. “Weir Minerals Australia is a wellestablished name in Australian manufacturing,” said Mr Naimo. “Warman Pumps recently celebrated its 75th year manufacturing slurry pumps in Australia and is renowned globally as the benchmark in slurry pumping equipment. Furthermore, our state of the art domestic facilities for manufacturing the Cavex cyclones components and Linatex mining hose products are producing market leading products for customers around the globe. Our customers, both domestically and overseas, recognise the expertise we have in manufacturing the highest quality products at our Australian and global facilities. Through our continuous improvement objectives with our customers we strive to improve reliability while reducing total ownership costs. Our long history, experience and knowledge base allows us to provide the best available technical solutions for our customers. It’s this combination of service and equipment quality that leads our customers to choose us.” Added Mr Merry, “Our availability and the quality of the products we manufacture appeals to international importers. In addition, in Asian markets our location is important for product support.” For Mr Steverlynck, the answer is simple. “It just comes down to trust in our quality and service.” www.pumpindustry.com.au

Overall market position

For the 2013-14 year, the domestic pump industry recorded revenue of $1.6 billion and profit of $195.7 million. The product and service segmentation of this $1.6 billion is shown in Figure 1. The major markets for the Australian pump industry in turn are broken down in Figure 2.

Ongoing development in the resources and water treatment sectors, as well as an improving outlook for the rural economy, should stimulate demand for pumps and compressors. Revenue in the industry is forecast to increase at an annualised 1.9 per cent over the five years through 2018-19, to total $1.7 billion. ■

IBIS World forecasts that conditions in the Australian pump industry will remain stable over the five years through to 2018-19, underpinned by a relatively strong economy and healthy demand conditions in most downstream markets.

Pumping Excellence for Water Applications

Sulzer is meeting the demands of the water and wastewater industries’ most critical pumping applications. Our pumps are designed and optimized to provide high-efficiency operation over an extended period of time. Our state-of-the-art solutions include: • The XFP series of submersible pumps, with IE3 Premium Efficiency motors and excellent resistance to blockage with the Contrablock impeller design, is the ideal solution for both municipal and industrial wastewater applications.

• AHLSTAR A range type A long and close coupled end suction single stage centrifugal pumps are used for demanding applications to ensure process reliability, high efficiency and low operating costs. • SMD, the latest generation of axially split double suction pump designed for raw and clean water applications. Sulzer Pumps (ANZ) Pty Ltd Phone +61 (0)3 85813750 jonathan.fullford@sulzer.com www.sulzer.com

pump industry | August 2014 | Issue 8

MANUFACTURI NG

Paint and ink manufacturers improve efficiency The ink industry is a multi-billion dollar industry that is experiencing many challenges today. Rising raw material and operational costs, fierce competition and other factors are forcing ink manufacturers to look for new opportunities for innovation, operational efficiencies and cost reductions. Tim Yakup, Product Specialist with Hurll Nu-Way, acquaints Australian manufacturers with new process pumping solutions for chemical transfer applications. Evaluation

Tim Yakup evaluates manufacturersâ&#x20AC;&#x2122; chemical transfer applications, and identifies opportunities to improve efficiencies, reduce pump maintenance costs and lower overall cost of ownership for the dozens of air operated double diaphragm pumps used in production. Recently, Mr Yakup presented to several Australian paint and ink manufacturers the Sotera Systems SP100 Air Operated Double Diaphragm (AODD) pump manufactured by Tuthill Corporation to achieve these goals.

Challenging fluids for process pumps

Water-based, solvent-based and UV-curable inks, along with other coatings, varnishes and adhesives, are often abrasive and exhibit a wide range of viscosities. These formulations can be extremely shear-sensitive as well. Subjecting them to the high shearing action of gear or centrifugal pumps can alter formulations and cause foaming, which adversely affects production efficiency and print quality. For these reasons and others, air-operated double diaphragm pumps have been the top choice for years.

Improving efficiencies and reducing costs

Paint and ink manufacturers use dozens of pumps in transferring chemicals to mix tanks to blend final ink formulations. Pumps that can reduce pulsation, consume less air, and require less maintenance will generate significant operational efficiencies. Mr Yakup was quick to recognise the 30

Kylie Kinsella, Sales Manager of Hurll Nu-Way, is proud to bring the new pump from Sotera Systems to Australia. opportunities for his clients and offered to switch to the SP100 AODD pump to achieve these efficiencies and cost reductions.

Fluid compatibility

The SP100â&#x20AC;&#x2122;s innovative design and available elastomers easily accommodate the wide range of fluids used in the inks business. Rugged pump body construction and an advanced ball check and seat design that yields 20 per cent more suction lift allow the SP100 to handle abrasive formulations and varying viscosities without a problem.

Reduction in pulsation

The SP100â&#x20AC;&#x2122;s low pulsation and gentle, low-shear action help minimise

pump industry | August 2014 | Issue 8

in-system agitation that might otherwise negatively affect sensitive formulations, change viscosity and/ or produce foaming. This is achieved by a patented, non-centring ceramic air valve for extremely fast trip-over. This drive system requires no external lubrication, will not ice internally and is volumetrically efficient, transferring virtually no heat to inks and vital fluids being pumped.

Less maintenance

Reduced maintenance is engineered into the SP100. Whereas most AODD pumps are held together with an inordinate number of fasteners around the perimeter of pump body, the SP100 uses patented QuikSeal ring www.pumpindustry.com.au

MA N U FACT U RI NG

The Sotera Systems SP100 Air Operated Double Diaphragm (AODD) pump. technology. This innovative ring design eliminates these fasteners and ensures a 360-degree uniform seal.

per cent less compressed air, resulting in impressive savings in compressed air costs over the life of the pump.

This design greatly simplifies and speeds uproutine maintenance. Parts are easily and quickly replaced and the pump is back in service. It has the added benefit of minimising wear, increasing the life of the diaphragm and delivering reliable, consistent performance. The result is a dramatic 67 per cent reduction in maintenance time over most other AODD pumps on the market.

Overall performance

Improved efficiency

Compressed air energy costs are a major expense for ink manufacturers. In the industrial sector alone, compressed air systems account for an estimated $5 billion per year! The SP100 is designed to deliver 15 per cent more flow on 20

What Mr Yakup recognised and presented to his clients is that the total cost of ownership of an AODD pump consists of the combination of the initial purchase price, maintenance time, parts costs, and the life

expectancy of the pump. Sotera Systems SP100 Air Operated Double Diaphragm Pumps are available from Hurll Nu-Way in 1/2” and 1” models in a variety of materials and elastomers to handle most chemical transfer operations in the inks and other process manufacturing applications. A 2” model will be available soon. ■

About Hurll Nu-Way Hurll Nu-Way (HNW) has been serving the Australian industry for over a hundred years with over thirty years’ experience in supplying pumps, meters and mixers for high value fluids. Thanks to HNW’s technical expertise and extensive product and application knowledge, their customers are provided with the best possible solutions based on quality and value for money.

The Most Advanced AODD Today

Distributed in Australia by Hurll Nu-Way Visit www.hnw.com.au or call our Customer Service line on 1300 556 380

www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

S HAL E

R&D on a large scale In this ongoing series of interviews, we talk in depth with the end users of pumps across a range of industries and applications. Here we speak to Doug Bignell, who recently completed a role as a Senior Maintenance and Reliability Engineer at Queensland Energy Resources (QER). In his role at QER, Doug was involved in the operation of the Paraho II technology demonstration plant in Queensland, which was established to highlight the potential to tap into the Stuart oil shale deposit – a rich potential future fuel source.

oug’s career began with a role as a maintenance fitter working in heavy industry and maintaining and replacing pumps of various types and sizes. His pump experience started in a small workshop in Brisbane, Brecknell Engineering, which sold and serviced progressive cavity pumps, and this eventually led Doug to Queensland Alumina Limited’s (QAL) alumina refinery in Gladstone, working on large scale centrifugal pumps.

pump industry | August 2014 | Issue 8

“While at QAL, I was given the opportunity to work with reliability engineers solving pumping issues. This caused me to take a look at my aspirations and take on the challenge of completing an engineering degree to work as a reliability engineer,” said Doug. From QAL Doug went to Orica Yarwun as a plant engineer, a role that was similar to his role with QER, except for the R&D part. From Orica, Doug made his way to QER.

www.pumpindustry.com.au

SHA L E

In Doug’s role at QER, he played an important part in the company’s current focus on developing the technology to turn Queensland’s vast oil shale reserves into heavy transport fuels. QER’s plant in Gladstone, Queensland, is a small R&D plant testing the technology and using that information to upscale to a full commercial plant. “Our main output is data,” said Doug. “My role at QER has me responsible for the maintenance and modification of the plant. I am responsible for setting up the maintenance strategy for the plant, for ensuring all day-to-day and breakdown maintenance activities are carried out, reliability improvements are put in place and the plant is modified to comply with R&D changes as dictated by our project team. “Over the last 25 years I have worked on and played with a variety of pumps, from positive displacement, to centrifugal, to vacuum,” said Doug. “These included many brands and many

sizes with various media, from water, to slurry, to concrete, to acids and alkalis to oil-based products. I have also had the opportunity to work on various drive systems including diesel motors, electric motors, air motors, magnetic drives and steam turbines. “One of the biggest changes I have seen in the industry would be the acceptance of mechanical seals over packed glands. When I started out, mechanical seals were reserved for pumps in duties around flammable or hazardous products. Now almost all pumps are mechanically sealed.”

Can you explain a bit about the procurement process for pumping equipment?

Pump procurement at QER generally commences with a process engineer specifying a duty point for the new/ replacement/upgraded pump. It is the process engineer’s responsibility to supply a data sheet, obtaining the information from other engineering disciplines to correctly populate the information. He will talk to the mechanical engineer to decide on the pump’s materials of construction, footprint limitations and noise limitation, and to the electrical engineer for drive requirements and control philosophy. →

QER’s technology demonstration plant in Gladstone, Queensland. www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

SHA L E Once the data sheet is completed and sanity checked, it goes out to vendors as part of the request for quotation (RFQ) documentation. The RFQ document stipulates what information is required in the quotation packages from the vendors to assist us in selecting the right pump for the application (i.e. pump curve, availability, price, recommended spares, general arrangement drawings, etc.). When the quotation packages arrive, they are initially reviewed by each of the engineering disciplines, who compare the packages against the data sheet and short-list the pumps. The final pump selection generally happens at a group forum between the engineering

and operations groups, as both operability and maintainability play a part in the selection criteria. It is very similar to the recruitment process.

What testing do you conduct for pumping equipment?

The testing requirements are dictated by situation. If it is a new pumping system, then we typically go for factory acceptance testing (FAT). We generally witness these tests. Once on site we will quantify the FAT with a site acceptance test (SAT). This allows us to test the pump at operating conditions, including temperature and pressure. As most of our pumps are variable speed, we will usually put the pump through various conditions to allow us to fully validate the pump. For replacement and upgraded pumps, we only carry out SATs. The FAT and SAT results are reviewed by the process engineer and when there is an issue we normally carry out a risk assessment. From the risk assessment, actions are generated and prioritised. Priority 1 (P1) items will be addressed straight away, with P2 and P3 items being addressed within certain time periods. FAT issues are corrected before the plant has left the factory. As we are an R&D plant we need to ensure that all information we collect is accurate to allow for correct data to flow into the engineering and design of a commercial sized plant.

What are the best ways to ensure good communication and get the best results between client, consultant and supplier?

On site at Gladstone. 34

The best way to ensure good communication/support is to fully understand what you want and ensure everyone else in the process understands as well. Give the supplier all the information they need and they can give you an accurate product choice. The supplier, in turn, supplies the customer with all the information they require to allow them to make an informed decision. I have seen it in the past, where only part of the information is supplied, a choice is offered, a decision is made, and it has turned out to be a bad one. Or, the customer is not given all the details he needs to correctly install/operate the pump and it does not perform as expected. They then get the rest of the puzzle pieces and voila, it works. This usually leaves the customer with a bad taste in their mouth and a reservation about using that vendor again.

pump industry | August 2014 | Issue 8

What are the most important factors in pump selection?

At QER the most important factors are: suitability of the pump, cost, availability and the cost and availability of parts.

How important is energy efficiency and how does it factor into decisions?

Energy efficiency plays a large part in our pump selection. Due to the nature of our plant, we have a tight operating budget and power costs make up a large portion of that budget. However, as with other factors in plant selection, it is only one of the factors that are reviewed. On the commercial design, energy efficiency plays a large part in equipment selection.

How important are the maintenance and repair schedule and costs in project planning? For our R&D plant with its finite operating life, we viewed life-cycle costing as part of the selection criteria. However, it was only a minor factor with minor weighting in the decision making process. For our commercial design, the wholeof-life cost of a plant is a major factor. As we are going out seeking investors for that project, it is critical, in the engineering package of the commercial plant, that we have reasonably accurate forecasts of operation and maintenance costs to be able to give accurate estimates for return on investment. For this we use PAS55 and ISO55000 standards and a couple of different modelling software packages that take all the life cycle, operating and maintenance information from the vendor and real-world experience to accurately predict this.

Can you explain a bit about your on-site servicing and routine maintenance?

QERâ&#x20AC;&#x2122;s demonstration plant has had two primary purposes â&#x20AC;&#x201C; to highlight the operating performance of the Paraho technology and to provide data for the future development of a commercial facility. As a result, the plant is heavily instrumented and monitored. We know fairly quickly when a pump is underperforming and plans are put in place to correct this issue. This usually results in the offending pump being removed from service, and a replacement installed. The faulty pump is usually cleaned and overhauled and returned to the warehouse. For general maintenance activities such as lubrication, vibration www.pumpindustry.com.au

SHA L E analysis and oil analysis, we rely on our computerised maintenance management system (CMMS) to generate PMs to ensure this work is carried out at regular intervals.

Can you explain your view and relationships with the Australian pump industry?

I see the Australian pump industry as a vibrant, burgeoning industry, struggling against strong internationals. Some of the plants I have worked on have specialist pump systems that seem to be only available from Europe and the US. This leads to slow information exchange, long lead time for parts and generally high prices. I now see this changing, whether it is due to large companies buying into our market to get a local footprint, or our big players buying overseas to get specialist technology. This is a good thing. The more we can source locally, the better for Australian industry. I tend to see my pump and seal suppliers regularly and generally get great follow-up service. Being based in an industrial town, there tends to be local representation for most brands and the remainder travel to town often.

The one issue I do have is the trend for vendors and customers to carry minimal stock. This is not just restricted to the pump industry. I understand that it is a huge burden, financially, to have extensive stock holdings, and we all know how hard it is to convince the bean counters of the need to carry stock. However, it is the one thing I would like to see improved.

What are the most important issues in pumps today?

For me the most important issue in pumps today is not hardware related but more about maintaining experienced staff. This is from my side as well as the vendors’ side. The majority of reps that I see are middleaged, with the younger reps definitely in the minority. It may just be a local issue. With big money to be made in heavy industry, mines or construction, there is little chance for the service industry to attract young blood. The same goes for maintenance staff. With so much competition for labour in Central Queensland, especially in construction, it is hard to attract and retain quality staff, as small industry cannot compete with the salaries that are available to even non-skilled labour.

Where do you see the pump industry going in the future?

My hope is that the Australian pump industry continues to expand into the global market. I see this as a major improvement for all concerned in the industry, including the end users. I see it creating a more competitive and diverse market where technical systems that could only be brought in from overseas are able to be supplied locally, with local stock of spare parts and almost instant feedback for any technical issues that arise. The internet is playing a large part in this. More and more vendors have an online presence, allowing instant access to manuals, videos and other media, enabling the end user to selfhelp more and more, and allowing reps to supply instantaneous information. This can only be a good thing. ■

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pump industry | August 2014 | Issue 8

WASTE WATE R

Works on the scheme are already underway.

Bringing pressure sewer to small communities Gippsland Water’s latest project, a 2,700 property sewerage scheme in Loch Sport, Victoria, will resolve environmental and public health concerns in a unique area adjoining Ninety Mile Beach and Gippsland Lakes.

he Loch Sport Sewerage Scheme is the third backlog sewerage scheme Gippsland Water has delivered to small waterfront communities in the past six years. This project has followed delivery of similar schemes in Seaspray, also on Ninety Mile Beach, in 2008; and in the Coongulla/Glenmaggie townships adjoining Lake Glenmaggie near Heyfield in 2013. Gippsland Water’s Manager Major Projects Jim Somerville said, “Each community and scheme has been bigger than the previous and each has had its unique mix of challenges. What is common, however, is that each scheme is as much about connecting with the community as it is about the planning, design and construction of the scheme. 36

“From our own research, experience and customer feedback, we found that having an early and ongoing physical presence in Coongulla/Glenmaggie was the most efficient and cost-effective way to connect with customers, which later resulted in early and high rates of connections to the scheme,” continued Mr Somerville. “We wanted to take the same approach to the Loch Sport Sewerage Scheme, but do it bigger and better – although that was not an easy task, as the Coongulla/Glenmaggie scheme was very successful, with nearly 90 per cent of all Coongulla/Glenmaggie residents connected to the sewerage scheme within the first nine months.” →

pump industry | August 2014 | Issue 8

The Loch Sport Sewerage Scheme i-Hub. www.pumpindustry.com.au

WA STE WATER

The pumping unit After a detailed analysis, a pressure sewer system was selected as the preferred solution for this project because of its environmental, economic, health and service quality benefits. It was also considered the lowest cost and best technical solution. Pressure sewers can be installed by trenching or directional drilling where necessary, minimising the impact of construction works on the environment. The pressure sewer system is made up of a small collection tank (slightly smaller than a standard septic tank) and pump unit which is located on each property, and includes a transfer system that links each household to a sewer main network within the town. Wastewater will be pumped through the network from each property to one of two main pump stations, and then pumped to Gippsland Waterâ&#x20AC;&#x2122;s Dutson Downs site for treatment. A main pump station will be constructed on the corner of Loch Sport Road and Progress Road in the industrial estate, and a smaller collection pump station constructed at Snipe Street behind the Loch Sport Community Hall.

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pump industry | August 2014 | Issue 8

WASTE WATER

Locals check out the map for the scheme.

In December 2013, Gippsland Water and on-lot works contractor Pressure Sewer Services Australia (PSSA), established a dedicated project shop front on the foreshore precinct in Loch Sport, known as the i-Hub. The i-Hub is open Monday to Friday and weekends by appointment.

The next phase

“Essentially it is a face-to-face, one-stop shop for all customer enquiries about the scheme and the customer connection process,” said Mr Somerville.

Mr Somerville said, “We’ve had more than 85 per cent of property owners agreeing to where they want the pressure unit to go on their property, which is a fantastic result.”

Bill Klein from the Loch Sport Community Reference Group has praised the i-Hub and the service that it offers to local residents. “Gippsland Water staff and contractors have been fantastic,” he said. “I have had nothing but positive feedback regarding the project team’s approach to the community.”

Due to the scale of the project, property infrastructure and connections will be rolled out in four stages: Stages A, B, C and D.

This has been confirmed by the rate and high level of positive response of property owners during the individual property design process. 38

With the 30km sewer main from Dutson Downs to the edge of town almost complete, work has begun on installing pressure units on locals' properties. This marks a significant milestone and the next phase of the $40 million Sewerage Scheme.

concerns relating to septic tanks. Gippsland Water will continue to provide homeowners and businesses with support throughout this period to assist connection to the scheme by October 2015. The Loch Sport Sewerage Scheme is part of the Victorian Government’s Country Towns Water Supply and Sewerage Scheme Program, which listed Loch Sport amongst 35 priority towns to be provided with water or wastewater services. ■ For more information on the Loch Sport Sewerage Scheme and the i-Hub, visit www.gippswater.com.au or call 1800 631 688.

Customers in Stage A will be the first customers to have infrastructure installed on their properties. Residents in Stages B, C and D will follow progressively over the next 18 months. Connecting homes and businesses to the sewerage scheme is the key objective of the project, resolving environmental and public health

pump industry | August 2014 | Issue 8

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WA STE WATER

PUMPINDUSTRY INDUSTRY PUMP PARTNERSOLUTIONS SOLUTIONS PARTNER

Efficient and cost-effective wastewater pumping When a good wastewater pump is installed at a plant, it is hardly noticed – it does its job, and fitters and operators can get on with general plant improvements, improved efficiency measures, safety improvements and other issues critical to the plant’s operation.

wners of Gorman-Rupp pumps can focus on other tasks because Gorman-Rupp wastewater pumps have been engineered to do the job, are ruggedly constructed and are built to last. They require less maintenance than other wastewater pumps and are easily kept at their best efficiency point (BEP). Gorman-Rupp’s new Ultra V pumps are the most efficient self-priming centrifugal trash pump on the market today, according to distributors, Hydro Innovations. They can be applied on flows as low as a few litres per second (l/s) up to 150 l/s, with heads to 90 metres. They are often employed by plants that have had problems or maintenance issues with submersible pumps, lobe pumps or helical rotor pumps. They can be used for pumping industrial wastewater, raw sewage, grey water or sludge. Operators find Gorman-Rupp pumps a great choice because they choke less frequently than other styles of pump. They also find them easier to access because they can be located up to 7.5 metres above the water level (and prime every time). Fitters find working on the pumps very simple, as the pumps can be left in the piping for their service – no need to send them back to the workshop. Where operator safety is concerned, having a reliable self-priming pump means a vast improvement in OH&S and the elimination of confined spaces issues. Improved safety levels can lift morale, lift productivity and reduce costs. Mines, paper mills, steel mills, food process plants, sewage treatment plants, sewage pump stations, power stations and many other industries find GormanRupp pumps the preferred choice for safe, reliable and efficient pumping. ■

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pump industry | August 2014 | Issue 8

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PUMP INDUSTRY PARTNER SOLUTIONS

Upgrading the Kincumber sewage treatment plant

When the anaerobic digesters at the Kincumber sewage treatment plant began experiencing ongoing operational and process problems, a Rotamix process mixing system returned the plant to optimum operating performance.

n 2013, Gosford City Council initiated a major capital works program to refurbish and upgrade the Kincumber sewage treatment plant (STP). It was identified that new mixing systems should be installed to improve mixing within the plant’s three existing 18-metre-diameter anaerobic digesters, which had been experiencing ongoing operational and process problems, including deteriorating mixing capacity. Pump Systems Ltd, the authorised Australia and New Zealand distributor of Vaughan Chopper Pumps for 20 years, provided Council with a preliminary Rotamix process mixing system design, which was later accepted by way of formal tender.

Designed and developed by Vaughan USA, Rotamix consists of an engineered arrangement of internal mixing nozzles fed by an externally mounted Vaughan Chopper Pump. Backed by state-ofthe-art fluid dynamics modelling, Rotamix incorporates several basic principles of physics and hydraulics, including uniform field of flow, vortical field of flow, induced flow, and surface contact. The heavy-duty nozzle assemblies, which are constructed in ductile cast iron and are glass-lined to prevent abrasion and struvite adhesion, create multiple directional discharge points in order to evenly distribute flow to all areas of the digester. This approach allows the system to focus on problem areas within

pump industry | August 2014 | Issue 8

a particular process and eliminates the need for any rotational equipment such as gearboxes, crankshafts, pins, or any other high maintenance moving parts. Mixing flows are distributed through each nozzle simultaneously, which allows for very rapid development of rotation, maximising solids contact to optimise mixing performance. The Rotamix system is specifically developed to eliminate the ‘tea cup’ phenomenon – a problem with most rotational mixing methods. With its dual-zone mixing pattern, Rotamix evenly distributes flow to both inner and outer portions of the digester, preventing pressure zones from developing and prohibiting solids from migrating towards the centre floor area, raising and drafting solids outwards towards the digester periphery, where the greatest degree of natural rotation occurs.

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PUMPINDUSTRY INDUSTRY PUMP PARTNERSOLUTIONS SOLUTIONS PARTNER

WA STE WATER

Rotamix nozzles are permanently set in place at fixed, predetermined angles, and each nozzle assembly carries a ten-year full replacement warranty against wear and corrosion. Each of the three 4,300 cubic metre digesters at the Kincumber STP will be mixed by a single ten-inch discharge, horizontal end suction Vaughan Chopper Pump, direct driven by a 55kW, six pole speed high efficiency motor. The patented chopping action of the Vaughan Chopper Pump prevents rag and fibrous material from reweaving and forming into clumps, which in turn protects the mixing nozzles from plugging as well as helping downstream processes. The action of chopping and conditioning material to reduce particle size is of proven value in sewage treatment

plants. If digestible material is in smaller particles, then the surface area of these particles is relatively large in comparison to their volume. Bacterial action can then be more effective and rapid. Plants that use Rotamix and Vaughan Chopper Pumps for digester mixing or recirculation have seen that the reduction of particle size increases both the rate of decomposition of digestible material and methane gas production.

Kincumber STP, other major Australian sites using Rotamix include the Woodman Point wastewater treatment plant in Western Australia, the Christies Beach and Bolivar wastewater treatment plants in South Australia, the West Camden water recycling plant in New South Wales, the Mt Martha STP in Victoria and the Maroochydore STP in Queensland. ■

Pump Systems Ltd has extensive experience in the design and supply of sludge tank and digester mixing systems for projects throughout Australia, New Zealand and Singapore. In addition to the

For further information on Pump Systems Ltd, Vaughan Chopper Pumps, and the Rotamix Process Mixing System, visit www.chopperpumps.com.au.

UNMATCHED RELIABILITY

VAUGHAN CHOPPER PUMPS For more than half a century, the patented chopping action of the VAUGHAN® Chopper Pump has solved some of the world’s toughest solids pumping problems. With the unique ability to chop all solids at the pump suction, VAUGHAN® Chopper Pumps can handle higher solids concentrations than standard non-clog pumps, providing peace of mind for critical applications. AUTHORISED DISTRIBUTOR: PUMP SYSTEMS LTD Freephone: 1800 121 452 Email: sales@chopperpumps.com.au

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✓ Capacities of up to 880 L/s ✓ Multiple configurations available ✓ Discharge sizes from 3” up to 16”

✓ Fast payback on investment ✓ In use throughout Australasia ✓ GUARANTEED not to clog

pump industry | August 2014 | Issue 8

PUMP INDUSTRY PARTNER SOLUTIONS

Serving the industry’s needs

WASTE WATE R

Pumpserv has recently provided pumps for a number of projects completed by Frank Cooney & Sons in Condobolin, New South Wales.

ob Hourigan of Frank Cooney & Sons (FCS) contacted Pumpserv, on the recommendation of the team at Franklin Pumps. FCS had had difficulty in sourcing large enough vertical multi-stagers for the Condobolin Sewage Treatment Plant high-lift pumps, which transfer treated water to their holding tanks.

The team at Pumpserv moved quickly to supply three Lowara 125 SV pumps for the Condobolin Sewerage Treatment Plant. The vertical multi-stage pumps were built up as a triplex system, with 150mm in and out of the pumps to a common 250mm manifold. The Pumpserv team also completed all the site pipework involved for the job. In addition to this, Pumpserv also supplied FCR with two Flygt NZ 3153.181LT4B pumps for the same treatment plant. PumpServ installed these as a dry mount set up horizontally mounted on a 304 stand which was manufactured in house. For another project, Franklin supplied pumps direct to FCR and Pumpserv built the system. This involved two Franklin dual systems with standby all mounted into the one base. There was one standby pump for both dual sets.

A Franklin pump system supplied by Pumpserv.

Lincoln Beesley of Pumpserv said, “All of the pumps supplied were plug and play so that whichever system needed a standby, the farmer could just unplug one of the duals and plug in the standby without the need for any wiring.”

Pool pumps

Finally, Pumpserv also recently supplied FCR with two Franklin Electric ISO pumps for the Lake Cargelligo Swimming Pool. “We supplied two Franklin 150 x 125-250 CI/B2/SS motor pumps, with 11kW, 4 pde motors,” said Mr Beesley. “All wetted parts were ceramic coated to handle the chlorine from the pools.” ■

The Lowara 125 SV pumps for the Condobolin Sewage Treatment Plant.

Extensive professional pump industry knowledge attained through years of hands on experience •

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www.pumpserv.com 42

pump industry | August 2014 | Issue 8

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PUMPINDUSTRY INDUSTRY PUMP PARTNERSOLUTIONS SOLUTIONS PARTNER

Optimal drive T

he solar pump drive is delivered to pump manufacturers and system integrators who then build the complete package and supply it to farmers. There is a huge need for this intelligent drive system in the Indian market, due to the limited supply of grid power. The drive system has a lot of potential, particularly throughout Asia, Africa and South America. The current business for this product is either to replace old diesel pumps with new PV cells and drives, or to provide a new installation of a complete system. The complete system consists of four components: PV cell, ABB drive, motor and pump. The current implementation of the ABB solar pump drive system uses a PV cell as its power source, which is connected to the DC busbar connectors on an ACS355 machinery drive. The drive is connected to the motor that runs the pump. After dawn, when the intensity of sunlight is sufficient to trigger the PV cell, the drive automatically starts the motor and runs the pump to draw water. At sunset the drive turns off the motor and the flow of water ceases. It is also possible for customers to run the drive using power from the grid.

Grid Supply

4-pole change over switch

Solar pump inverter

Motor and Pump

PV cell

To inverter U1, V1, W1

To inverter DC connection

ABB’s solar pump drive system is now available in Australia. It is particularly suited for the irrigation of farms, where energy savings are a prime concern, as well as water pumping applications at remote sites, where it is simply not possible to connect to the power grid. ■ For further information, please visit new.abb.com/drives/ acs355-for-solar-pumps or call ABB on 1800 222 435.

A video on the Pump Industry website explains the solar pump drive in greater detail. To check it out, head to www.pumpindustry.com.au/abbsolarpumpdrive/4927/

Solar pump drive. Exploiting the power of the sun.

ABB’s Solar Pump Drive System delivers power for remote pumping applications, without damaging the environment. The system supports the irrigation of farms, where energy savings are a prime concern, as well as water pumping applications at remote sites, where it is simply not possible to connect to the power grid. This rugged system comprises of a PV cell, an IP66 ABB drive which doubles as an inverter, a motor and a pump. Maximum power output is achieved throughout the day via a maximum power point tracking feature. A built-in flow measurement and flow detection function turns the drive off in case of dry run. With additional remote modules, you can monitor the solar pump parameters from anywhere. The dual supply mode also enables connection to the grid if required. For further information, please visit http://new.abb.com/drives/en/acs355-solar-pump ABB Australia Pty Limited Contact Centre: 1800 222 435 www.abbaustralia.com.au

www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

DRIVES

ABB India has come up with an innovative solution that uses solar power as a reliable source for pumping water throughout the day. The result is the ABB solar pump drive, which is designed to use maximum power point tracking technology for optimal solar power use.

C O MPRES SO RS

Optimisation of centrifugal compressor re-wheel design by Arun Karuppasamy

Centrifugal compressors are sensitive to changes in operating conditions, with operations outside set parameters resulting in sub-optimum performance and risking serious damage. To accommodate different process conditions they may be re-rated or re-wheeled. However, this process must be undertaken with a sufficient understanding of the requirements and limitations of the specific case for the full benefits to be realised. In this article we examine a case study where the shortfalls of an original re-wheel were optimised to meet specific objectives and utilise the full potential of the re-rate design.

entrifugal compressors are similar to centrifugal pumps in design and operating principle. However, the performance of a centrifugal compressor is more sensitive to changes in operating conditions of molecular weight, suction temperature and gas pressure, due to the relatively high compressible nature of the operating medium. The performance envelope of centrifugal compressors is comparable to that of a centrifugal pump, however the boundary limits of surge and stone wall are more rigid. Operations outside the limits may result in performance shortfalls, leading to high levels of vibration, temperature rise, or even serious damage to the compressor. 44

Similar to centrifugal pumps, centrifugal compressors can be re-rated to optimise their performance in changing operating conditions. The re-rating of compressors to either accommodate increasing/ decreasing flows or discharge pressure requirements must be carried out with due diligence. A good understanding of the compressorâ&#x20AC;&#x2122;s process conditions and field operating limitations is necessary to fully capitalise on the advantages of re-rating.

Case study

The gas compression system consisted of two compression stages; Low Pressure (LP) and High Pressure (HP) compressors. Due to reduced flow rates, the compressors were operating in excess recycle mode and were a

pump industry | August 2014 | Issue 8

source of severe downtime due to high compressor discharge temperature trips. The compressors were re-rated to accommodate the reduced flows of the declining field and improve the overall availability of the compression trains. The objective of the original re-wheel design was to accommodate lower production rates, minimise recycle rates and improve compressor efficiency to provide better power driver margin. This initial re-wheel design was not fully optimised as the re-wheel compressor operations were limited by two factors. Firstly, the operating envelope was limited by the discharge temperature limit, and any compressor head www.pumpindustry.com.au

C O MPRES SO RS

Figure 1. LP and HP gas compression train schematic.

available above the temperature limit was unusable. This was compounded by the low efficiency associated with the re-wheel design (high head and low flow design), resulting in a higher discharge temperature, further reducing the useful compressor operating envelope. A design audit was carried out with the following objectives: â&#x20AC;˘ To understand the limits of the original re-wheel design and the limiting operational issues. â&#x20AC;˘ To list a set of design tenets and guidelines for new re-wheel design. Following these revised objectives and design guidelines, a new re-wheel design optimised for low flow operations was produced.

Compression introduction

The gas compression system examined in this case study is based on an offshore platform in the North Sea. The compression system consists of two identical compression trains consisting of two in-line barrel type radially split centrifugal compressors (LP and HP) driven by a gas turbine driver. The LP and HP compressors each have a separate discharge cooler and dedicated Anti-Surge Control (ASC) www.pumpindustry.com.au

recycle valve feeding into a suction scrubber as shown in Figure 1. The following objectives were proposed to carry out the re-wheeling of the compressors to meet the declining production rates.

Minimise excessive recycle rates and driver power demand

The existing LP and HP compressors were originally designed for higher flow rates, and due to the reduced production, both the compressors were operating in high levels of recycle. Performance tests of the compressors showed high levels of performance loss, both in terms of head and efficiency performance. This prevented the existing compressors from achieving the original design pressure ratio and their operations were further limited by driver power. The main objective of the re-wheel design was to minimise recycle operations with the aim of saving fuel gas and providing a driver power margin to meet later-life field operations with degraded compressor performance.

Maintain production rates and delivery discharge pressure

One of the most cost-effective means to maintain production rates on a declining field without any external intervention is to reduce the FWHP (flowing well

head pressure). However, there is a limit to how much the FWHP can be reduced. The lower limit depends on many factors, the most critical being the compression limit (pressure ratio). The other objective of the re-wheel exercise was to explore whether it was possible to increase the pressure ratio capability within the existing driver power limits.

Typical compressor re-wheel limits Pressure ratio or the polytropic head capability of any re-wheel design depends on the capacity of the existing casing to accommodate an increased impeller count or impeller diameter for a given gas composition and gear ratio (speed limit). Once the head capacity limits of the existing casing are established, the next major check would be the driver power availability. It is also prudent to make sure that there is enough driver power margin available for later-life in-service (degraded) performance. In addition to design and performance limits, it is also important to identify any operational limits like compressor discharge temperature limits. As the pressure ratio increases the discharge temperature increases, and a major bottleneck can occur if there are â&#x2020;&#x2019;

pump industry | August 2014 | Issue 8

C OMPRES SO RS any operational temperature limits. In this case study, the original re-wheel design overlooked an existing discharge temperature limit; hence the re-wheel design had to be optimised to take this operational limit into account.

requirements of flow and pressure, the OEM produced a re-wheel design. During the initial design review it was found that the re-wheel design for both LP and HP compressors were not very different from the original design in terms of flow and head capability. The key objective of reducing recycle for future low flow operations was not met.

Design audit of original re-wheel design Based on the re-wheel design

A detailed design audit was carried out and it came to light that the high head impeller design selected for the initial re-wheel design limited the shifting of the compressor performance towards lower flows. The critical aspect of this re-wheel design was that the additional head available could not be fully utilised due to the discharge temperature limit.

LP Compressor Original Re-wheel Design Original Re-wheel Design LP Compressor 25000

20000

Polytropic Head (m)

Discharge Temperature Limit 15000

105% speed

10000 100% 90% 5000

80%

70%

0 6000

11000

16000

21000 26000 Suction Flow (Am3/hr)

31000

36000

41000

Figure 2. Original re-wheel design operating envelope limited by discharge temperature limit. LP Compressor NewDesign Optimised Re-wheel Design LP Compressor New Optimised Re-wheel 25000

20000

Polytropic Head (m)

Discharge Temperature Limit 15000

10000

105% speed

105% 100% 90%

5000

80% Original Re-wheel Design

70%

100% 90%

80%

New Re-wheel Design 0 1000

6000

11000

16000

21000 Suction Flow (Am3/hr)

26000

31000

36000

41000

Figure 3. Comparison of new and original re-wheel compressor performance. 46

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www.pumpindustry.com.au

C O MPRES SO RS The original LP compressor re-wheel design performance with the discharge temperature limiting the useful compressor operational envelope is shown in Figure 2. Taking into account the limitation of the original re-wheel design, new re-wheel design tenets were drafted to make effective use of the re-wheel opportunity to optimise the design benefits.

New re-wheel design tenets In addition to the original design objectives, the following tenets were added to the new re-wheel design: • Re-wheel design must effectively take into account the unusable compressor envelope restricted by discharge temperature limit.

The driver power margin has greater significance in respect to low flow compressors, as the low volume flow compressors are prone to degradation, resulting in loss of both head and efficiency performance. The improved driver power margin would provide buffer for later-life degraded performance.

Conclusion In addition to relevant aerothermal design knowledge, a good understanding of the process conditions and operational limits are very important in order to develop a fully functional centrifugal compressor re-wheel design.

• Optimise the impeller selection towards low flow design to reduce recycle rates and efficiently tackle the discharge temperature limit issue.

Sterling Submersible Motors. Engineered and proven in the toughest conditions

Re-wheel design optimisation

The main drawback of the original re-wheel design was the high head (large diameter) design that restricted the design selection to high flows. There are limited impellers available to meet low flow high head requirements. Due to the maximum head limit imposed by the existing discharge temperature limit and the revised design tenets, it was possible to optimise the re-wheel selection for the required low volume flows and still adhere to relatively better compressor efficiency. The low head requirement allowed the selection of a smaller diameter impeller, which also helped improve the efficiency. The new re-wheel design, optimised to take into account the discharge temperature limit and minimise future recycle operations, along with original re-wheel design’s performance is shown in Figure 3.

Advantages of design optimisation

Due to the diligent re-wheel design audit and careful selection of new design tenets it was possible to optimise the design to maximise the benefits of the re-wheel exercise. The new re-wheel design met the basic design objective of reduced recycle operations. A design optimised for low flow operations resulted in an improved driver power margin and fuel gas savings. www.pumpindustry.com.au

In this case a fully optimised re-wheel design was able to restore the design pressure ratio, minimise recycle operations and provide a driver power margin for future degraded operations. Since commissioning, the re-wheel design compressors have operated successfully with high availability. ■

• • • • • •

4” 0.5kw to 7.5kw 6” 7.5kw to 45kw 8” 30kw to 93kw 10” 75kw to 150kw 12” 93kw to 300kw 14” to 30 “ up to 2500kw

2 pole, 4 pole, 6 pole and 8 pole 415v, 1000v, 3300v, 6600v and 11000v. All motors are wet stator re-windable. Materials of construction include: Cast Iron, 304ss, 316ss, Duplex 2205, Super Duplex 2507, CuNi 90 10, NiAl Bronze, Zeron 100. Sterling Pumps is an ISO9001 certified company.

Manufactured in Melbourne · service facility in Melbourne & Perth

14 Sharnet Circuit Pakenham Victoria 3810 Australia P +61 3 9729 5044

F +61 3 9729 3522 E info@sterlingpumps.com.au

WWW.STERLINGPUMPS.COM.AU pump industry | August 2014 | Issue 8

PUMP INDUSTRY PARTNER SOLUTIONS

AG RIC U LT U RE

The SUN-BUDDY™ submersible pumping system offers an effective new solution for pumping water on small-scale farms and rural lifestyle properties.

Solar powered pumping solution A new product launched by NOV Mono offers an effective solution for pumping water on small-scale farms and rural lifestyle properties. The new SUN-BUDDY™ is a solar powered submersible pumping system that has been designed to combine outstanding performance, long life and minimal maintenance requirements.

anaging water movement on a small rural property can be a challenging task, with water that has to be drawn from rivers, bores, tanks and stock dams for small-scale crop irrigation, stock watering, garden watering and general household use. The Mono SUN-BUDDY™ uses advanced technology that was previously only available to large-scale agricultural operations, and offers a versatile variable flow capability which is suited to a wide range of different applications. The result of Mono’s 30 years of solar-powered pump experience, the SUN-BUDDY™ is a genuine, easy to install ‘plug and play’ solution. Its minimal maintenance requirements can be handled onsite, making the SUN-BUDDY™ a set-and-forget solution which delivers high-quality and costeffective performance. Driven by solar energy, this small but efficient pump requires no diesel, grid power, wind or batteries to run. This 48

environmentally-friendly method enables the operator to quickly recover the initial cost by eliminating all future fuel and electricity bills.

output of the 195 watt solar array to maximise power generation and increase or decrease voltage to suit the demands being placed on the pump.

“The SUN-BUDDY™ offers many benefits for operators using it on hobby farms and other small-scale rural properties,” said Mono Agricultural Industry Manager Nick McNamara. “It uses a progressing cavity action with a helical rotor element, which allows it to deliver maximum output, even if the water contains silt or iron oxides. A variable speed control allows the flow to be regulated to suit different conditions such as low yield bores, while a low speed operation capability provides extended rotor and stator life.”

Manufactured in Australia, the SUN-BUDDY™ is supported by Mono’s extensive national dealer network. For more details visit www.monopumps.com.au/sun-buddy or call 1800 333 138. ■

Designed to operate in harsh conditions, the SUN-BUDDY™ incorporates a robust, brushless, submersible DC motor. This delivers high torque, high efficiency performance and features thermal overload protection that ensures long life and reliable operation. A solar maximum power point tracker adjusts the voltage

pump industry | August 2014 | Issue 8

SUN-BUDDY™ specifications • Delivers discharge pressures up to 35 m • Performance range: from 3 m3 per day at 35 m, to 14 m3 per day at 10 m • Can accommodate 100 mm boreholes • Easily automated using a float switch • Compatible with water temperatures from 8°C to 34°C, and pH values between 6.0 and 8.5 www.pumpindustry.com.au

get sun-Buddy Be water wise a greener way to green your property

SUN-BUDDY,™ a new release from Mono™, is a reliable, cost effective way to move water, whether you’re farming on a small scale or enjoying a rural lifestyle property. SUN-BUDDY™ can pump water from bores, rivers, lakes, tanks or dams and is ideal for small-scale irrigation, stock watering, watering gardens and general household use. Contact your local Mono™ dealer to discuss your options. monopumps.com.au/sun-buddy

FO O D

The Primo Smallgoods plant in Wacol, Brisbane.

Central vacuum supply for meat products Primo Smallgoods is one of Australia’s largest producers of ham, bacon, salami and smallgoods. Their facility in Queensland relies on a centralised vacuum unit from Busch Australia for its vacuum supply, which guarantees the necessary vacuum on all packaging lines around the clock.

rimo Smallgoods was founded in 1985 and today has manufacturing plants and abbatoirs all across Australia. In 2012, the company built a new manufacturing facility in Wacol, Brisbane, which is planned to be Australia’s largest smallgoods manufacturing facility, with the second stage of construction already started. The Busch unit utilised on side is an important part of production and guarantees that the meat products are hygienically, quickly and reliably packaged, so that they can make their way to their destination as quickly as possible.

Italian specialities including prosciutto, smoked speck and pancetta; and a variety of packaged meat including a free range selection. The national company supply Australia’s major retail groups and cater for both the domestic and export markets. Many of these products are produced at the company’s manufacturing facility in Brisbane. Primo found an ideal partner in Busch, as their main criteria for using central vacuum supply were its hygienic aspects, the dispersal of waste heat created by the vacuum pumps in the packaging room, as well as easier and less frequent maintenance.

Primo Smallgoods produce a variety of ham products, including triple smoked leg ham, bacon, salami;

Construction of the central vacuum supply

In order to run each of the packaging

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lines with minimal energy expenditure whilst keeping the number of cycles as high as possible, the packaging rooms are evacuated in two stages. The critical drop in pressure is utilised and therefore a quick evacuation is made possible. The first stage of evacuation is done by a low vacuum pump stand and the second with a medium vacuum pump stand. The change-over valves with the corresponding re-routing electronics are directly attached to the individual packaging machines. They control the transition from a low to a medium vacuum. A third vacuum pump stand provides the forming stations in the packaging machines with vacuum. There, the base film of the packaging is heated and thermoformed www.pumpindustry.com.au

FO O D with a vacuum and compressed air, and thus the packaging depression is formed. This vacuum pump stand works independently of the low and medium vacuum pump stands. This separation of different vacuum stations is necessary for the supply to packaging machines, as these have a thermoforming and a sealing function that have to run with vacuums of varying degrees. The pipe work serves as a vacuum buffer with over 850 linear metres of piping in the roof. This buffer is necessary to keep the packaging pressure at a constant level, even when all the packaging machines are running with the same number of cycles. The central vacuum unit is fully automated and runs as required, which means that when a vacuum is required, it switches on and it switches off when the packaging machines are not in use. If a problem occurs in a vacuum pump when it is in low, medium or thermoforming mode, then a reserve pump is automatically activated. Thus, the reliability of vacuum supply to the packaging machines is maximised at the same time as ensuring it is as energy efficient as possible. The centralised vacuum unit is integrated with the control technology at Primo

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The centralised vacuum unit is integrated with the control technology at Primo Smallgoods, which controls and monitors the entire utility supply – ensuring permanent access to the operating data of each individual vacuum pump in the unit. Smallgoods, which controls and monitors the entire utility supply. This ensures permanent access to the operating data of each individual vacuum pump in the unit. This data is automatically archived, meaning that it can be analysed over extended periods of time. The system capacity of the rough vacuum at 15,000m³/hr at 50 mbar and the fine vacuum at 12,500m³/hr at 5 mbar provides very fast evacuation time, therefore reducing the cycle time and increasing production rates. The system capacity of the system while on standby is 3,000m³/hr. The Busch central vacuum system ensures economic efficiency by offering approximately 140kW of power reduction.

Hygienic packaging

The packaging lines at Primo are classified as ‘high risk’ hygiene areas; products are cut and portioned immediately before being packaged. Thus the surface of the product is at greatest, and therefore most probable, risk of contamination in this area. With regard to hygiene, having the centralised vacuum supply outside the production and packaging rooms minimises this risk, as this precludes the possibility of the meats being contaminated with any emissions from the vacuum pumps. A further advantage is that no maintenance of the vacuum pumps is required in the production and packaging rooms and therefore no maintenance personnel → need to access these areas.

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FO O D Preventing waste heat

The central vacuum supply prevents waste heat by keeping the vacuum pumps in a cooled room. This means that the climatisation in the packaging room is less costly in regards to air conditioning. Thus savings are made with the air-conditioning itself as well as with the energy costs. In addition to this, by centralising the vacuum pumps, approximately 33 kW of heat load can be removed from the packaging room, saving money on refrigeration costs and reflecting the energy savings of the central vacuum systems.

Modular unit construction

The central vacuum unit was constructed modularly by Busch, which makes it possible to adapt the unit to differing production conditions. In the beginning, the vacuum unit was configured conservatively. But even as early as the production start-up phase, rising demand became apparent, which meant that the central unit was expanded by several modules to deal with the current daily production and to be able to cope with output peaks.

Maintenance

The system is cost effective due to reduced maintenance costs, as there are fewer vacuum pumps installed â&#x20AC;&#x201C; the

Packaged bacon produced by Primo Smallgoods. installed vacuum pumps decreased from approximately 85 units to 24. To further minimise the risk of high costs and outage of the running plant, Busch has offered to take care of the maintenance. This involves controlling the maintenance intervals and the work and services that need to be done, at the same time as providing a basis for an extended warranty for the vacuum unit. In practice, maintenance work is carried out by Busch customer services twice a year. Incidentally, Busch are able to provide fast support in an emergency due to the close proximity of their service locations. Maintenance

takes place whilst the unit is running, without having any adverse effects on production. This is another advantage of a modularly constructed central unit, as the modules in the vacuum system control can be individually disengaged. A reserve pump stand is automatically activated if a module is switched off. Busch customer services record the data from the vacuum pumps, maintenance work and the results of vacuum level and energy usage. Primo is therefore informed of the current condition of, and possible necessary changes, to the vacuum unit. â&#x2013;

The central vacuum system supplied by Busch. 52

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BA L A NCI NG

Basics of balancing Over half of electric motor breakdowns are caused by damaged bearings, due mostly to the vibration occurred by the rotors imbalance. Industrial balancing and vibration analysis on rotating range of rotating equipment requires machinery enables the early detection of faults before breakdown,Aindustrial balancing for optimum and help facilities to reduce their maintenance costs. performance. Imbalance is a common source of faults in rotating assemblies, pumps and fans. Unbalance exists when the centre of mass does not coincide with the centre of rotation, when the mass centre axis is different to its running centre axis. The forces which result in vibration are primarily due to minor imperfections in the rotating components. Practically all newly machined parts are non-symmetrical due to many factors, including low holes in castings, uneven number and position of bolt holes, parts fitted off centre and machined diameters eccentric to the bearing locations among others. Balancing is the procedure where the mass distribution of a product (roller, impeller, etc) is checked and adjusted in order to ensure that the forces on the bearings, at a frequency corresponding to the devices operational speed, are within specified limits as specified in International Standards (see Balancing to a standard, Pump Industry February 2013). An uneven distribution of the mass is called unbalance. Because the bearings restrict this movement, the centrifugal force due to the unbalance causes the device to vibrate. This vibration causes

wear to the bearings, creates unnecessary noise, and can result in complete failure. Balancing is the process of improving this mass distribution of a body so that it rotates in its bearings without unbalanced centrifugal forces. The process of balancing is the removal or addition of weight to the unit such that this effective mass centre line approaches the true axis, adding or removing weight so as to make the two centres coincide. There are two forms of balancing: static and dynamic

Static

Out of balance is unevenly distributed mass on the rotating objects axis causing the heavier side of the object to fall to the lowest position when it settles at the point of rest. It is a form of unbalance that can be corrected by adding a single correction weight directly opposite the heavy spot on the rotor. (180 degrees from the unbalancing weight.) This type of balance can be corrected by removing the weight or by adding an equal weight directly opposite. Either measure would move the centre of mass back to the centreline of the part.

Dynamic

Out of balance can only be detected when the object is rotating. It is the result

of unevenly distributed masses in two or more planes of rotation. This type of unbalance requires at least two different planes along the shaft to correct. To create a true dynamic unbalance on a centrifugal fan wheel, first add a weight on the inlet side of the fan wheel. At the same time add an equal weight (at the same radius) on the back side of the wheel with the second weight rotated 180 degrees from the first weight. This is also called â&#x20AC;&#x2DC;couple unbalanceâ&#x20AC;&#x2122;. To correct this type of unbalance, one must compensate for both eccentricity (caused by static unbalance) and wobble (caused by couple unbalance). In practice, any dynamic unbalance can be corrected by making adjustments in two axially separated planes. Industrial balancing and vibration analysis on rotating machinery enables the early detection of faults before breakdown, and assists commercial and industrial facilities reduce their maintenance. Balancing has become an essential operation in the manufacturing and performance of high quality rotating equipment. â&#x2013; For more information on how industrial balancing can assist with machine reliability please visit www.precisionbalancing.com.au

....helping things flow! Imbalance is a common source of faults in rotating assemblies, pumps and fans.

Precision Balancing can help!

(03) 9758 7189

precisionbalancing.com.au

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pump industry | August 2014 | Issue 8

MAI NTE NANC E

Pump rebuild shops: facts and considerations (Part 2)

by Heinz P. Bloch, PE, Process Machinery Consulting, Robert Bluse, Pump Services Consulting, and James Steiger, HydroAire

In the February 2014 edition of Pump Industry, we published Part 1 of this article looking at the facts and considerations one must take into account when trying to identify a facility for the upgrade of existing pumps. In Part 2, our authors present an actual case study outlining the benefits a competent pump rebuild shop can offer owners of existing pumps.

recent study on energy efficiency showed that 90 per cent of pumps were not correctly sized. It is well known that many systems are simply sized too large at the project design stage, and incorrectly sized pumps incur higher operating and investment costs. The article reporting on the study stated that energy accounts for fully 94 per cent of the total life cycle cost of pumps (Ref. 1). This points to the importance of combining maintenance and upgrades when working on pumps. We define maintenance as restoration to the previous condition, whereas upgrading implies optimisation of life cycle costs. Such optimisations are certainly feasible given the status of current pump rebuilding technology and given the ability to take into account changes to a system’s performance which occur over time. In particular, we often find compelling reasons to systematically upgrade the efficiency and potential run length of large (and, sometimes, oversized) centrifugal pumps used in the power generating and Hydrocarbon Processing (HPI) industries. Of course, this upgrading must be pre-planned so it may be carried out during a maintenance outage. Also, this raises the question of whether an intelligent and well thought-out combination of maintenance and upgrading should be entrusted only to the original equipment manufacturer (OEM), or if qualified non-OEMs should be considered as well.

Dealing with multistage boiler feed pumps

Experience shows that a highly qualified independent rebuild shop with demonstrated capabilities and experienced personnel can offer high-quality upgrades that improve both uptime and efficiency. Such a shop can do so consistently with current pump system performance requirements. With the considerable consolidations in the pump industry, the distinct possibility exists that the OEM may not be able to 54

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offer the same engineering competence they previously had and that independent shops should be considered. Part 1 of this article was published in the February 2014 issue of Pump Industry. This follow-up segment, Part 2, relates an actual case study where a competent pump rebuild shop (CPRS) had been pre-selected just in case a technical issue arose with repairs, a desired schedule had to be met, or upgrading was to be part of an overhaul effort. Pre-qualification emphasises the importance of a CPRS having instant access to hundreds of definitive guidelines on performance-related issues. Permissible clearances between impeller tip and diffuser vanes are among these issues and are best explained by an example. In this instance, it involved a nine-stage boiler feed water pump. The pump had been previously repaired and was subsequently shipped and reinstalled at the owner’s site. When the field installation crew was ready to hand the pump over to operations, the rotor would not turn and there was zero axial float. The owners lost little time shipping the critically important pump to the pre-qualified CPRS. As soon as the pump reached the CPRS workshop, a work scope was developed on an expedited basis. The CPRS immediately disassembled and inspected the components. To carry out a proper repair, all of the pump’s internal parts had to be accurately measured. Fits and clearances had to be reviewed and recorded in computer-generated sketches (Ref. 2). Because the CPRS was eminently qualified to perform all-encompassing upgrade work, its personnel analysed, among other tasks, a number of hydraulic issues and did the following: • Calculated suction specific speed (they were cognisant of the Hydraulic Institute advisory considering as high energy pumps those with specific speed values below www.pumpindustry.com.au

MA I NTENA NCE Gap B as Percentage of Impeller Radius Type Diffuser Volute

Gap A 0.0 50 in 0.050 in

Minimum

Preferred

Maximum

4% 6%

6% 10%

12% 12%

Gap A = Radial distance between impeller shroud OD and diffuser or volute wall Gap B = Radial distance between impeller vane OD and diffuser or volute tongue (ID) Gap B = 100 (R3 -R2) / R2, where R3 = Radius of diffuser volute inlet and R2 = Radius of impeller.

1,300 that generate more than 900 feet of head per stage). • Calculated suction energy (again, there was an awareness of the differential head value for high energy dropping from 900 feet at a specific speed of 1,300, to only 200 feet at a specific speed of 2,700). • Calculated NPSH margin. • Compared susceptibility to internal recirculation-induced damage. • Verified that radial clearances comply with hydraulic shock avoidance criteria for high (discharge) energy pumps. Recall (from Part 1) that the CPRS was in possession of comprehensive checklists on pump-internal clearances and upgrade options. Its employees made copious use of these checklists during the incoming inspection and repair scope definition process for this nine-stage pump. Impeller and diffuser gap ‘A’ and ‘B’ modifications were mentioned in the CPRS documentation that had been made available to the user-owner while he made his earlier vendor qualification assessment visits (again see Ref. 2).

CPRS restores recommended radial gap guidelines

It has been observed that not every original equipment manufacturer (OEM) delivers pumps with internal clearances designed and manufactured for optimised hydraulic and mechanical performance. Adhering to the radial gap criteria outlined in Table 1 above is very important. These are based

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Table 1: Radial gap criteria.

on Dr Elemer Mackay’s widely reported and groundbreaking work with the Electric Power Research Institute (Refs. 3 and 4). It should be noted that if the number of impeller vanes and the number of diffuser/volute vanes are both even, the radial gap must be considerably larger (10 per cent minimum). A repair facility must maximise impeller performance as needed and this CPRS knew what to look for: 1. Bring the impeller middle shroud plate out to the impeller OD to reinforce the impeller structure. 2. Stagger the right and left side of the vane to reduce hydraulic shocks and alter the vane-passing frequency. 3. Avoid even number of impeller vanes for double volute; or, if the diffuser vanes are even numbered, increase the impeller sidewall thickness. 4. Reduce clearances to optimum between shrouds and casing (Gap ‘A’). 5. Impellers manufactured with blunt vane tips can also cause trouble by generating hydraulic hammer even when the impeller OD is the correct distance from the cutwater. The blunt tips cause disturbance in the volute. This effect may be partly or entirely eliminated by tapering the vanes by overfiling or underfiling the trailing edge, as described in many texts, among them Refs. 4 and 5. →

pump industry | August 2014 | Issue 8

MAINTE NA NC E

Figure 1. An arrow points at the diffuser vane tip that’s too close to the impeller.

Figure 2. Diffuser tips were cut back (shown here before final radius machining).

Figure 1 shows the deficiency noted during initial dismantling; the diffuser tips are not equidistant from the impeller periphery. The tip clearances had to be brought into compliance with Gap ‘A’ and Gap ‘B’ guidelines by cutting back (Figure 2) and re-contouring the diffuser vane tips. The CPRS quoted a delivery estimate of only two to three days and, upon completion of the project, offered a final report showing documentation in accordance with its quality assurance program.

overall maintenance costs by improving equipment mean time between failures. The ultimate effect will be reduced life cycle costs for the pump.

Shop repair procedures and restoration guidelines

Pump manufacturers usually supply pump maintenance manuals with detailed assembly and disassembly instructions that are either generic, or specific to a particular pump style and model. In essence, a number of important checks should be performed by the CPRS for users whose serious goal is to systematically eradicate failure risk. Both CPRS and user have responsibilities in ascertaining that all quality checks are performed with due diligence. Experience shows that after years of repairs, many pumps are due for a series of comprehensive dimensional and assemblyrelated checks. As a minimum, every vital pump deserves much scrutiny. After the well-known dial indicator checks (see Part 1) are complete, the dimensional ‘before vs. after’ findings should be recorded in either the (preferred) electronic, or, as a minimum, paper format. This constitutes part of the documentation, and knowing the before vs. after geometry holds the key to failure analysis and future failure avoidance. A CPRS will take time to record these pump repair data and will be on the road to reach the user’s failure reduction objectives. Using the CPRS assessment scoring matrix (discussed in Ref. 2), a CPRS will have been pre-selected. Still, when the repairand-upgrade opportunity presents itself, it is incumbent upon both parties to agree on work scope and critical repair part sourcing decisions. In other words, more definitive repair and restoration guidelines should be consulted in a meeting of user-owner and CPRS representatives at this time. Some of the data provided during the assessment phase of a potential CPRS will have been rolled into an operating mode document that reflects the manner in which the CPRS is conducting business. By that we mean the CPRS will work from written shop procedures, checklists, and upgrading guidelines. Moreover, the CPRS will offer warranties as solid as those of the OEM. Jointly with the CPRS, the user makes critically important repair part sourcing decisions. The right choice will lower 56

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The point is that reliability-focused professionals strongly advocate selecting a CPRS that assists in collecting and examining all the parts of the pump. The CPRS will tutor the client in looking for tell-tale signs of problems on each component. The CPRS will use a thorough checklist and go way beyond the usual repair steps to ascertain that every optimisation opportunity is thoroughly explored and explained. In working with a CPRS, our goal is to purchase knowledge and experience in the process.

The case for a CPRS

Rebuilding a vintage process pump to original OEM specifications makes no sense given current pump rebuilding technology and changes to the system performance that occur over time. However a CPRS, a highly qualified independent rebuild shop with guidelines, checklists, procedures and a willingness to cooperate with the owneruser, can verifiably offer high-quality upgrades that improve both uptime and efficiency consistent with current system performance requirements. With the considerable consolidations in the pump industry, the distinct possibility exists that the OEM is not able to offer the same engineering competence they previously had. If one simply makes these statements, the issues can be debated for a long time. However, assessing vendor competence and making comparisons using a rigorous and repeatable approach makes the selection process more objective. To the electric power producer, such assessments may, ultimately, be worth a small fortune in maintenance cost avoidance and run length extension. ■ References 1.

Wikstroem, et al; “Supersizing Our Way to Energy Inefficiency”, Supplement to Control Engineering, November 2008.

Bloch, Heinz, Robert Bluse and James Steiger; “Combining Pump Maintenance and Systematic Upgrading” ASME POWER2008-60065. Full text also available also from www.hydroinc.com

Bloch, H. P. and Budris, A. R., 4th Edition (2013), Pump User's Handbook: Life Extension, Fairmont Press, Inc. Lilburn, Georgia (ISBN 0-88173-720-8).

Bloch, H. P., 1988, Practical Machinery Management for Process Plants Vol.1: Improving Machinery Reliability, Second Edition, Gulf Publishing Company Houston, Texas (ISBN 0-87201-455-X).

Bloch, H. P. and Geitner, F. K., 1985, Practical Machinery Management for Process Plants, Volume 4: Major Process Equipment Maintenance and Repair, Gulf Publishing Company, Houston, Texas, (ISBN 0-88415-663-X).

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PUMP INDUSTRY PARTNER SOLUTIONS

MA I NTENA NCE

Reducing sludge treatment costs Reduction of sludge treatment costs is a challenge at sludge treatment plants across Australia. Engineers from seepex recently worked with a team from UK water authority Severn Tren to improve the performance of their plant, highlighting the role their pumps can play in improving sludge treatment plant performance around the world.

he engineers from seepex and Severn Trent came together at the utility’s sludge thickening plant in Packington, England. This site, near the town of Ashby de la Zouch, treats sewage from a population of 28,000, so system reliability is crucial to both Severn Trent and the local population.

The situation

The sludge thickening plant had been experiencing excessive downtime for some time and system failures were causing poor performance of the sludge discharge pump. Breakdowns were causing frequent pump repairs, with associated maintenance costs and also the cost of sludge movement on site by tankers. As the problems in the process were becoming more regular and pump replacement failed to solve them, a new approach was needed. seepex were asked to look at the whole system with Severn Trent engineers and to use their combined experience in sludge pumping to diagnose the causes of downtime. The investigation found not one problem but a series of small issues which, when combined, led to poor overall performance of the sludge thickening plant. Understanding the requirements of pump performance within the system was crucial to the subsequent proposal to solve the issues and restore sludge thickening performance.

The solution

seepex offered an open hopper pump from the BT range with a larger capacity than, and different design to, the existing pump. The discharge chute from the thickening units was adapted to feed directly into the pump hopper and the integral auger screw pushes the sludge into the pumping elements of rotor www.pumpindustry.com.au

and stator. This improved configuration handles sludges of varying consistency from the thickening plant. In addition, the control system was automated to use ultrasonic level control in order to vary the pump speed (by use of a VSD), and balance the discharge rate to the thickener output, thus eliminating high level problems and subsequent shutdown of the equipment. The discharge pipework was changed to a surface mounted installation with increased diameter. Access and inspection are easy and should post pump blockages occur, removal of these will be straightforward.

The benefit

The reliability and performance of the sludge thickening system has been improved by the ability of the pump to handle sludges of varying thickness and the automatic control of pump speed linked to level controls. Downtime and maintenance time and costs have been reduced, and associated sludge tankering costs removed. Andrew Perry of Severn Trent said, “To date we have not incurred any tankering costs as a result of this issue and the unit has not stopped at all since the installation. Our aim is to resolve all problems in such a professional manner.” ■

The seepex pump on site.

Key facts • Pump type – Range BT • Open hopper pump with auger feed screw • Ultrasonic level control linked to pump speed • Quick maintenance • Improved reliability • Significant cost savings • Reduced downtime • Reduced maintenance costs • Reduced sludge disposal costs

An illustration of the new system at the Severn Trent plant.

pump industry | August 2014 | Issue 8

PUMP INDUSTRY PARTNER SOLUTIONS

MAINTE NA NC E

Making maintenance easier Warman Accumin lubricators have been specifically designed to enhance the life and operational efficiency of Warman pumps.

ussell Beaumont, Accumin Product Manager at Weir Minerals Australia said “Automatic lubricators aren’t exactly new technology, but Accumin is the only lubricator on the market to have been specifically designed for use with Warman pumps. “Accumin allows for quick and easy pump lubrication. You simply bolt the lubricator onto your Warman pump, set the dosage and timer, and it does the rest. Accumin ensures that the required lubricant dosage is consistently supplied to key parts of your pump. For a relatively small investment you are cutting down on maintenance and increasing the life of your Warman pump.” Glen Priestley, Weir Minerals Director of Pumps, was also impressed. “We are constantly looking for ways to improve our pump performance and longevity, and Accumin is one extra tool to help our customers achieve best practice pumping. “What differentiates Accumin from other lubricators is the grease. Premium synthetic grease has always been specified in the Warman pump manuals, and now it is available in an automatic lubricator.” In addition to the unique grease, Accumin lubricators utilise the latest innovations in design and technology. This was confirmed by Martin Naimo, Slurry Pump Product Manager for Weir Minerals. “The name Warman has been synonymous with advanced technology and durability for centrifugal slurry pumps for more than 75 years. We have made sure that Accumin is produced with the best design, materials and construction to match the quality of Warman pumps. Reliability is paramount on site, so we have done everything possible to make sure Accumin can stand up to any conditions thrown at it.” 58

Warman Accumin Lubricator 250 Premium is designed for use in the most arduous conditions. Accumin is available in two sizes, with two grease options to suit site specifications. Accumin Premium is a premium synthetic based grease as specified for Warman pumps in the Warman pump manual. It provides superior lubrication with less volume of grease, and is particularly suited to the extreme conditions found on many mine sites. Accumin Premium grease is fully compatible with lithium-based greases, meaning it can be retrofitted onto any Warman pump without any concerns about grease compatibility.

pump industry | August 2014 | Issue 8

Also available is the Accumin Standard, which is a lithium-based grease that provides excellent adhesion and is highly resistant to water contamination. “Warman is known for superior quality. Why wouldn’t you use the best grease and lubricator system for the best pump?” concluded Mr Priestley. ■ For more information on Accumin Lubricators or Warman pumps, please call 1300 WARMAN (927 626) or email info@weirminerals.com.

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E XPERT

Pump Industry is seeking qualified experts in various areas of pumping to join our Expert Panel.

he pump industry relies on expertise from a large and varied range of specialists, from experts in particular pump types to those with an intimate understanding of pump reliability; and from researchers who delve into the particulars of pump curves to experts in pump efficiency. To draw upon the wealth of expert knowledge the Australian pump industry has to offer, Pump Industry is establishing a panel of experts, who will share their knowledge with the Australian pump community, and answer specific questions we receive from readers.

Don’t be shy! Are you an expert in a particular aspect of pumping – whether it be equipment, manufacturing, service or research? Don’t be shy, join our expert panel and help develop the industry by sharing your expert knowledge! To nominate for our panel, or nominate a colleague in confidence, contact Pump Industry Managing Editor Laura Harvey at laura.harvey@monkeymedia.com.au.

Our Expert Panel will have a regular column in every edition of Pump Industry, and will have a dedicated presence on our website, www. pumpindustry.com.au, providing our Expert Panellists with a good opportunity for exposure within the industry. ■

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pump industry | August 2014 | Issue 8

PUMP INDUSTRY PARTNER SOLUTIONS

PROD UCT SHOWCA SE

New products available through White International Pressure tanks by Global Water Solutions

or over 10 years Global Water Solutions (GWS) has been a market leader in the supply of pressure tanks. GWS products have distribution in more than 100 countries worldwide, including Australia and New Zealand.

Recently, GWS released the All-Weather Pressure Tank exclusively with White International. The tank is constructed with a high grade steel encased in a rugged polypropylene outer shell.

White International has always been the preferred distribution partner of GWS’s market leading products. GWS offers a comprehensive range of pressure vessels for heating, thermal, pressure booster, water hammer, reverse osmosis and water well applications. GWS unique product offerings include both its patented CAD2 diaphragm tanks, as well as its line of single diaphragm tanks with a patented water connection. Now a series with a replaceable, tiered membrane design is also available. All GWS products undergo a series of tests to ensure excellent quality.

The patented PLASTEEL shell creates an impenetrable protective layer that shields against the harsh elements. Wind, rain, sleet or sun is no match for the All-Weather Pressure Tank, making it the perfect solution for marine and mining applications, as well as in harsh environmental conditions. With the highest quality and all major global approvals, the GWS All-Weather Pressure Tank represents a great innovation in pressure tank technology. GWS sees the market for pressure tanks continuing to grow, with many new and innovative technologies. Such tanks are not only designed to provide constant pressure on traditional pressure systems, but when configured and sized

correctly, GWS pressure vessels can provide seamless water supply without starting the pump repeatedly. This reduces the start draw required by the motor, saving energy and money for the end user. To support this effort, GWS has provided a range of pressure tanks labelled as energy saving devices which can be selected using their innovative “Pressure Tank Calculator” app for iPad, iPhone and iPad. The first application of its kind, the GWS app is a helpful tool for sizing pressure tanks and contains a number of features to help users choose the right pressure tank for their system, as well as calculate tank drawdown volumes. ■ Distributed by White International Pty Ltd. Phone 02 9783 6000 or 1300 783 601 www.globalwatersolutions.com.au

Pressure Tanks • • • • •

Rugged Polypropylene outer shell 10 bar pressure rating Single diaphragm design Comprehensive testing Virgin Polypropylene liner

• Patented stainless steel water connection • Leak free O-Ring sealed air valve • Maintenance free

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pump industry | August 2014 | Issue 8

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pump industry | August 2014 | Issue 8

Alan Rowan PI O NE E RS

Over 50 years ago, Alan Rowan began his career in the pump industry as a teenage apprentice. He then went on to enjoy a career spanning a wide variety roles at a number of different pump companies. Despite retiring from full time work in 2005, he has remained involved in the pump industry and provides consulting services, including commissioning pumps. He served as President of the PIA for three years and remains heavily involved in the organisation as a Council Member and is Executive Officer for Publications and Training.

lan Rowan was born in Glasgow, Scotland. He left school at 16 and completed a Diploma in Mechanical Engineering at Stow College of Engineering while completing an apprenticeship.

How did you first get into the pumps industry?

By accident. I originally wanted to join the Merchant Navy as a cadet officer but, being colour blind, failed the eyesight test. My first job was as a shop boy in a Glasgow shipyard. I then got an apprenticeship at Drysdale & Co., a water pump manufacturer which was part of the Weir Group. I have been in the pump industry one way or another with a few short breaks for all of my working life. An apprenticeship with Drysdale & Co allowed me to go to sea as a shipâ&#x20AC;&#x2122;s engineer. At the time in the UK, if you were in the Merchant Navy until you were 25, you did not have to do National Service. However, National Service was abolished before I finished my apprenticeship. I did still plan to go to sea when I was finished; however, as soon as my apprenticeship was over Drysdales offered me a job as a trainee application engineer, which looked very interesting. I did that job until I left Scotland for New Zealand in 1967. This period of my life laid the foundation for the rest of my career in the pump industry, teaching me how all types of centrifugal pumps worked. Starting with selecting single pumps, I ultimately ended up putting together complex pumping systems.

What do you like about the pump industry?

Many years ago I was asked if working with pumps was boring, as they seemed 62

Alan Rowan with his wife Roberta. to be quite simple machines. This is most definitely not the case. The wide variety of pumps and their applications always brings something new and interesting to learn. I started learning about pumps and their systems when I joined the industry over 50 years ago; and I am still learning today.

What other companies have you worked for during your time working in pumps?

When I left Scotland I worked in New Zealand for a couple of years for a small engineering consultancy, mainly working in the dairy industry. Our major project was the design of a new cheese factory including a new style of automated cheese making machine with associated machinery including a few pumps.

pump industry | August 2014 | Issue 8

After this, I got my first taste of pump sales with Andrews & Beaven, selling to local industry. The remainder of my time in New Zealand was in sales, mainly in pumps, although I did spend an interesting two years designing and selling sewage treatment plants, ranging from small packaged plants to city sized plants (including plants for the cities of Rotorua and Hamilton). My last job in New Zealand was with Fletcher Engineering selling Ingersoll-Rand products, mainly pumps, where I was introduced to API process pumps and got a job offer from Ingersoll-Rand to come to Australia. An interesting anecdote about my arrival in Australia is that I had taken two large orders, from Shell BP & Todd www.pumpindustry.com.au

PI O N EERS

in New Plymouth and Reid Rubber Tyre Plant in Auckland, and a couple of smaller orders before I left. On visiting Ingersoll-Randâ&#x20AC;&#x2122;s Dandenong plant I saw that 90 per cent of the pumps going through the plant were my orders. I spent nearly ten years at IngersollRand and rose to National Sales Manager with a focus on the petrochemical industry, including supply of pumps to a number of pipeline projects. During this time I first got involved with the PIA (or APMA as it was known then), and was on the Technical Committee with well-known characters like Ron Astall, Geoff Daniels, Lex Torr and others. I worked on the Technical Committee from the late 70s until 1987. Around 1981 I became a Councillor and served on the council till 1992 including three years as President. After my time at Ingersoll-Rand I joined Kelair Pumps as their Melbourne Branch Manager. After a year I transferred to Tasmania to run Douglas & Fraser who Kelair had just bought. I ran the company and the branch it became till 1997, overseeing the development of the business, acquiring new premises, overseeing the transition to a Kelair branch and setting up Kelair's first service department outside Sydney. On leaving Kelair I spent a short time with Blakers Pumps in Melbourne then spent over a year in the UK with my wife which allowed me to do a market survey for Southern Cross Pumps on their Ultimate Pump Systems. We returned to Australia in late 1998 and I joined Southern Cross Pumps as their Ultimate Product Manager in June 1999 for 18 months. Then I moved to Link Pumps in a sales/engineering capacity until my retirement from full time work at the end of 2005. Since then I have done consulting work including commission of pumps.

How has the industry changed during your time in it?

When I arrived in Australia in 1976 you could count the number of medium to large pump companies on both hands and the vast majority of pumps were Australian made. The market was dominated by Thompson of Castlemaine, Kelly & Lewis, Ajax, IEL www.pumpindustry.com.au

I started learning about pumps and their systems when I joined the industry over 50 years ago and I am still learning today. The wide variety of pumps and their applications always brings something new and interesting to learn. (now United Pumps) and Ingersoll-Rand in the centrifugal pump market; Mono & Ebsray in positive displacement pumps and Warman for slurry pumps. In the late 1970s many people left their major pump employers and started out on their own on the basis that they could offer a better, more personal service to industry and at the same time find better products from overseas. This contributed to the demise of Australian manufacturing, along with steep reductions in tariffs and the start of the rapid rise of pump imports to where it is now. Of course, the reduction of tariffs over time in the mid-1980s spurred the growth of importation, leaving few companies which exclusively market for the Australian market - probably the only ones left are United Pumps and Warman. Reflecting on the changes over the years, a job I was involved with in Tasmania with Kelair illustrated the changes. I called in on a pulp mill in southern Tasmania to find their multistage split case Australian-made log washing pump had died on them and was going to cost upward of $50k to fix. I was able to point out that we could get them a segment ring pump made in Europe much cheaper and at a similar delivery to the repair. As a result they bought the import. I did have to convince the plant engineer that modern segment ring pumps were easily maintained and did not have flat face sealing between the stages.

What was the most memorable moment in your career?

This is a difficult one but I think winning an order at Ingersoll-Rand for a new

pump to pump crude oil from Moonie to Brisbane. This involved the supply of an API610 multistage pump driven through an API613 gearbox by a large Caterpillar crude oil fuelled engine, all to be delivered in 18 weeks ex works, which we achieved. Another memorable moment happened at Kelair Pumps in Tasmania, where, in about 1994, head office decided all the branches should have their own service departments. This was a good idea for Tasmania, as customers were not keen on pumps being shipped off the island. Over a period of three to six months I brought together the equipment needed and hired a pump serviceman and started servicing pumps with 18 months to become profitable. We did it in less than a year.

Did you have a mentor at any time in the industry?

Over the years I had several. In Scotland when I started as an application engineer my boss then, Jimmy Gorman, gave me an in-depth education on the application and selection of pumps, and made sure I understood the intricacies of the affinity laws, NPSH and applying centrifugal pumps to handle the pumping of oil. Jimmy was a stickler for getting it right and taught always to make sure that the best pump we had available for the job was offered. When I came to Australia to work at Ingersoll-Rand, guys like Richard Royds, Bob Haylock and Bob Paterson guided me on how best to work with the Australian pump industry. Richard Royds got me onto the APMA Technical Committee, Bob Paterson onto the Council, and the greatest pearl of wisdom Bob Haylock gave me was â&#x2020;&#x2019;

pump industry | August 2014 | Issue 8

PI O N EERS to know when not to argue with a customer about a claim. At the time, the rule of thumb was if the claim was less than $400 then the argument was likely to cost you more than the claim and would end with bad feeling from the customer.

Tell me about some of the other personalities in the industry that you have worked with? In this case, you can be spoilt for choice so I will stick with two.

First, Ron Astall. I first met and got to know Ron around 35 years ago when we were both on the APMA Technical Committee. Over the years Ron’s knowledge of pumps and their applications has always impressed me, and he is always happy pass his knowledge on, usually in is normal self-deprecating style with a few of his bad jokes thrown in. I can’t count the number of mean Scotsman jokes he has told me. The second is John Link, whom I have known for 25-30 years. John has always run his own business — mostly in pump hire, sales and service, with a good deal of flair and his own unique style. If you are looking for a problem solution from left of field John is the one to ask, and they often work.

What are the most significant developments you have witnessed in the industry?

Without a doubt the most significant development has been the change from mainly Australian made products to the clear majority of pumps now sold in this country being imported, along with the blossoming of smaller pump companies who import their own product and sometimes distribute pumps from the major importers such as Grundfos. Another development I consider significant is what I would call the modernisation of pump control systems. We have transitioned from simple automatic starters controlled by float or pressure switches to sophisticated electronic controls with variable speed drives and soft starters working with SCADA and PLC controls. Even pressure switches and float switches can be replaced by pressure transducers and ultrasonic level controls.

Are you still involved in the industry today?

Very much so; I have been on the PIA Council for a second stint since 64

The one thing that is for sure is that the world is not going to stop needing pumps. The future will be bright if the industry accepts and overcomes the challenges it faces.

around 2003 and also serve as Executive Officer for Publications and Training which involves looking after PIA’s publications, keeping them up to date and publishing them. 2013 saw the latest editions of the Pump Technical Handbook and Pipe Friction Handbook printed, the latter with minor update, while the Technical Handbook underwent a major update with new chapters on Positive Displacement Pumps, Energy Efficiency and Troubleshooting, with many other chapters being substantially upgraded. At present I am working on an installation and commissioning training course which will have theory and practical components, and is designed to prepare people to confidently install and commission pump sets.

What are the greatest challenges facing the pump industry? What does the future hold for pumps? Today there is a fantastic range of excellent pumps of all types and sizes available in Australia and to me there are two great challenges that the industry faces. Firstly, to convince the buyers of pumps to stop buying on lowest dollar and start evaluating pumps and their systems for their efficiency, both from the point of power consumption and cost of operation over the life of the pump, its driver and its system.

The second big challenge is training and retaining people so that they are willing to make a career in the pump industry. Today there are too many employers (both within and outside our industry) who want to hire trained personnel only and leave the training to others. Over the years I have found that it is next to impossible to pick up staff with any worthwhile pump experience. Unless you get really lucky, you have to put some sort of training program in.

pump industry | August 2014 | Issue 8

There are plenty of good basic training courses available; however if that is not enough you need follow up with practical supervised experience until the trainee has got the basics right and then make sure they keep on learning. In my view it takes five to ten years to make a good pump guy who has a reasonable knowledge of pumps and the industry, but most of all understands that he is on a lifelong learning process. As to the future, the one thing for sure is that the world is not going to stop needing pumps. So the future will be bright if the industry accepts and overcomes the challenges we have been discussing.

What advice would you give young people in the pump industry?

The principal advice I would give is to realise that while pumps are relatively simple machines, due to the wide variety of types and styles and the many variations of construction materials, learning about pumps and selling them is a lifelong adventure which is very rewarding.

What do you like to do in your spare time?

I love fishing on Port Phillip Bay and have a small boat from which I fish as often as I can between early October and late May. I am afraid last summer I didn’t get out as much as I would have liked for various reasons, but I plan to use this winter to get my boat and gear in order and get out more often in the coming summer before I get too old. ■

www.pumpindustry.com.au

PUMP SCHOOL Question: How is the volume of pump sumps or pits determined? Is there an optimum size?

umps in pits would normally be started and stopped by means of level switches of some type. There will be a maximum and minimum level in the pit. The volume between these levels is called the useful volume. The flow from the pump will change as the liquid level in the pit changes as the system resistance changes due to the variation in static head. The minimum allowable useful volume, V, of the pit is given by the formula:

In reality the inflow is rarely constant and will differ according to the time of day, the weather, etc. The formula will provide a calculated sump volume that is over-specified leading for periods where the pumps are inactive, i.e. during dry weather and night flow conditions. Yet it will ensure that the sump does not overflow. â&#x2013;

Article courtesy of Kelair Pumps Australia â&#x20AC;&#x201C; When Pump Knowledge Matters.

V = 3600 x Qi x (Qa-Qi)

For more information call 1300 789 466 or visit www.kelairpumps.com.au.

Smax x Qa Where: V = useful volume in litres Qi = inlet flow to pit in l/sec Qa = Q1 + Q2 2 Q1 = pump flow at pump start level in l/sec Q2 = pump flow at pump stop level in l/sec Smax = maximum allowable starts per hour The size of a pump pit is determined by the allowable number of starts per hour, Smax. The number of allowable starts per hour is normally a function of motor design and this information will be provided by the motor manufacturer. The formula above can be used if inflows are constant and pump flows are known. If a sump is being designed from scratch, then assumptions need to be made. Safe assumptions are to design the pump flow to be twice the maximum inflow. This useful volume is then calculated from:

V = 1800 x Qi Smax www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

TEC HNI CAL

Understanding pump curves #8 : Are your pumps running too slowly? (Part Two) by Ron Astall, United Pumps Australia

In the last article we discussed the dangers associated with arbitrarily specifying pump running speeds. Based on specific speed theory, the recommendation was to aim for a pump with the best shape impeller and retain an open mind about the pump running speed.

or a given duty point, the Specific Speed (Ns) formula can be used to predict the likely impeller shape based on the expected running speed “N” and the head per stage “H”. If Ns is a low number, a less efficient pump can be expected. Last time we focused primarily on selecting pumps with a higher running speed to enable a larger Ns value and hence the possibility of a better impeller shape. Of course, we could obtain a similar result by selecting multistage pumps which would reduce the head per stage in the formula. For single stage pumps, the assertion was made - controversially perhaps - that where a higher running speed provided for a better impeller shape, there was no reliability downside. In fact, I went as far as saying that in these circumstances, when comparing a low speed pump versus a high speed pump for the same duty conditions, the higher speed pump ought to be more reliable and will not have inherently higher wear rates than the comparable low speed pump. OK, the faster pump will be smaller and less expensive to purchase, but to many people, this is completely

counterintuitive. How can a faster running pump be more reliable than a slow speed pump? We must remember that we are comparing pumps operating in the same service conditions; i.e. the same flow and the same differential head. We are thus comparing a large slow speed pump containing a correspondingly large impeller with a more compact pump with a smaller impeller. The issues I am now going to consider are internal wear and erosion, bearing loads, noise and vibration and suction performance.

To assist with this discussion, I have selected some 2980 rpm pumps and some 1450 rpm pumps for the same service conditions – See Figs 2 & 3 below. In each comparison, the respective pump drawings are shown correctly scaled relative to each other. I have deliberately selected pumps operating a little below Best Efficiency Point (BEP) flow so that the effect of hydraulic radial side thrust can be seen. All pumps are double volute and the hydraulic radial side thrusts have been calculated on this reduced basis and are assumed to act in a direction around 60-70O from the cutwater. The Resultant Radial Thrusts are the vector sums of the impeller weights and the hydraulic radial side thrusts. The Volute Outlet Velocity is the mean fluid velocity at the volute exits. For the Axial Thrust calculation, all impellers have been considered to be hydraulically balanced with equal diameter back and front rings and with balance holes through the impellers. For these overhung pumps, the axial thrust is thus simply the product of the inlet pressure times the effective seal balance area.

Internal wear/erosion

Wear is generally assumed to be related to impingement velocity to the power of 2 to 2.5, so the issue is primarily fluid velocity. To generate the same head at a 66

pump industry | August 2014 | Issue 8

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TEC H N I CA L lower running speed, a correspondingly larger impeller diameter is required, so in theory the fluid velocities in the volute should be pretty much the same in each case. In one of the comparisons, the volute outlet velocity is actually a bit higher for the low speed selection, but in general it is safe to say that casing fluid velocities will be the same and that there is no wear penalty at the higher running speed in the casing. Where this may not hold true is in the suction side where impeller entry velocities will be typically higher; as also evidenced by the NPSHr values. In clean liquid service this is not an issue provided there is adequate inlet pressure. For slurry and solids handling; velocities must be kept low all round and for this reason low speed (and low head) pumps are preferred for solids handling. For clean liquid service there is no wear penalty with a well selected higher rpm pump for the same service conditions

Bearing loads

From Fig 4 below it can be seen that whilst a lower rotational speed will produce an inversely direct corresponding increase in bearing life,

an increase in the bearing load will dramatically decrease bearing life to the power of 3 for ball bearings and to the power of 10/3 for roller bearings. The impact of the load is much more significant than rotational speed. I have not bothered to calculate actual bearing life for the above examples, since in each case the pump designer will design the bearing frame accordingly. What is very clear however is that the bearing loads are much larger for the low speed alternatives. The radial bearing loads are typically four to five times larger. This is due to the larger diameter and hence much heavier impellers that are required for the low speed selection. The larger peripheral area of these impellers will also impact the hydraulic side thrust at partial capacities. Axial bearing loads in an overhung pump depend on the impeller hydraulic balance and the inlet pressure. The lower speed selection will normally have a larger shaft diameter, thus generating larger axial loads when there are significant inlet pressures. Bearing loads are significantly higher for the slow speed alternatives, requiring larger bearing frames if the same bearing life is to be achieved.

Noise and vibration

For a given out of balance mass, a faster running speed will create a higher out of balance force and hence potentially higher vibration levels. To ensure acceptable vibration levels, a better balance grade is important for higher speed equipment. As the lower speed pumps are doing the same hydraulic work but have a

larger surface area it could be argued that there is potential for more radiated noise from the slower units, but I have personally no experience of this because pumpset noise levels are generally more dependent on the driver than on the pump. At higher speeds, acoustic driver fans may be necessary to ensure noise levels are not exceeded. Lower speed pumps do have a theoretical advantage in terms of noise and vibration, however, from experience the potential for noise and vibration can be managed with suitable balancing and by managing driver noise levels. Historical test results for the above ranges of pumps show this to be the case; with acceptable noise and vibration performance at either running speed.

Suction performance

Modern hydraulic design techniques such as computational fluid dynamics and inducer technology can expand the application of high speed pumps in low NPSH service, but all things being equal, a low speed selection will have better (lower NPSHr) suction performance than a high speed unit in the same service. If the suction conditions are challenging, this may preclude a higher rpm selection.

Summary

There is no doubt that a given pump will last longer when operated at slower running speeds. This is not what we are discussing here! We are comparing different speed pumps selected for the same hydraulic conditions. We have seen that internal velocities, and hence wear, will be the same in single stage pumps selected for the same head. We have also seen that where a good high speed selection is available, a lower speed alternative will almost certainly be heavier, more expensive, and will have higher bearing loads. The recommendation is to select your pumps on the basis of the hydraulic duty and specify your other primary requirements directly; such as NPSHA, noise and vibration. Then let the pump vendor select the best pump for the job; unrestrained by speed constraints. The best speed may be 2980 or 1450, or 980rpm or even lower. It depends on your hydraulic conditions. If you end up with a faster running speed, pump reliability will not be compromised. Most likely it will be more economic, more energy efficient and more reliable. â&#x2013;

www.pumpindustry.com.au

pump industry | August 2014 | Issue 8

Editorial schedule November 2014

Deadline: 12 September 2014

Main feature

Instrumentation, control & monitoring

Energy efficiency

Industry Focus

Power generation Fire protection Irrigation

Pressure and temperature gauges Vibration instrumentation Flow meters Condition monitoring sensors

Pump Products I NDE X

February 2015

Deadline: 28 November 2014

Main feature