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MPTSee the Value ofMechanical Seal
Energy Audits
How to Save a DyingSeptic System
Internal Gear Pumps inIndustrial OperationsProviding Solutions for the Worldwide Pump Industry
www.modernpumpingtoday.com
Modern Pumping Today®
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CONTENTS
www.modernpumpingtoday.comP.O. Box 660197 | Birmingham, Alabama 35266
Modern Pumping Today®
No part of this publication may be reproduced or transmitted in any form or by anymeans, electronic or mechanical, including photocopy, recording, or any informationstorage-and-retrieval system without permission in writing from the publisher. Theviews expressed by those not on the staff of Modern Pumping Today, or who arenot specifically employed by Highlands Publications, Inc., are purely their own. AllIndustry News material has either been submitted by the subject company or pulleddirectly from their corporate website, which is assumed to be cleared forrelease. Comments and submissions are welcome, and can be submitted to jay@modernpump ingtoday.com.
For information about advertising, call
205.795.0245
14
CHRIS GARMON
CFO
DONNA CAMPBELL
VP, Editorial
TIM GARMON
CEO/President
RUSSELL HADDOCK
COO/Publisher
www.highlandspublications.com312 Lorna Square | Birmingham, Alabama 35216
T: 866.251.1777 | F: 205.824.9796
@ModPumpMag
JEFF FLETCHER Publisher
J. CAMPBELL Editor
MICHELLE SEGREST Editorial Consultant
SCOTT GORDON Art Director
LISA AVERY Assistant Art [email protected]
TONYA BROWNING Associate Publisher
DAVID MARLOW Account Executive
INGRID BERKY Admin Assistant
MPT
EDITORIAL ADVISORY BOARD:
Terry Bell Product Manager, Baldor Electric Company
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting
Robert G. Havrin Director of Technology, Centrisys Corporation
Michael Mancini Consultant and Trainer, Mancini Consulting Services
John M. Roach Engineering Manager for New Product Development, Trebor International,Inc.: A Unit of IDEX
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
32
28
A NOTE ON THIS ISSUE:
Very soon many of us will welcome small visitors to our
doorsteps bearing the familiar greeting “trick or treat,” butfor process pump users—especially those at refineries
and petrochemical plants—one trick they are on watch for
throughout the year is energy loss due to mechanical seal performance. To that end, we’re proud to offer a treat in this
issue: The first instal lment of a four-part series by Tom Groveand Heinz Bloch on the value of mechanical seal energy audits.
With new performance regulations soon taking hold across the
industry, the need for energy efficiency—and monitoring that
efficiency—has never been greater.
Another treat: This issue’s “Pumping Trends” features
a conversation with Aaron Zahn, the president and CEO
of Florida-based NuTerra. His company has a compelling vision to transform thewastewater and organic waste industry in response to the growing global water crisis.
In a relatively short time, NuTerra has been able to deliver an impressive 100 percent
success rate on a lifecycle basis for its client facilities.
Finally, I’d like to extend a thank you to all of the people who stopped by the MPT
booths at the recent TPS and WEFTEC shows. It was a pleasure seeing both familiar
and new faces of our friends and partners in the pump industry.
J. Campbell, Edito r
Modern Pumping Today
http://www.mpt.com/http://www.mpt.com/http://www.mpt.com/https://www.linkedin.com/company/modern-pumping-todayhttps://www.facebook.com/Modern-Pumping-Today-262372740522483/https://twitter.com/ModPumpMaghttp://www.mpt.com/http://www.mpt.com/http://www.mpt.com/
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INDUSTRY NEWS
TRADE SHOW PROFILE
CASE STUDIES
WATER & WASTEWATER SOLUTIONS
MAINTENANCE SOLUTIONS
PUMP SOLUTIONS
DEWATERING SOLUTIONS
MOTOR SOLUTIONS
POWER GENERATION SOLUTIONS
PROCESSING SOLUTIONS
VALVES & CONTROLS SOLUTIONS
SEALING SOLUTIONS
MODERN PUMPING PRODUCTS
PUMPING TRENDS
14 From Fresh to Frozen... Fast
16 Electrical Signature Analysis
12 POWER-GEN INTERNATIONAL 2015
6
52 Featured Product Release: GRIFFCO VALVE Y-Strainers for Chemical-Feed Systems
20 North Las Vegas Wastewater TreatmentPlant Upgraded
22 Peach Lake Finds a Solution fora Dying Septic System
Part 1 of 2
28 Root Cause Analysis: The Justification Game Part 2 of 2
30 Reliability Starts from the Ground Up
32 The Benefits of Internal Gear Pumpsin Industrial Operations
Part 1 of 2
36 Copper Mine Quadruples Pump Wear Life
40 Reliable Energy Is Looking Up Down Under
56 The Growth of Big Green
46 Mechanical Seal Energy Auditsand Their Value
Part 1 of 4
44 Managing Assets, Saving Time
42 Minimizing Leaks and Environmental Hazardsfor Fluid Transfer
38 Turning Away from Tradition
OCTOBER 2015
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I N D U S T R Y N E W S
RELIABILITY CONCEPTS PURCHASES
ALIGNMENT SUPPLIES, INC.
Michael Olszewski, president of Reliability Concepts
based in Michigan is pleased to announce that RC has
recently purchased Alignment Supplies, Inc. based in
Maumee, Ohio. Alignment Supplies has been a provider of
machinery laser alignment and measurement equipment
for almost thirty years. This experience in distribution,
sales, and customer service, along with Reliability
Concept's expertise in the full spectrum of predictive
technologies and broader product line offering will
provide customers with a complete resource for al l of their
predictive, corrective, and preventive maintenance needs.
With this acquisit ion, Alignment Suppl ies, Inc. will now
be offering the Hamar Laser Instrument Stealth Series™
line of Laser Shaft Alignment systems. Stealth Series™
shaft alignment systems offer a full suite of features and
capabilities to meet the most demanding of alignment
scenarios.
Alignment Supplies, Inc. has off icia lly become the US
Master Distributor for the innovative B.A.T. Belt Alignment
Tool®. With national reach, the collective effort of our
merged resources will broadcast the proven concept of
the fast, Dual-Cross Firing Laser technology, which slashes
belt alignment time by 75 percent and eliminates errors
inherent with single laser and puck target systems.
GE’S WATER BUSINESS TO ACQUIRE
NETHERLANDS-BASED IMT SOLUTIONS
GE announced that it has agreed to acquire IMT Solutions,
a private Netherlands-based manufacturer of ultrafiltration
and microfiltration membranes for water treatment. With
IMT’s ultrafiltration membrane technology, GE will be
expanding and complementing its existing ZeeWeed
advanced ultrafiltration hollow-fiber membrane portfolio.
The acquisition of IMT will enhance GE’s water treatment
product offer ings and further GE’s commitment to
excellence in water treatment. GE will use its global reach
to take IMT’s membrane technology, integrate it with its own
and proliferate it across the world.
“Over the past twenty years, the ZeeWeed family has
grown and evolved to become the vast, industry leading
ultrafiltration membrane portfolio it is today. GE is
committed to continued technology advancements and
growth in water reuse, wastewater, and tough-to-treat
water technologies. The acquisition of IMT Solutions and its
polyethersulphone membranes will complement our current
offerings and offers terrific opportunities for further growth,”
says Heiner Markhoff, president and CEO—water and
process technologies for GE Power & Water.
Our technologies have great synergy and together will
be able to reach a broader market,” says Nico Marsman,
general manager, IMT Solutions.
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KSB ANNOUNCES NEW FOUNDRY
AT GIW INDUSTRIES INC.
GIW Industries Inc., the leader in the design, manufacture,
and application of heavy-duty centrifugal slurry pumps,
announces its foundry grand opening. The foundry is part
of a large expansion that includes a new distribution center,
additional heat-treat and casting cleaning facilities, CNC
machines, and an assembly center.
This expansion is one of the largest in the company’s
history and is the biggest project ever undertaken by GIW,
a fully owned subsidiary of KSB. The foundry construction
and related expansion projects are just the f irst phase in a
path of cont inuous investment for the company. Phase one
included the new foundry, which features 72-foot ceilings
and is about the size of a football field. These new facilities
will more than triple GIW’s current manufacturing capability.
Long term, this expansion will give GIW and KSB a
significant advantage in the mining market. The investment
will allow for better handling of the sizeable castings
needed by GIW’s customers; some produced by GIW
can weigh well over 40,000 pounds and are bigger than a
cement truck. This expansion will allow GIW to keep up with
current market demand and to be able to quickly adapt to
support future growth.
SMITH STEPS DOWN FROM VAL-MATIC
Val-Matic announces the retirement of Vice President of
Sales and Marketing Carl W. Smith. After a thirty-two-year
career with Val-Matic Valve and Manufacturing Corp., Carl
W. Smith wil l retire form the company on March 31, 2016.
Over his tenure, Mr. Smith opened new markets for
Val-Matic across the globe in international sales and later
became National Sales Manager. As Vice President of
Sales and Marketing he helped launch several new valve
products and buil t a successfu l representat ive network in
the water and wastewater industry. He also represented
Val-Matic for many years as a member and board member
of several industry organizations inc luding Water and Sewer
Distributors of America (WASDA), Water and Wastewater
Equipment Manufacturers Association (WWEMA) and the
American Water Works Association (AWWA).
President and CEO, Ted Makowan says, “Throughout
his career, Carl Smith has demonstrated an enduring
commitment to our Company and its mission to provide
quality products and service to our customers. His servicehas been important to the success of Val-Matic.”
CASHCO NAMES NEW VICE PRESIDENT
OF OPERATIONS
As par t of i ts plan for growth and future succession, Cashco,
Inc. recently promoted Darrin Vanderbilt to the position
of Vice President of Operations. Although Vanderbilt most
recently served as Engineering Services Manager, he has
assumed a number of responsibilities since joining Cashco
fulltime in 2005 as engineering lab manager. Ironically, his
history with the company goes back even further to when he
worked as an intern for Cashco, after growing up in nearby
Brookville, Kansas.
“Darrin has proven to be able to adapt to change quickly
and incorporate process improvements to both improve
the quality of our products and provide his group with the
proper tools to do the tasks easier and more eff icient ly,”
says Clint Rogers, president of Cashco, Inc. “With this
new position, all of manufacturing will now operate under
Darrin’s direction, while Quality Control will continue to
report directly to me in order to provide the checks and
balances ISO requires.”
Since returning to the area a decade ago, Vanderbilt has
since built a home for his family near his own boyhood
home in Brookville, where he and his wife, along with two
sons, manage to keep busy with school activities and sports.
DANFOSS
PARTICIPATES
IN SECOND
WHITE HOUSE
INDUSTRY LEADER
ROUNDTABLE
Danfoss participated
in an industry leader
roundtable hosted by
the White House to
reduce greenhouse
gas emissions from
hydrofluorocarbons
(HFCs).
Danfoss North
Amer ica President John Galyen provided an update on
the company’s ongoing commitment to a Codes and
Standards Task Force, which is helping address major
barriers in broad adoption of mildly f lammable, low-GWP
refrigerants. Galyen noted what the Task Force has already
accomplished and what it hopes to accomplish over the
next twelve months.
Additionally, Danfoss announced a mul ti-mill ion dollar
investment in a new Application and Development Testing
Center to increase the amount of available laboratory
capacity to help air conditioning and refrigeration
equipment manufacturers prepare to meet both energy
efficiency and refrigerant regulations, as part of the
company’s commitment to the adoption of low-GWPrefrigerants.
Other par ticipants included leading executives
from refrigeration and air conditioning equipment and
component manufacturers, refrigerant producers and
industry associations in a roundtable briefing of senior
White House off icia ls, including Depar tment of Energy
Secretary Ernest Moniz and Environmental Protection
Agency Administrator Gina McCarthy. The event was
moderated by Assistant to the President and Senior Advisor
Brian Deese, who oversees climate, conservation, and
energy policy.
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I N D U S T R Y N E W S
XYLEM’S GOULDS WATER TECHNOLOGY
FACTORY SCHOOL RELEASES Q4
TRAINING SCHEDULE
Goulds Water Technology announces its 2015 four th quarter
Factory School schedule for in-person and online training.
Live in-person training sessions are available at the
educational facili ty in Seneca Falls, New York. Classes
provide hands-on training in water systems, variablefrequency drives, wastewater and commercial applications.
This training is designed to provide attendees with
extensive, firsthand experience in the Campbell Education
Center laboratory.
The Commercial/Industrial Pump Product and Application
seminar will take place October 26 through 29, and the
Advanced Pumps and Drives Operations course will occur
November 9 through 12. Note that the latter course requires
participants to possess a minimum f ive years’ experience
with pumps and drives.
Online training is also available. These seminars provide
users with up-to-date product information, troubleshooting
support and industry knowledge. Training can be accessed
from anywhere with an Internet connection, and courses
are offered once per quarter to ensure availability for each
topic.
For a complete list of online courses, or to register for in-
person training, visit goulds.com/factory-school.
ENDRESS+HAUSER INTRODUCES CA80AM
AMMONIA ANALYZER
Endress+Hauser introduces the Liquiline System CA8AM
ammonium analyzer for monitoring critical control points
in water and resource reclamation facilities. The CA80AM
analyzer and its sample preparation systems provide an
automated approach to process control and regulatory
compliance.
To keep discharges at permitted levels and to avoid
penalties, managers of water t reatment and other
resource recovery facilities need accurate and reliable
measurements in their nutrient monitor ing systems. The
Liquiline CA80AM colorimetric analyzer provides these
measurements by using the standard indophenol blue
method, which is compliant to ISO 7150-1, DIN 38406-
5 and GB 7481-87 standards. The CA80AM analyzer
also provides data storage and retrieval using on-
board logbooks to allow continuous documentation for
reporting to regulatory agencies.
Multiple communications methods—including
EtherNet/IP, Modbus, Ethernet and an integrated web
server—allow the analyzer to be integrated into any
control system. The integrated web server allows a user
to remotely analyze process disturbances and decide
on required measures quickly, all through any web
browser. ◆
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T R A D E S H O W P R O F I L E
Power-Gen
International is
the world's largest
power generat ion event
focusing on the industry's
latest innovations,
technical trends, and
business strategies.
Presenting a broad
range of qualified power
professionals with the power to purchase, Power-Gen
International is the place not only to assess the direction
of the industry’s future but also to get business done
today! Throughout its history, Power-Gen International
has provided a global meeting space for the innovations,
ideas, and solutions that shape the industry now and in
the future.
THE PLACE TO BE
With a record-set ting
expected attendance of
more than 22,000 power
professionals from more
than ninety countries and
a show floor comprised of
more than 1,400 exhibiting
companies, there's no other
place to be for education,
networking, and new business development that the 2015
meeting of Power-Gen International. Attendees will hear
from more than 200 of the industry’s top speakers and
have access to more than fifty educational conference
sessions.
Events at Power-Gen International 2015 will also include
multiple Competitive Power College courses, networking
POWER-GEN
INTERNATIONAL 2015The industry comes together to charge into the future
POWER-GEN 2015 AT A GLANCE
Where: Las Vegas Convention Center,
Las Vegas, Nevada
When: December 8–10, 2015
Website: www.power-gen.com
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events, technical tours, as well as
online conference proceedings.
Power-Gen’s wide array of
offerings draws professionals from
myriad specialty fields, including
electric utilities, fuel suppliers,
independent power producers,
architects and engineers, original
equipment manufacturers, power
industry consultants, power plant
designers, equipment inspection
and repair specialists, construction
contractors, maintenance service
providers, and many, many more.
WOMEN IN POWER
LUNCHEON
A luncheon hosted by the Women
in Power committee that features
the 2015 Woman of the Year and
finalists. The Power-Gen Women
in Power committee selects a
Woman of the Year each year to
serve as a role model to inspire
young women to pursue careers in
energy. Luncheon attendees will
have the opportunity to network
with women in the power industry
and learn about the career paths
of some of the most successful
women in the industry. The winner
of the Power-Gen 2015 Woman of
the Year Award will be announced
during the Awards Gala on
Monday, December 7 at 6:30 pm.
AN INDUSTRY UNITED:
POWER GENERATION WEEK
Covering every aspect of the
power generation industry, Power-
Gen International, Nuclear Power
International, Renewable Energy
World Conference and Expo
North America, Coal-Gen, and
GenForum converge in 2015 toform Power Generation Week.
Benefit from five days packed
with pre-conference workshops,
technical tours, more than seventy
conference sessions, panel
discussions, three exhibition days
,and multiple networking events.
This unique collaboration provides
attendees with the chance to
access nearly every facet of the
market—all under one roof. ◆
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C A S E S T U D I E S
From Fresh to
Frozen… Fast
Pinguin Foods is a leading, international processor of
harvest fresh vegetables priding itself on delivering
fresh to frozen produce that are tasty, healthy, and
of the highest quality. Pinguin is an independent division
of the major European Food Group, Greenyard Foods,
which processes over 440,000 tons of product annually
over eleven production
sites. However, moving
food from fresh to frozen
requires solids handling
that is reliable, efficient,
and fast. Hidrostal Ltd.,
the UK distributor for
the major Swiss pump
manufacturer, has
provided an international
processor of fresh to
frozen vegetables with
the perfect pump for
passing peas.
MOVING FROM FIELD TO FORK
At Pinguin’s site in Boston Lincolnshire, the company
utilizes a field to fork approach that encompasses the
washing, de-stoning, separation, blanching, and freezing
of raw vegetables. Hidrostal’s “F” type pumps, ideally
suited for food processing, are employed to transfer the
field harvested peas
directly with the use
of recycled mains
water as the motive
media.
Pea season
typically runs from
June unti l August
where the produce
is being transferred
at a rate of up to
11 tons per hour
per line during this
period. The process
Hidrostal’s “F” pump passes peas for Pinguin
By Lucy Ogden, Hidrostal Ltd.
“Hidrostal’s pumps have proved
extremely reliable with minimal
maintenance required. They
need to be reliable otherwise
production stops.” —Barry Cooper,
Pinguin engineering stores manager
Pinguin’s food processing involves washing, de-stoning, separation, blanching, andfreezing of raw vegetables.
Pea processing at Pinguin
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involves peas picked fresh from the
fields which are then put through
an ongoing process to remove, silt,
stones, soil, and loose pods and
skins before entering the blanching
and freezing process.
KEEP IT MOVING, KEEP IT CLEAN
This solution allows the vegetable
produce to be pumped and piped
to its destination in favor of an
open belt conveyor system, which
under these open environment
circumstances would be susceptible
to contamination, debris, and product
loss. In addition it has the added
benefit of allowing Pinguin to retain
the main road through its premises
and not affect the traffic and transport
of product across its yard.
The Hidrostal pumped option was
selected due to its proven ability
to handle and transfer delicate
product with zero damage due to its
low velocity and low shear design
hydraulics while retaining optimum
efficiency and maximum energy
saving.
MORE THAN JUST PEAS
After pea season the same pumps
are then used to transfer cauliflower
and broccoli florets with the same
level of output and accuracy. These
pumps are critical to the successful
continuation of the entire production
cycle.
Both the client and the manufacturer
are delighted that their pumps
have functioned so well for Pinguin
and ensured the safe and speedy
processing of peas from production to
our plates. ◆
For more than thir ty years, Hidrostal
Ltd. has been at the forefront of
designing and delivering innovative
pump solutions that deliver real
benefits to business. For more
information, contact Lucy Ogden
at Hidrostal Ltd . via email at lucy.
[email protected] or visit
www.hidrostal.co.u k.
http://greatsouthernpump.com.com/http://naglepumps.com/http://gusher.com/mailto:[email protected]://www.acousticalsurfaces.com/
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C A S E S T U D I E S
Electrical SignatureAnalysis
Originally put into operation in 1999, Pump
Station P-19A supplies drinking water to
the City of Henderson, which is the second
largest city in Nevada. Serving a population well
over 270,000 people, P-19A is one of the most
critical potable pump stations operated by the city.
The pump station originally utilized three pumps
when its operation began, but in 2006, two more
vertical pumps were installed in the pump station
(Pumps 1 and 5).
CAUSE FOR CONCERN
In 2006, the pump size was increased, but the motor
horsepower remained the same. The motors have a
service factor of 1.15 and often exceed 105 percent
of nameplate full -load amperage (FLA). Although
this is within the capabilities of the motors, they
operate at near maximum output.
In November 2014, vibration analysis was
performed as par t of the plant’s Predict ive
Maintenance Program. While those test results
suggested the possibility of early bearing
degradation in Motor 5, the rotor bar passing
frequency was within range
The vibration summary concluded that systemswere operating within acceptable l imits and that
no maintenance actions needed to be taken at
that time.
Two months later, in January 2015, Motor
5 exhibited signs of overheating; reaching
temperatures that exceeded 320 degrees Fahrenheit
(160 degrees Celsius). Although the other pumps
did not show any symptoms similar to that of Motor
5, the maintenance team took action and initiated an
in-house investigation of all five pump motors using
their predictive maintenance equipment.
As performed on vertical turbine pumpmotors in municipal application
By William Kruger, All-Test Pro, LLC,
and Alex Panattoni, City of Henderson Dept. of Utility Services Electrical Section
The All-Test Pro 31 troubleshoots start-up and quality controlof AC/DC electrical motors, generators, or transformers.
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COMPREHENSIVE TESTING
TO PREVENT MOTOR FAILURE
The in-house maintenance team utilized their hand-held
All-Test Pro 31™ and All-Test IV Pro™. These high-tech
instruments, which are used for de-energized testing, are
designed to detect potential winding faults and provide
indications of rotor problems.
First, they used both the All-Test Pro 31™ and All-Test
IV Pro™ to perform winding tests and confirm that the
windings were in good condition.
Then they used this equipment to conduct ‘insulation
to ground’ tests to prove the insulation was not grounded.
Next, they performed a rotor inductance test, which
measures the inductance of all three phases of a motor
at different individual rotor positions. During the test, the
rotor is positioned at exact intervals, as seen in the picture
to the r ight.
The City of Henderson performed an extensive rotor
test—taking readings every 5 degrees of shaft rotation
using the All-Test IV Pro™—only then did indications show
an issue with both Pump 1 and Pump 5.
While the tests indicated the poss ibility of a rotor
problem, the results didn’t show the problem def initively.
Technicians knew the current was modulating and put a
time trace on it, but needed to do more extensive testing.
At the main tenance team’s request, a third-par ty
specialist went to the pump station to perform vibration
analysis. When the vibration analysis did not indicate
Vertical Turbine Pump Info
GPM 7400
# of Stages 5
Size 20x20 GHC-5
Suction Size 20-inches
RPM 1200 All-Test P ro 31™ for init ial tests Rotor Tested at 5-degree Intervals All-Test IV Pro™ for initial test
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C A S E S T U D I E S
any electrical faults (pole pass
frequency sidebanding) in the
associated vibration FFT signatures
the decision was made to bring in
technical support from ALL-TEST
Pro to perform additional testing.
An All-Test Pro technician
went to the pump station
in January to perform
an Electrical Signature
Analysis. Electr ical
Signature Analysis is a
diagnostic technology
that uses the motors
supply voltage and
operating current to
identify existing and
developing faults in the
entire motor system. To
perform the Electrical
Signature Analysis, he
brought with him the All-
Test Pro On-Line II™. The
ATPOL II™ is an energized
motor testing tool which,
when in ESA mode,
evaluates the condition of
incoming power, the control
circuit, the motor itself ,
and the driven load. Kruger
requested that MVA data be
taken simultaneously while the
Electrical Signature Analysis wasbeing performed.
ELECTRICAL SIGNATURE
ANALYSIS REVEALS BROKEN
ROTOR BARS
During the energized motor tests,
data was taken at different times;
first shortly after star t-up, then
again after the pump had been
running. Of significance was the
large change in rotor speed with a
very small change in motor load.
The rotor was running considerably
below name plate; after running
about thir ty minutes, the rotor
speed was 1171 rpm. This was
also confirmed by an independent
tach system provided by the third-
par ty who performed the vibration
analysis. While the results of the
vibration analysis did not show any
indications of rotor problems, the
speed and the ESA data taken with
the ATPOL II™ indicated that several
rotor bars were broken.
Rotor bars are solid continuous
bars that run through the rotor’s
steel laminations, which are
spaced to allow air f low to cool
the rotor. Once the maintenance
team received the report from the
Electrical Signature Analysis, which
showed severe indications of rotor
bar issues (Pump 1 had a severity
rating of 6 out of 7 and Pump 5 had
a severity rating of 7 out of 7), they
pulled Motor 5 and found that 30
percent of the rotor bars were in fact
broken.
REBUILDING THE ROTOR WITH
DIFFERENT METALLURGY
After discussing the issues with
the motor manufacturer and a third par ty motor repair company, the
maintenance team chose to have
both Motor 1 and Motor 5 rebuilt
with copper rotor bars. Pumps 2,
3, and 4 had copper rotor bars and
did not have the same issues as
Pumps 1 and 5. The original rotor
bars in Pump 1 and Pump 5 had
been made of aluminum. This was
believed to be the root cause of the
problem.
ALL-TEST PRO On-Line II
ESA Data from ATPOL II™
Pump 1 Pump 5
Pump Speed: 1183 RPM 1175 RPM
Demand Power: 738.98 HP 726.96 HP
Load: 100.7% 99.1%
Output Load: 507.95 KW 495 KW
Severity Rating: 6 out of 7 7 out of 7 Rotor bar breaks all occurred in the middle three rowsof laminations.
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W A T E R & W A S T E W A T E R S O L U T I O N S
North Las VegasWastewater TreatmentPlant Upgraded
Located within the greater Las Vegas metropolitan area,
North Las Vegas, Nevada, also sits in the majestic
Mojave Desert, which means that how the city treats
and manages its water supply is of premium concern. The
upgraded water reclamation MBR facility, one of the largest
in the United States, treats the municipal wastewater for more
than 300,000 of North Las Vegas’s residents and processes up
to 25 million gallons of wastewater per day.
MAKING THE LEAP
Earlier this year, GE provided the city with its high-
performance LEAPmbr membrane bioreactor (MBR)
technology for an upgrade to the city’s wastewater treatment
plant. By using GE’s LEAPmbr system, the c ity will reduce
its energy and maintenance costs including an estimated 29
percent reduction in membrane scour energy costs.
With GE’s LEAPmbr and ZeeWeed 500 membranes, the
newly upgraded facility can more efficiently treat the city’s
wastewater. Historically, the city of North Las Vegas relied on
the city of Las Vegas to treat its wastewater, but in 2012, North
Las Vegas built its own plant using GE ZeeWeed membranes
and MBR technology. The city then upgraded the facility with
LEAPmbr technology three years later to provide the same
treatment capacity and highly treated water quality while
reducing energy and maintenance costs and increasing
productivi ty.
SAVING GREEN BY GOING GREEN
“Environmental and economic concerns led us to upgrade our
wastewater treatment plant with GE’s LEAPmbr technology,
which provided us with a more energy-efficient and cost-
effective way to operate our facility,” says Dave Commons,
water reclamation facility administrator for North Las Vegas.
“The retrofit will give us a 29 percent energy reduction on
membrane aeration and will save more than $100,000 per year
in energy and maintenance costs.”
GE’s LEAPmbr technology providesreduced energy and maintenance costs
By GE Power & Water
Increased Surface AreaZeeWeed Module
Simplified Aeration Piping
No Air Cycling Valves
OptimizedTank Design Increased
ZeeWeedProductivity Lower Energy LEAPmbr
Aeration Technol ogyReduced Blower Size
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GE’s LEAPmbr aeration technology
provides optimal energy usage by
reducing membrane air scour costs
along with essentially eliminating
cyclic valve maintenance. In addition,
the plant’s advanced SCADA system
allows the city of North Las Vegas to
have minimal staffing at the plant and
the wastewater treatment facility can be
controlled remotely.
“LEAPmbr is our latest innovation
in membrane technology and
upgrading to it gives the city of Nor th
Las Vegas a more cost-effective and
energy-efficient method of aeration.
Additionally, LEAPmbr improves water
quality, increases water treatment
capacity and offers the lowest life
cycle costs available from any MBR
technology,” says Yuvbir Singh, general
manager, engineered systems—
water and process technologies for
GE Power & Water.
RETROFIT KITS PROTECT INITIAL
INVESTMENTS
Specifically for the project, GE
retrofitted the existing membrane
cassettes by supplying LEAPmbr retrofit
kits. This allowed the plant to take
advantage of the lower air and energy
requirements while continuing to get
the full lifecycle operation out of the
originally installed membranes.
LEAPmbr builds on tweny-five years
of experience to deliver the most
advanced MBR solution to date. At the
core of LEAPmbr is GE’s ZeeWeed 500
membrane, an advanced ultrafiltration
technology that separates solids,
bacteria and viruses from water or
wastewater. GE’s ZeeWeed ultrafiltration
membranes offer an unmatched
combination of performance, energy
efficiency, durability, ease of operation
and reliability. More than 1,000 plants
worldwide use this technology to
produce superior quality water.◆
LEAPmbr Technologyenables the City ofNorth Las Vegas tooperate the plantmore efficiently,
while increasing productivity.
GE Power & Water provides customers
with a broad array of power generation,
energy delivery and water process
technologies to solve their challenges
locally. Power & Water works in all
areas of the energy industry including
renewable resources such as wind
and solar; biogas and alternative
fuels; and coal, oil, natural gas and
nuclear energy. The business also
develops advanced technologies tohelp solve the world’s most complex
challenges related to water availability
and quality. Follow GE Power & Water
and GE’s water business on Twitter
@GE_PowerWater and @GE_Water.
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W A T E R & W A S T E W A T E R S O L U T I O N S
Peach Lake Finds aSolution for a DyingSeptic System
It only took a few generations and
several hundred dying septic
systems to age an idyllic vacation
spot like Peach Lake.
A CLOSER LOOK
AT PEACH LAKE
Fed for millennia by fresh flowing
springs—with no creeks or rivers
for drainage—a basin eventually
matured into a 1.5-mile long and half-
mile wide aquatic paradise originally
named Pechquenakonck by the
Kitawonks, a Mohegan group.
Around the dawn of World War I ,
vacation homes star ted to occupy the
pristine shoreline of what pioneer
Dutch farmers first named Peach
Pond; later, Peach Lake. Inevitably,
water quality deteriorated as the
reservoir's spring intake was
supplemented by wastewater flushed
from these summer bungalows
and cabins, equipped with septic
systems that only have a normal life
expectancy of ten to forty years.
By the 1990s, the problem of
wastewater—mostly during the peak
Memorial Day to Labor Day period—
was aggravated by the arrival of full-
time residents who were upgrading
once simple seasonal properties
in lakeside communities like North
Salem and Southeast into pleasant
abodes with additional bathrooms,
washing machines and dishwashers.
"Most of the people are here
year-round but we do have the 20
to 30 percent that are there in the
summer months," says Warren Lucas,
supervisor of the Town of North
Salem. "These communities grew
Part 1 of 2
By Joseph Harmes
Peach Lake is a quiet, private lake located in Putnam and Westchester counties in New York, about a ninety minute commute from Grand Central Terminal. Single-family homessurround the lake, consisting of both seasonal and full-time residents.
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up around the lake back in the 20s
and 30s and at this point we have in
some cases the second or third home
rebuilt on these properties."
Young families purchasing their
first houses, retirees and even work
day commuters to Grand Central
Terminal about ninety minutes away
further pushed Peach Lake's fragile
ecology to the brink.
THE PUSH TO IMPROVE
WATER QUALITY
A campaign to improve the water
quality of Peach Lake began over
forty years ago and gained traction
when the Citizens Statewide Lake
Assessment Program (CSLAP),
a volunteer lake monitoring and
education program, began sampling
Peach Lake's water in 1999.
Over the next decade, the project
found the "recreational suitability
of the lake to be unfavorable" and
"'slightly' to 'substantially' impacted
for most recreational uses" like
swimming and boating as failing
septic systems had a negative impact
on water quality.
CSLAP's reports noted "High
coliform counts (resulting in
occasional beach closures), along
with algal blooms and excessive
aquatic weed growth strangled
areas near the shores. The aquatic
growth may also depress dissolved
oxygen in the lake to the point where
the fishery may also be affected"
and storm events frequently led to
fish kills.
A wastewater study showing
eutrophication (an excess of nutrients
such as nitrates and phosphates) led
to Peach Lake's inclusion on New
York State's List of Impaired Waters.The situation was fully addressed in
2010 when a new sewage treatment
system was designed to replace the
area's 470 deteriorated septic tanks.
LOOKING FOR CAUSES
. . . AND SOLUTIONS
Engineers blamed the septic
failure on multiple origins. Scores
were situated too close to streams,
drainage ditches or the lake. Leach
fields at many properties were sized
to the original summer cottages and
not adequate for the additions or
newer homes; current regulations
require 5 feet between the septic tank
and groundwater. Significant numbers
failed percolation tests due to poor
soil conditions and shallow bedrock.
Executing the 2010 plan would be
no easy task as it required the input,
cooperation and approval of 1,000
citizens and four lake association
boards; the formation of sewer districts
which included inter-municipal
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projects, planners needed to win close coordination and
cooperation from homeowners for property visits, maps,
surveys, deed preparation, easement negotiations/
acquisitions and construction observation on private
proper ty.
Seemingly the biggest concern of residents was that
an adequate sewer system might increase the density of
homes or create condo development. It was agreed that
only existing land surveys would be acknowledged with
the caveat each home could be expanded or replaced
with one new structure.
North Salem and Southeast were divided into two
separate State Environmental Quality Reviews for
efficiency and less complication given the size and
impact of the project.
"I have 74 percent of the homes (360)," says Nor th
Salem's Lucas. "Southeast has 26 percent (120)."
The sewage treatment facility is owned in a 74-26
par tnership between the two towns.
In order to pamper local sentiment, the head works
and micro-filtration facilities of the Peach Lake Sewer
Treatment Plant (a small, mostly-automated facility
designed to process 170,000 gallons per day) are
housed in red and white buildings camouflaged to
mimic the ubiquitous horse barns synonymous with the
pastoral landscape. Alar m pane ls are located on the ou tside of t he home to a ler t the homeowner or ser vice
person about a problem.
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W A T E R & W A S T E W A T E R S O L U T I O N S
A LOOK AHEAD
Two sewer proposals were considered:
A gravity/low-pressure hybrid with
eight pump stations and a low-pressure
sewer system employing grinder
pumps at each home (or, where
housing is dense, a duplex pump
serving multiple dwellings). Next
month, we’ll conclude this case study
by exploring Peach Lake’s decision
and the benefits they discovered. ◆
With corporate headquarters in
New York and regional off ices
and distribution throughout the
industrial ized world, Environment
One Corporation (E/One) is a
manufacturer and provider of
products and services for the disposalof residential sanitary waste and
utility systems for the protection and
performance optimization of electric
utility assets. For more information,
visit www.eone.com.
E/One grinder pump stations (shown) can be buried on small lots. Only a few inches of green lid are visible to thehomeowner.
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M A I N T E N A N C E S O L U T I O N S
Root Cause Analysis:The JustificationGame
In last month’s introductory article,
we discussed some of the barriers
to selling not only the concept of
Root Cause Analysis (RCA) but also
the recommendations generated
as a result of these analyses. We
also laid the framework for making
better predictions by generating
and accessing better data—namely
predicting our Mean Time between
Failure (MTBF) and Mean Time to
Restore (MTTR) earlier and, therefore,
implementing a fix faster.
Given this background, let’s
explore how we can now justify
conducting a RCA and implementing
the recommendations as a result of
the analysis. By and far, conducting
a true RCA is viewed as luxury not a
necessity. Think about the objections
we hear when we offer the idea of
gathering RCA teams. What follows
is a list of common objections to RCA
accompanied by rational justifications
that any manager can employ.
OBJECTION: WE DO NOT HAVE
TIME TO DO RCA
We do not have t ime to do RCA
because we are so busy firefighting
that we do not have time to analyze
why the fires are occurring in the
first place or how to prevent their
recurrence. If this paradigm is
permitted to exist, then the conclusion
is that the best we can do is sharpen
our response time and accept that
the fires are a cost of doing business.
How much money is being accepted
as the cost of doing business? Hint,
how much is your maintenance
budget worth?
OBJECTION: WE DO NOT HAVE
THE MONEY TO BACK A RCA
EFFORT
Maintenance budgets are pr imarily
developed to respond to failures that
are expected to occur. Man-hours
and materials are assigned and
budgeted. Therefore, if it is in the
budget, it is not a failure because we
have compensated for it. It is a cost
of doing business. This does not have
Part 2 of 2
By Robert J. Latino, Reliability Center, Inc.
See Part 1 onmodernpumpingtoday.com
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to be the case. Just as with safety, we
should have a zero tolerance policy
with failure. We should question
why the things in the budget are
acceptable and look at how to
eliminate failure.
Secondly, when failures occur that
are compensated for in the budget,
they oftentimes affect production
hours in terms of downtime. The cost
of a failure should be measured by the
man-hour dollars + material dollars
+ the lost production dollars. This is
a true measure of how much is lost,
and subsequently, how much is to be
gained. Just because a $50 bearing
fails, does not mean that it did not
cause $50,000 in lost production.
OBJECTION: WE DO NOT HAVE
THE RESOURCES TO CONDUCT
RCA
However, it does seem that we
always have the resources to fix the
problems that occur daily. If we were
to support a RCA effort, the reactive
work would decrease over time,
as many problems would not exist
anymore. This would free up the time
of the people that we have as reactors,
and better utilize them in proactive
activities such as RCA, predictive
maintenance, etc.
OBJECTION: IMPROVEMENT
WORK CAN WAIT UNTIL
RESOURCES ARE AVAILABLE
If this is the prevailing attitude,
pack up your RCA bags because
these resources will never be made
available. This is where management
support is a must. We must make
accommodations in our work order
systems to effectively implement RCA
recommendations through assigningthem a higher priority. If this is not
done, then they are “back burner”
items and will likely never get done.
This will have resulted in a lot of work
on behalf of the RCA team and a lot of
cost in their wages while they were on
these teams. The larger impact will be
on the morale of the team, as they put
their best effort forward and no one
listened. This is where the program-
of-the-month paradigm originates.
THE VALUE OF THE INTANGIBLES
In the world of RCA, we must learn
the value of the intangibles and their
effect on the tangible world. This all
revolves around the dollar and all
aspects of the organizational system
are interdependent to optimize profits.
Here is a list of such intangibles:
• Lost profit opportunities —the
cost of a lost downtime hour on
the spot market at that time.
• World class analytical skills —
investing in our people’s skills
makes them better decision
makers and problem solvers. This
allows them to do things once
and do them right. How much
does it cost to replicate the same
activity over and over again?
• Teamwork —when people
work on RCA teams, they gain
an appreciation for how other
departments perceive given
situations. When this occurs, it
affects future decision making
because they tend to take into
consideration why people do
what they do. This empathy
results in a more synergistic
operation and a more educated
workforce.
• Morale —research shows that
failure rates tend to be higher
in organizations that have poor
morale. Why? Because when
our workforce feels alienated
their focus is distracted with the
emotional baggage they carry.
This distraction causes errors in
decision making which lead to
physical failures. By allowing theworkforce to demonstrate their
knowledge of how the process
works and to solve problems
utilizing their experience, their
morale is improved along with
their ownership over their work.
How much is this worth to the
organization?
These are just a few of the intangible
benefits of conducting RCA. Although
the returns from the tangibles alone
are self-justifying, imagine if we were
able to focus the creativity of the
workforce towards the betterment
of the organization. Remember, we
cannot do what we cannot imagine! ◆
Robert J. Latino is CEO of Reliability
Center, Inc. Mr. Latino is a practitioner
of root cause analysis in the field with
his clientele as well as an educator.
Mr. Latino is an author of RCI's Root
Cause Analysis Methods© training and
co-author of Basic Failure Analysis
Methods© workshop. Mr. Latino
has been published in numerous
trade magazines on the topic of root
cause analysis as well as a frequent
speaker on the topic at trade shows
and conferences. His most recent publication is titled "Root Cause
Analysis—Improving Performance
for Bottom Line Results." He can
be contacted at 804.458.0645 or
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M A I N T E N A N C E S O L U T I O N S
Reliability Startsfrom the Ground Up
A solid foundation is a proven way to increase the mean
time between planned maintenance for most types
of rotating equipment. Pump bases and foundations
constructed of polymer concrete provide many benefits
over their cast and fabricated metal counterpar ts. Often
referred to as a poly, granite, or mineral cast baseplate, this
material is a special combination of well-defined grain size
aggregates bound to a thermoset epoxy or vinyl ester resin.
Manufactured in a controlled environment during a transfer
molding process, these materials can be cast to precision
tolerances while offering the high mechanical properties
suitable for most industrial applications.
VIBRATION DAMPING
The polymeric matrix of the material provides damping
ratios 20-30 times greater per identical geometry than steel
or cast iron materials. Rotating equipment is often associated
with its stability under the inf luence of various disturbances
and polymer bases can effectively minimize vibrations
without the need to increase the mass size of the component.
PRECISION MOUNTING
Cast mounting surfaces are typically flat within 0.002 inches
per feet, which reduces soft -foot and speeds alignment.
Threaded insert holes are typically cast in place or
located with a CNC machine to insure precise location and perpendicular ity, which eliminates bolt bound conditions
often occurring with inexpensive metal bases. Difficult
to machine features can easily be cast in place. Thermal
expansion rates of most polymer concrete formulations are
considerably less than cast iron and maintain the consistent
alignment of equipment in a wider range of operating
conditions.
CORROSION RESISTANCE
Advanced resin systems along with inert natural aggregates
provide excellent protection from many fluids that would
otherwise require an expensive alloy or corrode standard
cast iron or steel. Polymer concrete systems eliminate the
need for additional protective coatings or periodic upkeep
and maintenance activities.
FASTER INSTALLATION
Polymer concrete baseplates will not twist, bend, or
diaphragm like most metal designs. This eliminates the need
for time-consuming field adjustment dur ing installation. Most
designs also incorporate threaded leveling inserts along with
a bottom surface ready for adhesion to grouting material
without modification or special preparation. Bases can either
be stilt mounted or grouted in place like a conventional
hollow design.
Outlining the benefits of polymerconcrete baseplates
By Scott Sapita, BaseTek, LLC
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Grouting a polymer concrete
baseplate requires considerably less
labor and mater ial. Grout volumes
are greatly reduced resulting in less
material and labor to pour. Greater
skill is often required in grouting a
hollow steel frame to insure all voids
are eliminated as grout is intended
to be in 100 percent contact with
the underside surface for proper
performance and vibration damping.
Since the solid pre-cast polymer
concrete base will maintain structural
integrity without requiring grout,
many potential installation errors can
be easily avoided. Stilt mounting a
polymer concrete assembly takes
advantage of the structural stability of
the mounting surface while allowing
the equipment to react to the forces
and moments of the piping system.
PROVEN RELIABILITY
In addition, polymer concrete mater ials
offer low levels of heat conduction,
act as an excellent electrical insulator,
are non-magnetic, and resist water
absorption. Mechanical properties
are suitable for most indoor-outdoor
environments found in the process
industries.
The proven reliability of polymer
concrete baseplates for rotating
equipment is rapidly expanding as the
features above continue to add benefit
for applications of most every shape
and size. By combining a consistently
flat, vibration damping structure that is
easy to install and maintain, polymer
concrete baseplates will continue to
be the choice of Reliability Personnel
worldwide. ◆
Scott Sapita is co-founder and
managing partner of BaseTek, LLC
in Middlefield, Ohio. Scott has over
twenty-eight years of experience
in the rotating equipment market
including product design, product
management and industrial sales. He
carries a BS in marketing from the
University of Dayton. Contact him at
MPT
Modern Pumping Today®
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MORE
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SURVEYING THE OPTIONS
Industrial manufacturers have a wide
range of pump options to choose
from when outfitting their facilities.
There are also a number of factors
that go into their choice of pumping
technology. Operational reliability
and being able to meet very specific
fluid-handling requirements are
among the most important. With
manufacturing operations governed
by operating budgets and expenses,
equipment acquisition costs and
subsequent maintenance are also
primary concerns.
This article will illustrate that while
all pumping technologies can have
their positive points in industrial-
manufacturing operations,
positive displacement internal
gear pumps can offer the precise
and consistent transfer of highly
demanding fluids—in this case,
dangerous chemicals—that is
critical in creating a reliable,
efficient, cost-effective, and safe
pumping system.
No acid, polymer, resin, or caustic has the same handling characteristics, which makes pump versatility a primary concern for chemical processors. Maag G Ser ies Internal GearPumps overcome many handling concerns by featuring a method of operation that can successfully and safely transfer fluids of differing viscosities and chemical makeups.
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P U M P S O L U T I O N S
THE CHALLENGE OF
CHEMICAL PROCESSING AND
MANUFACTURE
Chemical processing and manufacture
is one of the most complex industrial
operations in the world. In fact, the
chemical-manufacturing process is so
intricate that there are several “unit
operations” within the process, from
cracking, distillation and evaporation,
to gas absorption, scrubbing and
solvent extraction, among others.
Within that family of unit operations,
one touches every stage of the
manufacturing process and stands out
above the others in its importance:
fluid transfer. Often over-simplified
as transporting fluid from one point
to another, fluid transfer in chemical
manufacturing is so much more.
Fluid transfer is a spectrum of
applications, with responsibilities
all along the chemical-production
chain. For example, thin or viscous
raw materials can be transferred
to storage tanks or blending and
mixing tanks. Final formulations can
be transferred to holding tanks, and
finished products can be loaded
into IBCs for delivery or consumer
packaging.
In many cases, chemical-
manufacturing processes require the
use of dangerous chemicals, such
as strong acids, caustics, solvents,
resins, and polymers. Despite their
inherent danger, these substances
are necessary for the manufacture
of thousands of consumer goods or
facilitate other industrial processes.
The challenge for users of these
dangerous chemicals is to construct,
handle, and transfer them in a
reliable way.
A LOOK AHEAD
Next month, we’ll take a closer lookat the benefits positive displacement
internal gear pumps have continually
offered pump users seeking reliability
and cost-effectiveness when handling
raw materials and f inished products—
with a specific breakdown of Maag’s
own G Series Internal Gear Pumps. ◆
Chrishelle Rogers is the global gear pump product manager for Maag
Industrial Pumps, Grand Terrace,
California, and PSG®, Oakbrook
Terrace, Illinois. Ms. Rogers can
be reached at 909.222.1309 or
Maag Industrial Pumps is a leading
brand of internal gear and screw
pumps and a product brand of PSG, a
Dover company. For more information
on Maag Industrial Pumps or PSG,
visit to www.psgdover.com.
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D E W A T E R I N G S O L U T I O N S
Copper mining involves working with some of the
harshest materials in the world. As a result, mining
companies must carefully monitor wear of their
slurry pumps and schedule frequent shutdowns to replace
worn parts. The cost of this maintenance goes far beyond
just the price of parts; downtime and lost revenue can run
into hundreds of thousands of dollars.
SEVERE WEAR RAISING COSTS
KSB's subsidiary, GIW Industries Inc., has produced
success at a South American copper mine.The GIW ®
Minerals product solution quadrupled pump wear life and
created dramatic savings for the mine's tailing pumping
operations. The South American company had struggled
for years to reduce maintenance downtime in its tailings
operations.
Tailings—the material left over after the valuable metal
has been extracted—consist of very fine par ticles that are
highly abrasive in slurry. The material was wearing out
pumps more quickly than other equipment in the tailings
line, increasing the frequency of downtime. They were
having such severe wear that they were repairing the
tailings pumps every 400 to 450 hours.
When considering replacement par ts, manpower, and
revenue lost due to downtime, the costs the copper mine
was facing on a regular basis were staggering. They
desperately needed a solution for more efficient operations.
FINDING A BETTER WAY
GIW offered the South American copper mine the answer.
An LSA centrifugal slurry pump was installed in a tail ings
booster application where GIW's exclusive Enduraclad™
material was applied to the new suction liner.
With the application of this new material, the miningcompany has been able to extend wear life up to 2,000
hours and also improved wear life of other related pump
par ts. This success comes from years of hard work and
innovation from GIW's team of hydraulic and metallurgical
engineers.
Copper MineQuadruples PumpWear LifeGIW Enduraclad™ increasesoperations from 450 hours to 2,000
By Ronnie Willis, GIW Industries
Enduraclad Liner at 550 HoursMetal Liner at 450 HoursLSA centrifugal slurry pump
SIDE-BY-SIDE COMPARISON
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When Enduraclad made its debut
in 2009, its uses were limited. It was
only applied to suction liners and
increased wear life up to three times.
But since then, its capabilities have
expanded to allow coating on other
essential parts and enables it to
provide even greater longevity for
GIW pumps.
GETTING YOUR
MONEY’S WORTH
Although Enduraclad-bonded parts
might be more expensive, they are
well worth the price. They will cost
more than uncoated par ts, such as
suction liners, buy end-users save on
costs by using fewer par ts, reducing
maintenance costs, and not suffering
the downtime revenue loss. To remove
and replace the parts on one of these
pumps requires two to four people
working with tools and lifting devices
for 6 to 8 hours. So the longer a
company can keep the pump running
with nobody touching it, the more
operational costs they will save.
Economy is just one of the things
GIW values and tries to deliver to
its customers. Users are seeking
par tners concerned with their best
interest, who are not just developing
these really specialized materials and processes and charging higher prices.
GIW is continually looking for ways to
reduce the cost of materials to provide
a product that serves customers'
needs and fits their budgets.
CONTINUOUS IMPROVEMENT
IS A MUST
GIW is constantly looking at new
materials and processes that
can improve pump wear life for
customers like the South American
copper mine. Metallurgical experts
are already testing new cladding
materials that will last even longer
than the current ones, and there may
be even greater improvements
in the future with enhanced
Enduraclad material. GIW believes
solutions that add value to their
products will meet and exceed
their customers’ expectations for
continuous improvement. ◆
Ronnie Willis is senior product
manager of new materials at GIW
Industries, Inc., a full subsidiary of
KSB. Through the GIW ® Minerals
product brand, KSB strives to be an
innovative partner that provides you
with the best and longest wearing
slurry solutions. We are your par tner,
today and in the future. For more
information, visit www.ksb.com.
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M O T O R S O L U T I O N S
Turning Awayfrom Tradition
Companies around the world
have come to rely on screw
conveyor drive systems for
reliable drive solutions to meet the
demands of transporting bulk material.
For these critical applications, open,
two-way communication between
OEMs and end-users is essential to
help drive customers with an accurate
assessment of each individual
application. To understand the
demands of industry, a manufacturer’s
goal should be to provide users with a
drive assembly that will reliably serve
the needs of a plant for many years to
come.
For example, NORD’s screw
conveyor packages, with their rugged
output seal and innovative CEMA
drive-shaft, are designed for reliable
performance in screw conveyor
applications. Some of the industries
that rely on screw conveyors include
agriculture; oil and gas; chemicals
process ing and handling; stone, g lass,
and concrete, food products, and
wastewater treatment.
BUILDING A MORE RELIABLE
DRIVE ASSEMBLY
NORD's industry leading ratio range
allows for the elimination of external
rotating components such as V- or
synchronous-belt drives. Eliminating
the belt drive results in a safer and
more reliable drive assembly. By
combining high quality gearing with
a leak free design, NORD delivers
reliable transmission of power to the
driven shaft.
Depending on the type of conveyor,
different applications can see
significant benefits right away. For
example, shaftless screw conveyors
have proven ideal for handling sticky
and sluggish bulk materials and are
equally well-suited for material with
high moisture content.
In addition, screw feeders and live
bottom conveyors incorporate either
a single or multiple gearbox design
and provide a means of moving a
wide variety of material from bins or
hoppers at a constant and controlled
rate of flow. This type of conveyor is
one of the most accurate and efficient
to meter bulk materials. Lastly, vertical
screw conveyors are ideal for elevating
dry to semi-f luid materials from
free-flowing to sluggish at very steep
inclines and are totally enclosed for
dust and vapor-tight requirements.
THE ALTERNATIVE TO
TRADITIONAL SCREW
CONVEYOR DRIVES
The NORD Screw Conveyor Package
offers a compact and cost effective
alternative to traditional screw
conveyor drives. Closely stepped
speed reduction ratios combined
with a directly coupled gearmotor or
NEMA C-face input design eliminates
the need for top motor mounts,
pulleys, belts, or guards. Minimizing
parts and eliminating the belted input
systems provides for easier system
maintenance, increased reliability,
NORD screw conveyor drive proves itselfcompact, reliable, and cost-effective
By Alie Foy, NORD Gear Corporation
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and superior drive performance.
NORD screw conveyor drive options
feature a UNICASE™ reducer housing,
Quadrilip™ reducer shaft sealing and
optional high capacity output bearings
with CEMA standard flange mounting
and CEMA drive shafts ranging from
1-1/2 to 3-7/16 inches.
The Screw Conveyor Package
(SCP) design is available for both
CLINCHER™ Parallel Shaft gear units
and Helical-Bevel Right Angle gear
units. The CEMA flange assembly
offers superior protection against
unwanted debris with its dual Viton™
gap seals (0.03 inch gap) on either
side of the grease filled felt packing
seal. Drive shaft material evacuation
por ts in the flange help protect the
drive system from debris. A slight lead
taper on the reducer shaft provides for
easy mounting and removal, allowing
for some screw pipe misalignment and
reduced bearing loads.
BENEFITS FOR END-USERS
For end-users, the NORD Screw
Conveyor Package offers many
benefits even beyond the reduced
cost, from the large ratio range to
direct drive motor options (Integral
or C-face). Fur thermore, there is no
belt maintenance or belt guarding
required. The advanced design means
reduced parts, higher reliability, and
space savings while also providing
higher efficiency and more direct
torque transfer. More than just an
alternative to tradition, the NORD
Screw Conveyor Package is a
step beyond. ◆
Alie Foy is marketing specialist for
NORD Gear Corporation and can be
reached at [email protected]. As a
privately-held, family owned company,
Nord believes in the long term with
a global perspective—providing a
broad range of products, the highestquality standards in mechanical and
electronic technologies, continued
reinvestment into production,
and a global presence. For more
information, visit www.nord.com.
Clincher SCP Unit Helical-Bevel SCP Unit
Torque Capacity Up to 53,100 lb-in Up to 42,480 lb-in
Power Range 0.16 – 60 horsepower 0.16– 30 horsepower
Ratio Range 4.32:1 – 1,585.08:1 8.09:1 – 4,246.38:1
Output Speed 1.0 – 405 rpm 0.41 – 216 rpm
Efficiency Up to 97% efficient Up to 95% efficient
CEMA Drive Shaft Sizes 1-1/2, 2, 2-7/16, 3, 3-7/16 inches 1-1/2, 2, 2-7/16, 3, 3-7/16 inches
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Woolpert Discipline Director Kirk McClurkin and Project Manager SteveSchwabe discuss the software implementation with ActewAGL’s MarkChenery and Chris Kelly at ActewAGL offices.
Phase Manager Jamie Munro and Market Director Dave Feuer work in amakeshift office in the Woolpert team’s apar tment in Australia.
Institute of Asset Management (IAM) cer tification, with thirteen
professionals cer tif ied.
“In Australia, as in Europe, the IAM standards are very highly
regarded, but most U.S. companies have been late to that party,”
said Feuer, who is IAM certified. “We were pleased that AAD
came to America to get support with its overall asset management
program, knowing we adhere to these elevated international
standards.”
LOOKING OUT FOR CUSTOMERS
The bulk of the work on this project is complete, but Woolpert
continues to support AAD by evaluating ideas on their issue log,
scoping, and developing system enhancements, and additionally
delivering the advanced functionality the AAD-user community
needs to meet its operating requirements. ◆
Woolpert delivers value to clients by strategically blending engineering
excellence with leading-edge technology and geospatial applications.
Woolpert’s mission is to help i ts clients progress—and become more
progressive. For over 100 years and with more than 25 off ices across
the United States, Woolpert serves the needs of federal, state, and local
governments; private and public companies and universities; energy and
transportation departments; and the United States Armed Forces. For
more information, visit www.woolpert.com or call 937.531.1258.
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P R O C E S S I N G S O L U T I O N S
Minimizing Leaksand EnvironmentalHazards for FluidTransfer
Transporting and securing
hazardous material
while also minimizing its
exposure are the twin goals o f any
processing engineer. Many of the
fluids transferred during chemical
processing can be corrosive to
equipment or dangerous to operating
staff. And although well-maintained
connections in the piping or pumping
system is a must, Ingersoll Rand
has introduced a product that thinks
outside the box by putting a pumping
system inside the box: the ARO
Station.
REDUCING LEAKS AND FUMES
The ARO Station is a customized
solution that houses an ARO pumpand piping in a durable housing in
order to reduce leaks and fumes
during chemical transfer from one
container to another. Standing
independently from a truck, the ARO
Station helps operators comply with
changing environmental regulations,
while enhancing operator safety.
ARO understands the importance
of transporting and securing
hazardous material and minimizing
its exposure. The risks with chemical
handling are a daily reality and the
ARO Station was designed to protect
operators as well as the environment
during the transfer of these materials.
DIFFERENT PUMPING OPTIONS
The ARO Station can accommodate
three different size pumps, the
1 inch, 1-½ inch, or 2 inch Expert
Series Pumps (EXP) ARO diaphragm
pump. With the capability to pump
material from 1,320 to 7,900 gallons
per hour, the ARO Station can be
calibrated to pump the appropriate
quantity for each application. Use of
the ARO Station increases the safety
of chemical installations during the
ARO Station provides a safe solution
for processing needs
By Fausto Lotti, ARO Fluid Management
One of two sizes of the Exper t Series Pumps (EXP) ARO diaphragm pump can be placed inside the ARO Station.
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unloading process by reducing risks
of water hammer that occur during
the pressurization of the tanks.
A leak detector that communicates
possible leakage, helping to minimize
air pollution and risk from fumes.
• A heater to prevent freezing in
extreme situations.
• An alarm that monitors the level of
liquid in the tank and whether the
system is running dry.
IMPERVIOUS TO CORROSION
Made of high-density polyethylene,
the ARO Station is impervious
to corrosion, and features a drip
collection tray that can hold up to 52
gallons of fluid. The ARO Station can
be used as a free-standing pump
solution or it can be equipped with
wheels for mobility. Compact and
ready for use, the ARO Station is a
standardized skid size thus reducing
integration costs.
MAKING SUCCESS FLOW
Ingersoll Rand introduced the ARO
Station pumping system at the 2015
ACHEMA tradeshow in Frankfurt,Germany, to an enthusiastic crowd
of professionals in the compressed
air and gas systems and services,
power tools, f luid management, and
material handling equipment industry.
Ingersoll Rand product experts
interacted with attendees, answering
questions and demonstrating the
details of how the new closed
pumping system could benef it their
facilities and operations. ◆
Fausto Lotti is marketing leader for ARO Fluid Management. ARO is a leading worldwide
manufacturer of fluid handling products expertly engineered to deliver performance and
serviceability, enabling customers to achieve the best total cost of ownership. For eighty-
five years ARO has been helping customers solve their most complex fluid handling
challenges to keep their business moving. For more information, contact 800.495.0276 or
"The risks with
chemical handling
are a daily
reality and the
ARO Station wasdesigned for
protection."
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V A LV E S & C O N T R O L S S O L U T I O N S
Managing Assets,Saving Time
A cross a range of industries
connected to oil and gas
or water and wastewater,
companies are experiencing a
worrisome trend. As a great number of
long-time technical experts retire, they
are not being replaced by an equal
number of younger skill workers.
However, companies’ requirements
to manage assets dispersed over
large areas has not diminished, and
Schneider Electric has recognized
the growing need for integrated and
automated control systems that today’s
workforce can operate reliably and
efficiently.
SAVING ENGINEERS TIME
Schneider Electric’s new open and
scalable software for telemetry and
remote SCADA applications, SCADA
Expert ClearSCADA, controls budgets
throughout each project, captures
relevant and reliable data from remote
and challenging locations,
and also minimizes
system security r isks.This software improves
the user experience
with better maintenance
tools, improved data
accessibility, and enhanced
security in telemetry
and remote SCADA
applications.
Cementing its position
as a global specialist
in energy management
and automation, Schneider Electric,
has also announced the release of
StruxureWare, an add-on to SCADA
Expert ClearSCADA that continues
to improve on the user experience
and provide functionality based
on customers’ needs. Template
expressions save engineers time
during implementation; alarm
summaries help pinpoint maintenance
issues faster, and the seamless
integration with a tier-2 historian
facilitates data accessibility across the
entire enterprise.
EXPANSIVE FUNCTIONALITY,
REDUCED OPERATING COSTS
These functionalities are part of a
software platform that is designed
to lower the overall operating costs
of remote assets while providing a
complete, comprehensive overview of
site operations. Other features include:
• Enhanced WebX user interface–
Process information is available
anytime, anywhere through any
device with HTML5 cross-browser
support for trends, alarm lists,
event lists, and queries.
• Extended integration of telemetry
hardware–Enhanced integration
with the Realflo software, a flow
measurement application, now
including support for Realflo
Liquids 6.91, plus native support
for well-known third-party flow
computers via a new oil and gas
EFM Driver suite.
• Increased system security–A
substantial increase in security
features includes enhanced
user account security, auditing
of the system security through
a dedicated security event
list and dedicated security
logging queries.
By providing remoteconfiguration capabilities
and collecting data from
multiple ClearSCADA
systems into a central
enterprise repository,
ClearSCADA software
helps reduce costs
while providing
crucial, business-
relevant data across all
operational levels.
StruxureWare SCADA Expert ClearSCADAsoftware fills the market’s need
By Brad Shaw, Schneider Electric
EcoStruxure Web Services-ready, SCADA Expert ClearSCADA seamlessly integrates products and systems from the Sch neider E lectr ic busin ess segments.
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SCADA EXPERT CLEARSCADA
The SCADA Expert ClearSCADA
system foundation is built using open
standards, naturally providing industr y-
leading integration with external
business and IT systems. Critical
infrastructure management business
systems, including GIS and ERP,
can share data with SCADA Expert
ClearSCADA using open SQL ODBC
and OLE-DB standards. Interchanging
data with a wide range of controllers
and PLCs, and other process systems
can be done seamlessly using
extensive OPC interfaces. SCADA
Expert ClearSCADA client and server
API fac ili ties provide ult imate flexibili ty
using the latest in OLE and .NET
software technologies.
All SCADA Expert ClearSCADA
facilities can securely interoperate
with business and IT systems to turn
asset and infrastructure SCADA data
into valuable business information.
Additionally, SCADA Expert
ClearSCADA is EcoStr
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