Pipes, Pumps & Valves Africa Nov-Dec 2018

ENDORSED BY SAPMA, SAPSDA, SAVAMA AND VAMCOSA

Nov / Dec 2018

Tips for pump cost savings Flywheel pump prevents damage to infrastucture

Pumps that solve problems Accurate, versatile chemical pumps Cut chemical costs through higher accuracy metering Simple drop-in installation eliminates ancillary equipment Flow rates from 0.1 to 2000 ml/min and up to 7 bar Fully sealed for life, one minute tool-free maintenance REVOLUTIONARY PERISTALTIC PUMPHEAD

Heavy duty pumps for abrasive slurries Pumps with no seals or valves to wear, clog or leak, up to 100 cubic metre/hr to 16 bar Minimal maintenance - just change the hose Suction lift capability to 9.5 metres, self-priming and dry running Ideal for abrasive products, high viscosities and shear sensitive fluids

watson-marlow.com/za-en info.za@wmftg.com

JOHANNESBURG: Tel: +27 11 796 2960 RUSTENBURG: Tel: +27 14 592 0919 CAPE TOWN: Tel: +27 82 776 2872 LIMPOPO : Tel: +27 82 896 9936

CONTENT COVER STORY M & H PUMPS proving that ‘Service is King” M & H SABS approved GENE series flow meter launch event

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ENDORSED BY SAPMA, SAPSDA, SAVAMA AND VAMCOSA

Nov / Dec 2018

INDUSTRY NEWS Pipes, Pumps & Valves Golf Day 2018

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Verder no. 1 in the top-100 Dutch manufacturing industry

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PRODUCTS & SERVICES BMG’s dependable Garlock seals and sealing systems

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PUMPS

On the cover

Atlas Copco WEDA 50+ and 60+ pumps take dewatering solutions to the next level

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Flywheel pump prevents damage to infrastructure

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Pump Selection - How to choose the best pump for thickener underflow

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Dirty water no problem for Sykes water transfer range

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Robust pre-assembled panel systems for pumping applications

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Advanced new range of verticle turbine pumps

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New variable speed drives (VSDs) provide crucial reliability at a key unmanned pumping station

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Tips for pump cost savings

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Pump installation tips

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Warranty on Grindex Pumps extended by Integrated Pump Technology 34 Danfoss enters industrial wastewater markets with high efficiency pumps

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PIPES Plasti-Tech supplies HDPE pipes

Tips for pump cost savings Flywheel pump prevents damage to infrastucture

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VALVES 200 AVK Valves supplied to wastewater treatment plant

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Solid as a rock: The importance of gas storage plants is growing

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BEARINGS SKF Cooper bearings get a facelift

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BUYERS GUIDE

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M & H Pumps

Tel: +27 (0) 11 864 1404 Email: info@mhpumps.co.za Web: www.mhpumps.co.za

Pumps & Valves Africa

Managing Editor:Electra Surita Marx Mining Report Back Tel: +27 (0) 11 475-0010 Overcoming dry spells Cell: +27 (0) 83 281-5761 Email: info@pumpsandvalves.co.za Web: www.pumpsandvalves.co.za Sales: Lusana Mrkusic Email: lusana@pumpsandvalves.co.za Sales: Kyle Rametsen-Spalding Email: info@pumpsandvalves.co.za

Advertisers Air & Vacuum Technology 33,39 Atlas Copco 35 Chick Henderson 25 Cyclone Industries 29 Garnet Cross 36 Invincible Valves 9 Kew Foundries 15 KSB Pumps 23 Macsteel 27 M & H Pumps OFC,OBC Pamodzi Unique 42 Pumps, Valves & Pipes IBC SAM Engineering 17 Water Week 43 Watson Marlow IFC

Disclaimer

Opinions in this Publication are those of the authors and do not necessarily reflect those of this publication, its editorial board, its editor or its Publishers SAPMA. or VAMCOSA The mention of specific products in articles and advertisements does not imply that they are endorsed or recommended by this Publication or its publishers in preference to others of a similar nature, which are not mentioned or advertised. Reliance on any information contained in this journal is at your own risk.

While every effort is made to ensure the accuracy of editorial board makes no representations or warranties, express or implied, as to the correctness or suitability contained and/or the products advertised in this publication. The Publisher shall not be liable for any damages or loss, howsoever arising, incurred by readers of this publication or any other person/s. The Publisher disclaims all responsibility and liability for any damages, includes pure economic loss and any consequential damages, resulting from the use of services or products advertised in this publication. Readers of this publication indemnify and hold harmless the publisher, its officers, employees, and servants for any demand action, application or other proceedings made by any third party and arising out or in connection with the use of any services and/or products or the reliance on any information contained in this publication.

Pipes, Pumps and Valves Africa - Nov/Dec 2018

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COVER STORY

M & H PUMPS proving that ‘Service is King’ King’ When you have little knowledge you have no choice but to utilize your intuition to navigate your own path. By simply navigating hard times and having the gumption to pursue the non-traditional path can inspire other people. Family businesses are often an overlooked form of ownership.

As family businesses expand from their entrepreneurial beginnings, they face unique performance and governing challenges.

Just as special skills are needed for any company to survive, so it is for M & H PUMPS as the skills set and culture with the company is often associated with family ownership which is unusually well suited to such a challenging industry.

“We have no shareholders to satisfy so we can focus on any long term strategy such as increasing our product line or even diversification into any other allied industry, depending on the opportunities that come our way, especially in today’s uncertain political and economic climate,” said Mac Magill, Founder of M & H PUMPS. Mac Magill is a true blue entrepreneur, having started the company 26 years ago in the garage of his home doing flow meter servicing. He recalls that his early days were spent at Ingersoll Rand in their pump division which saw him gaining valuable experience for four years while working there. A twist of fate saw him unemployed for a period of time and it was during this period, he met a benefactor who gave him an opportunity to service pumps and meters as a means of earning an income. The opportunities opened up for Mac (As he is well known today) as a result of his determination and resolve to succeed. A prime example of this was him travelling to service clients’ units by hitchhiking to get there. From those humble beginnings he purchased his first vehicle and rented premises in a

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

small industrial area in order to have a base away from his garage.

Today M & H PUMPS is in the forefront of the industry, providing field services for fuel depot engineering work, encompassing gantries, flow meters, valves, construction and design, all within the ambit of safety regulations, key for success in the industry. In 2000, Mac Magill purchased the property in Alrode where the business is based and some 18 years later the company boasts a staff compliment of 30 people offering comprehensive services throughout South Africa and various other African countries. Distance is not a problem for the company, for at a moment’s notice a spare part or new component is despatched by road, air and sea to any destination where it is required.

COVER STORY

“Expertise in my business comes from the right people I employ who provide the necessary skills to meet the challenges synonymous with an industry which operates under strict government controls. All meters used in the dispensing of fuel have to coincide their accuracy whether it is from source to tanker and then to the storage unit of a client. A major consideration is temperature compensating affected by changes in ambient temperatures. I have no qualms about learning from the people I employ as we are now faced with the electronics era and require the necessary expertise to maintain our service levels,” added Magill.

Flow meter accuracy and respectability are two criteria for flow meters to meet or exceed the benchmark. The company’s sophisticated test bench facility is a state-ofthe-art design which tests meters and calibrates both mechanical and electronic flow meters and pump sets to guarantee accuracy of products to customers.

The current economic climate has given rise to innovative strategies in many companies. So too has M&H PUMPS risen to the occasion with their flow meter and pump remanufacturing programme which has become an integral part of their business model.

The company is continuously purchasing all the used meters available in the market in order to feed their remanufacturing business. New meters have become very expensive in some quarters so the availability of remanufactured units has stimulated a different market demand. These meters are fully stripped down and

remanufactured to OEM specification using only new parts and supplied with a 12 month warranty.

M & H PUMPS have recently effected some changes in their business model in that they have broadened the scope of their activities from flow meter supplier and service provider and for the first time, into product supplier under their own brand name as well as turnkey installations.

The new Gene flow meter range is manufactured in the East, exclusively for M&H to full specifications to meet local conditions and is the only company to provide a full range, from 40 mm (1.5 inch) to 100 mm (4 inch) from one manufacturer. An added advantage of the new product is the SABS approved rating which will also provide entry into the African countries who have been applying pressure for certified equipment.

“We have built the company on service even though it has been at times expensive to do so. Our excellent relationship with our clients is what have been the strong pillars of the company. We have also extended the relationship to our suppliers who have supported us in all facets of the business where they have been required to meet our demands in ensuring the highest quality in our product range,” concluded Mac Magill.

Contact: Mac Magill, M & H Pumps Tel: +27 (0) 11 864 1404, Email: info@mhpumps.co.za Web: www.mhpumps.co.za

Pipes, Pumps and Valves Africa - Nov/Dec 2018

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M & H SABS approved GENE ser Mac Magill and his dedicated team hosted key suppliers who showcased their latest product innovations at the event.

METER SYSTEMS Now part of Torre Parts and Components, established in 1978, striving to be the premium Southern African equipment supplier to the Petroleum, Chemical and Lubrication industries. Meter Systems are solutions driven with an extensive product range, supplying products for all industries and customer focused with a dedicated, skilled team to tend to your requirements Tel: +27 11 923 7000 Website: www.torreparts.com.

Dupleix Liquid Meters With over 55 years’ experience, Dupleix Liquid Meters (DLM) offers expert advice on a range of products. We are renowned for providing the right solutions for overpressure protection; flow, level and density measurement; automation and control requirements. We maintain substantial stock holding and have a branch infrastructure capable of providing skilled technical and sales service. DLM has in-house technicians to service products, an engineering team that is capable of delivering small projects as well as a workshop and test facility. DLM has three divisions, namely Valves, Flow and Instrumentation.

Tel: +27 11 457 0500 Website: www.dlm.co.za

Firebreak SA A Level 1 BBEEE company specialising in Fire Servicing & Safety Products; Portable Breath Testers; Gas Detection; Confined Space & Rescue - MSA Channel Partner.

Tel: +27 11 908 6960 / 865 5945 Website: www.firebreaksa.co.za

Hatz Diesel Hatz Diesel manufacutres a range of Air & Water cooled diesel engines with a power band of 1.4Kw to 62Kw. Hatz Diesel is the ideal partner when “Creating Power Solutions”. Applications of use include compaction euipment, skid steers, mobile elevation platforms, dewatering pumps, generators, lighting plants etc.

Tel: +27 11 574 0911 Website: www.hatz.co.za

MEGA LUBE Specialise in the blending and supplying of virgin based oil and lubricants to various types of industries. Quality oil for Transport, Industrial, Agricultural and Supportive Products.

Tel: +27 11 907 0941 Email: etienne@Megalube.co.za Website: www.megalube.co.za

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

ries flow meter launch event Gorman-Rupp Gorman-Rupp Africa’s representation covers countries in Sub-Sahara Africa, who service markets in: Sewage, Industrial effluent, Petroleum, Construction, Mining, Agriculture, Irrigation and Fire Protection. We manufacture one of the largest selections of pumps worldwide, over 6 500 pump models including: self-priming centrifugal, rotary gear and vertical in-line turbines. A purchase from Gorman-Rupp does not give you a “lump of cast-iron” but rather a lifetime of quality, service and satisfaction.

Tel: +27 11 397 3536 Website: www.grpumps.com

National Hygiene Manufacturer of top quality chemicals since 1984 and was awarded the African Gold International Global Award in 2010 for hygiene chemical technology. They supply top quality chemicals to industries such as food & beverage, engineering, hospitals, airports etc. Hygiene SA strive to formulate new chemicals for the workwear industry, PPE, cleaning equipment and hygiene to the industry.

Tel: +27 11 900 4387 Website: www.national-hygiene.com

Liquid Movers Liquid Movers supplies pumps, compressors, valves and related equipment to customers all over the country. We focus on the mining, chemical, fuel, process plant and food industries. Products include centrifugal and magnetic drive pumps, gas compressors & much more. We distribute the best pump brands including Blackmer, ARO, Flowserve etc.

Tel: +27 11 708 0600/08/13 Website; www.liquidmovers.co.za

Pneumax Established in 1987, they have built a solid reputation as one of the leaders in the pneumatic and automation fields, offering innovative, modern products, priding themselves on developing and maintaining relationships with customers.

Products offered by PNEUMAX include amongst others, air preparation units and air management devices such as manual and solenoid operated valves, actuators and handling equipment.

Tel: +27 11 923 7000 Website: www.torreparts.com

Soliflo Since 1984, Soliflo is synonymous with highly specialised bulk liquid control, tanker offloading systems & services in the Southern African Development community SADC countries & beyond. As the region’s liquid control & tanker specialists, we are a principal supplier of safe, efficient & environmentally-friendly liquid control, fluid & gas transfer solutions to various industries & leading brand access & loading equipment for road, rail & marine tankers. Our portfolio includes Loading Arms, Tanker Access equipment, Tank Truck equipment, Grounding & Earthing devices, Pumps, Instrumentation & Flow Control equipment, Industrial Hoses & Assemblies, Dry Break Couplings, Adapters and Breakaway Couplings.

Tel: +27 11 792 2196 Website: www.soliflo.co.za Pipes, Pumps and Valves Africa - Nov/Dec 2018

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C.R.I Pumps Established way back in 1961 with the attempt to produce a few irrigation equipment using limited facilities of an in-house foundry. Eventually the founder’s dream was coming true as the small production unit he started kept growing rapidly. Today C.R.I Pumps is one among the few pioneers in the world to produce 100% stainless steel submersible pumps, having achieved record production capacity of over 2 million pumps per annum.

Tel: +27 11 805 8631 Website: www.cripumps.co.za

John Bean Technologies (Pty) Ltd (JBT) John Bean Technologies (Pty) Ltd (JBT) Energy in South Africa is a specialized business that concentrates in custody transfer measurement systems. JBT’s partnership with FMC Measurement Solutions, FMC Loading Systems, Scully Signal Company and Lomo Soft Logistical Management has resulted in an unequalled solutions orientated provider to the oil industry.

Tel: +27 11 422 2290/2 Website; www.jbtcorporation.com

E’ Afrifil (Pty) Ltd E’Afrifil, a liquid filtration company. We offer complete filtration solutions that not only offer protection to but further prolong life of our clients equipment.

Cellphone: 0827851205 Tel: +27 11 452 5444 Website: www.afrifil.com

Marelli Motori Marelli Motori S.p.A has a tradition dating back to 1891 when Ercole Marelli founded the Company. With over 100 years of manufacturing excellence and experience, Marelli Motori is recognized as a leading supplier to the Power Generation, Industrial, Petrochemical and Marine Industries sectors offering a complete range of Low, Medium and High Voltage Motors and Generators. These quality products are backed up by an organisation of skilled people providing sales, service and technical support to the high standards demanded by our customers.

Website: www.marellimotori.com Tel: +27 11 392 1920

Legend Bulk Diesel Legend Bulk Diesel supplies pure quality 50ppm diesel at the most competitive price in the industry. Our customers include fleets of well established transport company’s and a variety of depots. We are notorious for testing our fuel quality with advanced apparatus. When it comes to supreme quality fuel, our customer’s fleets are in excellent hands.

Cellphone: +27 76 819 6526 Tel: +27 72 508 0615 Website: legendkevin001@gmail.com

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

From the desk of Pamela du Plessis, Managing Director of Invincible Valves

Invincible Valves (Pty) Ltd 33 Shaft Road, Knights, Germiston TEL: +27 (0) 11 822 1777 | FAX: +27 (0) 11 822 3666 EMAIL: enquiries@invalve.co.za | WEB: www.invalve.co.za

South Africa has an abundance of mineral resources which plays a huge role in the local and global economy.

Globally we see a mining crisis, which has affected mining regions around the world, but in particular South Africa’s mining sector. Not only are we faced with the global pressures of commodity prices and currency fluctuation, but in South Africa we face additional factors that contribute to the crisis. These would include volatile labour relations, tough government interventions as well as regulatory uncertainty.

The impact of Eskom’s load-shedding and rising power costs has an additional adverse effect.

Due to many of these factors a number of Mining Companies have been forced to reduce overheads and head office costs, which has resulted in job losses throughout and a rather light operational level staff compliments. Banks in South Africa have been forced to re-assess and track their exposure and proactively manage these, therefore less lending and higher interest rates add to the crisis. With commodity prices having declined significantly over the past months which in turn means fewer are able to meet the risk management requirements.

With all that said we should be mindful of the fact that we do indeed have a rich mineral resource country with many opportunities for profitable, successful and sustainable mining in South Africa.

If it's not INVAL®, it's not Invincible

Pipes, Pumps & Valves

Pipes, Pumps & Valves Africa hosted another successful Golf day on the 26th of Oct 2018 a manufacturers of the pipes, pumps & valves industry. We would like to thank all players and

Our sponsors and players included: Actom, Ainsworth, APE Pumps, Control Liquid Systems, Placements, Natal Stainless Steel, Sulzer Pumps, Turbo Fluid, Weir Minerals, Zest WEG

s Africa Golf Day 2018

at the ERPM Golf Course in Boksburg. A fun filled day spent with suppliers and d sponsors for attending. Without you it would not have been possible!

, CRI Pumps, In Quest Investigations, Integrated Pump Rentals, Invincible Valves, Lifting

INDUSTRY NEWS

Verder no. 1 in the top-100 Dutch manufacturing industry Verder has been elected by Management Team as the number one (#1) brand in the Dutch top-100 Made in Netherlands manufacturing industry report.

The first edition of the top-100 was published in 2013 and at that time Verder ranked at number three (#3). In the years that followed the company consecutively remained in the top four (#4) – but for 2018 Verder is at the top of the list!

This ranking is published annually by the Dutch magazine Management Team, listing the 100 most successful Dutch manufacturing companies with a turnover of less than 500 million Euros. Manufacturers that are financially stable, achieve healthy growth and take Dutch industry to a higher level with innovative products are chosen for this list.

Verder was selected based on the following criteria: turnover, average revenue growth, profit growth and return on investment in the past five years.

Verder focuses on innovation and technology and offering customer solutions. Started as a trading company in 1959, the number of own products has grown considerably over the years. In addition to expanding the product lines pumps and laboratory equipment for the Scientific division, Verder also acquired companies such as Retsch, Carbolite Gero, and the last acquisition: Qness. In 2014, the Liquids division of the Verder Group acquired the Italian company Microdos and in 2015 the pumps manufacturers Ponndorf (German) and Packo (Belgian). By creating partnerships with producers and a dynamic own R&D, Verder also gives an extra impulse to market penetration.

The Verder Group still is a family business, based on the core values which it was founded on: integrity, respect, with the emphasis on human rights, honesty and ecological sustainability. The company continues its tradition of technical excellence, finds innovative solutions to existing problems and forges new ways and anticipates to the problems of the future.

Andries Verder, CEO of the Verder Group, said: “The lines between manufacturer and distributor will be shortened.

These changes require a complete revision of the organisational structures as we have known them up to now. It also offers great opportunities for internationally organised companies.”

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

Andries Verder also indicated that technology and “Industry 4.0” will play a very important role in this change process, but that the road to the way of working in the future cannot be achieved without a focus on organisational structures. “We see a clear trend where customers are better informed and look for suppliers that are objective in their selection of technologies.

Our mission therefore is to have all possible know-how in niche market technologies in the field of manufacturing, in order to offer customers real solutions.”

“We are incredibly proud of this achievement, and to represent this innovative multinational organisation in Africa. This accolade is a testament to the quality and performance assurance of not only our industrial pump solutions, but our services as a completely integrated offering,” said Darryl Macdougall, Managing Director, Verder Pumps South Africa.

Contact Kirstin Adam, Verder Pumps South Africa, Tel: +27 (0)11 704 7500 Email: kirstin.adam@verder.co.za

BMG’s Garlock seals and sealing systems have been developed by Garlock Sealing Technologies for safe and dependable performance in extreme operating conditions.

“The demands of modern engineering have made the selection of suitable sealing components a critical consideration – both in the design of new equipment and in the correct installation of products to replace those that are no longer suitable. Failure to install the correct sealing system is highly dangerous, particularly in extreme conditions,” says Marc Gravett, BMG’s business unit manager, Seals and Gaskets.

“The company’s commitment to supplying only quality branded products that meet stringent specifications in terms of performance and uniformity, results in unvarying, dependable performance, even in the most demanding process applications.

“Garlock sealing products, with a user-friendly design and advanced materials, ensure dependable sealing in all sectors. These industries include chemical and petrochemical, pulp and paper, power generation, electronics, food and pharmaceuticals, as well as steel mills, mining and OEMs.” Garlock seals and sealing systems include metallic and Gylon gaskets, oil seals, bearing isolators, expansion joints and butterfly valves. Components extend from a standard sealing ring, available from BMG stock and ready to install, to designs, which are fabricated to specific requirements.

Garlock Klozure oil seals and bearing isolators are designed to retain lubricants, but exclude contaminants, like moisture, dust and dirt, from penetrating the primary seal or bearing houses. These components play an important role in protecting bearings, preventing downtime and extending the service life of the system, even in arduous operating conditions.

Klozure oil seals are available from BMG in numerous shaft sizes, materials and designs, including solid and split configurations. Seals with a reverse bevel lip allow installation in either direction without rollover and Stainless Steel garter springs provide tension to create an effective seal against the shaft. Klozure oil seals with a GLYON®. lip material offer reduced creep and cold flow, compared with the standard PTFE material.

Garlock ISO-GARD® bearing isolators, with a unitised twopiece PTFE construction, provide excellent chemical and temperature resistance. The non-contact design eliminates shaft scoring, as well as drag and frictional heat, which means no lubrication is required. These bearing isolators are the ideal alternative to lip seals in non-flooded oil or grease applications.

The glass-filled PTFE material provides excellent chemical resistance and can withstand operation in a wide temperature range (- 30ºC to + 204 ºC). These bearing isolators, which are available with FDA-compliant O-rings, have a press-fit design, which means installation is easy and no tools are necessary.

GUARDIAN™ metallic bearing isolators provide bidirectional sealing, offering both ingress and egress protection and are suitable for electric motors, pumps, gearboxes and pillow-blocks used in dirty, dusty and wet environments. These bearing isolators have a cam-lock system and an internal PTFE unitising seal feature.

PRODUCTS & SERVICES

BMG’s dependable Garlock seals and sealing systems

Included in BMG’s Garlock range are non-asbestos gasket materials, which comply with strict environmental regulations. New to the range, are GYLON EPIX™ gaskets, which have been designed for improved functional performance, increased compressibility and a broader range of applications than conventional PTFE gaskets used in worn and pitted flanges.

These gaskets, with advanced PTFE materials, have a hexagonal surface profile that provides the torque retention and blowout resistance of a thin gasket and the conformability of a thicker gasket. GYLON EPIX materials are available in one universal thickness (2,4 mm) eliminating the need to stock a variety of material thicknesses for different stress requirements.

Various high-performance sheet materials in this range are suitable for use in different applications, including acids, steam, chlorine, water, solvents, gases, refrigerants and hydrocarbons.

Metallic gaskets for extreme conditions are available in a wide selection of materials and designs to suit exact process requirements. These gaskets include a new spiral wound design that eliminates the radial buckling problems of conventional spiral wound gasket Compression packings ensure reliable sealing in valves, pumps, agitators and other rotary equipment. Expansion joints are engineered to absorb movement and dampen vibration, reducing stress on pumps, pipes and anchoring systems.

Contact Marc Gravett, BMG World Tel: +27 (0) 11 620 1575 Email: marcg@bmgworld.net Web: www.bmgworld.net Pipes, Pumps and Valves Africa - Nov/Dec 2018

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Atlas Copco WEDA 50+ and 60+ pumps take dewatering solutions to the next level

PUMPS

These pumps have been designed to provide customers with enhanced levels of performance alongside improved efficiency, hassle-free maintenance as well as augmented capacity.

The WEDA pumps range contains a built-in starter and motor protection system that allows for optional automatic level control. The pumps’ smart modular design includes machined slots that allow for the easy separation of the different parts of each pump. All stainless steel bolts and nuts used within the machine are the same size, therefore making it possible to use one effective tool to complete the entire operation. Other standard components include a reinforced cable entry, built-in run capacitor / contactor, an adjustable discharge connection of 90° or 180°, Class F insulated stators with thermo switches in all windings as well as external plug for grease filling.

Manufactured to deliver optimum performance in the harshest conditions, these pumps have adjustable wear resistant nitrile rubber diffusors and hardened high quality clog-free chrome impellers. Adding to its durability, the machine’s lightweight and compact design allows for easy transportation, installation and storage in confined areas.

Featuring a low friction unique sealing system, operators are able to change seals, the impeller and other components within minutes. Maintenance is simple thanks to the WEDA ISP (Instant Service Pack) that contains the seals, bearing oil and oil housing that can easily be changed onsite.

Encompassing many features from the successful Atlas Copco WEDA range, WEDA+ range has taken these features and strengthened them with additions such as for example the use of improved aluminium alloy with higher corrosion resistance thereby increasing ruggedness and machine lifespan. The advancement of WEDA+ pumps’ cable entry system not only allows for the use of a wider range of cable configurations but also improves sealing The powerful and portable pumps have been built by skilled technicians, using the highest quality materials and offer an extensive range of dewatering solutions for construction, industrial, emergency and maintenance applications. “The WEDA range of electric submersible dewatering pumps are reliable and robust, featuring a custom-made sealing system and modular design that contribute to them being amongst the most flexible pumps in the business,” states Sarel Bekker, Atlas Copco Power Technique Business Development Manager, Portable Products. He continues that the WEDA+ range has taken all the impressive features of the founding WEDA range and has further improved on them with cutting-edge additions.

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

A novel feature across this range is the rotation control and phase failure protection that prevents the risk of the impeller rotating in the wrong direction and in the case of phase failure will halt the pump.

The economical WEDA+ range features a fuel-efficient new motor design with greater efficiency and reduced start current, double row ball bearings with better lifespan as well as new hydraulic ends for boosted productivity and LCC. The 50+ and 60+ pumps are offered in a normal head (25m and 30m) and high head (41m and 52) respectively with the 60+ also available in a super high head (76m). The WEDA 50+ features an impressive maximum flow between 1173 – 2347 l/min while a maximum flow of between 984 – 2650

PUMPS

l/min can be achieved with the 60+ pump, according to the head size used. The 50+ only requires a maximum power input of 7.5kW and has the capability of a shaft speed of 3460 rpm. Following suit, the 60+ pump needs a maximum power input of 10kW with a 3470 rpm shaft speed capacity.

Both units have a maximum solid handling size of 8mm.

“Atlas Copco is proud of the new Super High Head WEDA 60+ model that is the most compact and lightweight within its class and delivers unrivalled performance combined with easy portability. Both the WEDA 50+ and 60+ dewatering

pumps provide customers and end-users with service excellence, a factor which Atlas Copco strives to uphold throughout our comprehensive product and service portfolio,” concludes Bekker.

Contact Atlas Copco, Tel: +27 (0) 11 821 9000 Email: wendyb@za.atlascopco.com Web: www.atlascopco.co.za

Cast with Skill – Delivered with Speed KEW Foundries taps into 100 years of Foundry and Pattern Shop experience to develop innovative solutions to unique casting requirements.

We work closely with our Clients in the design and development of a diverse range of patterns to produce small to large castings servicing the pumps, valves and water reticulation industries.

KEW is an ISO 9001 listed company.

Contact us for your casting needs today: Tel: +27 (0) 53 841 0474 Fax: +27 (0) 53 841 0473 e-mail: info@kewfoundries.co.za Web: www.kewfoundries.co.za

©Creamer Media 090916CG

• Specialists in various grades of Grey and SG Iron • Sophisticated castings up to 10 500kg • Mass weights and simple castings up to 11 000kg • Non-Destructive Testing performed on Site

Pipes, Pumps and Valves Africa - Nov/Dec 2018

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PUMPS

Flywheel pump prevents damage to infrastructure A unique flywheel water pump system that is able to continue pumping long enough to mitigate the possible effects of water hammer in the event of power failures was developed by KSB Pumps and Valves Local pump manufacturer, KSB Pumps and Valves, showedoff its world-class engineering ability recently when it was called upon to develop a unique flywheel water pump system able to continue pumping long enough to mitigate the possible effects of water hammer in the event of power failures.

Ruan Nel, KSB Pumps and Valves project engineer, explains that the pump was developed for the rural Tsomo District Municipality where it is required for critical high lift pumping of potable water to supply water transfer requirements. Due to unstable electricity supply the municipality however, required a solution to prevent the potentially catastrophic backward rush of water in the event of a power failure that could lead to water hammer and the destruction of its water infrastructure.

This required the technical team to develop a reliable and failsafe method of maintaining water pressure long enough to reconnect power, or in the event of no availability of power, to (gradually) slow down and arrest the flow without air bubble-causing cavitation. Due to the rural location of the pump station, the team also needed to develop a reliable solution with minimal maintenance requirements.

High RPM

“The requirement for a flow of 380 cubic metres of water 16

Pipes, Pumps and Valves Africa - Nov/Dec 2018

per hour, at differential height of 261 meters with an efficiency of 80.8%, called for a powerful pump and motor combination with the addition of a heavy flywheel.

“Weighing in at 681kg each, the flywheels spin up to 3000 RPM and provide enough momentum to pump water for at least four minutes after power is interrupted. With a flywheel central to the design chosen, the pump selection was based on our high-efficiency Multitec multistage pumps which we configured in an inline orientation with the suction side on the left front side of the pump and discharge on right front side to make room for the flywheels.

“Considering the critical application in which the pump is to be used we also elected to manufacture all internals in bronze for corrosion resistance and low maintenance as well as added durability. In the end this is one of the only times worldwide that a flywheel pump of this size and such high revolution has been undertaken and paves the way to apply a smart solution to an old problem,” says Ruan.

Well balanced

He continues that incorporating the flywheel was a particularly challenging undertaking requiring them to be specially designed and manufactured to high standards with balancing to G2.5 at 3000rpm, which is a particularly close tolerance to ensure near perfect balance. Mating to the pump also required careful engineering requiring

Contact Annett Kriel, KSB Pumps & Valves, Tel: +27 (0) 11 876 5600, Email: Annett.Kriel@ksb.com Web: www.ksbpumps.co.za

www.sameng.co.za

CS X MP PU

The entire project was completed in just a few months from order in October 2017 to acceptance in 7 June 2018.

The project was commissioned by Partners in Development as the consulting engineers with Derek Vorster from Mercury Intertrade as the main contractor.

CP S MP PU

“Our flywheel solution now ensures that the inertia of the flywheel keeps turning the pump and eliminates air pockets and water hammer if power is interrupted. It is just the kind of reliable, mechanical solution that is required in this isolated rural area,” adds Ruan.

E DL N

Best solution

CP 7

MP PU

The system also required a heavy-duty base plate made from channel type steel and reinforced around the flywheel plumber block pedestal similar to large industrial baseplates and ensures the system remains perfectly balanced at all times.

HM

• Horizontal Split Water Pumps • CPX/HMX Type • SP Type • Vertical Turbine • CPW Type • CSR Type

MP PU

The system also uses a variable speed drive (VSD) to synchronise the motor, pump and flywheel speeds and makes use of specialised couplings to ensure the transfer of energy between the motor and flywheel remains seamless at all times including start-up, power outages and restart while the flywheels are still turning.

P -C

self-centring ball bearings able to withstand high pressure, as well as special grease to allow for the high rpm.

Operational bearing temperatures was tested to remain at 19-21°C during extended operation.

VERTICAL SP I

Our range of pump products include: • CP/CPO Series • CP7 Type • Vertical Spindle/ Cantilever Pump • HM Process Pumps • CSW Type • CSY Type • Process Pumps

PO

Ruan Nel, KSB Pumps and Valves, Project Engineer

C

PUMPS

Over 25 years of experience in designing and manufacturing a complete range of centrifugal pumps for a broad spectrum CSO/CP of industrial, process and general applications.

Providing customised pump solutions to various industries

Pump design techniques that ensure our pumps are manufactured to last

High performance - high quality products, excellent service

Alloys to suit all applications Proud Manufacturers of SAMCO® Pumps

Pipes, Pumps and Valves Africa - Nov/Dec 2018

17

Pump Selection

PUMPS

How to choose the best pump for thickener underflow.

Thickener or Clarifier Pumping Clarifiers and thickeners are both means of separating liquids and solids. Thickeners are used to concentrate solids, whereas clarifiers are designed to purify liquids. Effective thickening or clarifying is typically done with the aid of flocculants or reagents. These flocculants often have long polymer chains that are like the tentacles of an octopus.

If the wrong type of pump is used to pump these flocculants to the clarifier or thickener, then the flocculants may be damaged by the pumping process. One would want to utilize a low shear pump in this application. Some typical low shear pumps would be diaphragm, progressive cavity or peristaltic. High shear pumps would be centrifugal, gear, or rotary lobe pumps.

If a high shear pump is utilized the thickener or clarifier may require significantly increased volume of expensive flocculant.

Thickeners or Clarifiers can be gravity flow devices but in most cases, especially when there is high solid content out of the bottom thickener, it will require a pump to deliver the medium to its desired location. Many times, the thickened solids are fed to pressure filters of various types to dewater the solids. In some cases, the solids may be valuable product and other cases the solids may be simply a waste product.

How well the thickener controls the density of the thickened solids can determine how profitable or productive the process may be. If the filtration is filtering

Peristaltic- ESR Gland Water No Risk of Cavitation No Siphoning when Pump is Stopped No Self-Priming Yes Dry Run Capable Yes Fixed Volume Yes Reversible Yes Shearing of Medium No Frequency of Repair Low Cost of Repair Low Suction Lift Yes Flow Capacity Moderate

a valuable mineral or metal, then the effectiveness for the both the thickener and filtration process may be critical.

How the thickener and filtration process work together may result in significant higher costs of filtration or vice versa. If the thickener only supplies 30% solids thickened slurry to filter, then the filter may require additional fill time and pressing time.

This slows the process and production. However, if the thickener delivers 65% thickened solids concentration consistently, then both fill time and pressing can be reduced. Thus, providing increased production and cost effectiveness.

Choosing the Best Pump for Thickener Underflow Typically, there are three types of pumps that are often found on thickener pumping. Those pumps in many cases are centrifugal, progressive cavity or peristaltic pumps. All three types have their strengths and weaknesses. Some of the weaknesses of the various designs are found below.

As the percent solids is increased both the progressive cavity and centrifugal pumps require more frequent costly repairs. The number of components requiring repair on both the progressive cavity pump and centrifugal are significant and carry a significant repair cost.

The peristaltic pump typically only requires a new hose and a small amount of glycerin. The cost of repairs on an eccentric single rolling design peristaltic pump can be a fraction of what it takes to maintain both the centrifugal and progressive cavity pumps.

Centrifugal Yes Yes Yes No No No No Yes High High No High

*ESR - Eccentirc Single Roller 18

Pipes, Pumps and Valves Africa - Nov/Dec 2018

Progressive Cavity Yes Yes Yes No No Yes No No High High No High - Moderate

Best Case Scenario of Better Pump Selection

A Baltimore chemical factory was utilizing two progressive cavity pumps for thickener underflow pumping. Now you see two Flowrox peristaltic pumps that replaced those pumps. The progressive cavity pumps required repair every 6 months at a cost of $17K per pump or $34K. The plant purchased two Flowrox eccentric rolling design peristaltic pumps.

The Flowrox pumps ran continuously for more than 1.5 years before the first hose changes were required. The cost of the two hoses was less than $3.5K.

The inputs are the influent flow rate, flocculent delivery, rake speed, bed layer, overflow, underflow density and underflow pumping. When all is working, the underflow density and underflow pumping rate is at its optimal level.

Upsets can occur that cost money and lost production.

Figure 1: Best Case Scenario of Better Pump Selection

Six Flowrox 2.5” pumps with variable frequency drives were selected for thickener underflow pumping at a Chicago steel mill.

PUMPS

Thickeners and clarifiers are utilized in numerous industries from water and waste water, mining, chemical, steel making and others. There are numerous inputs and outputs of a typical thickener or clarifier that if all is working well will produce the desired outcome.

The pumps replaced centrifugal pumps to deliver thickened sludge to plate and frame filter presses.

The Flowrox peristaltic pump was selected due to its ability to handle abrasive materials with higher solids concentration levels. The thickened mill sludge contained coarse carbon particles which rendered the centrifugal pumps a poor selection due to intense wear and repair costs.

Figure 2: Six Flowrox 2.5” pumps with variable frequency drives were selected for thickener underflow pumping at a Chicago steel mill.

The steel mill was using many man hours replacing impellers, seals and casings. The estimated annual cost reduction was $177K. Notice the isolation valve to the pump was a Flowrox 2.5” slurry pinch valve. These valves are long-lasting valves for the world’s most abrasive slurries.

A Mexico mining operation determined that increasing thickened slurry from 7–10% to 30% to the filter presses would result in a 20% increase in tonnage.

This increased production and profitability. The specific gravity of the medium was 1.546. The customer ordered 5 pumps: two 3” and three 1.5” Flowrox eccentric single rolling design pumps. Frictional sliding shoe peristaltic pumps were not an option because the temperature of the process was 197°F. Exotic alloy centrifugal pumps were used prior to the Flowrox pumps.

The process was hot and had acids present, so the centrifugal pumps were manufactured out of exotic alloys at a considerable cost. The maintenance savings on these five pump replacements was more than $250K annually.

Gland seal water was eliminated by changing to the Flowrox peristaltic pumps. This region of Mexico has a high cost of consumed water. There were two sets of pumps.

The two 3” pumps were pumping jarosite and the three 1.5” pumps were pumping lead and silver slurry.

Figure 3: A Mexico mining operation determined that increasing thickened slurry from 7–10% to 30% to the filter presses would result in a 20% increase in tonnage

Pipes, Pumps and Valves Africa - Nov/Dec 2018

19

PUMPS

IIoT Monitoring, Cost Savings and Process Optimization The industrial internet of things (IIoT) is bringing substantial opportunities to processing facilities. Process facilities of all types do not have to invest millions to begin reaping rewards.

complete facility monitoring can be employed. In recent years instrumentation and sensors costs have decreased substantially. Instrumentation can be added to provide valuable insight and monitoring. It is estimated that in the next few years there will be 4–5 sensors for every human on the planet.

Simple processes can be optimized, maintenance cost and downtime reduced and maintenance can evolve from reactive to proactive by receiving advanced warnings of equipment fatigue. Minor repairs such as early bearing vibration can be detected and fixed prior to more extensive and costly repairs.

Connected assets are exploding and utilizing intelligent and cost-effective monitoring is ready right now from companies that can provide solutions to nagging problems.

Assets that require constant repair and have significant downtime are excellent targets. Compliance or safety are also excellent targets for IIoT monitoring.

Machine learning is employed to determine normal performance and when anomalies are detected warnings can be sent to key personnel. Some companies fully employing IIoT monitoring and aggressive proactive maintenance strategies claim they are gaining one additional month of production per year.

Depicted above is a typical thickener process monitored by Flowrox’s Malibu™.

The various inputs are monitored for proper delivery of the optimal density and slurry concentration to be delivered to the filtration process. As mentioned earlier in this white paper, there are significant gains in production and improved profitability.

Flowrox developed its IIoT solution named Malibu™ over the past several years. Virtually any asset, process or

Figure 4: Depicted above is a typical thickener process monitored by Flowrox’s Malibu™.

Depicted above is a vacuum filter that was connected to IIoT monitoring by Flowrox.

By optimizing filter functions, Flowrox was able to reduce energy consumption on this machine by 50%.

Thickeners, Clarifiers and other abrasive high solids slurries are perfect opportunities for peristaltic pumps. With Flowrox’s IIoT monitoring, an existing pump or other asset can be analyzed for effectiveness and cost. If a customer has two brands of pumps in a similar process, Flowrox can install instrumentation and a Smart Cube on both brands and 20

Pipes, Pumps and Valves Africa - Nov/Dec 2018

help the customer to understand the full cost of ownership of each brand. The results will be clear for all to see.

Flowrox can also imbed a document management system into its IIoT monitoring solution. All documentation such as drawings, manuals and even repair videos can be retrieved at a moment’s notice from any smart phone, tablet or PC that has an internet connection.

The interface also includes digital twin imagery of the equipment with dashboards that can be customized to the owners liking. Flowrox’s Smart Solutions™ are typically used for monitoring only, so the plant PLC or DCS continues

PUMPS Figure 5. Depicted above is a vacuum filter that was connected to IIoT monitoring by Flowrox. to control the operation of all equipment. The Smart Solutions™ security is TLS encryption which is the same utilized by the internet banking industry.

Virtually any asset can be monitored. In many cases, information from existing instrumentation can be captured and analyzed to improve asset cost of ownership, reduce downtime and improve profitability.

Contact Flowrox, Tel: +27 (0) 10 590 8374, Email: sales-rsa@flowrox.com Web: www.flowrox.com

Pipes, Pumps and Valves Africa - Nov/Dec 2018

21

PUMPS

Dirty water no problem for Sykes water transfer range The Sykes auto-prime pumps has hardened stainless steel internal components which ensure high performance and low maintenance.

Water transfer applications in many industries across Africa must often deal with unpredictable water quality, so it is important to specify a pump built for African conditions tough, reliable and robust.

According to Henru Strydom, Sykes product specialist at Integrated Pump Rentals, the hardened stainless steel internal components on its range of Sykes auto-prime pumps is a key factor in ensuring their high performance and low maintenance needs.

Strydom points to the tough 316 stainless steel impeller and wear plate construction in the pump range from Sykes, making it suitable for harsh construction, mining and sewage by-pass environments with high water flow and long pipe runs.

“These pumps are at home transferring anything from clean water to slimes, sewage, sludge and liquids laden with solids,” he says. “In addition to the robust design of the internals, the priming design is also very user-friendly; our contractor pumps feature fully automatic priming and can run dry for extended periods without damage.”

This is achieved by an innovative oil bath mechanical seal assembly that allows priming with long suction hoses and suction lifts of up to nine metres.

“As fluid levels fluctuate, the pump will ‘snore’ until there is enough liquid for it to fully re-prime itself automatically,” he says. “This means that they can be run mainly operatorfree, as the diesel powered units come standard with a 22

Pipes, Pumps and Valves Africa - Nov/Dec 2018

minimum of 27 hours of fuel supply – much longer than the usual refill intervals of about 12 hours.”

Efficiency is also a strong point for Sykes, with an average efficiency across the range of about 78%, while handling larger solids than most other auto-priming units on the market, he says, highlighting the higher shaft stiffness ratios due to an over-designed shaft and bearing housing.

“The construction sector will find the rental units on trailers particularly versatile and easy to operate, especially as Integrated Pump Rental can provide all the pipework for quick and easy set-up as well as lay-flats, couplings and adaptors,” says Strydom. “Where a specific application needs a solution to be designed and managed, we also conduct project work to the customer’s specifications These pumps can be coupled to either diesel engines or electric motors. As the agents for Sykes for the past three years, the company also conducts in-house builds of electrically driven pumps in permanent installations with variable speed drives for lower energy consumption. Its generous stockholdings of wet ends shorten the lead-times on these builds by up to four weeks.

Contact Lee Vine, Integrated Pump Rental, Tel: +27 (0) 11 894 2906, Email: lee@pumprental.co.za, Web: www.pumprental.co.za

Standardised

Customised

Systems-based

You choose. We supply.

Our wide range of standard pumps and valves provides plenty of scope for individual demands. You can select the materials, hydraulic systems and drives. When you’re facing complex tasks, we’re with you from Day One – whether you want planning guidance, specially designed components or help with commissioning. But see for yourself. Test our products for quality and versatility, and discover why KSB is so often first choice.

KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za tel: +27-11-876-5600

Our technology. Your success.

Pumps

n

Valves

n

Service

One provider

PUMPS

Robust pre-assembled panel systems for pumping applications The range of pump panel systems from EM not only reduce energy costs, but also conserve water and maximise productivity.

Additional benefits are automatic ‘sleep’ and ‘wake’ functions, and enhanced motor and pump protection such as Class II surge protection.

“Using Huba’s 528 pressure transducers, and Delta’s CP2000 pump-purpose drive, creates a robust combination that is exactly what the industry demands,” Cameron stresses. The drive’s customised keypad layout means operational data is displayed on one screen, while submenu settings are easy to navigate.

The pump panel systems are enclosed in weather-tight sheet-metal enclosures that are available in various sizes and variations, depending on the particular requirements of the installation. The uncluttered panel layout means there is sufficient working space in order to simplify installation, commissioning, and servicing.

Preconfigured Variable Speed Drives (VSDs) reduce the energy drawn by the pump motor controlling the speed, while maintaining a constant pressure on the line. This is critical in terms of overall efficiency, as even a small reduction in speed result in significant cost-savings.

The standard features of the irrigation pump panels are: a panel mount isolator, drive and control circuit breakers, power and control terminals, manual off/automatic selector switch, run and trip indication, cooling fans and vents, and a rotary setpoint selector.

Typical applications are irrigation, domestic water supply, fish farming, water livestock, solar-powered fountains, sprinklers, misters, and soakers, ground dewatering for excavation, and construction sites.

24

The standard features of the solar or photovoltaic pump panels are: a multi-status indicator lamp, an on/off selector switch, DC fuse protection (including a spare), no-flow input and underload protection, and maximum power point tracking software and manual override.

Cameron concludes that the niche irrigation and solar pump panel system market is aimed at not only diversifying into additional markets, but to be able to offer the full benefits of its latest technology and products to the full spectrum of South African industry.

With virtually every panel builder in South Africa using ubiquitous technology distributed exclusively by EM, the supplier continues to build on its strategy of providing the right product at the right price, for the correct application and specification at hand.

Contact Karen Zotter, ElectroMechanica, Tel: +27 (0) 11 249 5000, Email: karenz@em.co.za

Pipes, Pumps and Valves Africa - Nov/Dec 2018

Advanced new range of verticle turbine pumps

Strong demand for high efficiency vertical pumps has prompted global pump manufacturer, KSB, to manufacture a comprehensive range ofadvanced vertical turbine pumps for a wide range of applications.

PUMPS

The new “B-Pumps” are multistage vertical turbine pumps with a submerged hydraulic system comprising strong and efficient discharge casing assemblies, column pipes and pump bowls in the assembly. Depending on the size and application required the new range is available in 17 sizes with three different impeller types.

According to KSB Pumps and Valves regional sales manager for Sub-Sahara Africa, David Jones, the pump sets cover heads of up to 200 metres and flow rates of up to 720 litres per second with anything from one to 25 stages. Stage casing diameters range from six inches (15.24cm) to 24 inches (61cm) with various designs allowing above-floor or underfloor discharge. B-Pumps can be driven by vertically mounted electric motors or via a right-angle gear with a horizontal diesel engine or electric motor. The maximum permissible speed is 3500 RPM. A wide range of materials can be specified including standard grey cast iron and steel derivatives or special material including stainless steel, duplex and super duplex stainless steel or customised materials. Internally the pumps have intermediate pump shaft bearings which are lubricated by the fluid handled, or may be fitted with an external lubrication supply.

Externally, the casing is designed for a pressure of 16 bar; the discharge flange dimensions are compliant with DIN, BS and ASME standards. On request pressure ratings above 16 bar can also be supplied. The maximum temperature of the fluid handled should not exceed 105 °C. Contact Annett Kriel, KSB Pumps & Valves, Tel: +27 (0) 11 876 5600, Email: Annett.Kriel@ksb.com

Pipes, Pumps and Valves Africa - Nov/Dec 2018

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New variable speed drives (VSDs) provide crucial reliability at a key unmanned pumping station Nobody wants problems with wastewater, least of all companies managing a community’s entire water supply.

PUMPS

downtime and possibly expenditure on repairs, but also pose the danger of a wastewater spill into the nearby sea and potentially serious environmental impacts.

There is one problem that is common in all wastewater pumping facilities – clogging.

According to Mika Dahlman, a pump cleaning function provided by the drives has especially improved operations by reducing the need for manual cleaning. In addition to reduced downtime and lower manual cleaning costs, this brings lower pump running costs due to average higher pump efficiency.

Ease of installation and commissioning speed up work

The ACQ580 drives are designed to make commissioning and set-up, operation and access to valuable data easy. In this case, the mechanical exchange took less than a day.

Pietarsaaren Vesi is a municipally-owned utility in the city of Pietarsaari, a community of around 20,000 inhabitants on the west coast of Finland. Its job is to ensure an uninterrupted water supply for the population in the area.

The wastewater from the city and the surrounding areas is directed to a central treatment plan for processing. Around 80% of wastewater flows through one main unmanned pumping station and therefore reliable pumping equipment is absolutely essential.

“It has to be reliable. In the worst case, raw wastewater would flow directly into the sea if levels rise too high in the pumping station,” said Mika Dahlman, Process Manager at Pietarsaaren Vesi. At this unmanned station the company retrofitted five existing variable speed drives to ABB’s new water dedicated ACQ580 drives.

Optimizing operations

One drive at this station is always in use, with a maximum of four in simultaneous use, leaving one always reserved for redundancy. Rotation of the operation time of each pump helps ensure that wear and tear is spread evenly over the entire system. This also increases energy efficiency.

Controlling and managing water levels is essential in maintaining a smooth flow. Without this ability, there can be a risk of flooding. This would not only cause process 26

Pipes, Pumps and Valves Africa - Nov/Dec 2018

“This project was one of the easier projects I’ve worked on, actually,” said Pietec’s Andreas Ek. “It happened so fast.

The commissioning, everything just worked right off the bat.”

Long-term dependability lowers costs

The atmosphere inside Pietarsaaren Vesi’s main wastewater pumping plant is highly corrosive. ACQ580 variable speed drives have proven to be robust and reliable even under these conditions. “It’s very important that they are robust. You can trust that they are going to do what you want,” noted Andreas Ek. “The main thing is that it is reliable, that it works well in the damp, demanding conditions. That’s what is important,” added Mika Dahlman.Precise, smooth and reliable pumping operations ensure low energy consumption and extend the pumping system’s lifetime.

This adds up to lower costs, resulting in faster return on investment.

“I don’t expect any problems with these drives,” said Andreas Ek. “They’ve been running for over a year now and I have not needed to go to the site to look at anything, so I believe that’s a good sign that everything is just working.”

Contact ABB South Africa, Tel: +27 (0) 10 202 5000, Web: www.abb.co.za

PUMPS

Tips for pump cost savings Save costs by choosing the right pipe diameter Significant savings can be made in every pump system by using the optimum pipe diameters. You can easily determine the diameter yourself using our tools.

On the suction side, it is important to keep the fluid velocity below 4 m/s to prevent pump damage by cavitation. Use the Recommended Suction Pipe Diameter table.

On the discharge side, it is important to keep the friction loss as low as possible. A high friction loss in the pipe means that the pump will have to deliver a lot of pressure (TDH), which will result in unnecessarily high energy costs.

Optimise your pipe system with our Pump Head Calculator tool.

For example: You need to pump 350 m3/h over a horizontal distance of 100 metres with a height difference of 8 metres. To do this, you can use a diesel driven BA150E D285 wastewater pump. You now need to know whether to choose 6” or 8” piping.

28

Pipes, Pumps and Valves Africa - Nov/Dec 2018

Always use the automatic start/stop function Mobile vacuum-assisted pumps from the BA series are supplied as standard with an automatic level control (start/ stop function). This will allow you to save a lot of money during the life of your pump. You install the included floats at the high/low level, and set the key switch to ‘auto’.

As a result, the pump will run completely automatically and pump only when necessary. Thus, no unnecessary energy and maintenance costs.

Example: A BA180E D315 diesel driven pump is designed to maintain the sewage level during refurbishment works uses 350 litres of fuel per day (in 24 hours). Often this isn’t necessary. In such cases, there are peaks and troughs in usage.

The pump may only have to run for an hour during the night, and the same applies during the day, when few people are at home. In practice, the same pump with an automatic start/stop function will only run for a few hours

per day, so the fuel consumption will only be 50 to 60 litres per day. This also results in enormous savings on regular maintenance of the pump unit.

Massive cost savings due to extended maintenance intervals This can save you a lot of money. For single-cylinder diesel driven pumps, the engine supplier suggests maintenance intervals after 250 operating hours. The BA100K wastewater pump and PT150 wellpoint pump have standard maintenance intervals of 1500 operating hours. Advantages of the extended maintenance interval after 30,000 operating hours (average working lifetime of a diesel engine):

PUMPS PUMPS

•Oil change is 100 times less often (20 times versus 120 times) •340 litres less oil consumed (200 litres versus 540 litres) •Filter replacement 100 times less often (20 times versus 120 times) Therefore, you benefit from much reduced labour costs, savings on the cost of engine oil and filters and less environmental pollution associated with the disposal of the old oil and filters.

Select your pump always close to the Best Efficiency Point (BEP) When using mobile pumps, less attention is often paid to the BEP. However, you can still save considerably by choosing the right pump based on efficiency.

For example: A temporary sewer pumping system requires a working point of 200 m3/h at 25 mwc. If you can’t decide between a BA100E D265 or a BA150E D285 see the graph on page 2 of the spec sheets. The BA100E has a BEP of exactly 70%; with a power consumption of 20 kW, the fuel consumption will be slightly less than 6 litres per hour.

With the same working point, the BA150E is located to the left of BEP, with an efficiency of 62%. As a result, the power consumption is 22 kW, and the fuel consumption is more than 0,5 litres per hour higher.

Selecting a pump on BEP will also have a positive impact on the life span of the pump and reduced maintenance costs.

Contact BBA Pumps, Web: www.bbapumps.com

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

29

Pump installation tips Pump placement – general Place the pump unit on a flat surface that is capable of supporting the load.

Make sure the pump unit is placed in such a manner that it is not subjected to any distorting forces.

Make sure there is enough space around the pump unit for operation and maintenance.

PUMPS

• •

WARNING: • Make sure the top of the pump unit is not covered. This is important because the diesel engine driven pump unit draws in fresh air from the top.

• Make sure the front and sides of the pump unit are not covered. This is important because the diesel engine driven pump unit expels heat on these sides.

30

Pipes, Pumps and Valves Africa - Nov/Dec 2018

PUMPS

General piping guidelines • Select the diameter and length of the suction and pressure pipes as well as those of any additional components such that the inlet pressure remains above the minimum allowable value. The operating pressure must not exceed the maximum allowable value. The power rating of the installed drive system must be sufficient. NPSH graphs are available on request.

• The diameters of the pipes must be equal to or greater than the connection sizes on the pump.

• If possible, the transition between various pipe diameters must be made with a transition angle of approx. 8 degrees.

• The pipe must be properly aligned with the pump connection.

• It must be possible to connect the flanges of the pipes and pump together without putting any of the parts under stress.

• In the case of vibration and/or hot liquids, install expansion elements in the pipes.

• Support the pipes directly in front of the pump. The weight of the pipes and fittings may not be supported by the pump.

• Install shut-off valves in the suction and pressure pipes as close as possible to the connection flanges in order to allow isolation of the pump for maintenance and repair work. The shut-off valves must be of a type that allows straight-line flow, such as gate or globe valves. The internal diameter of the shut-off valve must be the same as that of the pipe.

• If there is a possibility that a backflow of liquid could cause the pump to turn in the opposite direction when stopped, a non-return valve must be placed in the piping to prevent this.

• Install measurement instruments in the piping for monitoring during operation.

• If applicable, connect the pump unit to a suitable safety system. This is left to the judgement of the designer of the installation.

• Insulate or shield hot pipes.

• Observe specific regulations that pertain to the suction and pressure pipes.

• Thoroughly clean all parts that come into contact with the transported liquid before putting the pump unit in operation.

Note: When pumping viscous liquids, there can be significant pressure losses in the suction and pressure pipes.

Components placed in the piping system, such as shut-off valves, bends, suction strainers, filters and foot valves, will make the pressure losses greater.

Suction pipe • Place the pump or pump unit as close as possible to the pumped liquid.

• The pipe must be as short as possible.

• Run the pipe so it slopes upwards toward the pump to prevent the formation of air pockets.

Refer to Figure 1 •

If the pipe tapers, the pipe must slope downwards toward the pump. Place a shut-off valve between the float chamber and MP to prevent overpressure on the MP. Refer to Figure 2 • Lay the pipe so as to prevent the formation of air pockets.

Refer to Figure 3 • • • •

Use the least possible number of bends.

Bends must have the largest possible radius.

The pipe system must be completely airtight.

In the case of a non-self-priming pump, in which the liquid does not flow towards the pump, install a foot valve with a sufficiently large flow capacity.

• In the case of polluted liquids, always install a suction strainer or solids separation screen with a sufficiently large net opening area. The filtration particle size of the suction strainer must be equal to or less than the solids handling specification of the pump.

Refer to Figure 4

Figure 1

Figure 2 Pipes, Pumps and Valves Africa - Nov/Dec 2018

31

PUMPS

Figure 3

Figure 4

Figure 5

• When there is a change of diameter in the piping, use an eccentric reducer to prevent the accumulation of air.

Refer to Figure 5 •

Make sure that the liquid intake will remain sufficiently submerged beneath the liquid surface so no air will be drawn in even when the liquid is at its lowest level.

Refer to Figure 6 •

Make sure the length of the pipe between a bend and the pump is at least four times the diameter of the pipe, especially when there is little margin between the available and required NPSH. A bend prevents the smooth inflow of liquid to the pump impeller and can have a negative impact on the suction conditions.

Refer to Figure 7 • When a T-junction is installed, use one with an inflow bend.

Refer to Figure 8 In the case of self-priming pumps fitted with a separate suction bend, this bend must never be removed or rotated.

• •

For liquids with a low viscosity, either install a foot valve with a diameter equal to or greater than that of the suction valve or install the piping without a foot valve in a U-configuration (see technical specifications BA series).

Do not install a foot valve when pumping high viscosity liquids. The foot valve causes extra pipe losses.

Figure 6 32

Pipes, Pumps and Valves Africa - Nov/Dec 2018

Figure 7

• •

To eliminate any air or gases present in the pump or suction pipe, the pressure pipe can be fitted with a bypass line.

The use of a bypass line will eliminate air from the pump more quickly. See also ‘Pressure pipe’.

In some situations the temperature of the liquid may be so high that the pump requires pre-pressure relative to the NPSH in the line (see technical specifications BA series).

PUMPS

Figure 8

Pressure pipe • The designer of the installation is responsible for including the safeguards, such as protection against overpressure.

• To prevent pipe losses, use the fewest number of bends possible.

• When the pressure pipe is long or when a non-return valve is used in the pressure pipe directly after the pump, install a bypass line, fitted with a shut-off valve. Connect the bypass line to the suction line or suction point.

• To bleed air from the pump more quickly, the bypass line must be connected to the supply tank or suction point.

WARNING • Prevent sudden closure of the pressure pipe that would cause water hammer.

• If there is a danger of water hammer, install a bypass, accumulator or pressure safety valve in the pressure pipe.

Suction strainer When pumping polluted liquid or liquid that may contain solid particles, install a suction strainer in the suction opening.

• • • • •

When selecting the suction strainer, carefully consider the mesh width so pipe losses are kept to a minimum. The net opening area of the suction strainer must be at least three times the crosssectional area of the suction pipe.

In the case of polluted liquids, always install a suction strainer with a sufficiently large net opening area. The filtration particle size of the suction strainer must be equal to or less than the solids handling specification of the pump.

Install the suction strainer such that maintenance and cleaning are possible.

Make sure the liquid being drawn in has the expected viscosity and can easily flow through the suction strainer. Heat the suction strainer if necessary.

Consult the technical specifications for the BA series for the maximum allowable particle size (solids handling capacity).

Contact BBA Pumps, Web: www.bbapumps.com

Pompetravaini, a market leader in the manufacture of Liquid Ring Vacuum Pumps – A&VT are the Sole Agents for Southern Africa.

SALES, SPARES AND REPAIRS

info@vactech.co.za

0861 VACTEC (822 832)

www.vactech.co.za

Pipes, Pumps and Valves Africa - Nov/Dec 2018

33

Warranty on Grindex Pumps extended

by Integrated Pump Technology

PUMPS

In an unprecedented move in the local pump industry, Integrated Pump Technology announced the extension of the warranty on Grindex submersible pumps from 18 months to 30 months at Electra Mining Africa 2018.

Managing director Colin Adams says that as the official sub-Saharan distributor of Grindex pumps Integrated Pump Technology has always held the belief that these pumps are well suited to the harsh applications found on the African continent. “Traditionally pump companies offer a warranty period of just 12 months, but the Grindex warranty has always been 18 months, and we made the decision to extend this to our customers in Africa as this is the level of confidence we have in the quality of these pumps.”

While quality has always been the watchword with Grindex submersible pumps, Adams is quick to note that performance and reliability go hand in hand in pumping applications, and for this reason it is critical that the most appropriate pump be selected for a given application.

“Integrated Pump Technology is not about selling a pump in a box,” he says. “We consider it important to understand the customer application and its specific requirements, and with this information our technical team is able to specify a pump which we know will match the requirement.

By leveraging off our extensive knowledge of pumping application we can ensure effective performance with lower total cost of ownership. And this is definitely not something that all pump companies can do.”

Colin Adams, managing director of Integrated Pump Technology.

Integrated Pump Technology’s operating philosophy is founded on providing quality OEM pumps and parts and has established a sound reputation for pumping solutions under all types of operating conditions. Adams says that

A Grindex Bravo pump ready to go into a process water plant in Limpopo.

34

Pipes, Pumps and Valves Africa - Nov/Dec2018

the company’s offering extends well past simply selling pumps providing technical and after market support to end-users which he says has been a value differentiator in the industry.

“When specifying a Grindex pump we know that the enduser will see a return on the investment, and this is largely due to the extensive research and development that underpins all the engineering of all the pumps offers by this international OEM,” he says.

The cartridge seal is preassembled for quicker and easier mounting, while the Hard-iron™ impeller and pump housing feature high wear resistance, which is critical in slurry applications. The large throughlet means that the pump can handle solids of varying sizes.

A leakage sensor allows for early detection of any problems, while the single adjustment screw makes it easy to tweak the impeller for optimal performance. The agitator has been designed specifically for coarser slurries, and is able to stir up and pump sand, sludge and solids in suspension.

Grindex Bravo pump at a platinum mine plant in Rustenburg.

PUMPS

The Grindex Bravo range has found particular favour in slurry pumping applications in the mining sector as these p umps are designed for moving fluids with high concentrations of abrasives including sand and stones.

Robustly constructed, these hardworking pumps offer a maximum submersible depth of 20 metres and do not require any support superstructure. This makes for quick and easy installation and less space needed for their operation.

“Handling slurries is certainly one of the toughest pumping applications and we know that the market looks to suppliers like us to offer appropriate products with good value-add. By further extending the warranty on the Grindex pump we anticipate even greater demand for this workhorse pump,” Adams concludes.

Contact Colin Adams, Integrated Pump Technology, Tel: +27 (0) 11 918 9034, Email: colin@pump-technology,

Pipes, Pumps and Valves Africa -Nov/Dec 2018

35

Danfoss enters industrial wastewater markets with high efficiency pumps

PUMPS

Danfoss launches a new series of APP pumps specially designed and built for Zero Liquid Discharge and Minimal Liquid Discharge (ZLD/MLD) industrial wastewater treatment. The new APP W HC pumps deliver total efficiency rates of 90% at pressures up to 120 bar.

In response to the growing demand for energy efficient ZLD/MLD solutions, Danfoss now releases its first APP pumps targeted large capacity industrial wastewater treatment plants.

“For the last 15 years, our axial piston pumps have proved their efficiency in reverse osmosis desalination. We have applied this know-how to match the demands of ZLD/ MLD, where utilities and system builders are looking for high efficiency and robustness, relentless reliability and low operational costs”, says Jesper Bentzen, Sales Director Danfoss.

The new APP W HC pumps that handle flow ranges from 11 to 24 m3/hour are made of Duplex stainless steel to provide maximum corrosion protection.

The ZLD/MLD APP pumps can be parallel-coupled to fulfill the required capacity at any time. If one of the pumps is out for maintenance, the remaining pumps automatically take over the full operation allowing the plant to run full speed around the clock.

Set and forget The APP W HC pumps deliver a constant flow no matter amounts and quality of the industrial wastewater.

“No matter the water quality, the APP pumps instantly adjust to ensure constant flow and efficiency in the ZLD/ MLD processes. The operation is extremely easy, since changes in pressure impact neither flow nor efficiency”, explains Kevin Evald, Product Manager.

The simple pump design with few parts allows easy installation, inspection and maintenance. Furthermore, the pump operates without oil to prevent contamination.

Danfoss high pressure pumps for ZLD/MLD industrial wastewater treatment.

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

At launch, the APP portfolio for ZLD/MLD industrial wastewater treatment comprises the following pump sizes: •APP W HC 15 with a flow range of 11-15 m3/h (48-66 gpm) •APP W HC 21 with a flow range of 11-21 m3/h (48-92 gpm) •APP W HC 24 with a flow range of 11-24 m3/h (48-106 gpm) All pumps are approved for pressures up to 120 bar (1740 psi) •APP W HC benefits at a glance •World-class efficiency – up to 90% at all operation points •Substantial energy savings up to 75 % compared to traditional thermal evaporation systems •Made of first-class Duplex steel to prevent corrosion in aggressive environments •Easy scalability when coupled in parallel •Low complexity with few moving parts and few system components •Easy to operate and maintain •The pump is oil-free to avoid contamination Contact Danfoss, Web: www.danfoss.com

Plasti-Tech supplies HDPE pipes Warmbaths Forever Resort has entrusted thermoplastic piping specialist, Plasti-Tech, to supply a big order of HDPE pipes and fittings in a short space of time.

PIPES

Plasti-Tech has won a large order to supply various sizes of high density polyethylene pipes (HDPE) and fittings for the upgrade of Warmbaths Forever Resort’s pump stations. Within easy reach from Johannesburg on the N1, Warmbaths is located in an African bushveld atmosphere.

The popular family resort sits between some of the most stunning game reserves in the Limpopo Province.

To keep the standards high at this fantastic family resort, management at Warmbaths recently went into the market for HDPE pipes to replace the ageing steel pipes, and engaged the services of Plasti-Tech. “The client made contact with us in March for the supply of HDPE pipes and fittings.

The order was a bit urgent but we managed to meet the client’s deadline accordingly,” explains Plasti-Tech managing member Brad Chamont.

Plasti-Tech has since supplied product worth in excess of R300 000 to date, and Chamont estimates that the total project supply value willreach over R1-million. The project, which is still ongoing, will soon move onto Phase 2, which will include some large bore HDPE piping.

Warmbaths is replacing aged steel pipes at its pump stations. The existing pipes have since corroded over the years and needed to be replaced with a long-lasting alternative.

Chamont notes that HDPE pipes and fittings are quickly becoming the material of choice for a wide variety of industry applications for the several benefits they offer.

HDPE is proven to be strong, durable, flexible and lightweight than competitive solutions. When fused together, HDPE offers a zero leak rate due to the seamless nature of the pipe system. It also offers a more environmentally sustainable footprint because it is nontoxic, non-corrosive and chemical resistant, thereby offering a long lifespan.

Contact Brad Chamont, Plasti-Tech Piping Systems, Tel: +27 (0) 11 609 5511, Cell: +27 (0) 82 471 5757, Email: brad@plasti.co.za, Web: www.plastitech.co.za Pipes, Pumps and Valves Africa - Nov/Dec 2018

37

VALVES

200 AVK Valves supplied to wastewater treatment plant

A comprehensive modernisation of Czajka Wastewater Treatment Plant has significantly improved both the efficiency of the plant and the water environment in Warsaw. AVK has delivered 1,200 valves for the project.

Until 2013, Czajka Wastewater Treatment Plant, the largest in Poland and located in Warsaw, only handled wastewater from half of Warsaw and from the neighbouring city of Legionowo. The rest of the capital’s wastewater was led directly into the Vistula River causing major environmental problems. After increased pressure from EU and due to Poland’s growing population, Warsaw City Council decided to modernise Czajka Wastewater Treatment Plant.

In 2008, AVK won the order to produce the valves for this enormous project – in partnership with Veolia Water and Krüger. Today, the plant not only handles all the wastewater from the two cities. It is also geared to cope with a rapidly growing population, and boasts a central, intelligent control system which ensures more efficient operation overall.

Improved handling of sludge

Industry Department Manager Miroslaw Kopyta from AVK Armadan, our sales company in Poland, was our on-site project manager ensuring that all products were delivered on time. Throughout the construction phase, he also worked as consultant on the technical solutions and equipment from AVK. After the refurbishment of the plant, particularly the handling of sludge has been improved. Previously, Czajka Wastewater Treatment Plant led the contaminated and untreated sludge out into fields, but heat treatment now ensures that organic materials are broken down and cleaned so that both odours and volumes are significantly reduced, explains Miroslaw Kopyta.

For several years, the Vistula River, which runs through the Warsaw metropolis, was under pressure from the city’s 38

Pipes, Pumps and Valves Africa - Nov/Dec 2018

2.1 million inhabitants producing more than 200,000 m3 of wastewater every day. But with the upgrade of Czajka Wastewater Treatment Plant, which has been designed to treat 435,000 m3 of wastewater a day – during peak periods up to 515,000 m3 – the local water environment has been secured for many years to come.

Intelligent control system

The comprehensive renovation project also involved a new and intelligent control system for all processes. The finished water treatment plant today employs 140 people who work in a hi-tech environment:

VALVES We are now able to monitor all systems from the control room, and it is easy for us to locate any defects, explains Osinski Marcin from Czajka Wastewater Treatment Plant.

In close competition with several of the world’s largest manufacturers, AVK won the order for nearly 1,200 valves for the plant. AVK supplied butterfly valves mainly used for aeration, ball check valves and swing check valves for use in the pumping stations, gate valves for clean water and automatic and manual knife gate valves for use in the treatment of sludge.

The treatment plant renovation project was started in 2008 and the construction was completed in April 2013.

Facts about the Czajka Wastewater Treatment Plant

•Czajka Wastewater Treatment Plant has been designed to treat 435,000 m3 of wastewater a day – during peak periods as much as 515,000 m3.

•The plant covers an area of 53 hectares.

•1,500 men and 21 cranes worked on the construction.

•During construction, 24,000 tons of steel were used three times more than the amount used for the Eiffel Tower and 155,000 m3 of cement.

•On average, 24 tons of sludge are produced an hour. This is equivalent to approximately 22 fully loaded trucks every day.

•The area has 60 kilometres of pipeline and seven kilometres of road.

Contact AVK Valves Tel: +27 (0) 11 908 3760 Email: greg@avkvalves.co.za Web: www.avkvalves.co.za

Robuschi Roots blowers / exhausters are some of the finest in the world – Made in Italy.

info@vactech.co.za 0861 VACTEC (822 832) www.vactech.co.za

Pipes, Pumps and Valves Africa - Nov/Dec 2018

39

VALVES

Solid as a rock: The importance of gas storage plants is growing.

Renewables are all the trend in some European countries. Depending on the weather, however, they can be real drama queens. To prevent bottlenecks, grids are increasingly being fed with electricity produced by gas As such, gas storage is becoming an important issue. For they can also store excess energy, and feed it back in when consumption rises. In unstable times, such storage facilities are as solid as a rock.

It is indisputable that demand for natural gas is rising in Europe – especially during transition phase away from nuclear power and CO2-intensive forms of energy.

According to the Arbeitsgemeinschaft Energiebilanzen (AG Energiebilanzen, Working Group on Energy Balances) natural gas consumption in Germany, for example, had a share of 20.9 percent in the total energy mix, by 2016 it had risen to 22.6 percent. With a growth of 9.5 percent, gas belongs to the big winners in primary energy consumption, while renewables came in second with 2.8 percent.

EU to import more gas

Gas supply is an important topic in nearly the whole of Europe. “In the future, the European Union will have to import more and more natural gas to meet demand in the home market. Therefore demand for additional natural gas tank farms is growing,” explain the companies Astora and EWE, project partners of the Jemgum natural gas storage cavern.

Gas storage will play a central role in securing the energy system transformation project, “as it is the only way to chemically store excess energy from renewables – wind and sun – in the form of hydrogen or green methane and secure the fluctuating balance,” states Maurice Walter, head of sales and services, Hartmann Valves. Or, in other words: if the wind isn’t blowing and the sun isn’t shining, gas compensates the power fluctuations of renewables.

“Storage ensures stable levels of availability and flexible usability of the energy source,” emphasises Astora.

Store gas in summer The German storage facility Wolfersberg makes an important contribution. In summertime, excess gas imports are stored in the storage facility located in Upper Bavaria, and in wintertime it is fed into the gas grid. Wolfersberg has a maximum storage capacity of 140,000 Nm³/h, a 40

Pipes, Pumps and Valves Africa - Nov/Dec 2018

maximum withdrawal capacity of 240.000 Nm³/h and a working gas capacity of 365.000.000 Nm³. Capacities, that actively supply energy to the metropolis Munich.

However, old shut-off valves had to be replaced in the natural gas storage facility Wolfersberg, which had been put into operation in 1973. In order to ensure an extremely high level of safety and maximal availability, Hartmann Valves developed highly compact twin ball valves, which are not only extremely gas-tight, but also solved the problem of limited space.

They fulfil an important duty for the facility: “We must be able to isolate every part of the plant which needs to be repaired or maintained. Two shut-off valves with the possibility to bleed off pressure in between serve as isolation. Thus, we ensure 100% that no gas enters the area concerned,” states operations manager Markus Schuster, DEA.

No problems for renewing isolation section

Most of the Hartmann ball valves installed are single ball valves. As safety requirements were especially high, 40 twin ball valves were installed. They offer a double barrier and two distinctly independent isolating mechanisms in one body. The easy to install, zero-bubble-tight system provides twice the level of safety, and it saves space, as the company states.

An extra compact special design of the twin ball valve was developed when an old isolation section in the main injection line had to be renewed. It consisted of a welded and flanged ball valve. Exchanging the welded valve would have resulted in a long downtime. Hartmann Valves therefore engineered a twin ball valve DN 250 PN 250 version, with the same length of the original standard valve.

After a successful trial period, further compact twin ball valves sharing the same dimension were also installed in the gas drying facility. The extreme shortening of the twin ball valve system was highly beneficial.

VALVES

Two seals in flow direction

A further custom valve was made for the suction lines.

Even the shortest TBVs were too long. Hartmann solved this problem by using a double piston system, providing two barriers in one valve. The system incorporates two seals in flow direction: one on the upstream, the other one on the downstream side. As such, it fulfils a two-barrier requirement, including a bleed-off in between.

Today, a total of 800 ball valves made by Hartmann Valves are installed, in the plant’s various facilities. Ten wells are operated here, as well as natural gas compression, pressure reduction, drying and temperature control facilities. With a depth of 2,900 to 3,000 meters, the depleted gas reservoir is the deepest gas storage facility in the whole of Europe.

15 caverns in Jemgum

The Wolfersberg plant is one of the older, yet still wellfunctioning gas stores. Growing demand for gas, however, means more storage plants are needed. Jemgum serves as a recent example, in 2013 gas filling of the storage facility commenced. In the next couple of years, EWE and Astora plan to construct 33 caverns in the Jemgum salt dome.

EWE plans to build 15 caverns with a volume of up to 700,000 cubic meters each, Astora will realise 18 caverns with a geometric volume of up to 750,000 cubic meters.

“The marketable working gas volume is approximately 4,1 TWh. The injection rate is 2.3 GW (= 55 GWh/day), and the withdrawal rate is 2.875 GW (= 69 GWh/day),” reports Ralf Riekenberg, above-ground project manager and department head at the Jemgum gas storage plant. The natural gas stored in Jemgum is to be provided mainly to the German and North-West European market.

High pressures, high differences

Jemgum was chosen thanks to its subterranean salt domes, which are especially well suited to store natural gas. The caverns being constructed are giant cavities in the salt domes, which are formed by leaching, using water. Deep under the surface the gas is safely stored in the salt formations. Salt walls have an advantage: they seal-off especially well. “Caverns are especially suited for the fast injection and withdrawal of natural gas. Demand fluctuations due to the time of day can be compensated optimally,” declare project partners EWE and Astora.

Valves make sure everything runs smoothly at the Jemgum storage plant. “They are used for pressure control, pressure protection and transmission control,” explains project manager Riekenberg. Valves are mainly made from steel, and “in most cases exposed to high pressures and pressure differentials”. The pressure range lies between 40 and 170 bar, the temperature range between -20 and 150 °C, and the flow rate between 20,000 m³/h and 250,000 m³/h.

Valves installed in the gas storage plant are exposed to glycole, which is used to dry the gas, and water, which, in turn, is used to pre-heat the gas. These create challenges the safety, control and shut-off valves have to overcome.

Gas is compressed

And this is how the Jemgum gas storage plant works: the natural gas to be stored is transported from the gas transmission net to the storage facility. Compressors then condense the gas natural gas to a pressure of up to 200 bar before injecting it into the caverns. “Driven by pressure, the natural gas passes the cavern head, the heart of each natural gas storage facility,” explain EWE and Astora. After passing through the cavern head, the natural gas is then stored in the cavern, and can be withdrawn on demand.

Pipes, Pumps and Valves Africa - Nov/Dec 2018

41

SKF Cooper bearings get a facelift BEARINGS

SKF Cooper split roller bearings will get a brand new look with new colour, product markings and box design . The new SKF Cooper dual product branding and identity will be applied for all split roller bearings.

The change from the current Cooper product brand and identity to the new SKF Cooper dual product brand and identity will begin 1st November 2018, and cover all products made by SKF Cooper. This will be a step by step implementation during the end of 2018 and into 2019, therefore customers will see the changes gradually over time as to cover all product ranges.

Key changes will be the housing branding, product name plates, packaging and labels, component markings as well as housing and cartridge paint colour.

Customers can rest assure that the changes are only visual and do not in any way impact the product’s technology or performance.

SKF Cooper products will continue to complement the growing SKF portfolio of complete solutions for the marine, mining, quarrying, construction and energy sectors. In addition to the brand name change, the channels to market for SKF Cooper products, including responses to customer enquiries, product supply and after-sales support, will be handled on a global basis through local SKF sales outlets going forward.

split cylindrical roller bearings and split double row tapered roller bearings, the latter with the ability to take axial loads in either direction. Both are housed and sealed in special swivel cartridges, which are suitable for mounting in pedestal or flanged outer housings.

SKF Cooper split roller bearings can be fitted, removed and inspected without having to dismantle surrounding equipment, providing savings in terms of reduced maintenance and downtime. The products include both

Contact SKF, Tel: +27 (0) 11 821 3602 , Email: samantha.joubert@skf.com,

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Different operations producing great results Support and save with local manufacture Range of Eco progressive cavity pumps and spares including explosive emulsion dispensing pump units.

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Tel: +27 (11) 826 6111 Fax +27 (11) 826 6162 Email: sales@uniqueeng.co.za Website: www.uniqueeng.co.za

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Pipes, Pumps and Valves Africa - Nov/Dec 2018

PUMPS HORIZONTAL SPLIT CASE PUMPS

AIR OPERATED DOUBLE DIAPHRAGM PUMPS

SLURRY PUMPS

KSB (Pty) Ltd

Cyclone Industries

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

T: +27 (0) 11 821 5900 F: +27 (0) 11 825 7707 E: reception@cyclonesa.co.za W: www.cyclonepumps.co.za

SAM Engineering T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

METERING PUMPS

Unique Engineering Walter Meano Engineering VersaFlo VSE Pumps T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za

T: +27 (0) 11 826 6111 F: +27 (0) 11 826 6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za END SUCTION PUMPS

BOREHOLE PUMPS

SAM Engineering Ernest Electro Engineering T: +27 (0) 11 792 9550 E: eeeaman@mweb.co.za W: www.ernestee.co.za

T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za FIRE PUMPS

Unique Engineering T: +27 (0) 11 826 6111 F: +27 (0) 11 826 6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za CENTRIFUGAL PUMPS

Ernest Electro Engineering T: +27 (0) 11 792 9550 E: eeeaman@mweb.co.za W: www.ernestee.co.z

T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: apepumps@mweb.co.za W: www.apepumps.co.za

T: +27 (0) 11 821 5900 F: +27 (0) 11 825 7707 E: reception@cyclonesa.co.za W: www.cyclonepumps.co.za 44

T: +27 (0) 10 210-4750 E: willie.vanwyk@flsmidth.com W: www.flsmidth.com

MULTISTAGE PUMPS

Pump and Abrasion Technologies

Franklin Electric T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

T: +27 (0) 12 666-0904/5 E: sales@pumpab.co.za W: www.pumpandabrasion.co.za SUBMERSIBLE PUMPS

Franklin Electric SPP Pumps SA (Pty) Ltd T: +27 (0) 11 393-7179 F: +27 (0) 86 425-7595 E: sales@spppumps.co.za W: www.spppumps.com FLEXIBLE IMPELLER PUMPS

CHICK HENDERSON

Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za POSITIVE DISPLACEMENT PUMPS

T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

Horma Pumps T: +27 (0) 11 452-4300 E: sales@horma.co.za W: www.horma.co.za

Chick Henderson T: +27 (0) 11 624-1400 F: +27 (0) 624-1432 E: rob@chickhenderson.co.za W: www.chickhenderson.co.za HIGH PRESSURE PUMPS

Cyclone Industries T: +27 (0) 11 821 5900 F: +27 (0) 11 825 7707 E: reception@cyclonesa.co.za W: www.cyclonepumps.co.za

Hawk High Pressure Pumps Cyclone Industries

FLSmidth Krebs

PLUNGER PUMPS

Franklin Electric T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

APE Pumps

T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za

Pipes, Pumps and Valves Africa - Nov/Dec 2018

Stewarts & Lloyds (Pty) Ltd T: +27 (0) 11 917-0778 F: +27 (0) 11 917-0769 E: peterk@sltrading.co.za W: www.stewartsandlloyds.co.za

Unique Engineering

Walter Meano Engineering VersaFlo VSE Pumps

T: +27 (0) 11 826-6111 F: +27 (0) 11 826-6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za

T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za

VALVES

PUMPS TRASH PUMPS

VERTICAL SPINDLE PUMPS

BALL VALVES

Tectra Automation C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

VACUUM PUMPS

Walter Meano Engineering VersaFlo VSE Pumps T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za VERTICAL TURBINE PUMPS

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

Industrial Valves & Engineering Supplies (Pty) Ltd

APE Pumps T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: apepumps@mweb.co.za W: www.apepumps.co.za

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

Atlas Copco T: +27 (0) 11 821 9000 E: wendyb@za.atlascopco.com W: www.atlascopco.co.za VERTICAL SUMP PUMPS

KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

SAM Engineering T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

SAMCO PUMPS (Pty) Ltd

BUTTERFLY VALVES

T: +27 35 751-1202 F: +27 35 751-1204 E: joffre@samcopumps.com W: www.samcopumps.com WELL PUMPS

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za CONTROL VALVES

Valcon Valve & Controls Ainsworth Valves T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

T: +27 (0) 11 971-9400 F: +27 (0) 11 971-9440 E: malan.bosman@tectra.co.za W: www.hytecgroup.co.za CHECK VALVES

T: +27 (0) 11 394-2066 F: +27 (0) 11 394-2476 E: sales1@industrialvalve.co.za W: www.industrialvalve.co.za

Air & Vacuum Technologies T: +27 (0) 861 822-832) +27 (0) 11 318 3241/2/3/4/5 F: +27 (0) 86 522-9188 E: burnm@vactech.co.za W: www.vactech.co.za

Everyseal

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

T: +27 (0) 11 453-7537 F: +27 (0) 11 453-6056 E: nick@valcon.co.za Web: www.valcon.co.za

VAG-Valves South Africa Klamflex Pipe Couplings T: +27 (0) 11 762-5326 F: +27 (0) 11 762-5674 E: o.galazka@vag-group.com W: www.vag-group.com DIAPHRAGM VALVES

KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

Stewarts & Lloyds (Pty) Ltd T: +27 (0) 11 917-0778 F: +27 (0) 11 917-0769 E: peterk@sltrading.co.za W: www.stewartsandlloyds.co.za

Ainsworth Valves T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

Pipes, Pumps and Valves Africa - Nov/Dec 2018

45

VALVES Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za PINCH VALVES

Macsteel T: +27 (0) 11 838-4028 C: +27 (0) 82 823-7703 E: thanesh.padayachee@macsteel.co.za W: www.macsteel.co.za SLEEVE VALVES Ts & Cs

Everyseal Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com PLUG VALVES

GATE VALVES

Ainsworth Valves T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

Everyseal

Cyclone Industries

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

T: +27 (0) 11 821 5900 F: +27 (0) 11 825 7707 E: reception@cyclonesa.co.za W: www.cyclonepumps.co.za

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com KNIFE GATE VALVES

Everyseal

T: +27 (0) 11 453-9741 F: +27 (0) 11 453-9894 E: reshmita.singh@rotork.com Web: www.rotork.com HYDRAULIC TOOLS

REPAIR VALVES

T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

T: +27 (0) 861 707-707 F: +27 (0) 861 707-706 E: sales@kiloton.co.za W: www.kiloton.co.za W: www.onlinetoolshop.kiloton.co.za MANUAL

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com SAVETY & RELIEF VALVES

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

Agrico T: +27 (0) 21 950 4111 F: +27 (0) 21 950 4208 E: alfred.andrag@agrico.co.za W: www.agrico.co.za HOSES

Kiloton Ainsworth Valves

Everyseal

PIPES

Rotork Invincible Valves (Pty) Ltd

C.R.I Pumps S.A. (Pty) Ltd

ACTUATORS

CHICK HENDERSON

Chick Henderson T: +27 (0) 11 640-1400 F: +27 (0) 624-1432 E: rob@chickhenderson.co.za W: www.chickhenderson.co.za FOUNDRIES

Tectra Automation T: +27 (0) 11 971-9400 F: +27 (0) 11 971-9440 E: malan.bosman@tectra.co.za W: www.hytecgroup.co.za MECHANICAL PACKING

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

KEW Foundries T: +27 (0) 53 841-0474 F: +27 (0) 53 841-0473 E: info@kewfoundries.co.za W: www.kewfoundries.co.za

KLINGER South Africa Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za 46

Pipes, Pumps and Valves Africa - Nov/Dec 2018

T: +27 (0) 11 842-8300 F: +27 (0) 11 827-8663 E: gareth.langton@klinger.co.za W: www.klinger.co.za

Viking Foundry (Pty) Ltd

Directors: W. Fourie (Chairman), N.P. Mnxasana (Non Exec) R Kruger, R. Dye, G.M. Scrutton Branch Manager: R. Dye Company Secretaries: Winhold Limited Reg No 1945/0196

T: +27 (0) 11 873-5093 F: +27 (0) 11 873-5695 E: sales@vfdy.co.za W: www.vikingfdy.co.za

11th

2019

11 - 13 JUNE 2019

Gallagher Convention Centre, Johannesburg, South Africa

ThE largEsT aNd mosT comprEhENsivE africaN TradE show dEdicaTEd To ThE iNdUsTriEs iNvolvEd iN ThE coNvEyaNcE of liqUids, gasEs & slUrriEs

ExpaNd yoUr bUsiNEss iN africa

gENEraTE frEsh lEads

fiNd NEw roUTEs To markET

fiNd oUT aboUT NEw proJEcTs

mEET NEw parTNErs

compaNiEs sUpplyiNg ThE followiNg iNdUsTriEs will ExhibiT: Mining * Construction & Consulting * Water & Waste Water * Petrochemicals * Chemicals Power Generation * Food & Beverage * Agriculture * Pulp & Paper

gUarENTEE yoUr sTaNd locaTioN Contact Dale Magaya to book your stand: dalemagaya@dmgevents.com +27 11 783 7250 Media and association partners:

www.pumpsvalvesandpipesafrica.com

Co-located with:

Organised by:

TEL: +27 (0) 11 864 1404 EMAIL: info@mhpumps.co.za WEB: www.mhpumps.co.za