Pump Industry May 2014 digital edition

ISSUE 7

MAY 2014

pumpindustry Retrofits increase

building efficiency

Features Environmental water Mechanical seals Peristaltic pumps Reliability engineering

When pumps go down, so does my production.

To see which pumps are in danger, I need real-time monitoring.

But how can I afford the upgrade?

With low-cost implementation and easy integration, Emerson Pump Health Monitoring means big savings now and in the long run. Our real-time predictive technology tells you what to pay attention to and when, so you stop wasting time, money and manpower. Automated asset monitoring also helps you avoid risks to operation, safety and environment, thereby increasing the reliability of your refinery. And with the advantage of Smart Wireless, installation is quick and painless. See how to unleash your plant’s and your people’s potential at EmersonProcess.com/PumpHealth

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

PU MP I N DU STRY

President’s welcome W

elcome to another high quality issue of Pump Industry magazine.

In my last President’s Welcome I was griping about the importance of having good specifications and that enforcing them was critical.

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

I am still on the specification hobby-horse.

Several times I have run a mini technical presentation entitled “Are Your Pumps Running Too Slowly?” Expecting it to be controversial, I have braced myself for argument and criticism, only to find that I am preaching to the converted.

The people I wanted to influence were not there!

Surely the writers of these specifications are sincere, so where is the disconnect?

Perhaps it is because some of the logic is counter intuitive. In this issue of Pump Industry, I have written a short article on this very subject. I encourage you to read it and I hope it prompts discussion as intended. In a market place where decisions are often made on the basis of the lowest bid, here is a discussion that is intended to enable a lower cost pump selection.

All of this is consistent with the PIA’s aim to develop a better educated industry.

Ron Astall President, Pump Industry Australia

Numerous colleagues in the industry have told me that they wished their customers and their engineering consultants could have been there for this presentation. They are selling to industries where purchasers regularly enforce inappropriate running speed requirements; all too often compromising the pump selection process for no good reason.

Tony Kersten - Councillor Grundfos Pumps Pty Ltd 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 | May 2014 | Issue 7

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ISSUE 7

MAY 2014

pumpindustry Retrofits increase

PUMP I NDU STRY

building efficiency

Features Environmental water Mechanical seals Peristaltic pumps Reliability engineering

Cover shows SA Water’s Lock Chamber Refurbishment. Jason Roos, Coordinator Major Maintenance, adjusting sump pump to ensure lock chamber is dry for major works.

Photographer - Tom Roschi

3,143 Audit Period: 01/04/2013 – 30/09/2013 This publication has been independently audited by the Circulations Audit Board.

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.net.au info@monkeymedia.net.au pumpindustry.com.au magazine@pumpindustry.com.au Editorial assistants: Michelle Goldsmith Design: Sandy Noke sandy@sandynoke.com ISSN: 2201-0270

W

Editor’s welcome

hile this magazine has not quite reached its second birthday, the association has been around considerably longer, and this year, Pump Industry Australia will celebrate fifty years of operation.

I’m very proud to be associated, albeit for a brief period of time so far, with such a great association and I look forward to celebrating this anniversary.

I’ve always been interested in the history of trade associations and industries, as our readers may have noted from our regular ‘Pump Pioneers’ feature, so I’m particularly keen to document what we can of the PIA’s history to mark this occasion.

Our November 2014 issue will be a special edition focussing on this occasion and I call on all our readers to submit their suggestions, reminiscences and any old photos. See pages 10-11 for more detail.

Moving from the past to the future, Pump Industry magazine is now offering a range of custom marketing services to companies that want to reach the industry and to reach pump users.

While a print ad in a quality trade magazine remains the most powerful way to get the attention of a niche industry, it is far from the only way and we are working with various companies on projects such as custom email newsletters, online lead generation, writing blog content and more. We’d love to talk to more companies who are interested in any of these options.

the HVAC industry. The correct installation of pumps and systems and use of variable speed drives is continuing to provide huge gains in energy efficiency and very real savings in dollar terms. I hope that our industry can continue to get this message out.

Chris Bland Publisher and Editor PS. SCAM WARNING I’ve heard from a few advertisers and PIA Members who are being approached by various magazines, some of whom have made claims to have support from the PIA or other associations, or claiming to have large circulations.

Just as standards are important in the pump industry, so too in the magazine publishing industry, and the best and safest way to ensure you are getting what you pay for is to only advertise in publications that are audited by the Audited Media Association of Australia, also referred to as the Circulations Audit Bureau.

This is an independent body that audits all media in Australia. We are a member and every edition of Pump Industry has been audited.

Please protect yourselves from wasting money, and avoid supporting cowboys, and do not advertise in a magazine if it is not audited.

We will be attending the ARBS show in Melbourne in May, and this edition has a specific focus on the role of pumps in

This magazine is published by Monkey Media in co-operation with the Pump Industry Association (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 publishers discretion.

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pump industry | May 2014 | Issue 7

www.pumpindustry.com.au

Your Partner in Industrial Pumping

The new 速 WILFLEY EMW range of Heavy Duty Pumps

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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................................................... 8 Index......................................................................... 72

MAIN FEATURES

22 HVAC The new space race.................................................................... 22

28

Pump efficiency vital to Sydney power savings......................... 25

18 Training The value of training................................................................... 18

28

Reliability

Pump system mechanics: on the floor at SA Water.............................................................. 28

33 Fans Fan resonance and balancing.................................................... 33

34 Water A flood of ideas............................................................................ 34 Centrifugal pump protection using flow controllers.................. 40

42 Seals API 682 dual seal design configurations................................... 42 Restaging a multistage offshore oil pump................................. 46 Custom engineering seals the deal........................................... 49

54

Seal-less pumps

Peristaltic pumps........................................................................ 54

PUMP PIONEERS 62

4

Bill Smith

pump industry | May 2014 | Issue 7

51 www.pumpindustry.com.au

IS SU E 7 | MAY 2 0 1 4

22

PROJECTS Tasmanian copper mine saves on maintenance with pump upgrades

51

A copper mine in Tasmania was looking to reduce pump failures, which were occurring frequently and at a high cost. The pumps on this site are located 2.4 kilometres underground which means pump maintenance can be both difficult and expensive. The pumps operate at a high speed to develop the high pressures levels required to dewater the mine.

34

AusIndustry Grant assists local manufacturer

52

In December of 2011, Crusader Hose was awarded a grant for the development of an innovative new hose process that would offer a variety of advantages to users as opposed to the commonly used poly pipe.

TECHNICAL Amiad Auto Micro Fibre (AMF) Filter meets stringent standards

68

Cavitation may be foremost in the minds of any pump system designer, and careful thought may be taken to avoid cavitation and the resulting damage to the pump(s), but cavitation is often overlooked or ignored when selecting automatic control valves and their location on the same pipework system.

Understanding pump curves

66

Are your pumps running too slowly? Part 1.

Pump school

71

NPSH and elevation

PIA News and events.........................................10 PIA Member News.............................................. 14 Industry News Valveless flow control.............................................16

Product Showcase Pressure tanks by Global Water Solutions...........58 Zenit pumps for all your wastewater solutions‌..59

52 www.pumpindustry.com.au

HNW introduces new AODD pump........................60 Increasing pump speed.........................................61

pump industry | May 2014 | Issue 7

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

Melbourne researchers create first liquid metal pump Researchers at RMIT University have developed the world’s first liquid metal enabled pump, a revolutionary new micro-scale device with no mechanical parts.

Lead investigator Dr Khashayar Khoshmanesh, a Research Fellow in the Centre for Advanced Electronics and Sensors at RMIT, said currently there was no easy way to drive liquid around a fluidic chip in micro-fabricated systems.

“Lab-on-a-chip systems hold great promise for applications such as biosensing and blood analysis but they currently rely on cumbersome, largescale external pumps, which significantly limit design possibilities,” he said.

“Our unique pump enabled by a single droplet of liquid metal can be easily integrated into a micro device, has no mechanical parts and is both energy efficient and easy to produce or replace.

“This innovation shows that micro- and nano-scale pumping can be accomplished with a simple system – a crucial

advance for the field of micro-fluidics.”

The unique design will enable microfluidics and lab-on-a-chip technology to finally realise their potential, with applications ranging from biomedicine to biofuels.

The design uses droplets of Galinstan – a non-toxic liquid metal alloy comprised of gallium, indium and tin – as the core of a pumping system to induce flows of liquid in looped channels.

When the alloy is activated by applying a voltage, the charge distribution along the surface is altered. This propels the surrounding liquid without moving the Galinstan droplet through the loop, using a process called “continuous electrowetting”.

The pump is highly controllable, with the flow rate adjusted simply by altering the frequency, magnitude and waveform of the applied signal. The flow direction can also be readily reversed by reversing the polarity of the applied voltage.

$3.1M sewerage upgrade begins in Qld Queensland Urban Utilities has begun work on a $3.1 million project to install a new 4.8km sewer pipeline in Gatton, located in the state’s south east.

The new pipe is being installed to ensure the sewerage network has the capacity to cater for future development in the area.

Major Projects and Commercial Services General Manager, Mike Griffiths, said Queensland Urban Utilities was committed to ensuring the long-term sustainability and efficiency of the region’s sewerage infrastructure.

“It’s important we extend the sewerage system’s operational life and improve the reliability of the local network,” he said.

The $3.1 million project is expected to be completed by the end of July 2014, weather permitting.

“The 250mm diameter pipes will be installed using a combination of open trenching and micro-tunnelling technology,” Mr Griffiths said.

“The first stage of construction is underway in Treatment Plant Road, Gatton. Work will then continue in stages to minimise the impact to the local community.”

The $3.1 million investment is part of Queensland Urban Utilities’ $3.2 billion 10-year capital works investment in south east Queensland.

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

6

DELIVERING PUMPING SOLUTIONS

pump industry | May 2014 | Issue 7

www.pumpindustry.com.au

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

Getting pumped for ARBS 2014 Pump Industry Australia (PIA) stalwarts including President Ron Astall and PIA executives Ken Kugler and Keith Sanders will take part in a panel discussing developments in pumping systems for the building services sector at ARBS (Air-conditioning, Refrigeration, Building Services) in May. The three panellists will address different aspects of pump technologies: • Ron Astall will talk about pump efficiency, specific speed and where the best gains can be made in reducing power consumption in pumps and systems

• Ken Kugler will discuss the new AS 2941-2013 Fixed fire protection installations - Pumpset systems standard, essential information for those who specify, procure or work with sprinklers and hydrants.

• Keith Sanders will offer insights into pump performance information and testing to AS 2417:2001 Rotodynamic pumps - Hydraulic performance acceptance tests.

Keith will also share his knowledge of current European trends in efficiency and power consumption, which looks at the Extended Product Approach and is

currently subject of a draft Europump guide.

“The European Community is generally more advanced than Australia regarding regulation of pumping equipment,” he says, “and their approach may be instructive.”

ARBS 2014 will be held at the Melbourne Convention and Exhibition Centre from 20-22 May 2014. Seminar registrations are now open on the ARBS 2014 website www.arbs.com.au.

The largest range of Solids Handling Pumps When Pump knowledge Matters

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75 mm solids handling capability irrespective of pump size Prime assist version available Diesel engine driven, trailer mounted versions for dewatering Flows up to 630 litres/sec

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Totally seal less design Self priming from dry Ideal for high solids concentrations such as thickener underflow Reversible rotation Corrosive liquids easily handled Zero slip so can be used for dosing

Sandpiper Air Operated Diaphragm Pumps Heavy Duty Flap Valve and Ball valve Pumps • • • •

Recommended for slurries and liquids with suspended solids Flap valves allow passage of linesize solids without damage of solid or pump shafts.

Special-built ball valve pump providing superior suction lift capabilities Ball valve pump ideal for all liquids thin or thick, even with significant concentrations of small solids.

Wemco Chopper Pump

Wemco Torque Flow Pump

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Chops solids, rags and fibrous material Prevents clogged pipe systems Hardened steel cutter bar

• •

Recessed vortex impeller pump Capable of passing stringy and fibrous material Ni hard and high chrome options for high abrasives Vertical option available

Local call Australia-wide 1300 789 466 - kelair@kelairpumps.com.au - www.kelairpumps.com.au www.pumpindustry.com.au

pump industry | May 2014 | Issue 7

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N EW S - C O N T R AC T S AWA R D E D

South East Water’s pipes and structures South East Water has announced that Comdain Infrastructure and joint venture partners Downer EDI and MWH Australia have been contracted to deliver up to $400 million of infrastructure projects over an initial 5 year term, as part of the company’s Pipes and Structures Program.

Comdain and its joint venture partners were appointed following a comprehensive and competitive market tender process and bring with them extensive knowledge and experience in designing and delivering capital works programs on Australian and International water and wastewater infrastructure.

Comdain General Manager for Civil and Program Manager for the joint venture, Simon Maher said: “We are excited about the opportunity to work collaboratively with South East Water and the collective experience that this joint venture brings will showcase our innovation and expertise in constructing complex infrastructure.”

For the latest news on contracts and tenders visit: www.pumpindustry.com.au

pumpindustry

Seqwater water treatment plant upgrades Seqwater has awarded two contracts to Aquatec Maxcon for major water treatment plant upgrade works at the North Pine and Lowood Water Treatment Plants in South East Queensland.

The works at the North Pine WTP, which services Brisbane consumers, involve upgrades to the fluoride doing system.

These include the installation of various flow meters and a fluoride analyser, works on associated sample lines and TISAB

waste storage tanks, and PLC/SCADA system upgrades.

The Lowood WTP upgrade contract involves works to improve the performance of major treatment equipment, such as installing a new dual-shaft drive assembly, replacement of filter media in open gravity filter cells, valve replacements and the construction of a chemical dosing pit for “Statiflo” static mixer and dosing points.

Harcourt rural modernisation The $40 million Harcourt Rural Modernisation Project is underway in Victoria and a number of contracts have been awarded for construction and the supply of materials.

The contract to supply the 19 kilometres of ductile iron pipes and fittings which will be used to construct the backbone of the new modernised rural pipeline system was awarded to Pentair.

Coliban Water has appointed Redline Mining and Infrastructure Pty Ltd, a multidisciplinary civil engineering company who specialise in pipeline construction, as the contractor for the installation of the new rural pipeline system for the construction phase of the project.

The tender for the supply of pumps has been awarded in two parts to Xylem for the Faraday site and KSB for the Barkers Creek site. These contracts are for the supply of the pumps and motor sets that will be needed for the new pump stations at each location.

“Redline has extensive experience in pipeline construction, delivering major projects in both New South Wales and Queensland, and through the competitive tendering process demonstrated their capability to undertake the works at Harcourt,” said Jeff Rigby, Managing Director of Coliban Water.

The Harcourt Rural Modernisation Project will provide rural customers in the Harcourt area of Victoria with a year round pressurised supply through a piped system, replacing the aged and now inefficient concrete and earthen gravity rural channel system that has served the region for over 100 years.

ONLINE

dewatering, pump hire & solution contracting www.vortexhire.com.au info@vortexhire.com.au 8

pump industry | May 2014 | Issue 7

www.pumpindustry.com.au

PIA NE WS

PIA to celebrate 50 years The history of the Australian pump industry dates back at least as far as the gold rush of the 19th Century, while the industry association itself will celebrate 50 years of continuous operation later in 2014.

450m / hr powered by the sun? I’d like to see that!

3

Well now you can. The LORENTZ PSk-CS surface pumps are vertical multi stage pumps designed to efficiently deliver the highest volumes of water from a solar power source.

Used in irrigation projects around the world, the new PSK range can achieve flow rates of up to 450m3/hour, and pump up to a 90m head. Each system consists of a pump and a controller to connect with tier 1 solar generation equipment.

Exclusively distributed in Australia by Solco Power &Water.

Contact us today on 1800 074007 or email sales@solcopowerwater.com.au.

www.lorentzpumps.com.au 10

www.solcopowerwater.com.au

pump industry | May 2014 | Issue 7

S

ome of Australia’s early history in pump manufacture is represented by two family owned businesses, which still operate, albeit with several changes of ownership since their early days. Both of these organizations are over a century old and have grown out of the earliest Australian export trades of gold and agricultural produce. The oldest, Southern Cross, started in Queensland in 1871 making wooden windmills for pumping ground water. The business grew over the decades to the point where Southern Cross became a household name in rural communities and has led to their current wide range of agricultural pumps and associated equipment.

In 1875, when the gold rush in Victoria was in full swing, much of the recovery of alluvial gold was undertaken using hydraulic sluicing methods. Thompsons Castlemaine had their beginnings with the manufacture of centrifugal and reciprocating pumps for sluicing and mine dewatering. In 1988, Thompsons merged with Kelly & Lewis to form TKL. These companies, now operating under the Flowserve banner, are still designing and making pumps and are among the leaders in their field.

Early in the 20th century, as Australia industrialised, more pump manufacturing companies emerged in Australia, including McPhersons (Ajax Pumps), Industrial Engineering, Mono Pumps.

These businesses became the core of the Industry to the point where the Australian Government saw the export potential for pumps in the region and encouraged the formation of a Pump Association, to promote the idea.

The Australian Pump Manufacturers www.pumpindustry.com.au

PIA N E WS

The November 2014 edition of Pump Industry will have a special focus on the history of both the industry and the PIA. Anyone with a suggestion, a story to tell or any old photographs is encouraged to contact the Editor at chris.bland@monkeymedia.net.au 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.

George Snow of Mono played a major role in the early years of the Association. In addition, many of the current PIA Life Members were active in the early development of the APMA.

www.pumpindustry.com.au

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 1990’s, 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 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.

pump industry | May 2014 | Issue 7

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Next PIA meeting: PIA NE WS

Brisbane, 13 May

The PIA will meet in Brisbane on Tuesday 13 May for a general meeting and social gathering

S

tarting at 4:30pm, PIA has invited Chris Tritton, President of the Queensland Branch of AHSCA (Assn of Hydraulic Services Consulting Engineers Australia) to address the meeting. There will also be other presentations of general interest and a social function to follow.

Plan now to come along with your colleagues and friends for a great evening networking with Industry friends.

• Where: Riverside Centre, 123 Eagle St, Brisbane • When: 4:30pm, Tuesday 13 May • Register: pumpsaustralia@bigpond.com

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pump industry | May 2014 | Issue 7

Upcoming Events • Tuesday 12 Aug 2014 Perth • Tuesday 11 Nov 2014 – AGM and social function – Melbourne

www.pumpindustry.com.au

LET’S EXPAND THE

POSSIBILITIES.

Introducing the new line of Lowara e-HM industrial-strength pumps.

More choice, more customization, more efficiency.

• Specifically designed for industrial applications • Multiple configurations to meet your needs • Compact yet powerful

• A giant step up in efficiency — up to 15% higher than other brands • Extended product life

Increase what’s possible. Select your horizontal multistage solution at lowara.com.au/e-hm today.

xyleminc.com | Lowara © 2013 Xylem Inc. Lowara is a trademark of Xylem Inc. or one of its subsidiaries.

PIA ME MBE R NE WS

Brown Brothers supplying Sakuragawa B

rown Brothers Engineers is the exclusive distributor for the Singapore-based Sakuragawa Pump Manufacturing Company for Australia and New Zealand.

This partnership provides customers with high-quality products, bolstered by top after-market support.

Renowned for quality, Sakuragawa submersible pumps play an active part in mining and industrial applications throughout Australia. The company’s pump range includes mining and dewatering pumps, as well as heavy-duty

contractor pumps that are used widely in the rental/hire pump industry.

Established in 1953, Sakuragawa are one of the world’s most experienced submersible pump manufacturers. The range is suited to a variety of requirements, from large volume pumps through to high heads, and includes a selection of agitator (dredger) style submersibles, and all pumps come with hard faced double mechanical seals in oil baths.

The pumps are also designed for dewatering applications, including mine dewatering; draining pits and quarries;

stormwater drainage; transferring liquids carrying sludge or sand; as well as more general dewatering duties on building and construction sites.

The benefits of the range are that the pumps are made from the highest resistant materials, which means longer product life; the pumps can be serviced quickly in-house with standard tools; the products are from a well-known, trusted and widely used brand in Australia.

For more information, contact Brown Brothers Engineers at www.brownbros.com.au

New appointment Brown Brothers Engineers Australia Pty Ltd has announced the appointment of David Seaman in the role of Business Development Manager, based in the Sydney Office.

David brings with him a wealth of industry experience with a successful track record of developing and implementing strategic plans across various market segments and achieving significant growth.

He has worked closely with key stakeholders and industry leaders throughout Australia and brings with him a proven record in relationship management.

As part of this new role he will focus on 14

links between Brown Brothers Engineers and the corporate sector across Australia.

Brown Brothers Engineers CEO, John Inkster said that "BBE is fortunate to secure David as BDM; this is a new position and will greatly assist BBE move forwards in the coming years. His 20 years’ experience and knowledge of the industry will be of great benefit to our Company"

pump industry | May 2014 | Issue 7

Brown Brothers Engineers is a leading pump supplier in both Australian and New Zealand supplying a wide range of products from small domestic and drainage pumps to large end suction and multistage pumps to industrial, commercial, municipal and agricultural markets including well known global brands Lowara, Goulds, Hydrovar, Vogel, Layne Bowler and Sakuragawa. www.brownbros.com.au www.pumpindustry.com.au

Revolutionary new diesel driven pump from Gorman-Rupp

T

he pump is a 75mm x 75mm centrifugal unit which can deliver flows from 3 litres per second (l/s) through to 28 l/s, with heads to 40m. The pumps have a patent pending “staggerwing” vortex impeller which is designed to enable the pump to handle a 76mm spherical solid along with stringy materials such as rags. The difference between this impeller and other vortex impellers is its vastly improved efficiency and head capabilities.

(Above) A compact Dewatering Pump that can Handle the Trash (Left) Patented Impeller Produces High Pressures and High Efficiency

The pump’s priming capability comes from Gorman-Rupp’s unique priming system which includes a compressor and venturi device “pulling” a vacuum through Gorman-Rupp’s own air separation chamber. This, combined with an over-sized, oil lubricated mechanical seal, allows pumps to prime reliably and to run dry continuously without damage.

Hydro Innovations advise that the PAV3B60C-3TNV70 is powered by a Yanmar liquid cooled diesel engine that is USA EPA certified to meet interim Tier IV emission standards. Standard “autostart” control panels include safety shutdown switches for high liquid temperature and low oil pressure. They also include tachometer, voltmeter, hour meter, coolant temperature gauge, oil pressure gauge, manual/stop/auto key switch, 10 AMP push-button circuit-breaker, start-up warning delay, muffler with weather cap, and throttle control.

This is just one pump in Gorman-Rupp’s line of PA (prime assisted) pumps, with capabilities to 800 litres per second, and heads to 180 metres with other models within the range.

The units are available as open skid mount units or with acoustically rated canopies and can also be fitted to road register-able trailers. More information on diesel driven pumps can be obtained from Hydro Innovations on 02 9647 2700 or email on sales@hydroinnovations.com.au www.pumpindustry.com.au

pump industry | May 2014 | Issue 7

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PIA ME MBE R NE WS

A new diesel driven, “Prime Aire” trash pump from GormanRupp is now available from Authorised Australian distributor – Hydro Innovations. The new pump has a revolutionary new [Patent Pending] impeller design which is said to be able to handle large solids while maintaining efficiency.

I NDU STRY NE WS

Valveless flow control The paradigm shift from centrifugal pump and control valve combinations to valveless flow control with progressive cavity pumps.

A

paradigm shift is a change from one way of thinking to another. It does not just happen, but rather it is driven by agents of change. There are current paradigms, or methods of thinking, that need to shift because they limit progressive cavity pump (PCP) usage. For many the logic is to utilize a centrifugal pump and control valve for flow control applications, however PCPs are particularly well suited for these applications due to their valveless design, controllable flow and low pulsation. The term for the innovative use of PCPs in such applications has been coined “valveless flow control�. In order to cajole a paradigm shift from the conventional use of centrifugal pumps with control valves, the many advantages of and opportunities for valveless flow control with a PCP must be revealed and easily identified. Typical applications where PCPs can replace centrifugal and control valve combinations include wastewater treatment, chemical metering applications, and any application in which flow control is vital.

For example, an application transferring slurry to a blending tank would typically prompt the need for a centrifugal pump and a control valve to control flow, but a PCP should be considered. PCP advantages include reliability, reduced maintenance, capital, and operating and energy costs. Various ranges of PCPs can and precisely meter and gently convey fluids of any viscosity, in a wide range of temperatures (especially with even wall stators), with or without solids. In a PCP, a single helix rotor turns insides a double helix stator to create cavities which progress from the suction to discharge. The compression fit between the rotor and the stator 16

creates seal lines that keep the cavities separate as they move through the pump with each rotation. The compression enables the pump to act like a valve. The result is flow with very little pulsation and low shear rates. Slip is less of an issue and when the pump stops nothing will flow through it. The compression between the rotor and stator even enables customers to mount the pumps vertically.

Centrifugal pumps are a very common type of pump that includes a shaftdriven impeller that rotates inside a casing. Liquid flows into the suction port, or inlet, of the casing and is propelled to the outside of the casing, exiting through a discharge port.

Centrifugal pumps are designed for high flow applications and conveying liquids with relatively low viscosity with consistencies like water or like very light oil. A flow control valve regulates the flow or pressure of a fluid and is generally incorporated as the final element of a control loop to control flow within the required operating range. Such valves can be identified as pressure regulators and flow control, altitude, or relief valves.

They can be fitted with actuators or can be automatic which do not require an external power source. Common issues with centrifugal and control valve combinations include cavitation, leaks, obstructions, erosion, hysteresis and modulation. Centrifugal pumps can lose prime between batches or from alternating pumps. If a valve fails the only choice is to repair or replace it.

Valves could be eliminated altogether.

PCP can solve a multitude of flow control issues compared to other pumps that require control valves.

pump industry | May 2014 | Issue 7

When considering process control, a progressive cavity pump, flow meter, and Variable Frequency Drive is much simpler than a centrifugal and valve combination. A PCP self-primes and acts as a pump and control valve in one, providing much better flow control. PCPs are not affected by changing pressures.

Hysteresis and modulation can be virtually eliminated. There is no worrying about internal or external air leaks or obstructions in the suction or discharge pipework.

Recent innovations in PCP technology such as Smart Conveying Technology (SCT) and the success of several flow control installations at chemical process plants has resulted in proof that using a PCP improves performance and cuts costs. The SCT design allows the stator to be re-adjusted due to the integrated retensioning device, giving longer stator and rotor life. By separating the stator into two halves, PCPs with SCT will reduce service times substantially and no longer have to be removed from the installation for maintenance. Typically, centrifugal pumps are easy to maintain (whereas control valves are not so easy because an entire separate set of calibration and diagnostic techniques comes into play), but a progressive cavity pump with Smart Conveying Technology (SCT) is extremely easy to maintain.

When comparing the costs of both potential flow control solutions, be sure to compare the cost of a PCP to the combined cost of a centrifugal pump and control valve. The control valve‘s power medium is often compressed air, one of the most expensive sources of energy in a plant. Electric actuators are www.pumpindustry.com.au

I N DU STRY N E WS

quickly becoming a popular alternative as plants seek ways to reduce energy costs and offer precision, but retrofit is costly. The cost of a complex control valve and actuator combined with a centrifugal pump often exceeds the cost of a PCP by 1.25 to 1.5 times.

What matters now is that you have experienced a paradigm shift and can now see valveless flow control with a progressive cavity pump as an option for your flow control application. Can you be an agent of change in your industry?

For further information regarding valveless flow control, please contact seepex Australia on (02) 4355 4500, or visit our website www.seepex.com

Why replace when you can adjust? seepex Smart Conveying Technology extends the life of your stator. Adjustment of the retaining segments takes just 2 minutes and restores 100% pump performance.

Tests have shown up to 3x stator life compared to conventional progressive cavity pump design Join the smart revolution and test our innovation “Smart Conveying Technology�.

seepex Australia Pty. Ltd. Tel +61.2.4355 4500 pvila@seepex.com www.seepex.com

www.pumpindustry.com.au

pump industry | May 2014 | Issue 7

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The value of training

By Keith Sanders

TR AI N I NG

Pump Industry Australia ran a member survey recently, asking for opinions on what should be prioritised for action within the industry. One respondent wrote, "TRAINING, TRAINING, TRAINING. The absolute need to re-introduce a high degree of professional expertise and try to stem the brain drain".

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n many respects this sums up a feeling expressed by many within the industry in recent years. It is often prompted when the level of expertise available for meaningful technical assessment of offers for pumping equipment is poor on both sides of the negotiating table. This may lead to purchasing decisions being made predominantly on price considerations without the engineers getting a say.

As a former CEO of a pump manufacturer in Australia, I understand and sympathise with the dilemma that many companies face when making the decision to invest in training for their key personnel. I recall agreeing to sponsor a young executive to undertake

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an advance marketing course to improve his level of expertise, obviously with a view to enhance the contribution that he could make to the business.

All went well and our young executive completed the course with flying colours. Our next step was to find a new role for him in the organisation that would provide him with greater opportunity and the company with increased resources. A real win-win outcome. Imagine my frustration when he came to see me and handed in his resignation. He was moving interstate to join one of our major competitors. I was "not happy Jan".

It is clear that companies need to invest in the skills development of their staff, but without some understanding that this investment will have a reasonable return, it becomes more difficult to justify these decisions, especially when the business environment is uncertain and profitability is under pressure. In tough times, the natural instinct is to "batten down the hatches" and cut out all unnecessary expense that does not improve the bottom line in the short term.

Training budgets and promotional budgets are often the first casualties in this process. This applies as much to pump users as to pump equipment suppliers.

pump industry | May 2014 | Issue 7

Now, as a training service provider, I see the issue from a different perspective. However, I still recognise that it is important for training to be seen as an investment decision rather than an expense. Pump Industry Australia has long been involved in activities that provide inexpensive training tools for their members. The latest editions of the two PIA publications, the Technical Handbook and Pipe Friction Handbook, are clear examples of a successful initiative in this direction. The PIA has also run a series of very good pump application seminars in recent years, but it is worth noting that these have not always been well supported by pump consultants or pump users. This has been a key dilemma for PIA in planning their programs on an annual basis. How do we spread the good oil?

Ultimately, it is people that purchase pumping equipment. There are plenty of suppliers out there in the market, so it becomes much more important for there to be an intelligent dialogue between client and supplier, to get the optimum pumping solution for any particular application. There is no "one size fits all" approach in this process and a knowledge of how systems operate is extremely important so that the pump selection parameters are clearly defined. Only then can one begin the task of determining the appropriate size and type of pump, the speed of operation and the materials of construction that are best suited to giving efficient and reliable operation www.pumpindustry.com.au

TR A I N I NG

Austr Australian Industrial Indus Marketing Mark PUMP INDUSTRY TRAINING LEVEL 1 - PUMP TECHNOLOGY (based on PIA technical handbook)

ADVANCED PROGRAM CUSTOM DESIGNED PROGRAMS TRAINING DELIVERED

BY KEITH SANDERS BSc Eng, MBA. in service. It takes time to undertake this analysis and, since time costs money, it is often not given the priority it deserves. Short cuts often result in bad outcomes when the equipment is put into service. Rectification costs become the subject of disputes and significant cost in litigation can ensue.

All this can be avoided, if the right analysis is done initially and updated if any changes occur during final design and installation.

One of my recent trainees from a major consulting engineering company was asked to provide feedback on the value he got from our Level 1 program. As an adjunct to his response, he indicated that several of his colleagues questioned why he wanted to know more about pumps. His answer was enlightening. "How can I make a decision to recommend equipment to a client, if I do not know how to properly evaluate the operating conditions and match these to the submissions I receive?"

Oh! How we wish there were more people who are prepared to make this level of self assessment and then do something about it. Unfortunately, there are plenty of pumping myths that are perpetuated by people who may not have been properly trained and it is important to be able to recognise fact from fiction. Too many people these days are assessed by KPI's that have little relationship with good technology or long term customer satisfaction.

www.pumpindustry.com.au

Pump Associations all around the world recognise the importance of technical training. This is available at a variety of levels and from a wide range of reputable sources. Australia is a big country with a small population, which makes face-to-face training somewhat more difficult, despite the fact these programs are available from local companies with expertise in this field.

PIA has these listed on their website.

The BPMA of UK and Hydraulics Institute of USA offer on-line courses, which provide excellent information for those who cannot make it to capital city locations, but still wish to improve their skills.

While it is evident that fewer bare shaft pumps are actually "Made in Australia", the demand for pumps increases year on year according to market statistics.

This means at the very least, we need to know how to evaluate submissions and ensure there is adequate capability to service and maintain that equipment in future. Otherwise we will be importing this expertise from overseas suppliers at great expense somewhere down the track. We owe it to the next generation of pump engineers, whether they be on the supply side or the user side, to provide them with the skills and experience to make good procurement decisions. This means setting aside some funds for structured training programs, both theoretical and practical, delivered by people that know what they are talking about. ■

Qualified Mechanical Engineer with over 40 years experience in the pump industry

GENERAL CONSULTANCY

• • •

Strategic Planning Product Evaluation Technical Services

UPCOMING COURSES LEVEL 1 PUMP TECHNOLOGY TRAINING COURSE • • • • •

Pump Construction Pump & System curves Operating conditions Pump Testing to AS 2417 Installation & Troubleshooting

CURRENT SCHEDULE Brisbane Sydney May 14 & 15 Jun 11 & 12 Perth Melbourne Aug 13 & 14 Sep 16 & 23

To register your interest email: aim1@internode.on.net Or visit pumps.asn.au/industry-training For information on other training programs and consultancy services, contact: Australian Industrial Marketing Ph: (03) 9890 0165 Mob: 0421 323 123

pump industry | May 2014 | Issue 7

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The latest weapon in the war on rising fuel prices Built tough for Australian conditions, the Diesel DogTM is purpose designed for the operationand control of diesel driven pumpsets. The panel is adaptable toall makes and models of diesel engines and pumps.

With simple operation and programming, the Diesel DogTM is extremely user friendly. It automatically monitors service intervals and displays the time until next service. If service is too far exceeded, the engine can be programmed to ignore a start command.

The Diesel DogTM saves fuel by automatically adjusting engine speed to maintain a constant pump pressure in a closed pressure system regardless of irrigation system flow requirement. The Diesel DogTM is also used on lift pump systems to maintain a constant level in a supply channel.

Diesel DogTM will monitor and safe guard against faults such as pump flow & pressure, engine

RPM, temperature, oil pressure, coolant level, battery voltage and alternator voltage.

Upon receiving a command to start, the Diesel DogTM will idle through a ‘warm up’ period beforecommencing into ‘line fill’ modeto gently fill and pressurise a piped system then continue on to maintain the pre programmed set pressure. Before completely shutting down, the Diesel DogTM will idle the engine for a short ‘cool down’ period.

Best of all, the Diesel DogTM can be operated on farm or via instant remote access to your mobile phone or home computer.

Starting, controlling or stopping a diesel pump set has never been easier.

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Designed solely for the operation of a pumpcoupled to a diesel engine.

Can be used on any make of diesel engineor pump.

User friendly with simple operation & programming.

Save Fuel (up to 15% in some instances). Diesel DogTM is designed to automatically adjust engine speed to maintain a constant pump pressure.

Prolong engine life via engine ‘warm-up and gentle ‘line fill’ mode to operating temperature prior to full load operation and engine ‘cool-down’ mode before shutting off.

Automatically monitors service intervals and records time to remind of next service.

Will completely shut down if service has been too far exceeded.

Monitors and safe guards against: Pump Flow & Pressure, Engine RPM, Temperature, Oil Pressure,

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Coolant Level, Battery Voltage and Alternator Voltage.

Save time by starting, stopping and accessing pump & engine information live via internet from anywhere in the world.

Single screen display showing all significant information.

Capable of multiple pressure set points which can suit some applications to dramatically further improve fuel use efficiency.

Capable of running two or more pump units in parallel, referred to as ‘Multi Dog’. One unit automatically becomes the ‘master’ and the other ‘slave’.

The slave will simply copy the master; however monitor its own safeguards.

Can be used to also maintain channel level in either a supply system or drainage system.

Built tough for Australian conditions.

The Diesel DogTM can run single or multiple pump units simultaneously, is capable of multiple pressure set points if required to dramatically further reduce fuel usage.

CONTACT YOUR NEAREST AUTHORISED DEALER:

A: Lot 1 / 1310 Hillston Rd Griffith, NSW 2680 P: (02) 6966 8951 E: rwe@rwe.net.au

Jason Veale, associate director, building engineering– AECOM.

Mark Lee, Affil.AIRAH, engineering manager – James L Williams

Peter Cass, M.AIRAH, associate, services cost management – Rider Levett Bucknall

Scott Brown, M.AIRAH, sustainability director – Waterman Group

Vince Aherne, M.AIRAH

HVAC

The new space race Increasing the energy efficiency of building services systems is essential, but it has resulted in an increased need for space. In this “view from all sides” article, Vince Aherne, M.AIRAH, speaks to four experts about how the construction industry is dealing with these spatial issues.

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ince 2010, NCC BCA Section J Deemed-To-Satisfy requirements for limiting the power used by HVAC fan and pump motors has resulted in an increase to system duct and pipe sizes. At the same time, Section J has also increased minimum insulation R values and has moved to a “Material R value” basis for insulation systems, leading to increased thicknesses for traditional materials. Although increasing the energy efficiency of building services systems is an essential action to control building-related energy use, the combined effect of these three changes has led to an increase in the spatial requirements of the services that need to fit into the plant rooms, shafts and ceiling spaces of BCA Deemed-To-Satisfy compliant buildings.

Ever since humans first started erecting buildings, there has been conflict around providing space for building services.

In days past this might have involved allowing space for tall ceilings to facilitate ventilation and comfort, or inserting large, high windows for adequate day lighting.

In many contemporary buildings the indoor environmental conditions are provided by building services systems, which all need to be accommodated within the often-hidden building spaces of plant rooms, shafts, false ceilings and raised floor spaces.

Smash the myth: GREEN HVAC is not lean HVAC

“There is a myth pervading the industry

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that being green means being lean, and that energy-efficient HVAC systems are somehow smaller than standard systems,” says Scott Brown, M.AIRAH, sustainability director with Waterman Group.

“It is not the cost of larger ducts or plant that is the issue,” says Lee. “It is the cost of the additional space required that seems to be the limiting factor.”

The truth is that while a green building might reduce dependency on HVAC, all things being equal, Brown says that energy-efficient HVAC systems are more likely to lead to an increase in spatial requirements, not a decrease.

The race for space

He says bigger ducts with more insulation need bigger shafts and deeper ceiling spaces. More efficient chillers and boilers need bigger heat exchangers, with more plantroom access.

“A greener system configuration with air-to-air energy recovery, for instance, means more ductwork and additional heat exchangers to fit in,” Brown says.

Brown notes that plant rooms with energy-efficient HVAC plant and air-to-air heat recovery can be 50 per cent or even 100 per cent bigger than they would have been had energy efficiency not been a concern.

Mark Lee, Affil. AIRAH, is engineering manager with mechanical contractor James L Williams. He says that generally speaking, building designers allocate the same or smaller spaces for building services as they have in the past, making access tight and providing for future maintainability very difficult.

So the same old battles are being fought by designers.

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Space, in other words, is the crunch point.

Jason Veale, associate director – building engineering with AECOM, agrees.

“Every project has a degree of tension between architects and engineers over spaces,” he says. “Section J is now increasing the need to coordinate and communicate about service space early.”

According to Peter Cass, M.AIRAH, who is associate – services cost management with Rider Levett Bucknall, architects are pivotal to changing space allowances because they own the building spaces.

But as Cass explains, extra space is not always a straightforward proposition.

“Developers are measuring new projects against the space ratios of the existing buildings that will compete for the same tenants,” Cass says.

Cass says that to some developers, any non-lettable space is viewed as wasted.

Brown, Cass and Lee all agree the reality is that allocating additional space is very expensive. Construction costs will change, which affects the profitability of an entire project. www.pumpindustry.com.au

H VAC “There may be occasions when bigger shafts might be accommodated,” says Veale. “But deeper ceiling spaces? No way.”

So, all agree that there has been no apparent change in spatial allowances for services, and that building floor-tofloor heights have not changed.

“The reality is that, in most cases, larger services are being squeezed into the same or smaller spaces to the point that coordination is almost impossible,” Lee says.

Although new tools such as BIM software and visualisation or clashdetection tools can predict and highlight clashes between services, it is the practicalities around the space needed for installation that is a key pressure point on site.

“The pressures exerted by architects, designers and builders mean that on site, it becomes a race to install your services first so that the other trades have to work around you,” Lee says.

Though 3D building models are useful tools for laying out services, they do not solve all the issues around access for installation.

Old solutions can no longer be applied

Lack of services space has always been a barrier to optimum performance. In the past, when a clash with existing services or immovable structural component was encountered, distribution systems could be made to work, by flattening ductwork or installing aerodynamically restrictive bends.

Some of these transitions are quite extreme, and these types of “solutions” reduce system energy efficiency. In fact, they are exactly the type of thing that the NCC Section J rules are attempting to address.

As Veale says, duct routes are often chosen with little regard to the impact on overall fan energy. Restrictions at the inlet and outlets of fans and airhandling units can significantly degrade the expected system performance. The motor power and energy consumed rises as the resistance along the distribution route goes up. Now these make-it-work options are no longer available due to overall power restrictions, so what is an industry to do?

What are the solutions?

Apart from providing additional space for services accommodation, there are a few alternative options available. www.pumpindustry.com.au

“The market is always keen to respond, and some HVAC solutions have different spatial requirements than others,” Cass says.

Brown notes that chilled beam systems tend to be more space efficient, and can be left exposed if aesthetically desirable.

Cass agrees, and notes that distributed systems – for example, many smaller systems rather that single, large central systems – and underfloor air distribution systems, are also becoming popular, for a variety of reasons, including space considerations.

Cass also says chilled and/or heated structures (floors, walls, ceilings) are

another option that is being adopted to keep ahead of the curve for building design.

However, as Brown points out, these solutions themselves tend to have a significant cost premium over the more standard HVAC methods, and this all needs to be added into the mix. Also, these solutions, if not correctly and appropriately implemented, can lead to issues with indoor air quality, condensation and mould.

All our experts agree that new attitudes regarding energy efficiency must be developed by architects, developers, and by the eventual building owners and tenants.

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H VAC “Building designers and developers are well aware of the benefits of energy-efficient services systems,” Lee says. “Those benefits generally flow to the occupier, who is often not the building owner, nor the entity paying the construction costs”.

So the same old split-incentive barriers apply.

Asks Cass: “Why should a developer or building owner pay additional construction costs to reduce operating costs for future tenants?”

Green leases go some way to addressing this, as do building rating systems that can be used to market a building for sale or lease.

“Engineers need to push harder and sell the merits of increased services space to designers and builders,” Cass says.

“Green Star and NABERS do a great job of recognising buildings designed with improved energy efficiency,” says Cass, adding that this includes HVAC systems that have larger ducts and pipes.

Eventually end users will drive this agenda when they begin to favour (that is to say, pay more for) energy-efficient building spaces.

In addition, as Lee points out, there are many other benefits of increased or reasonable services space, including less wastage and rework on site due to services clashes, faster installation time, reduced installation costs, and better access for maintenance and inspection for the life of a system. These benefits also need to be recognised.

Alternative solutions; life is a trade-off

“It is becoming increasingly common now for designers to use the alternative JV3 modelling approach to reduce insulation requirements for pipes and ducts to avoid increases in ceiling depths,” Veale says.

JV3 modelling allows trade-offs between system components because it is the overall performance of the system that is assessed.

“Over-complying on performance for chillers, pumps, fans and lighting can allow for a relaxation of insulation requirements and still produce an equivalent overall energy result,” Veale says.

A bigger chiller in the plant room might allow a smaller duct on the occupied floors, for instance.

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“If spaces are going to be squeezed to the extent that it affects the profitability of the project then JV3 is used to avoid that situation,” Veale says.

“JV3 modelling almost always improves the situation significantly, and the modelling and design work comes at a fraction of the cost of losing a floor off the top of a building.”

How can the awareness of these issues be raised within the industry?

One suggestion from Lee about how awareness can be raised is the introduction into the NCC of minimum aspect ratios for ducts, or a standard calculator, like that used for glazing. This would help consultants and contractors prove to builders that a system will not comply if it is forced into the restrictive spaces they propose.

Says Brown: “Education and awareness building is the key. The myth that green always means lean for HVAC systems needs to be broken.”

A suggestion from Veale is for engineers to document the final insulated dimensions of the ductwork, and not the sheet metal dimensions. Design drawings often show sheet metal sizes for pricing; construction drawings often show sheet metal sizes for fabrication. Yet these metal sizes are generally not the final spatial size required if the duct is to be externally insulated.

All agree that the design team needs to establish the spatial requirements very early in the process so it can be accommodated, and make sure all stakeholders know why it is occurring.

“A good design team will have a workshop to deal with it,” says Veale.

Communications around spatial requirements need to be ongoing as the project progresses.

Is better integration in the design process the key?

“The balance of benefits and costs does not appear to have been addressed holistically within building regulations,” Brown says. “A lot of attention has been given to the final energy efficiency of HVAC plant, but little given to the additional space, materials and embodied energy required to implement such plant.”

Given the imperative to reduce the energy consumption of buildings, it is surprising that building services – one of the major components of energy usage and cost – are rarely considered in the early stage of a design or as potential driving factors for form and spatial configuration.

It is the building orientation, form and fabric aspects that generally dominate the cooling and heating loads. In order for the form and geometry of buildings to be considered in response to energy efficiency and building services optimisation, multidisciplinary integration is required in the early stages of the design process, when the design proposal is still flexible.

So, to sum up, energy-efficient HVAC tends to be bigger than standard HVAC. Energy-efficient and green buildings tend to provide the same or less space for services than standard buildings.

Something has got to give. Engineers push for more space, and architects and developers push back or resist.

The final answer is somewhere in between, after both engineer and architect have pushed to be as efficient in their spatial requirements as possible.

JV3 energy modelling offers an alternative compliance path for those buildings and systems that encounter significant problems with NCC-driven Deemed-ToSatisfy pipe and duct sizes. ■

AIRAH would like to thank the following individuals for sharing their views in this article with Vince Aherne, M.AIRAH: Scott Brown, M.AIRAH, sustainability director – Waterman Group Peter Cass, M.AIRAH, associate, services cost management – Rider Levett Bucknall Mark Lee, Affil.AIRAH, engineering manager – James L Williams Jason Veale, associate director, building engineering – AECOM.

pump industry | May 2014 | Issue 7

www.pumpindustry.com.au

H VAC

Sydney Town Hall

Pump efficiency vital to Sydney power savings The City of Sydney has substantially reduced electricity use in their buildings, in some cases by up to 50 per cent, via a series of power and water efficiency retrofits. Large savings have been made across 45 buildings, including libraries, recreational centres and a recycling depot, many via upgrading the sites pumping systems to optimise efficiency.

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he retrofit works were completed under a $6.9 million contract with Origin Energy with the aim of cutting electricity use in the City’s buildings by 6.4 million kilowatt hours per year – enough power to supply 870 households for one year. This will save the City an estimated $880,000 in annual power bills and $160,000 in annual water bills, save power and water, and reduce emissions.

These upgrades were undertaken as part of the City of Sydney’s program to cut its own energy and water consumption overall by 20 per cent compared to 2006 levels. The City, which is already Australia’s first officially carbon neutral government, also intends to reduce its carbon emissions by 70 per cent, compared to 2006 levels, by the year 2030 – the most ambitious target set of any Australian government.

“As cities are the greatest emitters of greenhouse gas, we need to make our buildings more energy efficient,” Sydney www.pumpindustry.com.au

Lord Mayor Clover Moore said.

“New buildings are designed with energy efficiency in mind. We need to retrofit older buildings if we are going to make a real difference.”

So far, power reductions at City facilities include: • 68 per cent at the recycling depot • 52 per cent at Alexandria Childcare Centre • 39 per cent at Glebe Library • 32 per cent at Goulburn Street Car Park • 28 per cent at Customs House • 22 per cent at Paddington Town Hall • 21 per cent at Ian Thorpe Aquatic Centre • 17 per cent at King George V Recreation Centre • 5 per cent at Newtown Library

The efficiency measures employed during the retrofits ranged from those as simple as installing movement sensors on vending machines to switch off the lights when they are not in use, to overhauling various aspects of building’s engineering, upgrading whole systems and adjusting the voltage of the entire site.

As one of the primary energy users at many of the retrofitted sites, upgrades to pumping systems played a vital role in the retrofits.

For instance, HVAC systems of the City’s swimming pools and large buildings were improved by installing variable speed drives to pumps and by using refrigerant additives to optimise their efficiency.

Some of the major HVAC upgrades took place at the following sites:

The Ian Thorpe Aquatic Centre

Retrofitting the Ian Thorpe Aquatic Centre involved the installation of eight variable speed drives to reduce the energy consumed by the supply air fan and →

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H VAC return air fan of the air handling unit, the recirculation pumps of the leisure pool and program pool pumps, and the hot water pumps of the boilers.

Frequency converters, such as variable speed drives, are electronic motor controllers that convert the AC mains input into a variable AC waveform output.

The frequency and voltage of the output are regulated to control the motor speed or torque. The VSD can vary the speed of the motor in response to system feedback, such as changing temperature or pressure for controlling fan, compressor, or pump motors. This makes the system much more efficient. The frequency converter can also regulate the motor by responding to remote commands from external controllers.

In addition, the frequency converter monitors the system and motor status, issues warnings or alarms for fault conditions, starts and stops the motor, optimizes energy efficiency, and offers many more control, monitoring, and efficiency functions. Operation and monitoring functions are available as status indications to an outside control system or serial communication network.

The VSD’s used at the aquatic centre were Danfoss and ABB ACH550 models.

Energy consumption at the site has been reduced by 21% since the works were completed.

The Cook and Phillip Aquatic and Fitness Centre

The retrofit undertaken at the Cook and Phillip Aquatic and Fitness Centre involved the installation of three 7.5 kW ABB variable speed drives to reduce the energy consumed by the chilled water pump and river jet pumps. Differential pressure sensors were also installed across the header (supply and return) to control the chilled water pump.

In addition, the VSDs that were already installed on the pool pumps were commissioned and tuned to run based on the flow rate from flow meters.

This involved Innotech MAXIM 1010 controllers being installed with the existing flow meters to control the required flow rate during daytime and night-time. The MAXIM 1010 Controller was installed to operate as a standalone device, using its own universal inputs, and analogue and digital outputs to receive information from the flow meter (4-20mA) and control the existing variable speed drives. The device was installed for a 50 metre pool and tuned to deliver 450m3/hr during day time 26

(above) Town Hall House (right) 343 George Street (5.30 AM to 9.30 PM) and 350 m3/hr during night time (9.30 PM to 5.30 AM).

343 George Street

The retrofit of this government owned building on George Street involved installing variable speed drivers for two primary chilled water pumps, two condenser water pumps, two hot water pumps, two cooling towers, and seven air handling units, all with high level interface control from the building’s monitoring and controlling system. A differential pressure sensor was used to control the chilled water pumps and hot water pumps. The condenser water supply temperature to the chiller controls the cooling tower fan speed. In addition, all the air handling units are controlled by the high select of the temperatures with PID control between 40 to 50 Hz. Physical measurements were conducted to fix the minimum speeds of all the drives for different configuration of the pumps and fan operations to maximise efficiency without sacrificing performance.

Customs House

The variable speed drives in the building were configured to compare the return air temperature reading to its internal set-point in order to determine the speed of the fans. The VSD was set to provide the operating speeds between 40 and 50 Hertz.

The VSD PID (Proportional-IntegralDerivative) Control Logic continuously compares the return air temperature to the Internal Set point (24°C) and speeds up the fan towards 50Hz when the temperature is above the set-point.

The PID then slow the fan towards 40Hz when the temperature is below the set-point. The sensitivity of the speed reaction is set by the PID1 Gain and Integral Parameter setting.

pump industry | May 2014 | Issue 7

Total energy savings on the site since the retrofit have been around 28 per cent.

Victoria Park Pool

VSDs were installed on each of the two primary hot water pumps that serve the boiler and heat pump units at the Victoria Park Pool. The pumps are now controlled by the Carrier BMS system and run on a Duty/Standby basis which is rotated weekly. The operating pump speed is controlled to maintain a constant flow rate through the boiler and heat pump system whenever the pumps are called to run.

The existing VSDs on the three main pool circulation pumps were re-programmed to run at 45Hz. The pool staff have also modified operations to manually shutdown 1 pump each night from 19:45 – 05:45 to allow the filter to re-generate.

The VSDs used were Zener MSC-3 models.

307 Pitt Street

Variable speed drivers were installed for the car park supply air fan and return air fan with a master and slave control arrangement respectively. Two CO2 sensors were directly connected to the VSD of the supply air fan and control the VSD speed from 20 Hz to 50 Hz based on the high select value of the CO2.

Return air fan will be running at same Hz as supply air fan. The set point of the CO2 value is 10 ppm. This means that the fans will be triggered to run at higher speeds and circulate more air when the www.pumpindustry.com.au

H VAC

(above) Customs House (top left) Ian Thorpe Aquatic Centre

(above) Paddington Town Hall (left) 307 Pitt Street CO2 value is higher, while saving energy by running at lower speeds when CO2 is low. Differential pressure sensors were also installed across the supply and return pipe of the secondary chilled water header to control the VSDs of the secondary chilled water pumps.

540 George Street

At this site 7.5kW Vacon variable speed drives were installed on each of the two chilled water pumps of the air conditioning system. The pumps are controlled by the carrier BMS system and each pump serves a dedicated chiller, and is set to run when the chiller is required to provide cooling.

A differential pressure was also installed at the end of the chilled water pipe loop.

This allows the VSDs to control the pump speed to maintain the chilled water system differential pressure set point (90kPa) and the chiller vessel’s design pressure drop set point of 30kPa + 20% (Adjustable).

If both pumps are called to run they will operate at the same speed.

Additional efficiency measures:

A variety of other efficiency measures were employed throughout the retrofits.

This included induction lighting being installed at the City’s recycling depot, to

produce instantaneous and concentrated floodlight that triggers on and off with a movement sensor.

Across the whole portfolio, the City has introduced voltage power optimisation and is upgrading the power management system on personal computers.

Other retrofit changes include efficient lighting retrofits, waterless urinals, water flow controls, and water recycling and recovery systems.

Combined with their HVAC and other pumping efficiency upgrades, these changes have added up to make a big difference. ■

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

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www.pumpindustry.com.au

Fax: 07 3883 3933

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Email: operations@ndhs.com.au •

www.northerndiesel.com.au

pump industry | May 2014 | Issue 7

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RE L IABI L IT Y

Pump system mechanics: on the floor at SA Water In this ongoing series of interviews, we talk in-depth with the end users of pumps across a range of industries and applications. This edition features John Heaven, Mechanical Team Leader at SA Water’s Murray Bridge workshop.

About John Heaven

I started with the South Australian Engineering and Water Supply Department as an apprentice fitter and turner, 30 years ago. After I completed my apprenticeship I was kept on as a maintenance fitter at the Murray Bridge workshop and spent 20 years on the workshop floor. Working in pumps was a natural progression due the nature of the water utilities core function. For the last six years I have been the Mechanical Team Leader, looking after a team of eight tradespeople and two apprentices. Our workshop’s core work is the service, maintenance and repair of three major pipelines and associated equipment.

These pipelines supply water from the

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pump industry | May 2014 | Issue 7

Murray River to reservoirs and tanks supplying the city of Adelaide and the upper south east of South Australia.

Can you let us know about the range and types of pumps you have worked with?

Our work on pumps varies from large 1200mm vertical spindle and 900mm horizontal split case double end suction units, to 25mm centrifugal units. We also have a number of submersible borehole pumps and submersible sewer station units we are responsible for.

Over the years I have seen an improvement in impeller design in most pump types, but the most significant changes

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REL IAB I L IT Y

have been the introduction of vertical spindle multi-stage pumps that have all but replaced the end suction pumps for domestic and boosting options, the usage of variable speed drives and the development of high efficiency electrical motors.

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

The South Australian Water Corporation is a large organisation and incorporates system modelling, engineering and asset teams that are able to provide all the necessary information to determine the requirements for a specific system; from the system curve and duty point,

hydraulics involved (including surge) and a recommended pump type. The level of involvement for all the teams is usually dependent on whether the pump is a new unit or a replacement/upgrade, and its size. A new installation would most definitely be the most involved and would more than likely go to a tender process. A scope would be developed and consultation of the various teams and local operators would go towards the tender write-up. A replacement or upgrade would involve the local operators, assets and system modelling teams to ensure all bases are covered and, in most instances, a local purchase would be organised through the workshop.

What testing do you conduct for pumping equipment?

Testing of new units is an important aspect of the selection process for new pumps, and a supplier needs to prove their equipment is capable of meeting the scope set out by the corporation. → This would not always be via a sited

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works test, however a site performance test would be necessary to ensure the equipment performed to expectations and any deficiencies were eliminated.

This can be done with the supplier present or at a local level with supplier involvement limited to any corrective actions necessary due to problems encountered.

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

Involvement of all the relevant stakeholders from the beginning to the end of the process is the best way to ensure that the equipment purchased and installed will function as desired, be cost effective and will perform well into the future. From a workshop perspective, it is just as important that the unit can be maintained and repaired as quickly and safely as possible, as it is to be able to perform efficiently for its working life. A supplier’s ability to provide service and spare parts for the life of the pump is vital, and it is not cost effective to design an installation were maintenance staff has to work around obstacles to perform routine services or repair work.

What are the most important factors in pump selection?

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pump industry | May 2014 | Issue 7

The most important factors in selecting a pump will differ depending on who you are asking, but life cost and overall efficiency should be on everyone’s mind. The operators and/or maintenance staff will usually first look at the unit’s ability to perform the task. www.pumpindustry.com.au

REL IAB I L IT Y

Therefore the type, the construction type and materials, the ability to effectively maintain the unit into the future and continuation of supply will be important.

Energy efficiency is a very important aspect and the use of high efficiency motors and variable speed drives has allowed a pump that was previously only capable of a specific duty to be able to perform very effectively and efficiently

over a range of duties. Costs can sometimes be minimised by deferring a new installation and utilising a redundant or back-up unit instead.

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

Ongoing service and maintenance is made easier by monitoring pumps and

systems with a SCADA (supervisory control and data acquisition) system. We are able to monitor and alarm pressure, flow, and temperature in most instances and with this data we can determine existing and potential issues. The system also allows effective fault-finding to be conducted in the event of a breakdown and can go a long way in determining → a cause. We are fortunate to also

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RE L IAB I L IT Y

have a performance monitoring team available to test and monitor our larger pumping units. The team are able to detect any drop in performance through performance testing and vibration analysis and make a cost effective determination of any overhaul or repair requirements. For all our assets we have annual preventative maintenance programs, and through the collection of the programs data we are usually able to determine potential issues and therefore minimise breakdowns and downtime, and maintain a continuation of supply.

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

Consultation with suppliers is constant and ongoing, and a competitive market has meant any new technology is quickly disseminated into the relevant industries. We have tended to stick with products with a proven performance history and availability of service and spare parts; if the units are made/ produced in Australia this has tended to be more consistent. These days all reputable pump manufactures are very similar in technology and quality, so it is no longer uncommon to change a manufacturer or supplier when they meet all of our requirements and costs.

32

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

In our industry, where the use of a pump has remained consistent throughout the water and wastewater processes over a large period of time, the improvements in type, impeller design and more efficient electric motors have assisted in minimising overall pumping costs. However, the desire to minimise the infrastructure footprint and overall cost of building a system or process has meant that

pump industry | May 2014 | Issue 7

a pump and control system that is reliable is becoming ever more important. The ability to build a pressurecontrolled system to supply domestic customers is now a reality. A system can be built to compensate for varying demands, reduce the costs lost through leakage and eliminate the need for an elevated storage tank. The pump is fundamental to the process, and as the control demands change the pump will change to suit. â– www.pumpindustry.com.au

Fan resonance and balancing Mechanical components, such as transmission gear and bearings, generate a mechanical loss that reduces the power transferred from the motor shaft to a pump or fan impeller. Industrial or dynamic balancing of these system components can assist with the efficient running of any rotating equipment, and thus improve mechanical efficiency.

In Fan Impeller design consideration needs to be made in relation to the ability of the blade to withstand vibration caused by factors such as machine vibration, turbulence and the like. Here are a couple of examples.

This first impeller shown has unsupported blades and as such a simple “dong test”, a smart tap on the blade, reveals that it is acting like a tuning fork, likely a cause or contributing cause to the blade failure shown.

Analysis of a second impeller revealed a fractured edge highlighting a typical fatigue crack. Torsional vibration is rare

but can also occur. In this case the problem was shown to be the waveform from the Variable Speed Drive (VSD).

It also had a devastating effect on the impeller, as can be seen below. Significant cracking can be seen along the weld of the blade and around the rod (heal ring). This proved to be a particularly difficult case, as the stiffer the impeller the quicker it cracked!

FA N S

T

here is also another issue that can sometimes lead to problems in industrial fan operation, broadly termed “resonance”. Resonance is the tendency of a system to oscillate with greater amplitude at some frequencies than at others.

Blade failure due to resonance.

Fan impeller cracking.

In a practical sense fans can be designed to minimize or eliminate the tuning fork resonance effect, but this torsional vibration example highlights that you can only design for what is known. In this case it took many months, and several broken impellers, to finally track down the source of the problem (the VSD waveform).

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Precision Balancing Pty Ltd often gets requested to conduct industrial investigations of this nature. Precision

For more information on industrial balancing services and standards visit www.precisionbalancing.com.au

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Imbalance is a common source of faults in rotating assemblies, pumps and fans.

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pump industry | May 2014 | Issue 7

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A flood of ideas Adapted from a paper by Heather Peachey, Ben Dyer, Paul Sureda, Jack Smart and Hugh Christie

WATE R

The Murray-Darling Basin Authority has completed an ambitious project to artificially replicate the now scarce natural flooding events on which the Hattah Kulkyne National Park’s ecosystem relies (See ‘Flooding the Forest’, Pump Industry February 2014 edition). In this article we take a more detailed and technical look at the project and the design challenges and opportunities this novel pumping application presented.

About the Hattah Lakes project

Hattah Lakes, located in the Hattah Kulkyne National Park located south of Mildura in Victoria, consists of 20 perennial and intermittent freshwater lakes. These lakes naturally receive inflows from the River Murray through the Chalka Creek system during periods of high flow. Regulation and dry weather conditions substantially reduced the frequency and duration of flows to the Hattah Lakes. However, the disruption of the natural flooding cycle was determined to have a detrimental effect on the Hattah Lakes ecosystem.

To reduce the impact of regulation on flows to Hattah Lakes, a series of works including the construction of a permanent pump station were undertaken to deliver water directly to Chalka Creek.

One of the challenges in designing the works was defining an appropriate pump size that would allow sufficient water to be pumped to the lakes to provide acceptable inundation duration for the various vegetation present at the site. Detailed hydrologic modelling was undertaken to determine the temporal and spatial patterns of lake filling for a range of pump sizes, for comparison with target inundation times. This identified a large range of inundation durations that occurred naturally and showed that the target inundation times originally estimated when the project was conceived were too simplistic.

While the investigation identified the pump capacity required to deliver ideal flows, this needed to be balanced against cost and construction issues through the detailed design phase.

This work allowed the development of a project that was both affordable and ensured that the desired ecological outcomes were achieved.

The Living Murray project

The Living Murray (TLM) Environmental 34

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www.pumpindustry.com.au

WATE R Works and Measures Program is one of the largest ecological restoration programs to be undertaken on an Australian river system. It involves approximately $290 million of expenditure on environmental infrastructure works and measures to allow water to be managed for the benefit of the riverine and floodplain environments within an operationally constrained river.

The Hattah Lakes restoration project was one of six Icon Sites identified under the Murray Darling Basin Ministerial Council’s 'The Living Murray (TLM) Initiative' in 2002. The Icon sites were created in response to widespread concerns about the environmental and economic health of the River Murray system. Nine TLM ecological objectives were created for the Hattah Lakes Icon Site. Two of those objectives are to; restore a mosaic of hydrological regimes, which represent preregulation conditions; and maintain, and where practical, restore, the ecological character of the Ramsar site with respect to the Strategic Management Plan (DSE 2003). The other ecological objectives were dependent upon the hydrology and refer to increases in bird, fish and macrophyte numbers, and providing refuge habitat for local and international birds. These ecological objectives also

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Figure 1. Location map of Hattah Lakes showing the proposed works and the extent of inundation at 43mAHD (small flood) and 45mAHD (large flood). This map excludes the Dry Lakes. (Map provided by the Mallee Catchment Management Authority) provided a mechanism for evaluation and monitoring to help determine the success of the restoration project.

The frequency of flooding in the Hattah Lakes system was reduced over the past decade due to river regulation, with no natural flooding as a result the extended dry climatic conditions experienced over this time period. The aim of the

project was to enhance biodiversity and ecological values of the Hattah Lakes waterway systems through the construction of strategically positioned flow control structures within the National Park. Investigations determined the works as; regulators, blocking banks, sill lowering and a pump station, at an → estimated cost of $29 million.

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WATE R In developing a major works program it was essential the desired ecological outcomes could be achieved in a cost effective manner with minimal negative consequences.

About the ecosystem

The Hattah Kulkyne National Park wetlands are of varying areas and depths and are located at different elevations. This produces a unique mosaic of ecological vegetation classes creating different habitats. Lakes Hattah and Mournpall, which are deepest lakes in the system, are known to hold water for up to 3 and 7 years, respectively.

The site hydrogeology consists of sand and clay sediments which isolate the shallow local groundwater systems from the regional groundwater system in the sands below. Connection exists between these groundwater systems, however the available data suggests that this connection is quite restricted in the region of the Hattah Lakes system.

Under natural flooding conditions a flow of 152,000 ML/day at Euston (Lock 15) is required to water all wetlands (excluding the Dry Lakes and Lake Boolca in the most north western section, which requires a flow of over 300,000 ML/day at Euston. However, under regulated conditions river flows are rarely operated above 20,000 ML/ day at Euston unless the operating rules require additional flows to fill Lake Victoria or if high unregulated flows pass through the river system. In addition to this, the 2030 climate change model predicts flows in the River Murray will be reduced significantly (around 700 GL/ yr on average less at Euston) leading to less probability of flooding into the Hattah Lakes system.

Under natural conditions the Hattah Lakes system would, on average, receive a small flood every two years and a large flood every five years. Prior to the 2010-11 floods many of the further outlying lakes had not received water since 1996, Lake Kramen since 1993 and the Dry Lakes area since 1975.

The lack of connectivity to the river and the complete drying of the system had detrimental effects on the condition of the lakes’ ecosystem and its ability to act as a refuge for flora and fauna during prolonged drought periods. To address this issue, TLM water entitlements were accessed for emergency watering four times between 2005 and 2010 via temporary pumps. This provided water to stressed River Red Gums and understorey and provided 36

drought refuge for fauna.

The watering resulted in an improved condition of River Red Gums, germination and growth of aquatic vegetation in the lakes and promoted waterbird habitat numbers which exceeded 16,000 individuals. Native fish were found in the lakes, all of which entered via the pumps, presumably as eggs or larvae. Species present included Murray Cod, Silver Perch, Golden Perch and Australian Smelt and in low numbers, common Carp.

Although the emergency watering provided a temporary refuge for flora and fauna only vegetation at the lower

One of the challenges in designing the works was defining an appropriate pump size that would allow sufficient water to be pumped to the lakes.. elevations were watered. Water was also retained within the Chalka Creek and the wetlands. Without permanent works in place the vegetation on the higher elevations (Black Box and Lignum communities) was unlikely to receive water unless the River Murray flows reach above the 152,000 ML/day at Euston. The higher elevated watering was also necessary to connect the floodplain with Chalka Creek and the River Murray, providing opportunity for exchanging essential nutrients.

It became clear that unless something was done the Hattah Lakes system would change from a floodplain and wetland system to a dryland arid zone landscape. This would result in the loss of the ecological processes and

pump industry | May 2014 | Issue 7

associated cultural, commercial and environmental values that Hattah Lakes represent, with the site recognised as an internationally important Ramsar site and an Icon Site under The Living Murray.

Determining the right works

The River Murray is a 'working river' with operational constraints so water at Euston could not just be allowed to flow freely to solve the problem.

Therefore, a more innovative solution was required to find the perfect compromise.

Various works as part of large scale restoration project would be required.

Hattah Lakes’ initial investigations proposed approximately 20 small regulators, strategically placed to provide flexibility of water movement within the system, and a pump station. However, budget constraints reduced this to 4 regulators, a pump station, 3 stop banks, and refurbishment of an existing regulator (Figure 1).

The package of works to deliver water to the central lakes region consisted of: • Sill lowering in the southern arm of Chalka Creek (which carries water from the river to the lakes) to increase the frequency of inflows, • Construction of four new regulators and three stop banks and refurbishment of an existing regulator to retain water in the targeted lakes; and • Construction of a pumping station to deliver water to the lakes during extended low‐flow periods and top up small to medium natural floods to water vegetation at higher elevations.

The works aimed to water the central lakes using natural connectivity for small and medium flood events in the River Murray and use the pumps to top up the lakes to the desired level. The desired level for each watering event was determined using the history of watering from previous environmental flows and historical actual and modelled natural events, the ecological objectives at that point in time and the volume of environmental water entitlements available. After watering for the appropriate period water drains back to the River Murray via the natural waterway of the southern and northern Chalka Creek.

The works enabled watering of nearly 6,000 ha of wetlands and floodplain www.pumpindustry.com.au

WATE R communities, including all 12 Ramsar‐ listed wetlands at the site. This provides suitable conditions for large waterbird breeding events at least one year in eight; and most other years will support small breeding events.

Key design criteria

The key design criteria that were considered to be fundamental in determining the type of works required to achieve the TLM ecological objectives were; • the maximum elevation to which the lakes will be filled in a managed watering event, • the maximum rate at which water is to be pumped into the lakes from the River Murray, and • the maximum rate that water is to be released from the lakes back to the Murray via the southern and northern Chalka creek arms.

Maximum elevation

The maximum elevation chosen for the works to achieve was 45mAHD (Australian Height Datum). This was determined by examining a hydraulic model that showed elevations above 45mAHD increased the number of breakout points and that the scale of works required to achieve the ecological objectives above 45mAHD increased

It was essential the desired ecological outcomes could be achieved in a cost effective manner with minimal negative consequences. disproportionally to the environmental benefit.

Pump rate and drainage rate

The rate at which water levels rise and fall depends on the scale of pumps and regulator works. A hydraulic model of the lakes was developed and calibrated and was used to parameterise a detailed hydrologic model of the lakes.

The hydrologic model had the advantage of faster run times and was integrated into the River Murray system model. This hydrologic model could simulate natural conditions or scenarios over a 117 year period at a daily timestep.

The hydrologic model incorporated the proposed structures and a 2030 climate change scenario and was used as a tool to allow comparisons between different scenarios of inflow and outflow rates at three elevation levels (43mAHD, 44mAHD and

45mAHD) and three pump capacities (500ML/day, 750ML/day and 1000ML/ day). This provided critical information on the vegetation tolerances under a natural watering regime. The results showed the drainage rate (outflow capacity) of the regulators was generally not the limiting factor, with the conveyance of the creeks limiting the outflows far more than the outlet structure itself (Figure 2a). As such the study focused on the pump capacity rates.

Pumping rates and duration of inundation

Cooling (2009) reviewed exceedence tolerances of three vegetation types; fringing Red Gum, Red Gum with flood tolerant understorey, and Black Box. It was found that the low threat (75th percentile) duration of floods at different elevation levels for Fringing Red Gum → was 150 days, Red Gum with

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pump industry | May 2014 | Issue 7

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Days of Inundation

Days of Inundation

Days of Inundation

Days of Inundation

WATE R

Figure 2. Hydrologic Model showing (a) Comparison of different outlet capacities on duration of watering at Lake Marramook at 43mAHD and 44mAHD for different pump capacities (b) Inundation comparison at Lake Bitterang at 44mAHD (c) Inundation comparisons at Lake Mournpall at the elevations of 43mAHD, 44mAHD and 45mAHD for natural at 1000ML/day pump capacity (d) Pumping duration at 500ML/day, 750ML/day and 1000ML/day pumping capacity. flood tolerant understorey was 90 days and Black Box was 60 days. However, Cooling (2009) also noted that it would be problematic to assign flood durations at Hattah as there are many local variations in the water regime and vegetation which would undermine any generalisations. Furthermore, there was no local data on flood tolerances to draw upon.

The simplicity of these numbers and the uncertainty regarding how sensitive the vegetation was to exceeding these durations raised questions. For example 'did watering for a shorter period fail to meet the ecological requirement of the vegetation'? Further issues of pump cost were raised as it was essential the pump size was justified by ecological needs as operations looked to enhance 'natural events'. This meant the whole situation was subject to a further layer of complexity. To address these concerns the hydrologic model was used to assess the durations and frequency of inundation for a range of pumping scenarios. The analysis presented in Figure 2b and 2c determined the following findings; 38

•

Although the larger pumping capacity did not meet the frequency of inundation at higher elevations.

The operations would be flexible and pumping could be used to 'top up' natural floods to increase the extent of inundation and hence reach the higher elevations. Therefore the larger the pump the greater the flexibility to operate and match the natural water level.

• The smaller pump capacity resulted in the duration of inundation at lower elevations exceeding natural duration, which may lead to either killing the vegetation or stressing it excessively.

• The duration of pumping was bimodal with a small number of events requiring long durations of pumping and a large number of events requiring substantially shorter durations of pumping (Figure 2d). The long pumping duration relates to forced watering of the lakes from a low level, only by using the pumps. The shorter duration of pumping relates to

pump industry | May 2014 | Issue 7

topping up natural events – or only filling the lakes to the lower level.

This means that the chosen pumping capacity would incur a small environmental cost (ie. not match the natural hydrological regime at every wetland at each elevation).

Social and economic implications of pumping duration

The difference in pumping duration ranges from about 3 months (1000ML/day) to 8 months (500ML/ day) (Figure 2d). There are a number of issues associated with the duration and timing of pumping.

• Under natural conditions Hattah Lakes would have received high flows during the Winter/Spring period, with a small number of high flows during Summer.

• Winter/Spring watering at a longer duration (ie leading into Summer) may be deemed unacceptable because pumping during the summer periods may not follow the natural pattern, compete with irrigator demands and may be an inefficient use of environmental water. www.pumpindustry.com.au

WATE R • Low pumping rates will require less expensive works but would increase the time required to reach target water levels in any given event.

References

To address these issues it was decided that water would be delivered between August to November to minimise conflicts with irrigation supply, maximise environmental benefits (ensuring natural cues for local flora and fauna as well as international migrating birds are met) and avoid pumping during the hottest period of the year. The pumps would allow water managers and irrigators to take advantage of high passing flows, maximising efficiency and reducing pumping costs due to reduced lift.

Conversely, during periods of extreme low flow the delivery rate of water will be restricted.

Project AL033. Ecological Associates Pty Ltd. June 2009 (not published).

After much consideration it was concluded that the largest possible pumping capacity (1,000 ML/day) would best meet the ecological objectives while avoiding pumping during the hottest period of the year, thus reducing impacts on irrigation demands. The works therefore allow the manager of the site to provide a watering regime at the appropriate seasonality, duration and frequency at the various elevations to meet requirements of the associated ecological communities. ■ For more information on the works themselves and the contractors involved in the project, see Flooding the forest, in the February 2014 issues of Pump Industry (http://www.pumpindustry.com. au/flooding-the-forest/3864/).

Cooling, M. (2009). Hattah Lakes Flooding Enhancement Risks Associated with Filling and Draining Rates.

[DSE] Department of Sustainability and Environment (2010). Hattah Lakes Environmental Flows Project -­- Investment Proposal. Report by the Mallee Catchment Management Authority, for the Murray Darling Basin Authority.

Dyer. B and Lee, J. (2009). Hattah Lakes Icon Site – Pump and Outlet Capacity Investigation. MDBA Technical Report 2009/21. November 2009 (not published).

Ecological Associates (2007). Feasibility Investigation of Options for the Hattah Lakes. Final Report for Mallee Catchment Management Authority. Project AL006-­-3-­-A. GHD (2009). Hattah Lakes flood Management Project -­- Geotechnical Investigation Report. Report to Goulburn--Murray Water, Tatura.

GHD (2009). Concept Design of Water Management Works Report. Report to --Murray Water, Tatura.

GHD (2011). Hattah Lakes Pump Station Detailed Design Report. Report to Goulburn--Murray Water, Tatura.

[G-­-MW] Goulburn Murray Water.

(2009). Report for Hattah Lakes Living Murray Floodplain Management Project Ecological Assessment. Published by GHD. May 2009

Kingsford, R.T. and Porter, J.L. (2008).

Survey of Waterbird Communities of The Living Murray Icon Sites -­- November 2007, Report to the Murray-­-Darling Basin Commission, Canberra.

Lee, J. (2009) Results of different pumping and drainage rates for the Hattah Lakes system. MDBA (not published).

Lee, J. Sharma, P., and Close, A (2009).

Hydrological Modelling of the Hattah Lakes System -- Extension of the Commission’s water resources models and assessment of TLM structural options. Technical Report No. 2008--6.

Murray--Darling Basin Commission Lake, P.S., Bond, N., and Reich, P. (2007). Linking ecological theory with stream restoration. Freshwater Biology.

52, 597--615 [MDBC] Murray Darling Basin Commission (2008). The Living Murray Outcomes Evaluation Framework -­- The living Murray Icon Site Condition Report October (2007a).

[SKM] Sinclair Knight Mertz (2004).

Hattah Lakes Water Management Plan -­- Background Report. Report to the Mallee Catchment Management Authority, Mildura.

[SKM] Sinclair Knight Mertz (2006a).

Hydraulic Modelling of the Hattah Lakes -­- Final Report -- 15 May 2006. Report prepared for Mallee Catchment Management Authority, Mildura.

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pump industry | May 2014 | Issue 7

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WATE R

Centrifugal pump protection using flow controllers Last issue we looked at the benefits of flow controllers as a tamper-resistant method of protecting centrifugal pumps from possible damage and/or failure caused by running them off their curve. This case study, using a Maric flow controller, demonstrates this in practice.

Metres

Case study: Franklin FPS1A-13TS pump

Franklin FPS1A-13TS Performance

175

Head

150

Using a Maric flow control valve for pump protection in a high standing (high draw-down) water table condition.

FPS1A-13TS Pumped liquid = Water Liquid temperature = 20oC Density= 998.2kg/m3

125

The Franklin FPS1A-13TS pump suits the application at the 85m draw down level, however, it will run off the right hand side of curve with only 20m head against pump at start up resulting in pump and motor damage.

100 75

Installation details: Franklin FPS1A-13TS

50

Manufacturers performance curve below indicates flow should not exceed 1.4m3/hr (23L/min).

25 0 0 40

5

10

15

20

pump industry | May 2014 | Issue 7

25

30 LPM

Pump protection requirement

To prevent pump and motor damage www.pumpindustry.com.au

WATE R due to upthrust condition we must limit flow, or add sufficient head, during start-up.

1. Gate valve: They are cheap but can be noisy and can also result in a high headloss at the duty point, reducing pump output. As these valves can be adjusted by anyone, they are not tamperproof, and are often opened all the way in the endeavour to get maximum flow and can fail due to the gate vibrating loose.

2. Pressure sustaining valve: These are expensive, adjustable and can result in a potentially high headloss at duty point, reducing pump output. Again, as they are adjustable, they are not tamperproof, and are often opened all the way in the endeavour to get maximum flow.

3. Flow controller: These are the best solution for a high standing water table condition, with lower duty point conditions.

They are tamperproof, inexpensive and result in a low headloss at the duty point as can be seen in the graph above.

Rated flow (%)

Three options are available:

Flow Control Valve Performance

X

Pressure differential across valve Question:

Flow control valve performance:

What will the headloss be across the Maric valve and its effect on pump performance at the 85m duty point?

Flow control valve performance curve above indicated 60% of rated flow = 4 metres headloss only (see x).

Answer:

Conclusion:

Very little. Around 4 metres.

As in the above application, and many similar cases, the Maric flow control valve is an excellent choice for pump protection, due to its lower headloss, cost effectiveness, long maintenance free life and being virtually tamperproof. ■

Why?

At 85 metres drawdown (and resulting head against pump), flow rate will be 0.85m3/hr (14 lpm) only. This is 60% of the rated (23 lpm) flow of the flow controller, and at 60% of flow through the Maric valve, the pressure differential (or headloss) is around 4 metres only, having little impact on pump output.

Centrifugal Pump Protection Maric valves control flow to a constant pre-set rate regardless of pressure Ideal for:

• Preventing • Preventing • Preventing

Over-Pumping, Up-Thrust Damage & Cavitation Damage

Ph: 08 8431 2281 www.maric.com.au

f: 08 8431 2025 e:sales@maric.com.au

AUSTRALIA

www.pumpindustry.com.au

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S E AL S

API 682 dual seal design configurations Part 1 of 2: Comparing arrangements and reconciling requirements

By Richard Smith, Director, AESSEAL plc, Rotherham, England, and Heinz P. Bloch, Consulting Engineer, Westminster, Colorado heinzpbloch@gmail.com

Mechanical seal designers face challenges when developing dual seals for a multitude of users and industries. Although originally aimed at the Hydrocarbon Processing Industry, the American Petroleum Institute’s Seal Standard (API-682 / ISO 21049) is very widely used because it lists and explains many universally applicable requirements.

Dual seal arrangements

Dual seals are increasingly important in many industries, including hydrocarbon processing. Driving this are plant hazard safety requirements, reductions in allowable fugitive emissions and the quest for increased equipment uptime.

API- 682 / 3rd Edition (Ref. 1) and its appendix material collectively describe pressurized seal geometries as Arrangement 3. This arrangement comprises two seals per cartridge assembly and an externally supplied pressurized barrier fluid. Taken together, the seal layout and flush arrangement create a beneficial and life-extending seal environment.

The different configurations for Arrangement 3 are described by API-682 as: • Face-to-back dual seal in which one mating ring is mounted between the two flexible elements and one flexible element is mounted between the two mating rings or seats (Figure 1a).

• Back-to-back dual seal in which both of the flexible elements are mounted between the mating rings (Figure 1b).

• Face-to-face dual seal in which both of the mating seal rings are mounted between the flexible elements (Figure 1c).

However, the description “dual seal” is inadequate. It should be pointed out that the principal attribute of the faceto-back (“FB”, Figure 1a) configuration is locating the process fluid (pumpage) on the outer diameter of the inside set of seal faces. In the other two configurations the process liquid is on the inside diameter of the inside set of seal faces.

Note that in this context an outsidefacing set of faces would come into contact with the atmosphere.

Face-to-back arrangements are preferred, although back-to-back and face-to-face orientations are offered as purchaser’s options. In API-682, non-pressurized dual seals are called

Arrangement 2 and face-to-back is the only arrangement option available in the API 682 standard.

Advantages and disadvantages of back-to-back and face-to-face seal configurations

In the hydrocarbon processing industries, back-to-back and face-to-face configurations are widely represented.

They can potentially offer higher levels of performance-in large measure attributable to the cooling effect of barrier fluid flowing over both inner and outer seals. However, there also are disadvantages.

The main shortcoming of back-toback and face-to-face configurations is that the process fluid is on the inside diameter of the seal faces.

Centrifugal force action tends to throw any entrained abrasive solids towards the seal faces, which increases the potential for damage. The “dead zone” formed by a small volume of process fluid underneath the inner seal

Derived, by permission, from a segment in Bloch/Budris “Pump Users Handbook” 4th Edition, 2013, Fairmont Press, Lilburn, GA. The segment was compiled and contributed by Richard Smith, AESSEAL plc, Rotherham, Yorkshire, UK. Mr. Smith obtained valuable input from The American Petroleum Institute (which granted permission to use illustrations from API-682); Michael Munro, EEMUA Machinery Committee; Albany Pumps, Gloucestershire, UK; Jaguar Automobile Manufacturing Company, Halewood, UK; Chris Leeper, Thomas Broadbent & Sons, Ltd., Huddersfield, UK; also Dr. Chris Carmody and Chris Booth BA, MBA, AESSEAL plc, Rotherham, Yorkshire, UK

1

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pump industry | May 2014 | Issue 7

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SE A L S Flexible element

increases the probability of trapping fluid. Trapped fluids tend to congeal and solids are likely to accumulate in dead zone spaces. As the secondary O-ring will then move over a deposit-affected region of the sleeves (Figure 2), “hang up” is more likely to occur.

The application of reverse balance (which will be explained below) can be more difficult with back-to-back designs.

Upset conditions such as loss of barrier fluid pressure or increases in process pressure can adversely affect back-toback configurations. Positive retention of the inner-seal mating ring can be difficult to accomplish since there will always be unavoidable dimensional constraints of associated hardware and seal chambers.

So, unless properly retained, thrust forces acting during pressure reversal may cause a ring to become →

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Seal

Mating Ring Process Fluid

Process Fluid

Process Fluid Figure 1: Three styles of dual face mechanical seals for pumps

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SE A L S

Bac k To Back Proces s fluid on ID of Fa ce with Pote ntial for Hang up Inner Mating Ring un-re taine d

dislodged. Also, with some designs, reverse pressure loading will apply a hydraulic force to the inner seal spring plate. This reverse pressure then tends to open the seal faces.

These concerns have, over the past two decades, prompted chemical process industries to move toward face-to-back designs. Overall seal reliability has improved with face-to-back configurations.

Advantages of face-to-back seal configurations Figure 2: Explaining the potential for “hang-up”

L-type mating ring

Hydraulic retention Process fluid

Process fluid

Face-to-back configurations overcome virtually all the weaknesses of other designs with pumpage on the outside diameter of the seal faces. The preference for this configuration is noted by API-682 and is summarized below: ‘The advantages of the series configuration are that abrasive contamination is centrifuged and has less effect on the inner seal.’

A further note supports the case: ‘Liquid barrier seal designs arranged such that the process fluid is on the OD of the seal faces will help to minimize solids accumulation on the faces and minimize hang-up.’

Dual balance is easier to incorporate in

Process at higher pressure than barrier fluid

Process at lower pressure than barrier fluid

Figure 3 (Left): O-ring movement with pressure reversals

Fig. 4: Barrier fluid cooling compari-son face-to-back (right) versus back-to-back (below)

Little or no cooling to inner seal here

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SE A L S

Flow deflector baffle Figure 5: Face-to-back bellows seal with deflector baffle. This baffle guides the barrier fluid towards the seal faces (Source: AESSEAL plc., Rotherham, UK, and Rockford, TN) this configuration and the seal O-ring can be located so as to permit it to move to either side of the groove. This then supports a closing force regardless of the direction of pressure. Mating rings can be simply retained either positively or, with more modern designs, hydraulically (Figure 1b). Pressure reversal capability provides for greater safety; it increases the degree of tolerance for many process upset or loss of barrier fluid conditions. Again, API-682 reinforces this point in a note: ‘In the event of a loss of barrier fluid pressure, the seal will behave like an Arrangement 2’ Figure 2 illustrates O-ring retention and movement with pressure reversals.

Disadvantages of conventional face-to-back configurations

Of major concern in face-to-back designs is cooling of the inner seal. Seal designers have typically approached the issue by mounting component seals with adaptive hardware (sleeve and gland) to form a cartridge. However, the barrier fluid flow path to the inner seal is compromised by a region of low or zero flow.

The temperature in these stagnant areas will be elevated by heat soak and face-generated heat. The 2nd Edition of API-682 very eloquently provides a warning (Ref. 2): ‘Restricted seal chamber dimensions and the resulting cartridge hardware www.pumpindustry.com.au

construction can affect the ability of the barrier fluid flush to adequately cool the inner seal. Inadequate cooling of the inner seal can result in reduced seal reliability. Selection of a back-toback or face-to-face configuration may resolve an inner seal cooling problem.’

Accordingly, the challenge for seal designers is to provide both a seal with optimized cooling and to simultaneously provide resistance to “hang up” and pressure reversal.

Deflector baffle developments

An ordinary face-to-back (“FB”, upper right) seal would receive little or no cooling at the inner seal faces. That fact drove technology innovation to improve inner seal cooling. Superior cooling can now be achieved by incorporating a high performance circulating device and flow deflector baffle in dual seals. The deflector baffle in Fig. 5 diverts the barrier fluid flow to the inner seal; this provides cooling to the inner seal faces and represents an elegant solution to the dual seal challenge: good cooling and superior containment in a small dimensional envelope.

Deflector baffles have long been employed on single high-temperature seals connected to quench stream.

However, restrictions in seal chamber dimensions and somewhat large crosssection of conventional dual balanced pusher seals have generally inhibited the more widespread use of deflector

baffles. Except for bellows seals with their traditionally smaller cross-sections (Figure 5), incorporating deflectors has generally been limited to “engineered specials” rather than off-the shelf designs. Still, in applications where more space is available the deflector baffles can be optimally shaped and contoured. This contouring is now much more widely available from the true innovators. Proper contouring now guides the maximum amount of barrier fluid to the regions from which heat must be removed or where cooling is of greatest benefit.

In other words, well-engineered deflector baffles are now part of superior dual mechanical seal designs where they determine flow direction. Also, there needs to be flow-rate optimization for barrier fluids. Part 2 will elaborate on modern deflector baffles and pumping devices. ■ References 1. API Standard 682/3rd Edition; also ISO 21049, (2004): “Shaft Sealing Systems for Centrifugal and Rotary Pumps,” API (American Petroleum Institute), Alexandria, VA 2. API Standard 682/2nd Edition, (2002): “Shaft Sealing Systems for Centrifugal and Rotary Pumps,” API (American Petroleum Institute), Alexandria, VA

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S E AL S

Restaging a multistage offshore oil pump

by Arun Karuppasamy

In this paper we discuss a case study where a multistage barrel type centrifugal pump was re-staged several times to accommodate changing flow and pressure conditions. The restagings were carried out with the prime objective of accommodating decrease in flow and head requirements and were accompanied by frequent mechanical seal failures. We discuss the probable causes in detail and the short/long term solution options to address the issue of changing operating conditions and improving uptime.

C

entrifugal pumps are volume flow dependent machines designed for a rated point and optimised for good performance over a range of operating conditions (flow and head requirements). There is however a limit to the range where the pumps perform optimally. Operation beyond this range not only results in sub-optimal performance, but also results in mechanical issues such as vibration, temperature rise, high wear and tear, etc. In extreme scenarios it may even lead to trips and failure of the mechanical parts.

The operating conditions of flow and head are not constant for a declining field where the rate of production is declining. The rate of decline may differ depending on the field type, characteristics and operating philosophy.

Taking into account the need to design the centrifugal pumps to cater for the changing operating conditions, pumps are designed such that they can be re-staged to maintain optimum performance. Re-staging of pumps can be achieved either by changing the diameter of the impellers or, depending on the requirements, by addition or removal of impeller stages.

In the case of mature oil fields the current production rates may be just a fraction of the original design. The change in operating conditions for a pump may be sufficiently different from the original design conditions such that even re-staging of pumps does not alleviate the operating issues of high recycle flows and throttle operations.

This can lead to energy wastage and high operational expenditure cost due

Recycle Valve

to mechanical failures and frequent trips leading to loss of production.

Re-staging to some extent can address the issue of declining production however there are limitations.

Re-staging is similar to a new design selection, and therefore requires due diligence and consideration. If standard design procedures and validations are not carried out during re-staging, then this may become the potential source for serious operating issues.

Case study

The pump under consideration is a multistage barrel type Main Oil Line (MOL) condensate pump on an offshore platform. The MOL pump is backed by a Booster pump to provide a safe NPSH margin. Each pump has its own recycle line to ensure that the pumps always

Recycle Valve LCV Oil Meter

Cooler

MOL Pump

Booster Pump LP Separator

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Figure 1. Booster and MOL Pump System Schematic

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SE A L S

Figure 2.

Figure 3.

MOL pump design and re-staging summary

The MOL pump is a heavy duty, barrel type, multistage fixed speed design with a maximum impeller capacity of six impellers of maximum diameter of 460 mm. The pumps were initially installed with five impeller stages of 430 mm diameter. Later in time, due to changing operating conditions with new tie-backs the pumps were uprated to six stages (4x 430 mm and 2 x 400 mm).

Recently due to field depletion, both flow and pressures have reduced. The pumps were largely oversized for its matching duty hence it was de-staged to four impeller stages of diameter 430 mm. The schematic of the pump internals for the initial design and the re-staging summary is shown in the Figures 2 – 4.

Source of instability

Figure 4.

operate at a safe minimum flow. The recycle flow from the Booster is routed to the LP separator while the MOL recycle feeds back, via the cooler, to the MOL pump suction. A schematic of the flow diagram is shown in Figure 1.

Problem definition

The MOL pump systems were greatly oversized for its current operating duty and experienced frequent mechanical seal failures and trips due to a high level of vibration. Frequent shutdowns due to seal failures and trips were consequently affecting the production.

A study was initiated to review the pump and seal design to find the root cause of the problem and recommend modifications. The key objectives of the study were to provide a short term solution to improve uptime and availability and long term recommendations for possible future tie-back requiring increased head capacity. www.pumpindustry.com.au

Review of the operating data and maintenance history showed that the seal failures and trips due to vibration started sometime after the first re-staging, however the frequency of seal failure and trips were significantly higher after the second re-staging. The marked difference between the operating conditions and pump configuration from the first and second re-staging was that the flows were significantly lower after the second re-staging, and the number of impeller stages were two less compared to design capacity.

A detailed pump design and seal failure report review was carried out as a part of the root cause analysis to find the source of instability which resulted in the mechanical seal failures and frequent trips.

Pump design review

High recycle rates – shift in minimum continuous stable flow

During the operations review it was observed that the MOL pump recycle rates were circa 80% of the net flow, which was 30% more than the original design Mean Continuous Stable Flow (MCSF). MCSF is a minimum flow limit; operations at flows lower than this limit would result in high vibration. The design MCSF, which is a function of many parameters initially based on the original design, had changed considerably after the two re-staging activities.

Any attempts to operate at flows close to original design MCSF resulted in high vibrations. Hence historically the pumps operated with high recycle rates to keep the vibration to a minimum.

High recirculation flows either at the suction end or the discharge end of the impellers were the cause for the vibration at reduced flows. Depending on the ratio of inlet to outlet diameter, either suction or discharge recirculation is predominant. It is important to note that for multistage pumps, discharge recirculation occurs at a higher flow rates compared to the suction recirculation. A typical pump characteristic with flow instabilities is shown in Figure 5.

During the second re-staging the five impeller wheel configuration was de-staged to four wheels and the impeller diameters were increased by circa 7% (for the impellers stages 1, 3 & 6). The increase in diameter sometimes affects the discharge recirculation limit. Through theoretical calculations it was established that the second re-staging has resulted in a shift in the MCSF flow towards the high flow discharge recirculation flow rates.

This shift in the minimum flow limit is illustrated in Figure 6. From the design review it was found that the cause for high vibrations at flows closer to the original design MCSF was due to the shift in the minimum flow limit.

Effect of high recycle rates

The pumps have recycle lines to ensure that they always operate at a safe minimum flow. It is normal design practise to route the recycle flow back to the suction separator, which itself acts as buffer that eliminates the pulsation of the recycle flow which can affect the pump suction flow. In the case of the MOL pump, the recycle flow from this pump is fed back via the cooler to the MOL pump suction as shown in the pump system schematic in Figure 1.

In the absence of any mechanism to buffer the pulsation, this resulted in a cascading effect amplifying the disturbance introduced in the pump suction end in a cyclical manner. This introduction of highly unstable pulsating recycle flow at the suction of a high energy, heavy duty pump was the major source of destabilising excitation to the pump.

In addition to this, the de-staging from six to four stages also resulted in some residual axial thrust imbalance, as confirmed by the rotor-dynamics study report by the Vendor. The pulsating flow introduced by the high recycle rates coupled with the axial thrust imbalance → resulted in axial movements

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SE A L S affecting the mechanical and labyrinth seals.

Seal design review

The seal system consists of a double mechanical seal cartridge supplied with barrier fluid type ISO VG 10 at the drive and non-drive end. The seal faces are of tungsten carbide (rotating part) and carbon (static part) material. The seal oil pressure is maintained within the normal operational limits.

The seal vendor carried out detailed seal failure analysis after each failure.

The failure analysis reports showed clear evidence of axial movement and pitting on the rotating seal face, as well as chipping on the carbon stationary seal faces which is common when seal barrier fluid becomes contaminated with process fluid.

Figure 5 Centrifugal Pump General Characteristics.

In the design review it had been established that the high rate of pulsating recycle flow coupled with the axial thrust imbalance could have resulted in axial movement. This was confirmed by seal failure analysis. Further to this, continuous fluctuation of the inlet oil pressure at the suction could have set the rotor in a shuttling mode. Fluctuations (peakto-peak) of similar magnitude to the inlet pressure mean value were also expected. If the pressure peaks were higher than the barrier fluid pressure, contamination would occur, which would also result in the loss of dynamic sealing leading to leakage and failure.

Summary of pump design and seal failure review

The MOL pumps were forced to operate at high rates of recycle due to the shift in the MCSF as a result of re-staging.

The high rates of pulsating recycle flows coupled with the axial thrust imbalance introduced due the de-staging resulted in axial movements. These axial movements and the inlet pressure pulsations resulted in the contamination of the barrier fluid resulting in the frequent mechanical seal failures.

Short term solution

There were two sources for the possible cause of excitation of the destabilising forces; firstly the high rates of pulsating recycle flow, and secondly the axial thrust imbalance. The simple cost effective solution involved re-routing the MOL recycle flows to the booster pump separator, however this was not viable due to the location of the inter-stage oil meter; moving this meter to the MOL pump discharge would have been both complex and costly.

48

Figure Effect of Recirculation on Minimum Continuous Stable Flow.

The practical solution was to reduce the recycle flow rates, this could be achieved by re-staging with the most appropriate impeller selection such that the MCSF could be reduced and at the same time re-introduce positive axial thrust balance.

The recommendation was to re-stage the original hydraulic design impellers to six impeller stages of reduced diameter.

The Vendor carried out a design review and high level rotordynamics study to validate the proposed design and confirmed that the new re-staging would in fact reduce the recycle rates significantly and also introduce positive thrust balance.

Long term solution

The key requirement of the long term solution was a recommendation for

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a possible future tie-back that would require increased head capacity. With the existing pump design, it was not possible to achieve the required head by re-staging, and further, the expected flows were just a fraction of the current flows. The best solution identified was to install new pumps with an option to initially operate in 2x50 % mode, switching to 1x100 % at reduced flow later in life. â– Arun Karuppasamy is a Rotating Machinery Consultant at g3baxi partnership, UK. He has experience in the design and development of turbomachinery specialising in compressors, pumps and gas turbines for upstream oil and gas business. He holds a Masters Degree in Aeronautical Engineering from Indian Institute of Technology, Kanpur. www.pumpindustry.com.au

Custom engineering seals the deal W

hen Bill Kuczynski from Casey Industrial noticed a large amount of oil leaking from a gearbox on a SAG mill at a client’s copper milling facility in Arizona, he knew it was time to recommend a permanent sealing solution.

Bill, an Outside Services Manager for Casey Industrial, regularly visits the mill to monitor equipment and advise the client when to perform maintenance.

Bill recalled ongoing leaks and related maintenance issues with this gearbox

throughout the 10 years he had been visiting the mill. The gearbox used contact lip seals, which tend to have a short and unreliable service life because they use contact with the shaft to retain lubrication. Lip seals wear at the point of contact or groove of the shaft. As they lose contact, lubricant leaks at the point where the shaft enters the gearbox.

At the mill, the rising long-term costs associated with using low cost lip seals were becoming apparent. The lip seals

A custom engineered Inpro/Seal Bearing Isolator and external drain ensure proper lubrication levels to eliminate leakage.

S E AL S

Stevco Victoria were recently called on to repair a leaking SEW gearbox at the Norske Skog paper mill in Albury. Such problems are relatively common and this was reminiscent of a similar issue that Inpro/Seal recently faced in the US. needed to be replaced every three to six weeks. This was an expensive and time consuming repair because it: • could take place only during scheduled downtime • required three personnel • took three to four hours to complete Furthermore, the gearbox was in a confined location that limited access to the shaft, which complicated the already expensive repair. Between scheduled maintenance, the leaking gearbox caused a costly, messy and hazardous problem that was also an environmental concern. Large amounts of oil were being wasted as it leaked directly to the deck below the gearbox, causing a slip hazard personnel had to navigate. In addition, during each shift workers had to add oil to replace what was being lost because of the leak.

George Gillespie, General Sales Manager for Inpro/Seal said that, for many years, a leaking gearbox was considered an accepted cost of doing business. “I once asked a customer if he had any gearboxes that didn’t leak. He replied,’ I have one; it’s on a pallet on a shelf in the warehouse, and it doesn’t have any oil in it.’” George explained that leaking gearboxes are so commonplace that his clients often do not recognize them as a problem that needs to be corrected. “The problem is often reclassified as a preventive maintenance task. However, it’s not preventive maintenance if you fix the same problem every two or three weeks.”

Stricter environmental laws, an → www.pumpindustry.com.au

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SE A L S increased emphasis on safety and efforts to control costs are changing the way customers view a leaking gearbox. Permanent bearing protection products such as Inpro/Seal’s Bearing Isolator provide an opportunity for a permanent fix.

Bill was familiar with similar applications that used Inpro/Seal’s Bearing Isolator. He turned to George, who had designed seals for many gearboxes, including a similar application at another local mill, to investigate the leaking gearbox. Bill was confident an Inpro/Seal design would solve the problem. “Inpro/Seal provides full support during and after installation to help with any issues the installer or end customer might encounter.

They backup the products with an unconditional warranty. If they design a seal for you, and it does not perform as intended, they will re-engineer it on their own dime.”

Engineering a solution

George explained that high oil levels and oil splash make gearboxes notoriously difficult to seal, especially in industrial rotating applications. Lip seals are common on gearboxes, but because of their high failure rate they are ill-suited for industrial rotating applications such as SAG mills.

The sealing solution for the gearbox was based on Inpro/Seal’s patented VBXX-D Bearing Isolator. This is a noncontacting, complex labyrinth seal that consists of a stationary component, the stator, and a rotating component, the rotor. The stator has a large D Groove that captures the oil attempting to flow down the shaft, and through a drain port, channels it back to the gearbox oil sump. The rotor prevents outside contaminates from entering the gearbox by collecting them in the labyrinth design. Centrifugal force then expels the captured contaminants to the outside environment. The result is a permanent, non-contact sealing device that efficiently keeps the lubricant in the gearbox, where it belongs, and also prevents outside contaminants, such as water or dirt, out of the gearbox bearing housing.

An operational flood in the bearing housing compounded the challenge to a permanent seal for the SAG mill gearbox. Unlike most gearboxes that splash oil into the bearings, the gearbox on the SAG mill pumped oil into the center of the double row 50

spherical roller bearings. This ensured continuous lubrication to the bearings, but also tended to push the oil toward the lip seal. Oil that was attempting to flow back through the bearings to return to the sump was impeded, creating an operational flood. The operation flood placed additional pressure on the lip seal and increased the failure rate. A permanent solution needed to be able to perform in an operational flood and be installed onsite without decoupling equipment.

George and the Inpro/Seal team customised the VBXX-D bearing isolator to fit the gearbox application. Customisations included: • A split design allowed the seal to be installed at the mill without decoupling equipment • A larger D Groove sized to capture the volume of oil flowing through the system • An external drain and revamped system to return oil to the sump On many gearboxes, like the one at the mill, the drain back system to scavenge the oil from the area between the bearings and the seal is not very efficient. “Back in the day, many companies didn’t care so much if the gearbox leaked.” However, today the Environmental Protection Agency (EPA) and Mine Safety and Health Administration (MSHA) place strict limits on the acceptable levels of materials, such as leaked oil, which can create environmental and safety hazards.

George modified the seal to incorporate an external drain. The drain was plumbed back into the gearbox above sump’s static oil level but below the bearings. This isolated the returning oil so that on its return to the sump it was not impeded by the oil sitting between the bearings and the seal.

The returning oil had free flow back to the sump, and more importantly, was no longer leaking out of the gearbox through the seal.

According to George, Inpro/Seal’s custom-engineering expertise was the key to designing the permanent sealing solution. The Inpro/Seal team had experience with all the factors, including size restrictions, lubrication type, bearing type, and flooded applications.

The time and costs associated with maintaining this gearbox were greatly

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The Inpro/Seal Bearing Isolator provides permanent bearing protection by protecting against contamination ingress and lubrication loss. reduced because the customised seal and drain back system provided a permanent sealing solution. Less scheduled maintenance results in more production time for the SAG mill.

Personnel have a safer work environment because the environmental and safety hazards are eliminated. Also, while it was not the reason for the installation, the gearbox now includes permanent bearing protection.

The two Inrpo/Seal Bearing Isolators installed on this gearbox have now been in operation for two years.

According to Bill, “Everything continues to perform as expected, without any signs of a leak.” He added that George continues to check-in to monitor the performance of the bearing isolator.

“That’s the thing about Inpro/Seal – they don’t walk away after the install.”

About Inpro/Seal

The inventor of the original Bearing Isolator, Inpro/Seal, has been delivering innovative sealing solutions and outstanding customer service for more than 30 years. Their unique technologies increase the reliability of rotating equipment and provide real cost savings by improving the mean time between repairs (MTBR). Inpro/Seal’s superior customer service and streamlined production processes allow for same or next-day shipments on most products, even new designs. Headquartered in Rock Island, Ill., USA, Inpro/ Seal maintains a global sales and distribution network to provide responsive, localized support to customers worldwide. Inpro/Seal manufactures in the North America, South America and Europe. ■ www.pumpindustry.com.au

Tasmanian copper mine saves on maintenance with pump upgrades PROJ ECT S

A copper mine in Tasmania was looking to reduce pump failures, which were occurring frequently and at a high cost.

The pumps on this site are located 2.4 kilometres underground which means pump maintenance can be both difficult and expensive. The pumps operate at a high speed to develop the high pressures levels required to dewater the mine.

T

his site was experiencing regular pump failures with legacy 4/3DD-AH pumps. Bearing assemblies were running at extremely hot temperatures at an average of 105°C and had a short life of only 2 to 3 months. Excessive greasing was used in an effort to reduce the temperature, which was potentially compounding the problem. These pumps were also consuming excessive quantities of fresh water to lubricate the gland packing, at approximately 30 litres, per minute for each pump.

KETO worked with the site to solve these issues and recommended a K-IBA™ to be installed in the existing legacy pump.

These heavy duty bearing assemblies are designed to pump at high pressures and are interchangeable with the legacy bearing assemblies which were previously installed.

To reduce the water usage, a K-ISS™ seal was installed in the legacy pump. K-ISS™ seals can cope with high suction pressures while remaining leak free. A constant flow control valve in the K-ISS™ seals automatically compensates against changes in suction pressure and wet end wear.

Since the installation of the pump upgrades, the bearing assembly running temperature has reduced from 105°C to 65°C. It is now running at a normal touchable temperature at both ends. This has removed the need for excessive greasing.

The bearing assembly has been running for 12 months, that is, 4 times the average life of the legacy bearing assembly.

The K-ISS™ seal has had a significant impact on water usage.

The water usage on the pumps has reduced from 30 litres per minute to 6 litres per minute, a saving of over 12 million litres of water per pump per annum. www.pumpindustry.com.au

KETO are now working on the site to install the same arrangements on the bank of 6 pumps, and with other site installations to increase bearing life, minimise greasing requirements, and reduce water consumption.

The Tasmanian copper mine achieved savings of over $21,000 per annum on spare parts without even considering flush water and maintenance savings. ■ pump industry | May 2014 | Issue 7

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PROJECTS

AusIndustry Grant assists local manufacturer In December of 2011, Crusader Hose was successful in winning a competitive tender as part of the Australian Government’s Textile, Clothing and Footwear Strategic Capability Program (SCP). They were awarded a grant for the development of an innovative new hose process that would offer a variety of advantages to users as opposed to the commonly used poly pipe.

T

he resulting product, Flexibore 100, is now on the market.

Flexibore 100 is a lightweight, flexible laminated hose process for use in the bore water pumping industry and provides users with a simple and cost effective means of pumping ground water through flexible hose, as opposed to poly pipe.

Flexibore 100 series has been designed to reduce the time of installing bore pumps pumping at shallower depths (down to 100m), while maintaining the advantages of a flexible riser.

Suitable for many borehole applications, the hose is compatible with most submersible pumps and is available in 32mm and 50mm diameters.

As it is designed for simple installation and easy maintenance, it is useful in rural and domestic applications as well as remote areas with difficult access.

It removes the need for a safety cable due to its high tensile strength.

Another of Flexibore’s advantages over poly and PVC pipes is that it is resistant to the iron bacteria buildup that occurs in many systems. This results in better lifespan and saves electricity as the pumps don’t need to compensate for the resulting flow restriction.

The SCP grant opened doors for Crusader Hose, and over the last two years, the company has been able to increase its staff by approximately 50%, creating much needed jobs in the Victorian manufacturing industry.

The Crusader Hose plant where the hose is produced was also able to undergo an upgrade thanks to the new 52

Minister David Hodgett visits in August 2013 products success, adding more looms so that more hose could be produced for a rapidly growing customer base.

While the success of Flexibore 100 does not directly reduce imports, as poly pipe is already usually produced on Australian soil, the extra capability Crusader Hose gained through its success means that the Australian layflat hose can now be exported to a much greater extent to enjoy success on the international market. A great result for Crusader Hose and the Australian manufacturing industry in general.

Within the country, Flexibore 100 is finding ever more applications. These include use with solar bore pumps and other new technologies. Farmers in remote rural areas who may otherwise have to endure longer waits for someone to service their pumps are able to complete their own pump maintenance by simply pulling the pump up out of the bore over a roller. For

pump industry | May 2014 | Issue 7

someone living on the land who relies on bore water for their livelihood, such an option is far more than just a convenience. This has not been possible with polypipe or any other rigid riser type. A classic example is a farmer in the outback, far from his local store, or any other person for that matter, who can keep up the water for his livestock when the going gets tough.

In May 2013 the Victorian Minister for Manufacturing, David Hodgett, visited the Crusader Hose plant. He was given a tour of the facility and met the many staff responsible for Flexibore 100 and Crusader’s other products and was extremely impressed by this thriving example of a successful Victorian manufacturing business.

About the Textile, Clothing and Footwear Strategic Capability Program

The TCF SCP was a five year, $35 million, Australian Government AusIndustry initiative that took the form of www.pumpindustry.com.au

PROJ ECT S

a competitive grant program. Its aim was to support large projects to build innovative capability at the enterprise and workplace level of the Australian manufacturing industry.

The program began in July 2010 and ends in June 2015.

The minimum grant size was $250,000 and the recipients were required to match their grant on a dollar for dollar basis. This meant that the smallest project that could receive a grant had to have a budget of at least $500,000 in eligible expenditure, with $250,000 contributed by the grantee and $250,000 from the Australian Government. â– (Right) An example of the equipment which the SCP grant funding helped to finance.

FLEXIBORE 100 FLEXIBLE RISING MAIN

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

www.crusaderhose.com.au

INSTALL YOUR BORE PUMP ALONE www.pumpindustry.com.au

pump industry | May 2014 | Issue 7

53

S E AL- L ES S PUMP S

Peristaltic pumps Peristaltic pumps are self-priming pumps that operate on the peristaltic principle, using mechanical occlusion (or squeezing) to displace the fluid, thus moving it through the system. These pumps come in a variety of configurations and may involve hose or tubing made of various materials depending on the required function.

Principles of operation

The term peristaltic pump refers to various makes of pump colloquially known as hose or tube pumps.

Although there are specific differences between hoses and tubing, the terms hose and tube are interchangeable in this article.

Generally hose pumps have thick hose walls, polyamide reinforcing layers and are capable of handling differential pressure to 15 bars. Tubing has thinner walls and tube pumps are generally capable of differential pressures to 4 bars.

Peristaltic pumps are self-priming rotary positive displacement pumps that operate on the peristaltic principle.

The pump consists of three major parts: hose or tubing, housing and rotor. The hose is placed in the tubing bed between the rotor and the housing.

The rotor has a number of "rollers� or "shoes" attached to the external circumference. These move across the hose where it is occluded (squeezed), thus pushing the fluid. The hose behind the shoe or roller recovers its shape, creating a vacuum and drawing fluid in behind it.

Liquid is trapped between the rollers specific to the ID of the hose and the geometry of the rotor. Flow rate is determined by multiplying speed (rpm) by the volume of the trapped liquid.

The volume moved is consistent, even under a wide range of viscosities or density. The flow rate is directly proportional to the gearbox speed (rpm).

Dry-running design

This design incorporates a unique tube bed that always ensures one roller is occluding the hose. This is termed dry-running because the rollers that occlude the hose do not operate in a 54

pump industry | May 2014 | Issue 7

www.pumpindustry.com.au

SE A L- L ES S PU MP S is not required, a tubing pump may be a better option than a hose pump.

With recent advances made in the tubing technology for pressure, life and chemical compatibility, as well as the higher flow rate ranges, the advantages that hose pumps had over tube pumps are diminishing.

Tube pumps

Dry-running pump design.

Lubricated bath pump design.

lubricated bath. Dry running pumps generally have lower flow and pressure capabilities than lubricated pumps.

Description of hose versus tube pumps

Lubricated bath design

Higher pressure peristaltic hose pumps which can operate at pressures up to 15 bars, typically use shoes and have casings filled with lubricant to prevent abrasion of the exterior of the pump tube. This also aids in the dissipation of heat, and these pumps use reinforced tubes, often called "hoses". This class of pump is often called a "hose pump".

This design uses two sliding shoes on the rotor to occlude the hose. The rotor and hose operate in a lubricated bath that reduces friction on the hose and provides the long life typical of this type of hose pump design.

Benefits of peristaltic pumps

• Available in 15 different sizes that provide flow rates of 0 to 155 m3/h • Will handle fragile fluids with little wear • Since only the inside of the hose and hose inserts are in contact with the fluid, they can be processed without the devastating damage experienced by other pumping technologies.

• Hoses are constructed of natural rubber, NBR, EPDM, Hypalon, FKM • Provide high levels of volumetric accuracy for sampling and metering applications • Ability to pass solids in the material being pumped, 20% of hose ID

Hose Pumps

The hoses in a hose pump are typically reinforced, with a very thick wall.

For a given ID the hoses have much bigger OD than tubing for the roller pump. This thicker wall, combined with stiffer material typically used in the hoses, make the forces necessary to occlude the hose much greater than for tubing. This results in a bigger pump and motor for a given flow rate with the hose pump resulting in it consuming more energy to run.

The biggest advantage with the hose pumps over the tube (or roller) pumps is the high operating pressure of up to 15 bars. If the high operating pressure

Lower pressure peristaltic pumps typically have dry casings and use rollers and non-reinforced, extruded tubing.

This class of pump is sometimes called a “roller pump”, "tube pump" or "tubing pump".

These pumps employ rollers to squeeze the tube. They have a minimum of 2 rollers 180 degrees apart, and may have as many as 8, or even 12 rollers.

Increasing the number of rollers increases the frequency of the pumped fluid at the outlet, thereby decreasing the amplitude of pulsing. The downside to increasing the number of rollers it that it proportionately increases the number of squeezes, or occlusions, on the tubing for a given cumulative flow through that tube, thereby reducing the tubing life.

There are two kinds of roller design in peristaltic pumps: 1. Fixed occlusion - the rollers have a fixed locus as it turns, keeping the occlusion constant as it squeezes the tube. This is a simple, yet effective design. The only downside to this design is that the occlusion as a percent on the tube varies with the variation of the tube wall thickness. Typically, the wall thickness of the extruded tubes vary enough that the % occlusion can vary →

• Dry-run capability allows tank and line stripping.

• Seal-less design eliminates leaks, contamination and wear problems associated with difficult to seal products.

• Self-priming up to 9.8 meters at sea level on water

Hose pump.

• Reversible operation allows pumping in both directions • Durable construction of ductile iron and steel construction allows higher discharge pressures up to 15 bars.

• Low maintenance requirements of the hose and shoes www.pumpindustry.com.au

Tube pump. pump industry | May 2014 | Issue 7

55

SE AL-L ES S PU MP S with the wall thickness (see above).

Therefore, tubing at the high end of the wall thickness, but within the accepted tolerance, will have higher % occlusion, increasing the wear on it, thereby decreasing the tube life.

The tube wall thickness tolerances today are kept pretty tight so that this is not much of a practical issue.

2. Spring loaded rollers - As the name indicates, the rollers are mounted on a spring. This design is a bit more elaborate than the fixed occlusion, but helps overcome the variations in the tube wall thickness over a broader range. Irrespective of the variations, the roller imparts the same amount of stress on the tubing that is proportional to the spring constant, making this a constant stress operation. The spring is selected to overcome not only the hoop strength of the tubing, but also the pressure of the pumped fluid.

The operating pressure of these pumps is determined by the tubing, and the motor's ability to overcome the hoop strength of the tubing and the pressure.

Key design parameters

The key design parameter in hose pumps is hose life. Surveys have shown that 95% of spares value used on peristaltic pumps is on replacement hoses.

The major issues that affect hose life are as follows: Occlusion/shimming philosophy

The minimum gap between the roller and the housing determines the maximum squeeze applied on the tubing. The amount of squeeze applied to the tubing affects pumping performance and the tube life - more squeezing decreases the tubing life dramatically, while less squeezing decreases the pumping efficiency, especially in high pressure pumping. Therefore, this amount of squeeze becomes an important design parameter.

The term "occlusion" is used to measure the amount of squeeze. It is either expressed as a percentage of twice the wall thickness, or as an absolute amount of the wall that is squeezed. The amount of squeeze is influenced by the amount of shimming underneath the shoes. The means the greater the shimming depth, the greater the squeeze and the lower the hose life. As discharge pressure increases, additional shimming is required so the squeeze increases.

The occlusion is typically 10 to 20%, with a higher occlusion for a softer tube 56

material and a lower occlusion for a harder tube material. Rubber composition therefore becomes important so that efficiency is maintained without “over squeezing” the hose and affecting hose life.

Thus for a given pump, the most critical issues are rubber composition, the amount of shimming and wall thickness. An interesting point here is that the inside diameter of the tubing is not an important design parameter for the suitability of the tubing for the pump.

Therefore, it is common for more than one ID be used with a pump, as long as the wall thickness remains the same.

Mechanical capability of hose material

Mechanical capability is simply a function of the hose material and the number of times the hose is squeezed. The factors that influence the number of squeezes is the speed of rotation and the number of shoes or rollers. Therefore pump speed is a significant factor in hose life.

The hose needs to be elastomeric to maintain the circular cross section after millions of cycles of squeezing in the pump. This requirement eliminates a variety of non-elastomeric polymers such as PTFE, PVDF etc. from consideration as material for pump tubing.

Different hose materials have different mechanical flex life. The most common hose material is natural rubber. Natural rubber has double the mechanical life of EPDM and three times the life of Buna/ Nitrile and Hypalon.

Fluoroelastomers have been used but have very poor mechanical life that tends to make this material impractical. Some manufacturers are currently testing various compositions with the aim of improving fatigue life.

Chemical compatibility

The pumped fluid contacts only the inside surface of the tubing. There are no other valves, O-rings, seals or packings to worry about in a peristaltic pump.

Therefore, the only compatibility to worry about in a peristaltic pump is the hoses for the fluid being pumped.

The most popular hose materials (as distinct from tube) are: • natural rubber • EPDM (ethylene propylene diene monomer) • Buna also known as Nitrile • Hypalon • Viton fluoroelastomer

pump industry | May 2014 | Issue 7

Hoses are made in different ways by manufacturers. Some use full width in the particular material. Others use a common outside layer of natural rubber with an inside layer of other material selected for superior chemical compatibility. Some problems have been encountered with dual material hoses with the integrity being compromised due to pin holes in the inside layer and delamination between the two layers.

Typical elastomers for pump tubing (as distinct from hose) are silicone, PVC, EPDM+ polypropylene (as in santoprene), polyurethane, neoprene and a number of proprietary materials. Extruded fluoropolymer tubes such as FKM (viton, fluorel, etc.) have good compatibility with acids, hydrocarbons, and petroleum fuels. However, the material has poor fatigue resistance which decreases meaningful tube life.

There are a couple of newer pump tubing developments that offer a broad chemical compatibility - a lined tubing approach and the use of fluoroelastomer approach.

With the lined tubing, the thin inside liner is made of a chemically resistant material such as poly-olefin and PTFE that form a barrier for the rest of the tubing wall from coming in contact with the pumped fluid. These liners are materials that are not elastomeric therefore the entire tube wall cannot be made with this material for peristaltic pump applications. These tubing provide adequate chemical compatibility and life to use them in chemically challenging applications. There are a few things to keep in mind when using these tubes any pin holes in the liner during manufacturing could render the tubing vulnerable to chemical attack. In the case of stiff plastic liners like the polyolefins, with repeated flexing in the peristaltic pump they can develop cracks, rendering the bulk material again vulnerable to chemical attack. A common issue with all lined tubing is delamination of the liner with repeated flexing that signal the end of that tube life. For those who require chemically compatible tubing, these lined tubing options offer a good solution.

There are many online sites for checking the chemical compatibility of the tubing material with the pumped fluid. The manufacturers of these tubing may also have compatibility charts specific to their tubing.

While these charts cover a list of commonly encountered fluids, they may not include all fluids required for www.pumpindustry.com.au

SE A L- L ES S PU MP S any application. If there is a fluid whose compatibility is not listed anywhere, then a common test of compatibility is the immersion testing. A 1 to 2 inch sample of the tubing is immersed in the fluid to be pumped for anywhere from 24 to 48 hours and the amount of weight change from before and after the immersion is measured. If the weight change is greater than 10% of the initial weight, then that tube is not compatible with the fluid, and should not be used in that application.

This test is still a one way test, in the sense that there is still a remote chance that the tubing that passes this test can still be incompatible for the application since the combination of borderline compatibility and mechanical flexing can push the tube over the edge, resulting in premature tube failure.

NOTE. The natural starting point for selection of hose materials is chemical compatibility. This happens particularly with pump selection software linked to chemical compatibility charts. This can lead to serious errors as mechanical life is just as important If not more important than chemical compatibility. The correct selection philosophy is to consider both chemical and mechanical implications.

There have been many examples of where natural rubber, because if its superior mechanical life, has provided the best hose life notwithstanding chemical compatibility charts giving natural rubber a “poor” rating.

The best selection process is to start with natural rubber and then eliminate it if deemed to be totally unfit chemically.

Natural rubber is also the cheapest material so it is often worth trialling and then eliminating it.

Liquid temperature

The implications of temperature must be considered. The normal rated temperature for hose pumps is 40°C. Normal maximum temperature is 80°C subject to adjustments to either maximum pump speed or maximum discharge pressure.

Manufacturer’s selection charts would normally show derating requirements at higher temperatures. If not, contact the manufacturer.

Discharge pressure

As discharge pressure increases, additional shimming is required to maintain pump efficiency. This decreases hose life.

As discharge pressure increases, the maximum allowable pump speed and therefore flow rate decreases to compensate for the reduction in hose life due to additional “squeeze”. www.pumpindustry.com.au

1

3

2

1. Normal end-of-life over shimming.

2. Chemical attack under shimming 3. Over shimming.

Care should be taken when moving pumps between applications to ensure that those design parameters are not exceeded.

Recognising the cause of hose failure Over Shimming

Possible results of hose failure

If a hose ruptures, the following may occur dependent on where the rupture occurs: • the pump housing fills with the product • product drains from the suction line and suction tank into the pump housing and then leaks from the pump to the floor.

• product drains from the discharge line and discharge tank into the pump housing and then leaks from the pump to the floor.

Manufacturers do not provide any guarantee on hose life, product loss or consequential damage due to ruptured hoses. It is the customer’s responsibility to prevent pumped liquid loss or any other loss with additional hose rupture detectors and/or non return valves and automatic shut down valves.

Various rupture detection devices are available from manufacturers and these include: • float type magnetic reed switches which detect changes in liquid level in the hose housing • conductivity probes, however these are limited to use with products that are conductive • pressure transmitters fitted to the hose housing which detect a change in liquid level.

The best method of mitigating these losses is by preventative maintenance.

A hose replacement regime needs to be established so that hoses are changed prior to rupture occurring. This can be instigated after hose life is determined.

This does not mean that rupture detection systems can be forgotten.

• This failure occurs in the cheek of the hose as the hose starts to re-vulcanise • Rubber is built up under the shoe, leading to severe internal friction and a heat build up, resulting in • re-vulcanisation • The failure will occur over the rotor shoe’s full contact path Chemical compatibility

• The inner rubber has softened due to chemical action • Parts of the rubber breakaway when they are pulled and may stick together Under shimming or pulsation damage

• Damage occurs where the shoe leaves the hose • Failure is due to backflow of an abrasive product from severe pulsation • Remedy - remove the source of pulsation but do not increase number of shims • Shows as very high discharge side impulse loss ■

pump industry | May 2014 | Issue 7

57

PRO DUCT S H OWCAS E

New products available through White International:

Pressure tanks by Global Water Solutions

F

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 is the 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.

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

GWS offers a comprehensive range of pressure vessels for heating, thermal, pressure booster, water hammer, reverse osmosis and water well applications.

All-Weather Pressure Tank, making it the perfect solution for marine and mining applications, as well as in harsh environmental conditions.

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 insure excellent quality.

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

The GWS All-Weather Pressure Tank is constructed with a high grade steel tank encased in a rugged polypropylene outer shell. The patented PLASTEEL shell creates an impenetrable layer of protection that shields against the harshest of 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 harsh environmental conditions.

With the highest quality and all Major Global Approvals, the GWS All-Weather Pressure Tank represents the greatest innovation in pressure tank technology today!

All-Weather Pressure Tank

Call our Customer Service Hotline 1300 783 601 Email pumpsales@whiteint.com.au

www.globalwatersolutions.com.au 58

pump industry | May 2014 | Issue 7

www.whiteint.com.au

www.pumpindustry.com.au

PRO DU CT SH OWCA SE

Zenit pumps for all your wastewater solutions

T

he Zenit Group, established at the end of the 1950s, ranks among the top international names in the design and manufacture of water treatment technologies.

has become locally renowned for high quality submersible pumps ranging from 0.3kW to 16.0kW and carrying the highest certification levels available in each category.

Its core business is the design and manufacture of submersible electric pumps for both domestic and industrial use.

These include the IECEX Zone2, ATEX and now IE3 standards on our newly available Uniqa range with sizes up to 160kW.

Applying the knowledge and experience it has acquired over the years, Zenit has also created a comprehensive range of oxygenating and mixing products designed to meet the most demanding of applications.

The basis for Zenit’s continued growth in Australia has been the introduction of the IECEX Zone 2 approved range of Blue and Blue Professional submersible storm water and waste water pumps. Now these are also exclusively available fitted with IECEX approved float switches, ensuring that even the smallest facility can utilize an electrically safe product with competitive pricing.

Built on a strong foundation and solid tradition, dynamism and a desire for innovation, the Zenit brand continues to see steady growth, while allowing its origins and objectives to remain un-obscured.

Distributed exclusively in Australia by White International, the Zenit brand

To complete the range available in Australia, White International is pleased to announce the availability of the Uniqa range. This range was developed over recent years by Zenit to provide

an alternate offering for heavy-duty professional applications such as use in civil and industrial wastewater treatment plants, lifting sewage, pumping industrial sludges and rainwater containing solids, and recycling raw or activated sludges and biological liquids.

Uniqa represents a product range with unparalleled efficiency, designed to take into account the total life cycle cost of the product with an understanding that in developed countries, the energy costs involved in water supply are generally the second highest item on municipal balance sheets. This makes it vital to ensure that water systems are as efficient as possible by minimizing waste energy usage and utilizing only IE3 standard hydraulic and motor design techniques.

Distributed by White International Pty Ltd Phone 02 9783 6000 or 1300 783 601 www.whiteint.com.au (pumps) or www. zenitpumps.com.au

Logo Serie UNIQA

®

A Complete Range of Approved Waste Water Solutions ®

CMYK

®

Gray scale Zone 2 Approved

Call our Customer Service Hotline 1300 783 601

www.whiteint.com.au www.pumpindustry.com.au

Distributed by

®

BW

pump industry | May 2014 | Issue 7

59

PRO DUCT S HOWCAS E

Hurll Nu-Way introduces the SP100 Air Operated Double Diaphragm pump to the Australian Market

H

urll Nu-Way is proud to offer the most innovative air operated double diaphragm pump introduced in the past 20 years.

The SP100 Series, designed, and manufactured in the USA by Tuthill Corporation under the brand name Sotera Systems®, incorporates several key features unique to this pumping principle. The first is the patented QuikSeal® threaded ring construction. The threaded ring is designed for quick-turn access to clear ball checks and replace diaphragms. This clever design eliminates the need for multiple fasteners (bolts) on the manifolds and fluid caps reducing parts and complexity. It has the added benefit of reducing maintenance time by up to 50%. This design also reduces “pinch points” on the diaphragm resulting in longer diaphragm life.

The second is the patented, QuickFlow® air valve design. This non-centering

ceramic air valve features an extremely fast trip-over, resulting in a 67% reduction in pulsation and the highest and smoothest flow in the industry (up to 17.5 gpm for the ½” model; 57 gpm for the 1” model). In many applications pulse dampeners can be eliminated making the pumping system less complex and saving money.

The third benefit is a 20% improvement in air efficiency compared to competitive pumps. Less air consumption saves money over the long run.

SP100 can be configured in materials compatible with a wide range of chemicals making it as versatile as it is innovative. This, along with the elimination of stalling and freezing make the SP100 the most advanced AODD pump available today.

Contact: Tim Yakup Hurll Nu-Way Pty Ltd www.hnw.com.au 1300 556 380

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

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pump industry | May 2014 | Issue 7

www.pumpindustry.com.au

Increasing pump speed Pumping speed has again been considerably expanded for the Mink claw vacuum pumps from Busch

In total, Busch now offers Mink claw vacuum pumps in eleven sizes, which cover the range from 40 up to 950 cubic metres per hour operating at 50 Hz. The Mink MV 1202 A achieves an ultimate pressure of 200 mbar, making it the ideal vacuum generator in many industrial sectors and fields. The main areas of application are pneumatic conveying, clamping of work pieces onto CNC processing machines in the woodworking industry and degassing or forming processes in the plastics industry. Generally, this new size can also be used as a module in centralized vacuum systems.

Due to the sophisticated claw vacuum

technology, Mink vacuum pumps achieve an extremely high level of efficiency, which has a positive effect on energy consumption and performance. In practice, this means potentially great energy-savings and a consistently high performance compared to conventional vacuum generators. An additional benefit of claw vacuum technology is the virtually maintenance-free operation due to the non-contact operating principle; none of the moving parts inside the vacuum pump come into contact with one another, meaning there is no wear at all. The need for maintenance work, such as the inspection or replacement of worn parts, is completely eliminated.

Due to the completely dry compression without the need for any operating fluids in the compression chamber, there are no costs for purchase, provision or disposal. Mink claw vacuum pumps are air-cooled and they have high operational reliability and long life cycles as a result of their non-contact compression without

PRODUCT SHOWCASE

B

usch has again expanded its series of Mink claw vacuum pumps with the Mink MV 1202 A claw vacuum pump. With 950 cubic metres per hour for operation at 50 Hz and with 1150 cubic metres for 60 Hz-operation, this is now the largest industrial claw vacuum pump made by Busch.

Busch has again expanded its series of Mink claw vacuum pumps with the Mink MV 1202 A claw vacuum pump operating fluids. Due to wear-free operation, vacuum and suction performance remain consistently high throughout the life cycle of the vacuum pump. A smart silencer concept enables quiet operation.

For more information please contact Lydia Jennings at Busch Australia Pty Ltd on +61 3 9355 0600, email Lydia.Jennings@busch.com.au

is also online website

pumpindustry www.pumpindustry.com.au



digital edition



e-news

visit www.pumpindustry.com.au today pump industry | May 2014 | Issue 7

61

PI O NE E RS

Bill Smith Bill Smith is best known as the man behind Kelair. In this interview we talk to him about the history of the company, and also what drove him throughout his career.

I

met Bill at Kelair’s office in Arndell Park, near Blacktown, in Sydney’s industrial west. Bill related with a visible sense of pride and satisfaction the way the company continued to thrive after he left, reflecting that it had never been a one-man-band.

“Once Tony Sgro and Alan Veasey joined we all played a major part in the area of the company that our expertise lay.

I took the risks and at times I used to frighten the hell out of them, I would be driving the change - one thing would hardly be bedded down and we were onto another one. Because we'd see an opportunity, or I would see an opportunity and I just didn't want to let it go - a bit like a kid in a candy shop - don't let it go, it might not come back!”

Bill was born in Scotland, but a desire to travel brought him to Australia in 1963.

“I worked for Weir in Scotland so Weir Drysdale gave me a job. I had two jobs to come to actually - I was apprentice of the year for Babcock Wilcox and they offered me a job when I came to Australia. So I came with two job offers and I settled for the sales one with Weir.

In 1965 I had the good fortune to join Ingersoll Rand (I-R) as a sales engineer handling clients in the chemical and petrochemical industries, both end users and major contractors. This was an exciting time to be in the industry with major projects.

Developing in several refineries, the fertiliser plants were mushrooming and we were on the ground floor with Philips Imperial Chemicals’ green field plant at Kurnell. That job alone had about 80 process pumps, three large compressors and several portable compressors.

62

I was successful in landing this job and my career took off. This was an exhilarating time and I was on another steep learning curve.

I-R’s technical training was very good.

The technical information was second to none and the personnel were of a high calibre. The I-R recruitment standards were stringent so I had the opportunity to work and learn from some talented and dedicated people.

In 1969 I was transferred to Newcastle as resident engineer working out of the then agent for I-R, Bestobell. I was exposed to all of the I-R range of products which included drill rigs, pneumatic tools and a different group of customers in the steel and mining industries. I had a level of success which resulted in me being transferred 2 years later to Sydney office as the NSW Divisional Manager for the construction industry.

Within 6 months I was sent to Hobart as the Tasmanian Branch Manager. This branch ensured I was again dealing with a diverse group of industries (eg. mining, pulp and paper, power generation and mineral processing). It was a fancy title but I was also the Senior Sales Engineer along with my other responsibilities.

It was about this time I started to think of working for myself. I handled several I-R distributors and from what I saw I firmly believed I could do likewise.

In 1975 I returned to Sydney as the Engineering products Manager for NSW with a small team of sales engineers.

Within a few months I decided to take the plunge and left to form Kelair and act as a distributor for the I-R range of

pump industry | May 2014 | Issue 7

compressors and tools. The I-R pump range of mainly API standard process pumps did not have enough margin to allow for distribution at the time.”

Business commenced on the horses’ birthday, the 1st of August, in 1975.

With $2,000 In the bank I operated from a second-hand desk in my small family room. My wife Faye did my typing, book keeping and answered the phone whilst also looking after two small children, Lindsay and Lesley Anne.”

What sort of personality do you think it takes to take a step like that?

“Obsessed. I think from a fairly early age I always wanted to work for myself.

Looking at some of the other companies I’d seen I said, if they can do that then sure as hell I can do that. But working for yourself it’s 24/7. My son Lindsay was asked once in an internal survey here, ‘How long have you been working for Kelair?’ He said ‘since I was 12 years old’, he reckoned every dinner was a board meeting.”

What goals did you set yourself when you first stated the business?

“When I first started the goal was to be in business the following month. We had some fun in the beginning; I would help to spray paint the pumps, then I'd load the truck - with help of course - at seven o'clock at night and I'd drive the truck to my house. Then I'd wake up www.pumpindustry.com.au

PI O N EERS

I was never satisfied…. I would talk to anybody who I thought could give me advice to give me the edge at five in the morning and deliver the pumps to say, ICI at Botany - or wherever the pumps were going. I'd get there at half past six, seven o'clock in the morning, unload the truck, go straight back to the office and then I'd work all day. Then at night time I'd do whatever had to be done. That was just the way it was.

But it worked to our advantage as we could be flexible, where larger companies might not be able to deliver a part for a few days, we’d find a way to get it with the minimum of delay. There’s always a way.

In the first 3 months I sold a total of $20,000 which ensured the doors would remain open for a few more months. Very early on my pump knowledge came to the fore. I discussed pump problems with clients and offered solutions. They invited me to get involved and requested I supply the suggested pump. I now had to introduce Kelair to Ajax, Kelly and Lewis and Harland Pumps. Armed with their literature and price lists, my focus changed almost immediately. We were now seriously in the pump business.

Several clients expressed dissatisfaction with a number of major pump companies’ level of expertise of their salesmen and reliability of supply. I saw this as an opportunity to exploit this apparent weakness.

We moved to our first office into the local shopping centre and employed our first pump man, Harry Lawson, who had been the Manager for Blackwoods.

Harry was a top pump man and his arrival released me to be out full time, thus accelerating our growth. Within 18 months we moved to our first factory www.pumpindustry.com.au

unit and started mounting our own pumps and motors. About this time I convinced Tony Sgro and Alan Veasey to leave their secure jobs and join the fast track. Both these men were associates from my I-R days and I was confident they would take Kelair to another level.

I offered them a shareholding of 15% each based on 3% per annum for 5 years. However if they left under 5 years they forfeited the lot. I wanted a foundation for the company from which to grow and they provided it.

I began corresponding with overseas suppliers with international reputations for quality, that were also direct competitors to that already being imported by the majors. My rationale was that the bigger companies would not notice a small loss of business. I could nibble away undetected.

I made my first visit to an international pump exhibition in 1977 seeking new products, an action which was to continue for the next 25 years.

In that year we were appointed the agents for HMD seal-less pumps and Howard hygienic lobe pumps, both manufactured in Eastbourne UK. HMD advised they had been in the early stage of appointing an agent however felt my background was more suitable to sell this pump successfully in the chemical industry.

With these pumps we were developing an identity of our own. We were beginning the differentiation I wanted. We would no longer be seen as a “me too” reseller of standard products.

The HMD magnetic drive pumps were of a unique design specifically developed as a solution to prevent the leaking

of aggressive and dangerous liquids into the atmosphere. Within months we landed a 15 plus pump order from Powell Duffryn for a tank farm at Botany.

Orders flowed in from Shell, ICI and others. With persistent cajoling by Kelair and in conjunction with Shell, Geelong, we influenced HMD to design for the API market. Their first significant order was for Shell, Geelong and this lead to major orders for some 200 pumps for Russia.

The Howard pumps allowed us to compete head to head with Mono with the SSP equivalent (a breakaway from Howard). This was to be a great seller for many years in the food and chemical industry.

Over the next 2 years we added Rotan gear pumps, Anema hygienic pumps, Bornemann (bought from K&L), Sero (bought from Ajax), and Lewa metering pumps.

The major game changer came in 1982 when we secured the Wilden pump agency. The acquisition of the world leader in air operated pumps was to accelerate our growth beyond our wildest forecasts. It also gave us access to the best pump distributors in the country. This was an exciting time, sales went ballistic, 150, 300, 500 units per annum until in we sold 2000 in 1998.

The Wilden diaphragm pump had been poorly represented in Australia with sale less than 100 per annum. This included pumps we bought from the local agent.

I flew to California and met with the Wilden team which included the great man himself, Jim Wilden. Within 2 days I had convinced them to give us dual distribution. In our first year we sold more than 150. The following year we were granted sole distribution.

pump industry | May 2014 | Issue 7

63

PI O N EERS

The new Kelair building opened in 2002

Bill in 1983

Our biggest single contract was from Mt Isa mines where I landed an order in 1983 which ended up being for more than 200 pumps.

Our main competitor was Sandpiper.

They were handled by Clyde Industries and well established. In 1985 our Wilden sales surpassed Sandpiper. The Clyde sale manager had boasted to me they had just turned over $1 million for the first time, loose lips…we were now the number 1 for diaphragm pumps in Australia. Eventually we became one of Wilden’s major global distributors and featured in some of their promotional presentations around the world.”

The story of Kelair was one of continued growth from here, making acquisitions and expanding into further territories throughout Australia. For the full story of this chapter in Bill’s own words, go online now. http://www.pumpindustry.com.au/ the-kelair-story/4357 “In 1999 we opened up Kelair’s current premises near Blacktown with 3000sqm of factory and office. With first rate testing facilities comprising 80Kw installed power, a 50000 litre tank and two 5 tonne cranes. This facility has allowed Kelair to establish itself as a manufacturer and packager of container housed fire protection pumps sets, swimming pool sized sewage treatment plants and detailed metering pump packages.

This was not on my horizon when I started out and I am certain it was not on Tony’s or Alan’s radar either.

We were settling in nicely when we were given a massive shock. Wilden had decided to appoint a South African company as a second distributor in Australia. Behind the scenes we were 64

The original premises of Day Pumps at Silverwater NSW in 1984 undermined by a senior member of our sales team who had been seduced by a South African distributor to join them and compete with Kelair.

This had been supported at Wilden by a newly appointed manager in his first international role. This was a blow to us of mammoth significance after 20 years of association at a close personal level with the Wilden family. A bloody price war ensued with no real winners.

Our unit sales increased but margins on pumps and parts plummeted. I received a call from the international business manager of Warren Rupp, the manufacturer of the Sandpiper pump and the major worldwide competitor to Wilden.

The product was handled by Clyde Industries and both parties wanted out.

They asked us to meet with them and see if there was a way we could work together. Warren Rupp is a company in the Idex group which also had Viking , Pulsafeeder and Corken pumps in their

pump industry | May 2014 | Issue 7

stable. I flew to meet them in Cedar Falls Iowa and actually addressed the presidents for all companies mentioned.

Short version is that we agreed to take over the Sandpiper immediately with the other pumps to follow. We had $200,000 of pumps flown out and we moved all parts from Clyde Industries under cover. The next weekend we had our sales team fly in from all over.

They had no idea what they were about to hear. With Wilden these guys bled orange, the colour of the Wilden pump.

They were about to become blue bloods.

Sandpiper personnel addressed our shell shocked troops for all of Saturday and into Sunday. By the end we had discovered the Sandpiper had a feature Wilden people would have died for, it did not stall.

We attacked the market from Monday and within the first year we sold 1500 units at good margins. We aggressively www.pumpindustry.com.au

PI O N EERS promoted the range with the slogan “Quit stalling”, a not too subtle reference to the weakness we had discovered in the Wilden pumps. This catch cry has since been adopted by Sandpiper and is in all their worldwide literature. Within a year the South African company folded.

Kelair now has the sole distributorship for the Viking range which is the world leader in gear pumps and it is doing very well for them.”

Was there a point where you realised you'd arrived and you'd achieved the success you wanted, or once you got to a certain level did you always want to move up to the next level?

“I was never satisfied. I exasperated Tony and Alan. I was always saying we could have done better. That was the whole approach - if we could do that, we could do better than that. I would talk to anybody who I thought could give me advice to give me the edge.”

What do you think your staff and the people who worked with you over the years would say about you?

“That probably depends on who you ask! I think I'm very loyal, sometimes I was too soft - you'll maybe not think it's possible, but I was too soft. I found it extremely difficult to fire anyone. I delegated that to others. We had a great culture, where everyone’s birthday was remembered, successes were celebrated, I'd regularly take the staff out for dinner as a group. We always had a Christmas party and latterly we started having them on boats out in the harbour.

But I could be tough as well. I was demanding. I wanted - I wouldn't say my pound of flesh, that's not it - I wanted a guy to represent the company in the manner that I wanted it represented.

I didn't want his interpretation or a “She'll be right approach” to things. We trained and trained and trained and these guys, having worked for other companies, knew it was different here.

It was demanding - not doubt about it.

It wasn't a case of come here and rest on your laurels, it was come here and learn.”

Do you think you got your work-life balance right?

“I would imagine if you spoke to my family they'd say no. By the way, my daughter worked in the company as our full time marketing person for about six or seven years and she's got a business degree majoring in marketing. She www.pumpindustry.com.au

The Kelair Story 1975-Founded by Bill Smith in Sydney 1983-Entered into pump manufacture 1984-Acquired Day Pump & Engineering 1984-Established Victorian branch 1987-Established Tasmanian branch 1990-Established Queensland branch 1994-Established Western Australian branch 1994-Established Building & Fire Protection Division 1995-Established Wastewater Products Division 2004-Acquired by Brown Brothers Engineers Australia Pty Ltd 2005-Acquired Rob Laine Pumping Solutions 2007-Established branch office in Mackay did some brilliant work here, as did my son Lindsay. He's an engineer and he's also got a business degree majoring in finance and marketing. He did all the marketing after she left to have children.

So we had dedicated professional marketing people much earlier than a lot of companies of our size.”

How did your time at Kelair end?

“We had become a major client of Brown Bros. and formed a close working relationship with the MD, John Inkster.

John has been the driver of the growth of Brown Bros for many years and had mentioned to me on several occasions he coveted Kelair. Well John finally convinced us to sell to his company. This was not a decision taken lightly but in the end it was time to move on. The Kelair board knew we were handing our staff and clients to a company which would look after their best interests. This was completed in March 2004. Time has shown that our trust was well founded.

Kelair under the stewardship on Tony Sgro has continued to develop and grow in the manner set out over many years.

I was reminded by Tony that when he once asked me what drove me, I replied

“the fear of failure”. I wonder what my psychologist friends would make of that response? “

Did you find you didn't know what to do with your time when you first retired?

“It was a cultural shock. I went from the rooster to the feather duster. I sat in the office here where I was always handing out advice all around the country, then suddenly nobody wanted to talk to me.

The new owners wanted me to stay on for six months but I left in six weeks because it was no longer my company - I just felt that I was not making the contribution I thought I'd make. That's fine - I moved on. Tony knew everything about the business so it stood to reason that he took over and I moved myself to the other end of the building. Sort of out of the way, which was a complete change. But after six weeks I decided to seek other challenges. I did some consulting work for a small manufacturer for a while.

Now I am happy to play golf and involve myself with fund raising for my Rotary club.”

Any regrets?

“Not really. It was a great journey.” ■

pump industry | May 2014 | Issue 7

65

TEC HNI CAL

Understanding pump curves #7 : Are your pumps running too slowly?

By Ron Astall United Pumps Australia

E

veryone wants more efficient pumps and pumping systems. In some industries, the Engineers and system designers create massive stumbling blocks by specifying a maximum allowable pump running speed.

Putting arbitrary limits on running speeds will often preclude the best pump selection.

For clean liquid services, unless there are difficult suction conditions, there is no reason to fix a maximum limit on pump running speed. Energy efficiency has never been more important and yet we are still stuck with these archaic; dare I say ignorant specifications. Why? Is it because a slow running pump is perceived to have a “smoother” velocity profile, less turbulence and hence ought to be more efficient? As we will see later, this perception is plain wrong.

Is it because a slow running pump is perceived to have inherently lower internal wear, better bearing life and improved reliability? This perception is demonstrably equally untrue.

Could it be for reasons of noise and vibration? Yes, these aspects can be worse with a higher running speed, but not always. If these are the real issues, why not simply specify the allowable noise and vibration limits as direct requirements?

If you have read this far, you may be getting a little grumpy because much of this seems counter intuitive. Ought not a slow running pump be less stressed than a high speed unit? The real question ought to be; will a slow running pump of the same performance be less stressed than a higher speed model doing the same duty? For the same flow and same developed head, a slow speed pump will be larger and will be a different shape than a higher speed unit designed for the same hydraulic duty.

66

We are thus comparing different shaped pumps.

Fig 2

Fig 1 shows a range of impeller shapes versus a pump design parameter called “Specific Speed” (Ns). The formula for Ns is shown in Fig 2.

Ns is primarily a shape factor and this parameter is extremely useful as an aid to understanding why some pumps are more efficient than others.

Here it is. Specific Speed (Ns) is a simple formula involving the RPM, Pump Flowrate at Best Efficiency Point (BEP) and Head per stage at BEP. In Australia it is most common to use metric units of cubic metres per hour, metres and rpm; however; when comparing pump design data it is important to ensure that you are using the correct units.

It is effectively the same as the dimensionless pump type factor “K” in the test code standards, except “K” uses cubic metres per second as the flow unit.

Legendary pump designer, A.J. Stepanoff created this chart outlining the various components of pump inefficiency and showed how these vary with specific speed (Fig 3).

pump industry | May 2014 | Issue 7

From Stepanoff’s chart you can see that casing Hydraulic Losses and Disk Friction vary significantly with changes in Specific Speed. In these metric units the best impeller efficiency is around Ns of 3000.

As we saw from Fig 1, low Ns impellers are larger diameter, narrow radial flow units. Higher values of Ns relate to fatter more open shaped impellers.

This makes perfect sense because the fatter, more open shaped impellers will have less disk friction as a percentage of the hydraulic work being done by the impeller.

The bottom line is that narrow impellers are less efficient than “fatter” shaped impellers. See Fig 4.

Bearing the above in mind, it makes sense to aim for the best shape impeller when considering what type of pump to select. If you arbitrarily dictate the maximum running speed you may force www.pumpindustry.com.au

TEC H N I CA L

the pump selection into a low Ns shape and this will mean a more expensive and less efficient pump.

Consider the following pump selections for the same duty but different speeds (Fig 5): This is a tangible example of how specifying a maximum running speed of 1500 rpm will in this instance cost the end user dearly; not only in capital cost but in total cost of ownership.

Now some of you may be grumbling about reliability, noise and vibration being also important. Yes they are, but look at the size of the casing on the slower running unit, look at how much heavier its impeller must be and look at the greater surface area available to transmit hydraulic noise. In a later discussion I will look at these aspects in more detail and show how the faster running pump can indeed be more reliable and can be potentially quieter.

So what running speed should you specify?

You should not specify the running speed at all!

A great window on this process is the pump vendor’s range chart. A simple suggestion is to always start with the highest speed range chart. If this does not bear fruit, look at the next speed down. If there is a sensible selection at a higher speed it is almost certainly going to be a more efficient pump than a lower rpm unit doing the same duty.

To illustrate this, in Fig 6 below I have overlaid a 2980 rpm range chart (in red outline) over a 1470rpm range chart for the same manufacturer. Below the red outline you can see the regions where a 1470 rpm pump is going to be a better selection. Inside the red outline, a 2980 selection ought to be better. www.pumpindustry.com.au

Select on the basis of the hydraulic duty and specify your other primary requirements directly; such as noise and vibration. Then let the pump vendor select the best pump for the job; unrestrained by silly speed constraints.

The best speed may be 2980 or 1450, or 980rpm or even lower. It depends on your hydraulic conditions.

But what about multi-stage pumps and what about the impact of running speed on suction conditions? I will talk about these issues next time. ■ Next article: Are your pumps running too slowly? – the sequel.

pump industry | May 2014 | Issue 7

67

TEC HNI CAL

Amiad Auto Micro Fibre (AMF) Filter meets stringent standards

By Ruth Elfassi-Kamer

Providing reliability, consistency and meeting drinking water quality at a water treatment plant can be an ongoing task for water authorities in Australia. The Australian municipal water market will also face an additional challenge in meeting the requirements of the Australian Drinking Water Guidelines 2011 (ADWG 2011), which demand a higher level of water quality and closer monitoring than the preceding guidelines. (ADWG2004).

The following pilot study demonstrates the effectiveness of Amiad’s Automatic Micro-fibre (AMF) self-cleaning filter technology as a polisher filter reducing turbidity, total suspended solids and iron levels, while enabling consistent output results.

At the end of 2013, Amiad Water Systems received an enquiry from one of the Australia’s state government water authorities to assist with

a filtration solution on one of their existing water treatment plants. The water treatment plant consists of an iron removal scheme incorporating oxidation, flocculation, continuous wash upflow sand filtering and disinfection.

Following investigation, it was concluded that the filtered water in question contained residual iron particles in a ferric state (0.25- 0.35 ppm) and had a turbidity level around 0.6 NTU. Particle size distribution (PSD) analysis (Figure 1) demonstrated that total particles were greater than 2 µm, and based on volumetric tests the median particle size was around 10 µm. The local water authority’s standards for potable water when treating bore water are actually

1400 Incremental particle count

1200 1000 800 600 400 200 0 1.00

10.00

100.00

100 90 80 70 60 50 40 30 20 10 0 1000.00

10.00 9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 1.00

10.00

Particle size (μm)

100.00

Figure 1 68

pump industry | May 2014 | Issue 7

100 90 80 70 60 50 40 30 20 10 0 1000.00

Cumulative volume % undersize

Volume % in interval

Particle size ( μ m)

Cumulative count % undersize

T

his case study was undertaken to ensure that the reliability of the filter and the water quality (including iron and turbidity levels) achieved, met both the local government potable water standards for treating bore water and the national requirements. The local government standards are actually stricter than ADWG2011 for iron and manganese levels, requiring 0.1 ppm of iron (rather than 0.3 ppm, in ADWG2011). At this low level of iron a low turbidity is also expected.

stricter than ADWG2011, requiring 0.1 ppm of iron (rather than 0.3 ppm). At this low level of iron a low turbidity is expected. Lower concentrations of iron in the treated water will mean less iron deposited in the reticulation system, lowering the chances of dirty water events.

Figure 1: (Left) PSD based on cumulative count analysis. (Right) PSD based on volumetric analysis As the iron particles were in the ferric state and at a minimum size of 2 µm, the Amiad micro fibre self-cleaning filter with a 2 µm cassette package was chosen to resolve the problem on site. Amiad and the local water authority collaborated to conduct a pilot test. A pilot plant is essentially a smaller scale simulation of a treatment process. It may be used to test a proposed process with particular raw water or to evaluate different operating conditions for an existing plant.

The main criteria for this pilot were: • (i) To test the Amiad AMF filter for its operation reliability; • (ii) To perform performance testing of water quality pre- and post AMF filter for iron and turbidity; • (iii) To determine operational parameters for the large design scheme from the small-scale pilot trial.

1 X 2” AMF36K with 2 µm cassette (Figure 2) was installed on site where it was connected to a data logger that monitors and reports inlet and outlet turbidity, differential pressure, and inlet and drain flows. The pilot has now been running for few months and has been www.pumpindustry.com.au

TEC H N I CA L captured materials, chemical optimization, and lower operating costs. In short, AMF delivers clean water with clean technology.

Figure 2: AMF filter, pilot skid consist of feed pump, instrument, AMF filter, and control and data logger. found capable of testing water at various flow rates up to 20 m³/h.

Why was the Amiad AMF chosen?

Over the past 40 years, Amiad Water Systems (www.amiad.com) has developed a range of compact automatic and manual self-cleaning filters, incorporating innovative technology characterised by low operating costs and short capital payback. In addition to being used as a polisher filter for iron and turbidity polishing, Amiad’s automatic microfibre

www.pumpindustry.com.au

filters are typically installed in drinking water applications where they can protect against Cryptosporidium and play a vital role in effluent treatment processes, membrane pre-filtration protection, recirculation-water filtration systems, cooling tower main and sidestream filtration, stormwater filtration, and off-shore water injection projects.

The AMF filter was developed by aligning the concept of fibre filters with 21st century values, including minimising waste, reducing handler exposure to

The AMF filters both inorganic and organic particles as water flows through multi-layered microfibre cassettes.

These are attached to collector pipes as a cartridge package. As with wound cartridge filters, the diameter of the fibre and how it is wound determines the degree of filtration the cassette can deliver, ranging from 20 to 10, 7, 3 or 2 µm. Particles are trapped between the fibres. When a target pressure or time differential is reached across the filter, the self-cleaning cycle is activated using a high pressure stream of water (jet mechanism).

The AMF filters are designed with a large filtration area and are available in three different sizes: AMF36K, AMF93K and the AMF370K which is capable of running up to 300 m3/h per unit subject to flow, filtration degree and beginning water quality.

Amiad’s fibre technology has been evaluated by the UK Drinking Water Inspectorate (DWI) and approved by the UK secretary of state for use in the UK public water supply. The AMF filter with 20 µm cassette achieved the California Water →

pump industry | May 2014 | Issue 7

69

TEC H N I CA L Recycling Criteria (known as Title 22), where filtration technology must achieve the required turbidity level. The Title 22 approval identifies the Amiad AMF as a complement to an approved disinfection process such as chlorine, UV or ozone.

Furthermore, it has been accepted as a pre-disinfection filter in several areas of Japan, Israel, and recently been re-tested in New-Zealand in a laboratory environment with a live Cryptosporidium which demonstrated a 3-4 log reduction value.

Figure 5: AMF’s cassette filtration grade quality, testing with sphere particles and presenting the percentage removal comparison at the different filtration grade.

(Figure 7) Average turbidity & iron trend as a function of flow before and after AMF filter 25

1.2

0.8 Flow

15 0.6 10 0.4 5

0

Turbidity [NTU] Iron [ppm]

1

20

0.2

Aug-13

Nov-13

Dec-13

Dec-13 ()

Feb-14

Jan-14

0

Time Frame of Trial Flow (m3/h)

Inlet Turbidity [NTU]

Outlet Turbidity [NTU]

Inlet Iron [ppm]

Outlet Iron [ppm]

Figure 7: Average backwash as function of flow across the AMF filter (Figure 8) Average backwash cycle (dP/time) as a function of Flow 25

6 20 5 15 Flow

4 3

10

2 5 1 0

Aug-13

Nov-13

Dec-13

Dec-13 ()

Jan-14

Feb-14

Time Frame of Trial Flow (m3/h)

Max Pressure [m]

Minimum B/W Interval Time [hrs]

Figure 8: Average Turbidity and Iron before and after the AMF filter.

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pump industry | May 2014 | Issue 7

0

Pressure [m] & Time of backwash [Hours]

7

Fine particle filtration to allow good polishing of water and deliver consistent output results while also meeting ADWG2011 can be a difficult task. The AMF filter is a viable option to overcome this challenge. Because the filtration medium is constructed of fine fibre threads wound in layers, the Amiad technology combines the advantages of surface and depth filtration in a compact design. Figure 5 shows the particle filtration quality of the microfibre cassette (MFC) at different filtration grades.

Spherical particles have been added to inlet water so that the reduction of these particles between inlet and outlet of the AMF filter can be measured. The AMF’s cassette at all filtration grades provides a very high percentage removal of particles. These results demonstrate the depth filtration ability that the AMF filter provides. Even though filtration levels can be selected as low as 2 µm, the main advantage of the system is the large filtration area with a small footprint.

The high filtration area results in reduced backwash frequency with the further advantage of low wastewater production.

For instance, in the AMF36K (up to 20 m3/h) backwash is only 0.5 m3 water per cycle.

Using the ability to access online monitoring (Figure 6) and accordingly optimize the operation conditions of the pilot plant, a set of flow rates were tested.

These were 7, 10, 12, 15, 17, 18 and 20 m³/h. At each of the different flow rates the water quality improvement and the functionality of the plant were studied.

Summaries of the average results (dP, flow, turbidity) collected for each flow rate are depicted in Figures 7 and 8. These results were derived from 24/7 online monitoring, which recorded the reading every few minutes.

Figure 7 shows the average backwash interval time as a function of flow rate.

The higher the flux (filtration rate, m³/h/ m²) the quicker the differential pressure develops on the cassette, resulting in shorter interval time between flushes. At www.pumpindustry.com.au

lower flows (<15 m³/h, which is typically the recommended flow for such application) the AMF flushed only when a set time interval had elapsed resulting in one flush every four to six hours. As the flow increased the flushing frequency increased to once every two hours. It is important to note that the AMF36K at 20 µm filtration degree would be typically designed to operate at maximum of 30 m³/h (subject to feed water quality). At finer filtration degrees and in order to allow maximum efficiency of the operation one may consider operating at lower flow rates. In this study the AMF36K at fine filtration degree of 2 µm operated at high flow of 20 m³/h, yet provided a reliable and effective operation even in such demanding conditions.

Online Turbidity and sampled iron results are verified by a third party laboratory.

Figure 8 describes the water quality before and after the AMF filter as a function of flow. At the pilot plant, the Amiad AMF filter consistently provided iron level of less than 0.02 ppm and turbidity less than 0.2 NTU, regardless of the differing flow rates.

The AMF filter controller comes with human interface monitoring providing a user-friendly operation, requiring minimum onsite operation and maintenance. At the pilot, the AMF was flushed using some of the filtered water and was inspected during the pilot testing. During this period it demonstrated no appreciable wear and tear. The cassette was in excellent condition without chemical cleaning having taken place.

Overall, the AMF filters performances met the local water authority’s high standard of water quality, as well as the ADWG2011 guidelines. Throughout the entire period of pilot testing, the AMF filter has been reliable and effective in its operation and filtration performance.

The Amiad microfibre self-cleaning filter provides a highly effective filtration solution down to 2 µm, reducing iron and turbidity levels. The pilot testing continues to operate in order to conclude the commercial design scheme.

Acknowledgments The author wishes to acknowledge the local water authority for participation and support of this trial. The author also acknowledges Peter Spencer, David Masters, Michael Jovanoski, Rani Pisk, Syed Tanveer-Alim, Dale Harris, Jamie Pickford, and all other personnel involved in planning, designing, commissioning and operating the pilot. ■ www.pumpindustry.com.au

PUMP SCHOOL

NPSH and elevation Making sure your pumps are performing their best in their given environment can be vital. However, sometimes less obvious forces such as atmospheric pressure can come into play. Therefore, in this issue’s Pump School, we examine the impact of altitude on Net Positive Suction Head in centrifugal pumps.

Question: Do centrifugal pumps require more Net Positive Suction Head (NPSH) margin at higher elevations than at sea level?

NO. The recommended NPSH margin for a centrifugal pump does not change at higher elevations. The NPSH required (NPSHr) by the pump also does not change with altitude.

Altitude does, however, affect NPSH available (NPSHa)

NPSHa =

Pa 9.8 x SG

-

Pv

+ Hs - Hf

9.8 x SG

Where: Pa = atmospheric pressure in kpaA Pv = vapour pressure of liquid in kpaA Hs = static height from water level to pump centreline (on suction side) in metres Hf = friction loss is suction pipework in metres Therefore, as atmospheric pressure is decreased at higher altitudes, the NPSHa reduces.

This will not create any pump problems provided the NPSHa at altitude is greater than the NPSHr by the pump. A typical minimum margin is 0.5 metres. * Article courtesy of Kelair Pumps Australia “When Pump Knowledge Matters” Phone: 1300 789 466 www.kelairpumps.com.au pump industry | May 2014 | Issue 7

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pump industry | May 2014 | Issue 7

Vortex Hire..........................................8 Welling & Crossley .............................35 White International.........................58,59 Xylem Water Systems.........................13

www.pumpindustry.com.au

www.BuyFromTheLittleGuy.com

KETO Pumps isn’t as big as some of the mining pump companies out there but we pack a punch!

We always go for knock-out service (because when you’re not the biggest you have to).

For a smaller company we hold a lot of stock of impellers, bearing barrels, throat bushes, seals, bearings and most other items to fit our own and the bigger guy’s pumps - if you need mining pump parts as quickly as a rapid right hook, then try us out.

Our parts last longer too and we hold stock locally across most parts of Australia.

Try KETO Pumps - for heavyweight performance

To learn more about our capabilities and sign up for your FREE mine site assessment visit

www.BuyFromTheLittleGuy.com or call +61 8 6310 4100

TECO have the complete package NOW including the MAX-E3H66 High Efficiency and Hazardous Area Motors to 450kW Drives to IP55 Contactors to 630 Amps Vibrators to 23,000Kg Force SYDNEY

MELBOURNE

emd@teco.com.au

BRISBANE

PERTH

www.teco.com.au