ISSUE 19
AUTUMN 2017
pumpindustry Lessons learned from a major pump station upgrade
Is your diesel pump costing you money? Tips for irrigators More drive, less work – making motors more efficient
Why good seals don’t wear out
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PUMP INDUSTRY
President’s welcome I Pump Industry Australia Incorporated PO Box 55, Stuarts Point NSW 2441 Australia Ph/Fax: (02) 6569 0160 pumpsaustralia@bigpond.com Dave Alexander – President KSB John Inkster – Vice President Brown Brothers Engineers Kevin Wilson – Treasurer/Secretary Executive Officer Keith Sanders – Councillor Executive Officer – Marketing & Statistics Life Member Alan Rowan – Councillor Executive Officer Publications & Training Life Member
f the first quarter is anything to go by, Pump Industry Australia can expect a busy nine months to follow. Years of industry insight were put to good use when the PIA leadership team assembled for several conference call meetings early this year. For members, a technical meeting at Hydro Innovations in Sydney on 21 February was well received. The team have an impressive test bay at the Rydalmere facility. Hydro Innovations have it set up as a component of their dedicated training centre and it has been designed to feel as though you are actually in a pump station. At the meeting, David Goodchild from ABB presented on vertical gearmotor drives, focusing on the ABB vertical gearmotor (VGM), a highly efficient drive package for low-speed vertical pumping applications with high power requirements. Lifecycle costs were addressed in Keith Sander’s presentation, with
“total cost of ownership” of various pump options calculated over a period of years. Garry Grant also gave a presentation on Hydro Innovations’ products and the successes they’ve had. While I am talking about courses, I’ll draw your attention to a conditioning and monitoring seminar that will be held on 27 April in Melbourne. This will be a one-day seminar, and reviewing the initial agenda, it is looking to be a very interesting and informative day. I would encourage you to attend, and bring a colleague or customer. It’s my perception that the pump industry is experiencing an improvement in business, with project business in New South Wales looking especially promising. If you wish to see any specific topics covered in Pump Industry magazine – don’t hesitate to get in touch. Dave Alexander President, Pump Industry Australia
Ken Kugler Executive Officer – Standards Life Member Ron Astall - Councillor United Pumps Australia Ashley White – Councillor Davey Pumps Peter Passalacqua – Councillor Grundfos David Brooks – Councillor Flowserve FSD Jamie Dixon – Councillor White International
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pump industry | Autumn 2017 | Issue 19
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CONTENTS AUTUMN 2017
ISSUE 19
pumpindustry Lessons learned from a major pump station upgrade
Is your diesel pump costing you money? Tips for irrigators More drive, less work – making motors more efficient
Why good seals don’t wear out
Cover image highlights our feature on pump motors and drives in this issue.
4,153 1 April 2016 - 30 September 2016
Published by Monkey Media Enterprises
ABN: 36 426 734 954 PO Box 1763 Preston South VIC 3072 P: (03) 9988 4950 F: (03) 8456 6720 monkeymedia.com.au info@monkeymedia.com.au pumpindustry.com.au magazine@pumpindustry.com.au Publisher and Editor: Chris Bland Managing Editor: Laura Harvey Associate Editor: Jessica Dickers Contributing Editor: Michelle Goldsmith Journalist: Lauren Cella Marketing Director: Amanda Kennedy Marketing Consultant: Aaron White Marketing Consultant: Steven Golding Production and Customer Service: Titian Bartlau Senior Designer: Alejandro Molano Designer: Jacqueline Buckmaster ISSN: 2201-0270
NEWS Snowy Mountains Scheme 2.0 set to begin................................6 Construction underway on Tasmanian irrigation schemes........8 Three contracts awarded for Bendigo Groundwater project.....9 The importance of professional installation and commissioning.................................................................... 10 New pump training facility ........................................................ 11 PIA NEWS Getting technical at PIA’s Sydney meeting............................... 12 Vale Antony Grage ..................................................................... 13 PIA MEMBER NEWS As energy prices continue to rise, motor efficiencies will remain a hot topic . .............................................................. 14 Winning the battle against wipes.............................................. 16 Innovative solution to sewage pump station upgrade............. 19 Brown Brothers strengthens partnership with Layne Bowler vertical turbine pumps............................................................... 20 How to get the best out of your pumps.................................... 21 INDUSTRY NEWS Corrosive liquid pump................................................................ 18 Extreme conditions call for robust piping systems.................. 22 Four reasons to start using Shakti solar water pumps............. 24 Tsurumi construction kings....................................................... 26
This magazine is published by Monkey Media in cooperation with the Pump Industry Australia Inc. (PIA). The views contained herein are not necessarily the views of either the publisher or the PIA. Neither the publisher nor the PIA takes responsibility for any claims made by advertisers. All communication should be directed to the publisher. The publisher welcomes contributions to the magazine. All contributions must comply with the publisher’s editorial policy which follows. By providing content to the publisher, you authorise the publisher to reproduce that content either in its original form, or edited, or combined with other content in any of its publications and in any format at the publisher's discretion.
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pumpindustry
WATER & WASTEWATER Selecting the correct sewage pump impeller....... 30 Solving wastewater challenges in North East Vic. 34 Lessons learnt from the Alfred Street Pump Station Upgrade......................................... 36 IRRIGATION Irrigation innovation reaps a winning harvest....... 40 Energy saving at a Mundubbera citrus farm.......... 44 SEALS Why don’t good seals wear out?........................... 46 John Crane marks 100-year anniversary.............. 49 MOTORS, ENGINES & DRIVES Is your diesel pump costing you money?.............. 50 HATZ for diesel.................................................... 53 Serious power for serious pumping, now ready to go................................................... 54 More drive, less work – motor, pump and fan efficiency................................................. 56 VSD installation optimises Gold Coast prawn farm........................................................... 58 Optimising pumping using variable speed drives........................................... 60 www.pumpindustry.com.au
PUMP PIONEERS Kevin Wilson............................64 PUMP HANDBOOK Selecting and applying positive displacement pumps................66 REGULARS President’s welcome..................2 Ask an expert...........................28 Pump school............................69 Technical Meeting the system needs............ 70
Editorial schedule.....................72 Advertisers’ index....................72
pump industry | Summer 2017 | Issue 18
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NEWS
Snowy Mountains Scheme 2.0 set to begin
W
ork will soon begin on a plan for the Snowy Mountains Scheme 2.0, a project that aims to increase the generation of the Snowy Hydro Scheme by 50 per cent, adding 2000 megawatts of renewable energy to the National Electricity Market. Once completed, the project could produce 20 times the 100MWh expected from the battery proposed by the South Australian Government in one hour, but would deliver it constantly for almost a week (or 350,000MWh over seven days). The unprecedented expansion will help make renewables reliable, filling in holes caused by intermittent supply and generator outages. Prime Minister Malcolm Turnbull said, “For too long policymakers have put ideology and politics ahead of engineering and economics. “Successive governments at all levels have failed to put in place the necessary storage to ensure reliable power supply to homes and businesses.
“The energy storage infrastructure should be a critical priority to ensure better integration of wind and solar into the energy market, and more efficient use of conventional power. “By supercharging the Snowy Hydro precinct, affordable and reliable electricity for Australian households and businesses can be ensured.” The Australian Government, through the Australian Renewable Energy Agency (ARENA), will examine several sites, that could support large-scale pumped hydroelectric energy storage in the precinct. These sites would involve new tunnels and power stations, connecting existing storages. The project will have no impact on the scheme’s ability to supply water to irrigators in New South Wales, South Australia and Queensland. A feasibility study is expected to be completed before the end of 2017, and construction can commence soon after.
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pump industry | Autumn 2017 | Issue 19
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NEWS
Construction underway on Tasmanian irrigation schemes
T
he next round of Tasmanian irrigation projects is now underway, with the start of construction of the $31 million Southern Highlands Irrigation Scheme. The Southern Highlands Irrigation Scheme will increase water security for local irrigators and is part of many irrigation projects aimed at supporting regional development, and strong and sustainable growth in Tasmania’s irrigated agriculture sector. Deputy Prime Minister and Minister for Agriculture and Water Resources Barnaby Joyce, Tasmanian Deputy Premier and Minister for Primary Industries and Water Jeremy Rockliff, and Tasmanian Senator Jonathon Duniam, said works were progressing quickly on the $31 million project to expand the Southern Highlands Irrigation Scheme, the first project to break ground under Tasmanian Irrigation Tranche II. “The Coalition Government is contributing up to $60 million to the Tasmanian Irrigation Tranche II program, including $15 million towards works to expand the Southern Highlands Irrigation Scheme, which I’ve been pleased to inspect today,” Minister Joyce said. “This government has a vision for building the water infrastructure needed for our nation to reach its full economic and productive potential, and we are making unprecedented levels of funding available to make it happen.
“It’s a vision shared by the Tasmanian Government, who, together with local irrigators, have co-invested with us to deliver the exciting and important projects under Tasmanian Irrigation Tranche II. “Now, through the National Water Infrastructure Development Fund and National Water Infrastructure Loan Facility, we are putting $2.5 billion on the table to incentivise other state and territory governments to follow suit and get priority water infrastructure projects off the drawing board and under construction more quickly.” Senator Jonathon Duniam, said the Coalition Government’s commitment to the Tasmanian Irrigation Tranche II program also included $25 million approved for the Swan Valley and Duck schemes, which are also under construction. The proposed Scottsdale and North Esk schemes currently in the planning and approvals phase. “In addition to funding for Tasmanian Irrigation Tranche II, we are investing $1.78 million towards a $2.5 million project with Tasmanian Irrigation to fast-track a feasibility study into potential new areas for developing irrigation schemes in Tasmania.”
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pump industry | Autumn 2017 | Issue 19
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NEWS
Three contracts awarded for Bendigo Groundwater Project
T
he Victorian Government has awarded three contracts for separate works on Coliban Water’s Bendigo Groundwater Project. Victorian Member for Bendigo East Jacinta Allan said Lendlease was awarded a contract to design, construct, operate and maintain a groundwater treatment plant, Veolia Water Network Services would construct the pipeline, and Ward Bros from Rochester would construct the brine storage lagoon. In total, the state government has provided $29.77 million in funding to manage rising groundwater in mine voids beneath Bendigo. Previously, Bendigo Trust, the operators of the Central Deborah Gold Mine, had been contracted to pump the groundwater out of the mines. Ms Allan said, “The Victorian Government is fulfilling its commitment to the people of Bendigo by getting on with this essential project to protect the city and surrounding areas from contaminated groundwater from Bendigo’s historic mines.” The Bendigo Groundwater Project involves a total of 32 jobs across the construction, operation, and maintenance of the treatment plant, pipeline, and storage lagoon. Of the 32, five new jobs have been created across the treatment plant, pipeline and storage lagoon.
The refurbishment, construction, and operation will deliver a four-year solution for managing the rising groundwater in the Central Deborah Gold Mine and prevent discharge, and associated environmental and amenity impacts in, and around Bendigo. The groundwater has elevated levels of arsenic, heavy metals and salinity, and gives off an unpleasant odour due to the presence of hydrogen sulphide gas. With the treatment process in place, the groundwater will no longer need to be stored at the Woodvale evaporation ponds north-west of Bendigo, as was the previous practice. The appointment of contractors follows a tender process, and an agreement between Coliban Water and Kralcopic that will drive investment towards a solution that contributes to the long-term management of groundwater from mine voids beneath Bendigo. When complete, the groundwater treatment facilities will be operational for an initial period of four years while plans for the permanent solution are progressed. Naturally occurring groundwater within Bendigo’s network of disused and abandoned mines has been recovering to natural levels since mining ceased in 2011. Works have commenced on schedule and the interim solution will be fully operational by mid-2017.
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pump industry | Autumn 2017 | Issue 19
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NEWS
The importance of professional installation and commissioning
D
ue to the impacts of climate change, there is now an increased focus on industries employing strategies that reduce energy consumption. The Federal Government offers incentives linked to the Emissions Reduction Fund (ERF), including a scheme by the Department of Environment that covers large pumping equipment using the Industrial Equipment Upgrade method, and work on a new standard, AS/NZS3598.2 Energy audits – Industrial and related activities, is currently in progress. Despite these initiatives, the PIA says there still needs to be an adequate supply of resources to verify that these improvements do result in actual gains. PIA recognised the need to identify specialists that can effectively supervise the installation of pumping equipment, and then commission the plant to ensure that the operational requirements are satisfactorily achieved. While this expertise did exist in many pump companies, there was no uniformity in approach and these personnel were not easy to identify. Realising this, PIA developed a pump installation and commissioning training course to outline a consistent set of
guidelines. The one-day course was first introduced in 2016 at Link Pumps in Williamstown and includes both a theoretical and practical component. As a result, around 30 engineers are now accredited by PIA to conduct this work, and are listed on the PIA website. Recently, the course was held in Sydney where further engineers were added to the list. The Sydney training program was conducted in the new training centre at Hydro Innovations in Rydalmere. Alan Rowan and Keith Sanders conducted this course, with strong support from Zach Jerla of Hydro Innovations for the practical demonstrations. The mix of theory and hands-on activities helped participants appreciate the issues that need to be addressed when supervising the installation of pumping equipment, and the procedures for accurate testing of the plant on site. All participants achieved certification by PIA. Further courses are planned for the rest of 2017, with the next course being held in Melbourne on 24 May 2017. The program is open to both members and non members.
Register your interest at www.pumps.asn.au or, for further information, contact pumpsaustralia@bigpond.com.
THE NEXT GENERATION OF SOLARPAK
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pump industry | Autumn 2017 | Issue 19
www.pumpindustry.com.au
NEWS | PARTNER SOLUTIONS
New pump training facility H ydro Innovations has just opened a new training centre, called the Hydro Innovations Pump Institute, to assist their customers in the selection, troubleshooting, and maintenance of centrifugal pumps. The centre will focus most attention on self-priming pumps, but aspects of the curricula offered will include standard centrifugal and submersible pumps. The institute covers two floors, and houses a variety of training assets. The main attraction is a full-size functioning pump station on the first floor, with suction lines going down into a clear wet well system on the ground floor, demonstrating the self-priming process very clearly through clear acrylic suction lines. Other training assets include a glass-faced pump and a full-size “tear-down” pump The glass-faced pump is a full-size pump with a glass front. This allows observers to see the inside workings of a centrifugal pump, and is capable of demonstrating a raft of troubleshooting scenarios, including air binding, pipe blockages, and many others. The “tear-down” pump enables training for operators and fitters on disassembly and reassembly of a centrifugal pump, including tips on seal and bearing installation, setting pump clearances, and other key elements in repair and maintenance procedures. The Hydro Innovations team hope that this element of operator training, along with gauge reading and troubleshooting training will help keep pumping assets at their efficient best for a long and trouble free time.
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PPC RANGE Sub pump controllers
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MULTICUT RANGE Sub sewage pumps with cutter
pump industry | Autumn 2017 | Issue 19
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PIA NEWS
Getting technical at PIA’s Sydney meeting
P
ump Industry Australia started off a busy 2017 with a technical meeting at Hydro Innovations on 21 February. The meeting was a great opportunity for PIA members and guests to network with colleagues who operate in the Sydney pump market, and the event was well-received by those who attended. Presentations were made by Keith Sanders, Garry Grant, and ABB’s David Goodchild. Keith’s presentation, an introduction to lifecycle costs, explored total cost of ownership, and provided useful information to pump users and specifiers in attendance. Garry spoke about the recent activities at Hydro Innovations including their new test bay that opened in 2016. Attendees were given the chance to view the new test bay at the Rydalmere facility, which has been set up as part of Hydro Innovations training centre. PIA President Dave Alexander said the “impressive” centre was “designed to feel as though you are actually in a pump station”. David Goodchild, Business Development Manager for High Voltage Motors and Generators at ABB, presented on the Dodge vertical gearmotor (VGM), a solution for
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low-speed vertical pumping applications that have high power requirements. David, whose career at ABB spans more than 15 years, discussed the benefits of the VGM compared to pump drive technologies that utilitse large pole count motors, which can be expensive. He also talked about the applications the VGM is suitable for, including pumping stations for flood control and wastewater, circulating water in power plants, desalination plants, irrigation systems, and pumping systems for residential and commercial water supplies.
www.pumpindustry.com.au
PIA NEWS
Vale ANTONY GRAGE Long-time pump professional and PIA life member Antony Grage sadly passed away on 30 December 2016, aged 76.
O
ver his 22-year career in pumps, Antony worked at Thompsons-Byron Jackson; Thompsons, Kelly & Lewis; and Flowserve. He was also involved with Pump Industry Australia, including a period as president. Antony’s career began in the road transport equipment industry after joining Transpec Ltd as a part-time draftsman in 1963. After working at Transpec for 23 years, including in the position of Technical Director, Antony joined the pump industry in 1986 as Sales and Marketing Manager at Thompsons-Byron Jackson. This was shortly before the company took over Kelly & Lewis, forming Thompsons, Kelly & Lewis (TKL). Years later, TKL took over Ingersoll Rand Pumps, and was then acquired by Flowserve. Antony’s passion for pumps was evident throughout his time at these organisations, and he was held in high regard by his colleagues and the industry. In Antony’s last four years working in the industry he was the Business Development Manager for the mining industry at Flowserve, before retiring at 68. After retirement, Antony continued working part-time at a small industrial company that made emergency flashing
beacons, and kept in touch with many of his pump industry colleagues at regular lunches and PIA events. It was after retirement that Antony was also made a PIA life member. Outside of pumps, Antony also loved sailing and had a long association with the Flinders Yacht Club, serving as Commodore for a number of years. He also satisfied a lifelong interest in aviation history as the President of the Aviation Historical Society of Australia. Antony’s funeral was held on 9 January at the Flinders Yacht Club, and was attended by more than 200 friends, family members, and former colleagues, including Keith Sanders, Les Boelckey, and Bill Coulter from the PIA. “It is clear that Antony had a rich and meaningful life. He will be sadly missed by all of his industry friends and colleagues,” said PIA President Dave Alexander. Antony is survived by his wife Deidre, sons Paul and Nick, daughter Anna and his six grandchildren. You can read more about Antony’s career and life in Pump Industry’s 2013 profile on him, which can be viewed at www. pumpindustry.com.au/antony-grage.
Highly efficient and cost-effective solutions for large pumping applications?
Absolutely. The Dodge Vertical Gearmotor provides an alternative to common vertical pump drive technologies and offers significant benefits when compared to other systems. The Vertical Gearmotor is built on a standard low pole count motor platform utilizing proven Dodge planetary gear technology. This results in a smaller, lighter, more cost-effective and highly efficient package. www.abb.com/mechanicalpowertransmission
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pump industry | Autumn 2017 | Issue 19
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PIA MEMBER NEWS | PARTNER SOLUTIONS
As energy prices continue to rise, motor efficiencies will remain a hot topic by Spiro Fkiaras – Product Manager LV Motors at WEG Australia
R
educing the speed of a pump to deliver required levels of flow or pressure can result in significant energy savings. Whilst this statement is generally true and readily accepted by industry, those scrutinising return on investment and payback periods have often found them to be much longer than originally anticipated. Why? Often overlooked is the fact that with any reduction in pump speed and pump load, there will also be a reduction in motor efficiency. Power consumed throughout the speed range is therefore higher than expected, thus extending the payback period. To address this issue, WEG has further developed its highly successful CFW11 “Optimal Flux” drives. The new technology allows WEG motors to maintain high levels of efficiency, irrespective of pump speed and load, thus significantly improving return on investment. Figure 1 demonstrates the efficiency gains realised through the use of WEG motor and drive packages.
Continuing to lead the way in energyefficient solutions, WEG understands that many installations do not comprise variable speed drives and cannot benefit through the application of same. To that end, WEG offers a full range of IE4 induction motors. These deliver high efficiency and high starting torque and unlike some other IE4 motors on the market, are also suitable for direct on line and soft starting application. For installations where super high levels of efficiency are mandated, the ultimate energy-efficient solution comes in the form of a WEG WMagnet/ CFW11 motor/drive package. WMagnet is WEG’s latest range of permanent magnet AC motors delivering IE5 efficiency levels. In comparison to alternative technologies, including switched and synchronous reluctance, WMagnet delivers smoother operation, reduced audible noise, and reduced supply current draw, as outlined in Figure 2.
Figure 1.
Figure 2.
For more information, please consult your nearest WEG office.
Motors | Automation | Energy | Transmission & Distribution | Coatings
Highly Efficient Solutions for the Pump Industry
WEG Australia MELBOURNE | SYDNEY | BRISBANE | ADELAIDE | PERTH
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IE2 IE3 IE4 IE5
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PIA MEMBER NEWS | PARTNER SOLUTIONS
Winning the battle
AGAINST WIPES A
ustralian utilities fight battles against sewer clogs and the potential overflows that may result. The rise in the use of personal wipe products and their improper disposal has worsened the problem. Operators and technicians often crawl into confined spaces or hoist pumps out of wet wells to wrestle with rag monsters. KSB Australia is well aware of this issue and is leading a campaign to “Conquer the Clog”. The newly developed free-flow impeller for wastewater pumps will be the trade fair highlight showcased by KSB Australia at this year’s OzWater in Sydney. The F-max impeller incorporates different distances between its blades, arranged in groups with two small and two large distances. The asymmetrical blade arrangement offers impressively wide free passages, ensuring that even larger, rigid solids pass easily and are reliably handled by the pump. The blades were designed to create a swirl in the hub area. This swirling effect shifts fibers away from the impeller hub and transports them to the outside. Based on decades of experience in free-flow impeller design, KSB hydraulic experts employed the CFD method (Computational Fluid Dynamics) to gain detailed knowledge about the complex flow processes inside the pump via computer-aided simulations. The new F-max impellers are achieving efficiencies previously only reached by single-channel impellers. Subsequent balancing is no longer required. The radial forces and vibrations created by the new impeller are usually lower than those of single-channel impellers, so the service life of shaft seals and rolling element bearings is increased. Pumps with F-max impellers require only minimal maintenance. When they rotate, free-flow impellers develop a strong swirl which keeps solids suspended in the pump casing and, with the inclined suction area,
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generates an additional flushing action. This significantly reduces the risk of clogging in the impeller’s centre caused by long fibers, in particular by wet wipes.
KSB Australia’s holistic approach to clogging It starts with a good design – the pump and impeller must fit into design parameters. When properly executed, it all works together with minimal need for maintenance or downtime.
Station design While the increasing use of wipes is a challenge, different systems handle the problem differently, and variable fluid content influences performance. Engineering and planning of wastewater facilities requires an understanding of the pumped wastewater composition for trouble-free performance and energy efficiency.
Automation KSB offers highly specialised technologies to assist in the control and monitoring of the wastewater treatment process. This includes process control systems to monitor and optimise pumps, valves, flow rates, and other critical information.
Solids separation In all waste streams there are solid and liquid components. To “Conquer the Clog”, it’s best to first remove as many of the solid components as possible.
Hydraulics The heart of the hydraulic system is the pump and, more importantly, the impeller. The design and efficient operation of these critical components is essential for successful fluid flow. This is the systemic approach – all components must work together.
Impeller technologies There are many types of impellers – just like there are many types of pumps. This can make the selection process complicated if you don’t know what you need. Fortunately, KSB Australia makes a wide variety of impellers, which can be utilised in the same pump with minor modifications to the volute.
www.pumpindustry.com.au
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Pump station design Solids Separation Automation Hydraulics Each waste water plant is unique. Each clog is different. KSB solves these system wide problems with experience, perspective, and innovative technologies that minimizes downtime and improves operational efficiency.
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INDUSTRY NEWS | PARTNER SOLUTIONS
Corrosive liquid pump
A
new cast 316 stainless steel self-priming centrifugal pump has been introduced to handle corrosive liquids in mining and processing applications. The new range of electric drive pumps are close coupled and feature high efficiencies for both high and low head applications. Introduced by Australian Pump Industries, the pumps are designed to answer a serious need in mining and chemical industries for cost efficient, ISO 9001 quality products, capable of handling contaminated and corrosive liquids. “This product line has been developed for mine tailings and other difficult corrosive liquids including salt water,” said Aussie Pumps Product Manager Neil Bennett. “We perceived a major market opportunity for a top-quality stainless steel pump at a realistic price, and built strictly in accordance with our quality culture.” The first pump to be introduced is a 5.5kW 3” pump that delivers a maximum flow of 910LPM with the added ability to handle solids to 10mm. Like all of the Aussie GMP range, the pump is self-priming with the ability to
draft water from depths of six metres. The maximum pump head is 40m, making it ideal for high pressure water transfer or even machinery washdown. Power for the machine comes from a 5.5kW TEFC three phase, two-pole electric drive motor. Pump and motor are installed from the factory on a heavy duty steel base for ease of installation. Optional stainless steel or hot galvanised steel bases are available on request. “The pump’s big advantage is its ease of repair in the field and simplicity of operation. Even changing the seals is simple,” said Mr Bennett. “The pump is close coupled to the motor with a 316 stainless steel stub shaft. Disassembly of the pump body from the motor is a matter of minutes, giving access to the pump chamber for clean out or service.” The secret of the pump’s excellent self-priming characteristics are the big “shoulders” in the priming tank incorporated in the unit’s design. The high-mounted suction port also helps fast self-priming without the need for additional aids like vacuum pumps or compressors.
Aussie Pumps Operations Manager Hamish Lorenz checks out the new 316 stainless steel Aussie G3TK-A electric pump.
The new pump is available in nickel aluminium bronze, as well as with a semi-trash version available in the cast iron configuration. Seals are heavy duty mechanical style with nitrile elastomers. Optional Viton and silicon carbide are also available on request. The first pumps are going to Kalgoorlie where they will be used for mine tailings and washstand applications in high ph level liquids. Further information, including a free data pack, is readily available from Australian Pump Industries or Aussie Pump Distributors throughout Australia or at www.aussiepumps.com.au.
REDUCED ENERGY COSTS SCT PUMP The special design of SEEPEX progressive cavity pumps with Smart Conveying Technology (SCT) offers reduced energy consumption along with ease of maintenance, extended service life and significantly reduced life cycle costs. SCT pumps effectively convey the large range of fluids and solids in the water and wastewater industry and provide the best solution for your application.
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BENEFITS Use up to 25% less energy than conventional progressive cavity pumps Quick maintenance Reduced downtime Increased productivity Less space required for installation and maintenance Contact our experts now, to experience these benefits yourself.
pump industry | Autumn 2017 | Issue 19
SEEPEX Australia Pty. Ltd. info.au@seepex.com www.seepex.com
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PIA MEMBER NEWS | PARTNER SOLUTIONS
Innovative solution to sewage pump station upgrade
T
he asset owner at the Mount Piper Power Station, Mr Rainer Scheurer, was looking for a solution to the maintenance issues associated with his submersible sewage pump stations on the site. The problems were many and varied, including lifting chains breaking, pumps becoming stuck on their guide rails, as well as general reliability issues. Even with everything going well, operators would be exposed to a 7m fall into the pit whilst hoisting submersible pumps to the surface for maintenance. Mr Scheurer came to Hydro Innovations for some ideas on how he could get away from these issues. Hydro Innovations suggested the use of Gorman-Rupp self-priming sewage pumps, which would mean that only one operator would be needed for most of the maintenance issues, and any work could be done without opening wet well covers. Rainer liked the idea, but the pit was so deep that self-priming pumps could not be located at ground level. Hydro Innovations suggested putting
the pumps into the existing valve vault to get pumps closer to water level, reusing the path the old discharge lines took, and connecting directly into the existing rising main in the valve vault. Gorman-Rupp’s V3B60-B pumps were chosen for the job, to deliver the 15 litres per second flow rate, but most importantly, were capable of re-priming the required 7.6m suction lift – a tough ask for most self-priming pumps. Hydro Innovations explained that most self-priming pumps with a full casing of liquid are capable of priming to this level, but re-priming automatically, with only a partially filled casing (because casing siphoning can occur between pump cycles), is a totally different proposition. As Gorman-Rupp publish guaranteed re-prime lifts on their sewage pump curves, Hydro Innovations had no hesitation applying the pump on this suction lift. Hydro Innovations were duly given the go-ahead on the project and set to work designing a piping and valve system that could comfortably fit in
the valve vault. A compact but practical design was approved and the project delivered. Mount Piper Power Station now has a sewage pump station that is under cover, inside the valve vault, is easily accessed without the need for lifting apparatus, and can be safely maintained by one operator.
GORMAN-RUPP SELF PRIMING WASTEWATER PUMPS easy access lower life cycle cost fastest to service
less choking
no confined spaces longer lasting
T: 02 9898 1800 E: sales@hydroinnovations.com.au
HydroInnovations.com.au www.pumpindustry.com.au
pump industry | Autumn 2017 | Issue 19
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PIA MEMBER NEWS | PARTNER SOLUTIONS
Brown Brothers strengthens partnership with Layne Bowler vertical turbine pumps Layne Bowler’s history can be traced back to 1882, when the inventor Mahlon Layne drilled his first well and found himself in need of a pump to deliver the water from the well. He understood that the pump he required would need to be different from all existing pumps of that time.
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n 1903, Mahlon Layne and entrepreneur PD Bowler got together and created the Layne & Bowler Company in the Mississippi Basin, where they manufactured vertical turbine pumps for use in cased wells or where the water level was below the practical limits of surface pumps. From these humble beginnings Layne Bowler pumps are now installed in all parts of the world. Layne Bowler Pump Company Inc. was established in Ankara, Turkey, in 1965, where the innovation and engineering development never stopped, with Layne Bowler continuing to introduce new pump ranges. Layne Bowler’s premises in Ankara covers 42,000sqm, where its qualified engineers and experienced technicians continue to serve the energy, industrial, municipal, and agricultural markets. Brown Brothers Engineers is the exclusive nationwide distributor for Layne Bowler vertical turbine pumps in both
Layne Bowler vertical turbine pumps are designed primarily for heavy duty, continuous operation in irrigation, municipal, and industrial applications.
Australia and New Zealand, and carries a comprehensive range of pump components including column and shafting. The Brown Brothers engineering facilities allow them to promptly build the Layne Bowler product. The Melbourne facility has full testing capabilities to meet customer requirements, and the installed population continues to grow across Australia and New Zealand. For your vertical turbine pump requirements contact Brown Brothers Engineers today on 1300 4 BBENG (1300 4 22364) or at www.brownbros.com.au.
VERTICAL TURBINE PUMPS • • • • •
Flows to 2,300 L/Sec Heads to 350 m Power to 1000+ kW Temperatures to 150°C Bowls Diameter up to 45 inch
Design Advantages • Exceptional engineering quality • Highly efficient hydraulic design • Heavy duty component castings • Cast discharge heads • In-built thrust bearing with anti-rotation arrangement • Standard IEC electric motors • Superior quality column assemblies • Materials of construction options • Shaft sealing options • Engine drive options Applications • Irrigation • Water Supply • Process water • Geothermal • Cooling towers
• • • •
TASTE THE ENGINEERING
Fire protection Marine Water treatment De-watering
Exclusive Australian Distributor
03/17
Layne Bowler vertical turbine pumps have a proven record under the most demanding and toughest of conditions.
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Ph: 1300 4 BBENG www.brownbros.com.au
DELIVERING PUMPING SOLUTIONS pump industry | Autumn 2017 | Issue 19
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PIA MEMBER NEWS | PARTNER SOLUTIONS
How to get the best out of your pumps
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t’s the question that underpins everything pump users and specifiers do when monitoring and operating pumps: how do you ensure you’re getting optimal performance every time? PIA is hosting a technical seminar on 27 April in Mount Waverley, Melbourne, that will explore what steps need to be taken in pump design, testing, and performance monitoring to allow for optimum operating conditions. The seminar will also help pump users determine the best inspection and testing planning (ITP). Running from 9am – 5pm, the full-day program will include presentations from key players in the pump industry, and explore topics ranging from sensors and meters, to pump standards and guidelines. Keith Sanders, Ken Kugler, and Ron Astall will discuss pump standards, including ISO, and API 610, and compare approaches to pump specifications. Nasir Akolawala and Les Luke’s presentation will explore sensors and meters that have been developed for submersible sewage pumps. Ken Kugler and Ron Astall will then be back to talk about
PUMP SEMINAR
works testing (AS 2417) and how it stacks up to the results of site testing. Malcolm Robertson will present on the continuous performance monitoring thermal method, and demonstrate this through a case study. A presentation by WEG will cover motor MEPS operation and service recommendations, while Keith Sanders will explore the condition monitoring guideline ANSI/HI 9.6.5. The topic of process instrumentation remote monitoring of pump stations will be discussed by speakers Josh Pinto and Arash Louie, before the final PIA panel session, where Praveen Salian and Farukh Yaqub will cover remote on-line condition monitoring for pumps. These presentations together aim to highlight pump lifecycle costs, and the balance between reliability of service, and maintaining plant output programs. PIA’s technical seminar will take place at Bruce County Hotel, 445, Blackburn Rd, Mt. Waverley, VIC, 3149. To register, visit www.pumps.asn.au or contact the PIA secretary at pumpsaustralia@bigpond.com.
HOW TO GET THE BEST OUT OF YOUR PUMPS?
27 APRIL 2017
This will look at various aspects of pump design, testing and performance monitoring in the field to determine the optimum operating conditions and the most appropriate Inspection and Testing planning (ITP’s) for reliable operation through to eventual plant replacement. 27 April 2017, 9am - 5pm Bruce County Hotel 445 Blackburn Rd, Mt Waverley VIC 3149 $500 +GST for PIA members $600 +GST for non-members
www.pumpindustry.com.au
Registration and payment can be made on-line at www.pumps.asn.au Alternatively please contact the Secretary on pumpsaustralia@bigpond.com
pump industry | Autumn 2017 | Issue 19
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INDUSTRY NEWS | PARTNER SOLUTIONS
EXTREME CONDITIONS CALLS FOR ROBUST PIPING SYSTEMS
On the rocky Antarctic plateau adjacent to the Larsemann Hills, at temperatures down to minus 40°C, India has been operating a science research station since 2012. Named “Bharati”, after the Hindu goddess of wisdom and knowledge, it serves as headquarters for climate change and oceanographic research.
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his high-tech station consists of one main building, a fuel farm, fuel station, seawater pump house, a summer camp, and a number of smaller containerised modules. The main building offers regulated power supply, automated heating and air conditioning with hot and cold running water, flush toilets, sauna, cold storage, PA system, living areas and laboratory space. To enable Bharati’s researchers to continue their vital work in extreme conditions during the Antarctic winter, it required especially robust drinking water and heating solutions. Drinking water hygiene is particularly vital at the remote location. Contamination by legionella or similar harmful microbes would be disastrous, not only for the researchers– the very future of the mission would be placed at risk. That is why the planners chose Viega’s Sanpress Inox system with pipes made of premium quality EN1.4521 stainless steel, and Viega Easytop circulation regulating valves that ensure the hot water is kept at a constant 60°C. The facility’s thermal disinfection system provides further protection against legionella, while Easytop extraction valves allow easy regular monitoring of drinking water quality.
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Kerosene is used to generate heat and power, because it keeps liquid down to minus 54°C. So to aerate the tank, Indian engineers installed the Viega Sanpress Inox G piping system because of its permanent resistance to the media being pumped. Sanpress Inox G is usually used for gas and heating oil pipes. It was launched in Australia in 2013. The Viega Prestabo galvanised steel system was used for Bharati’s heating installation. To prevent the heating water from freezing, a 57 per cent glycol-L additive is mixed into it. For the project, Viega tested the reaction of the EPDM sealing rings to such extremely high glycol content levels. The end result: the sealing rings of the press connectors are fully usable for the heating water/glycol mix. They are also suitable for operating temperatures from minus 40°C up to 80°C plus. Some 25 people will be working under extreme conditions at the Bharati station all year round for at least 20 years – in part thanks to Viega press-fit technology. For more information, visit www.viega.com.au.
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The Wellmaster range is the Flexible Rising Main System for all types of ground water extraction and well monitoring operations. Features
Regulation 31 UK Drinking Water Inspectorate Regulation 27 Drinking Water Scotland Total corrosion, microbiological and internal scaling resistance Long operational life with a 10 year warranty* High abrasion resistant lining and cover Superior hydraulic performance with low friction loss for a reduced operating cost Rapid installation and retrieval resulting in substantial labour and cost savings Available with a range of reusable field-fittable high security 316 stainless steel couplings and a full range of other accessories Diameters from 38mm – 200mm Range includes WM150, WM250 and WM400 Manufactured under Angus Flexible Pipelines ISO 9001 Quality Management Systems accreditation Angus Environmental Management System complies with ISO 14001
Angus Flexible Pipelines Australia Pty Ltd
Ph: 07 3256 7624 9/67 Depot Street BANYO Qld 4014 *
if installed by an Angus approved installer
Its simplicity of installation makes Wellmaster the cost-effective alternative to rigid pipe. Wellmaster is manufactured from high tenacity synthetic yarns, circular woven and totally encapsulated in a tough elastomeric polyurethane lining and cover. The riser has an integral textile reinforced rib for location of the power cable strapping system. The larger sizes have two ribs.
INDUSTRY NEWS | PARTNER SOLUTIONS
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Four reasons to start using Shakti solar water pumps by Anshul Gupta, National Sales Manager – Australia, Shakti Pumps
Technological advances towards more efficient and environmentally conscious solutions have reached almost all strata of human habitation, including the oldest human profession; farming. In this article, Mr Gupta discusses Shakti solar water pumps and why you should be using them.
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pump industry | Autumn 2017 | Issue 19
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hakti solar water pumps are used throughout the world. Popular on farms and rural areas, these pumps provide water for domestic use, and for agricultural and livestock production. One of the main challenges in some countries is the difficulty of extracting water in areas that have no grid power supply. This process can be more expensive if you use wind turbines, and more labor intensive if you use livestock for turning the waterwheels. By using a Shakti solar water pump you can more easily save money, more efficiently utilise your resources, and extract and supply water for all your needs. Here are four reasons to start using Shakti solar water pumps:
1. Multifunctionality A Shakti solar water pump can be used to extract water for animals, plants and human consumption, and for farming and irrigation. Since the need for water is greater on hot, sunny days, solar technology is an obvious choice for this application. This is a simple, reliable process that requires almost no maintenance by the user. During the night that same system can also be connected to the grid and used to pump water.
2. Easy to use Those who have already worked with water pumps know that it is not a difficult system. Water pumping systems powered by solar energy are similar to any other pumping system. The only difference is the type of energy that feeds it: solar energy. Shakti solar water pumps usually consist of photovoltaic panels (modules), a HES motor, a bore pump, and a solar controller. Solar water pumping arrays are fixed, mounted or sometimes even placed on sun-tracking machines to increase the time and volume of pumping.
3. Reduced price The price of solar water pumps has decreased in recent years. This means that not only will you recover your investment faster, but you will also be able to use the pump for free for a longer period of time, which basically means free water harvesting for a long time.
4. Efficiency and quality The best photovoltaic water pumping systems installed can provide more than 30 years of reliable and continuous service. Most of the solar modules come with a 20–25 year warranty and an average usable life of 30–35 years.
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INDUSTRY NEWS | PARTNER SOLUTIONS
Tsurumi construction kings T surumi Pump is widely regarded as the global leader for construction site pumps. The company has established itself firmly in the Australian market in the last five years. Tsurumi has always had a clear focus on pumps for land reclamation, piling and the construction industry. “It’s easy to see the origin of Tsurumi design criteria for construction application pumps,”said Aussie Pumps Product Manager Neil Bennett. “The market calls for simple, robust, and reliable pumps that can take the rigours of working on sites where product abuse is not uncommon.”
Unique technology-based design Tsurumi’s breakthrough design technology led to the incorporation of a unique anti-wicking cable entry that prevents water incursion. It’s a simple device that protects against the wicking of water up the cable in the event of damage of the submerged end. They took a similar approach to mechanical seal design. Tsurumi ensured that both surfaces of the double silicon carbide seals used in their pumps are protected in an oil chamber. It is the immersion in oil of both seal surfaces that makes the difference. It eliminates spring failure caused by corrosion or abrasion and keeps both surfaces of the seal lubricated and cool. All Tsurumi KTZ dewatering pumps and KRS series sand pumps feature this combination of protective technology. “Tsurumi understands that the way to eliminate product failures is what they call ‘preventative design action’, so that ‘PDA’ philosophy has allowed Tsurumi to become the world’s biggest manufacturer of electro submersible pumps,” said Mr Bennett. Other key features include top-quality ball bearings. A unique oil
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lifter is fitted in the oil chamber that continues to lubricate seals even if the oil level falls. This increases the time between routine pump maintenance and cuts down time and costs. All heavy duty Tsurumi pumps use inbuilt thermal protection for the motor against overheating. Tsurumi’s dewatering pumps are heavy duty cast iron, with 316 stainless steel options readily available.
KTZ series The KTZ series is now regarded as the most reliable construction site pump on the market. The semi-open impeller is high chrome iron and the whole design is so simple that impellers and suction covers can be easily changed on site. The mechanical seal’s unique resistance to high pressure means that this series pump can be submerged to depths as low as 50 metres.
“Australian Pump Industries continues to build the Tsurumi reputation in Australia,” said Mr Bennett. “We are encouraged by the recent positive moves in mining and believe that the cost-conscious contractors, miners and construction material manufacturers can continue to reduce expenses based on using these ultra-reliable pumps.” Tsurumi pumps come with a unique three-year warranty. “Tsurumi believes that the clearest way to convey confidence in the product to the market is with the three-year guarantee!” said Mr Bennett. Free application stories, technical data, and selection guides are available from Australian Pump Industries on the website, by contacting marketing@ aussiepumps.com.au or by phoning Neil Bennett on 02 8865 3500.
KRS series The KRS four-pole, slow-speed heavy duty sand pumps are also a major asset for sites involving bridge building, piling, and even in concrete batch plants. These pumps are built around a dredger principle with a second impeller mounted below the pump chamber. The lower impeller, designed to agitate the slurry, prevents choking and allows high solid content.
SFQ series The 316 stainless steel SFQ series employs the same technology and features, but the pumps are manufactured from fully cast 316 stainless steel. That unique configuration allows the products to be used in the most aggressive mining applications, as well as with seawater, chemicals, and more specifically, chlorine used in wastewater or sewage treatment.
pump industry | Autumn 2017 | Issue 19
Neil Bennett supervises the installation of Tsurumi KTZ pump at a construction site.
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Repair, Re-Manufacture and Re-Design Service For ALL types of Centrifugal Pumps Efficiency Improvement Reconditioning Restore Clearances Re- Engineering P f Performance T Testing. ti Services available include:
• Inspection and trouble-shooting • Case build up and re-machining • Axial A i l split lit case facing f i and d reboring b i • Axial thrust balancing • Shaft and bearing API 610 upgrades • Mechanical Seal upgrades to API 682 • Bearing housing & back cover retrofit • Lube system upgrades • Composite Wear Parts • Tighter clearances • Hydraulic Re-Rating • Rapid R id prototyping t t i • Driver upgrades (MEPS compliance) • Baseplate adaptors and rebuilding • Custom Spare Parts • Rotating Element balancing • ASME & AS1210 qualified Welding • Hydrostatic Testing • Performance Testing • FFT Vibration analysis
A.B.N. 37 006 317 979
31 WESTERN AVENUE SUNSHINE, VICTORIA 3020 P.O. BOX 348, SUNSHINE, VICTORIA 3020 • PHONE +613 9312 6566 • FAX +613 9312 6371
EMAIL unitedpumps@unitedpumps.com.au http://www.unitedpumps.com.au/
ASK AN EXPERT SECTION HEADING
The pump industry relies on expertise from a large and varied range of specialists, from experts in particular pump types to those with an intimate understanding of pump reliability; and from researchers who delve into the particulars of pump curves to experts in pump efficiency. To draw upon the wealth of expert knowledge the Australian pump industry has to offer, Pump Industry has established a panel of experts to answer all your pumping questions.
PROGRESSIVE CAVITY PUMPS IN THE WASTEWATER AND SLUDGE TREATMENT INDUSTRY What are the benefits of using progressive cavity pumps for applications in the wastewater and sludge treatment industry? You’ll find out below.
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Q: Can progressive cavity pumps (PCPs) handle variable dry solids content sludge?
Q: One of the industry’s concerns is reducing energy costs. Do PCPs offer any special solutions?
A:
A:
Yes, PCPs can successfully handle a wide variety of sludge applications with differing dry solids content because of their following characteristics: • Stable, variable flow rates • Minimal pulsation • Excellent suction lift capability • Flexible installation • Accurate metering of flocculants • High self-priming capabilities • Lower energy use
Progressive cavity pumps are known to operate very efficiently, which typically results in reduced operating costs. Additionally, several PCP manufacturers have now incorporated new pump designs which offer reduced energy consumption, along with ease of maintenance, extended service life and significantly reduced life cycle costs (SEEPEX’s unique SCT is a good example of a modern progressive cavity pump innovation).
pump industry | Autumn 2017 | Issue 19
www.pumpindustry.com.au
ASK AN EXPERT
Q: How well do PCPs work in pumping systems? A: PCPs can be incorporated into numerous systems. They can be integrated into control systems to maximise productivity or used in connection with macerating, dosing, and/or chopping pumps. From primary to thickened sludge, progressive cavity pumps provide the best pumping solution designed specifically for your application.
One example of modern PCP technology–in this case showing SEEPEX SCT design.
Peter Vila, Managing Director of SEEPEX Australia, is a progressive cavity pump expert. He has been involved with pumps for over 35 years. Peter spent the first five years repairing pumps and the following 30 years in technical sales, 15 of which have been with SEEPEX progressive cavity pumps. For more information on progressive cavity pumps, please contact SEEPEX Australia at +61 2 4355 4500 or info.au@seepex.com
Are the Fire Panels that you supply FULLY AS 2941-2013 Compliant? Welling & Crossley Diesel Fire Control Panels are Fully Compliant with Australian Standard AS 2941-2013 The ones we’ve seen that are not, don’t have: 3 stage Battery Charger - Standard Ref. # 9.4.14 Jacket Heater Failure Indicator - Standard Ref. # 9.4.7 Battery Charge & Temperature Monitoring - Standard Ref. # 9.4.14
GO CHECK YOURS NOW! Don’t risk it with a non-compliant panel “The inspectors are coming” 59 Export Drv Brooklyn VIC 3012 Email: sales@wellcross.com.au
www.pumpindustry.com.au
. pump industry | Autumn 2017 | Issue 19
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WATER & WASTEWATER
Selecting the correct sewage pump impeller by Joe Evans, Pump Ed 101
The selection of an impeller for a sewage pump application has a significant effect on the efficiency, maintenance, and reliability of the pump. So, how should you determine which impeller is the suitable choice for your application? One way to differentiate between the various sewage pump impellers available is by examining how they accomplish the passing of solid material.
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he fundamental difference between a centrifugal sewage pump impeller and the clear water impeller is the former’s ability to pass solid material that would cause a clog in the latter. Although the mathematics that define the operation of an impeller can be complex (it is the stuff of Bernoulli and Euler), its purpose is straightforward. An impeller is designed to impart energy to a fluid so that it will flow, or, if it is already flowing, undergo some increase in its elevation or pressure. It accomplishes this by increasing the fluid’s velocity as it travels through its vanes from the leading edges, located at the eye, to their exits at the periphery. The ever increasing radius of the vanes results in an increasing rotational velocity that reaches some maximum at the periphery. The resulting linear velocity of the fluid, at the vane exit, is then converted to pressure in the volute. If one were to set out to design a typical radial vane impeller, several guidelines would be followed quite closely. For instance, the overall diameter of the impeller would closely match the volute and cut water diameters in order to reduce slippage of the pumped fluid in these areas. Also, depending upon the desired hydraulic characteristics, four or more vanes would be incorporated to smooth flow at the vane exit. Their leading edges would also be sharpened to reduce losses due to friction and turbulence. Unfortunately, if one followed these same guidelines when designing a solids handling impeller, the outcome would be doomed to failure. Unlike the typical radial vane impeller, those designed to accommodate solids violate many of the standard design rules. Small to medium-sized sewage pumps are often referred to as non-clogs and their impellers are designed to try to live up to that name. Although many factors contribute to the ability of an impeller to pass solids without clogging, one of the more important factors is its throughlet size. The throughlet is defined as the open internal passage through the impeller that ultimately determines the largest diameter solid that can be passed. All impellers, regardless of their design, have some maximum throughlet size. In order to maximise throughlet size, solids handling impellers limit the number of vanes so that the passages between them can be as large as possible. Let’s take a look at some of the common sewage pump impeller designs and discuss the benefits and limitations of each.
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Radial flow solids handling impellers The various members of the radial flow impeller family include the closed, open, and semi-open designs. Depending upon capacity, each design may incorporate anywhere from one to four vanes. The vanes are not straight, but describe a smooth curve that begins at the eye of the impeller and extends to its periphery. They may also be curved upward at their entry as in the Francis vane design. The closed impeller looks very much like an exaggerated version of the clear water impeller. The shrouds of the closed impeller enclose the impeller’s vane passages from the eye to the periphery and are designed to accommodate the largest possible diameter solids. The vanes themselves have large, rounded leading edges to prevent clogging by rags and stringy material that could become entangled at the vane entry. On pumps with suctions up to 12”, a two-vane (often referred to as a two-port) design is typical, while larger pumps may utilise a three or four-vane design. Most closed impellers also incorporate pump out vanes on the back side of the back shroud. These small, straight vanes keep the sealing area free of debris and also reduce the unbalanced axial forces that can occur due to back shroud’s larger surface area. The major wearing surface of the closed impeller is the area where the eye protrudes into the volute suction. Replaceable volute wear rings are used to maintain proper clearance and hydraulic efficiency. A typical rule of thumb calls for wear ring replacement when the factory set tolerance has doubled. Very large sewage pumps often use a mixed flow impeller for low head, high flow conditions. The mixed flow design utilises a double curvature vane that provides both radial (centrifugal) and axial (lifting) flow characteristics. Also, because of their extremely large throughlets (4” and greater) these larger pumps can utilise sharpened vane leading edges for greater efficiency. Another characteristic of the closed solids impeller is that its diameter seldom exceeds 80 per cent of the volute cut water diameter, as compared with about 92 per cent for a standard impeller. This diameter is restricted, at the expense of slippage, in order to reduce vibration and noise, especially at lower flows. This larger than normal clearance also reduces clogging in the area where the impeller periphery is closest to the volute case. Another closed design is the single-vane impeller. On the positive side, it allows for the largest possible throughlet.
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WATER & WASTEWATER
Since there is only one vane, there is only one leading edge, and thus potential clogging at the vane entry is reduced. Unfortunately, due to its lack of symmetry, it is inherently out of balance. Unlike the multi-vane impeller, most cannot be trimmed and must be replaced if hydraulic conditions change. The single-vane impeller also tends to produce a rather steep head-capacity curve. Although this can be useful in some applications, the flatter multi-vane curve generally has greater utility. By definition, the true open impeller consists of nothing more than vanes mounted to a hub that is attached to the pump shaft. They are usually seen in smaller pumps and are best suited for applications involving stringy materials. Because they are shroudless, it is less likely for material to become entrapped between the impeller and the front and rear portions of the pump case. A disadvantage is their structural weakness and, because of this, they are often strengthened by a partial shroud on the back side. If the back shroud covers the entire vane structure, the impeller is designated as semi-open. Since one or both shrouds are missing from each design, both are prone to wear at the vane edges and must be adjusted periodically in order to maintain hydraulic efficiency. Typical volute/vane clearances range from 0.020” to 0.030”
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and increases due to wear affect pump efficiency to a greater degree than the eye/volute wear of the closed impeller. The semi-open impeller, due to its lack of a front shroud, also tends to create greater unbalanced axial forces than does the closed impeller. Both pump out vanes and balance holes are often utilised to minimise these forces and prevent potential bearing damage. Although the radial flow impeller is the workhorse of the sewage pump industry, there are applications for which it is not well-suited. One example is low flow applications. By virtue of its large throughlet, flow rates will always be far greater than impellers of the same diameter designed for clear fluids. For example, even a small impeller designed to pass 2” solids will create BEP (Best Efficiency Point) flows of 80 to 120gpm. Increase solids size to 3” and the flow range increases to 400 to 700gpm. With conventional pumps, flow can be reduced by throttling the discharge. However, such a tactic is not acceptable when solids are involved. This problem is exacerbated when a low flow application is complicated by a high head requirement.
Radial forces When a centrifugal pump is operating, the pumped fluid exerts a force on its impeller both radially (perpendicular to the shaft) and axially (parallel to the shaft). When the pump pump industry | Autumn 2017 | Issue 19
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WATER & WASTEWATER is operating at its design point (BEP), relatively uniform pressures act upon most surfaces of the impeller. An exception is the area about the periphery where pressures are rarely uniform, regardless of the operating point. As flow decreases (or increases), unbalanced radial forces increase and usually reach a maximum at or near shut off head. This radial thrust, as it is known, is a function of total head, and the width and diameter of the impeller. Thus a high head pump with a large impeller will generate more radial thrust than a low head model incorporating a smaller impeller. By design, the sewage pump impeller is unusually wide and the radial forces created can be extremely high as operation moves to either side of BEP. Depending upon the particular pump, as much as the first 30 per cent of the entire performance curve is considered unsuitable for normal operation. High radial forces can damage a pump’s rotating components and can, in some cases, create enough vibration to dislodge a submersible pump from its lift out connection. One way of reducing the effect of radial thrust is to neutralise the force itself. The double volute pump accomplishes this by adding an internal wall to the casing that, in effect, creates two volutes. Although the double volute is found in very large sewage pumps, it is not a workable solution when small to medium-sized solids handling pumps are involved. Another method involves modifying the standard constant velocity volute by increasing the volute volume in the area about the cut water. Although this reduces efficiency by one to two per cent, radial forces at lower flows can be reduced by as much as 25 per cent.
Vortex (recessed) solids handling impellers So, is there another way to overcome the low flow, high head shortcomings of the radial flow impeller? The answer is
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yes but, since there is no such thing as a free lunch, there is a price to pay. The vortex impeller operates quite differently than the radial flow type. Instead of imparting energy directly to the pumpage, it creates a liquid vortex (whirlpool) which, in turn, imparts its energy to the pumped fluid. And, as with any multistage process, some energy is consumed by the intermediate step (in this case creation and maintenance of the vortex) and results in a lower overall hydraulic efficiency. Actual efficiency depends upon pump size and speed and can range from a low of 20 per cent, to better than 55 per cent. Nonetheless, such losses can often be tolerated if the end result allows something unobtainable otherwise. And, in the case of the vortex impeller, several distinct advantages are offered. The most obvious visual difference between the vortex pump and radial flow models is that its semi-open impeller resides completely out of the volute. This feature offers the sewage pump designer three distinct advantages. • The throughlet size can easily be made to equal that of the pump’s inlet. Therefore any solid that can enter the inlet can traverse the throughlet. • Since the pumpage traverses the throughlet via vortex action, its solids seldom come in contact with the impeller. This reduces the possibility that solids, especially stringy ones, will become entangled or clog it. For the very same reason impeller wear is minimised. • Due to its location above the volute, unbalanced radial forces are almost nonexistent. This allows the vortex impeller to run continuously at or near shut off head without damage. An important application of the vortex impeller is the centrifugal grinder pump. The grinder pump utilises a shredder assembly to macerate large solids into a fine slurry prior to
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WATER & WASTEWATER its entry into the volute. Since solids no larger than 1/8” are encountered, the volute and impeller can be designed for low flow at very high heads. Small centrifugal grinders offer flows to 40gpm at heads to 140’, while larger units offer flows to 180gpm at heads to 170’. These pumps are well suited for low pressure sewer systems because of their ability to vary flow dynamically depending upon conditions and to run at shut off head during periods when the system is loaded to capacity.
Centrifugal screw impellers The centrifugal screw impeller is another very different solids handling impeller design. The centrifugal screw pump is a hybrid that combines features of the positive displacement screw and the centrifugal pump. More often seen in the process environment because of its low shear and NPSHR characteristics, it is becoming more common in the wastewater industry. It offers relatively high efficiencies and good solids handling capability. The head capacity curve is quite steep, but is typically non-overloading. This allows operable range from about ten to 125 per cent of BEP. The portion of the screw that resides in the suction nozzle is prone to wear and is protected by a replaceable or adjustable wearing surface. Like open impeller pumps, these clearances must be adjusted periodically to maintain hydraulic efficiency. The major disadvantage of the centrifugal screw is that they tend to be quite costly when compared to other designs.
Which sewage pump impeller is most suitable? So, which impeller is the best choice for any given sewage pumping application? There is no easy answer to this question. If there were, there would not be such a broad selection from which to choose.
ACTION AQUATICS HAVE JUST CHANGED THE GAME
1986 and is passionate about the sharing of knowledge within the industry. To read more of his insights into the world of pumping, visit www.pumped101.com.
FUNCTIONS:
dehumidifier / heat exchanger units to the Australian market. Fully automated, scalable systems with programmable customised operating profiles, the systems are multifunctional, allowing them to be utilised for:
Evaporation, condensation, fungus, mould, sodium, chlorine and bromine combine forces to create corrosion problems in pool facility environments.
Joe Evans has been in the pump industry since
Multifunctional Dehumidification System
It’s Not The Heat, It’s The Humidity! Keeping humidity under control in enclosed swimming pool facilities is critical to the longevity of the facility.
It can probably be said that the closed, mixed flow impeller is the most efficient and trouble-free choice when large pumps are involved. In the case of small to medium-sized pumps, however, the particular application becomes an important factor in the selection process. Although the closed Francis vane tends to be more popular, the open vane design has its own strengths under certain conditions. The vortex impeller combines the positive traits of both but does so at the expense of lower hydraulic efficiency. Yet when it comes to high head, low flow applications, its lower efficiency is hardly factored into the equation. Several manufacturers have recognised these differences and the advantages that different impeller designs can offer in a particular application environment. For this reason they offer different impeller options for their more popular pump models. It is definitely worth considering these options when designing new sewage pumping systems. They can also often solve problems in existing installations that have undergone major changes in hydraulic conditions.
C-Series
Dehumidification
Fresh Air Ventilation
Air Heating
Shower Hot Water Heating
Air Conditioning
Energy Recovery Ventilation
Pool Water Heating
• Dehumidification
Keep them all under control with adequate dehumidification, designed into the facility from the outset or retrofitted after construction.
• Water cooling • Water heating • Air cooling
Save your clients money and add decades to the useful life of their facilities while saving them substantial maintenance and running costs.
• Air heating Programmed set points can be customised to your local conditions, to ensure prevailing seasonal humidity levels, temperatures and dew points are accommodated in the operating profile of the dehumidifier.
Action Aquatics have joined forces with one of the world’s leading pool dehumidifier manufacturers to bring a range of high efficiency
Action Aquatics Dehumidifier Range Technical Specifications Specification
C-250
C-350
C-500
Dehumidification capacity (kg H2O/hr)
25
35
50
60
80
100
120
150
180
Air processing intake (m2/hr)
6000
9000
12500
15000
24000
30000
36000
50000
60000
Air processing intake (cu.f/min)
3525
5288
7344
8813
Fresh air intake, mixed to output (m2/hr)
1800
2500
4500
4500
6000
7500
9000
12000
15000
Air heating capacity @30 C & 80%RH (kW)
48
67.5
95.8
114.1
142.5
175
215.2
291.4
322.5
Refrigerant type
407c
407c
407c
407c
407c
407c
407c
407c
407c
Dimension - Height (mm)
4350
Dimension - Width (mm)
1400
1680
1800
1800
1900
2050
2400
3150
3500
Dimension - Length (mm)
1430
1730
1780
1780
1980
2130
2380
1980
2130
Weight (kg)
1250
1550
2150
2300
2750
3050
3300
3750
4300
Power supply ( V / Hz / Phase)
415/50/3
415/50/3
415/50/3
415/50/3
415/50/3
415/50/3
415/50/3
415/50/3
415/50/3
Dehumidifier power consumption (kW)
15.3
21.0
30.0
34.4
45.7
58.5
69.7
89.0
103.6
Optional pool heating unit capacity (kW)
55
77
110
110
160
210
250
300
380
Optional electrical pool water heater (kW)
55
75
110
110
180
210
250
300
350
Air heating capacity @30 C & 80%RH (kW)
43
60
85
100
130
165
200
260
305
O
4500
5500
C-600
5500
C-800
14100
6200
C-1000
17625
7100
C-1200
21150
7800
C-1500
29375
6700
C-1800
35250
7200
WE HAVE AUSTrAlIA COVErED www.acTionaquatics.com.au/mfdh
Optional units
O
*Test standard: Dry bulb temperature of 30 C and Relative humidity of 80% O
www.pumpindustry.com.au
PH +61 7 3051 5861 FAX +61 7 3806 4528
**Specifications subject to change at manufacturer’s discretion
pump industry | Autumn 2017 | Issue 19
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WATER & WASTEWATER | PARTNER SOLUTIONS
Solving wastewater challenges in North East Victoria by Adrian Rijnbeek, Sales Engineer, Xylem, and President, Water Industry Operators Association of Australia
North East Water provides water and wastewater services to 41 localities across North East Victoria, Australia, serving an estimated 122,000 people in an area of approximately 20,000 square kilometres. The region extends from Corryong in the east, along the Murray River to Yarrawonga, then south to Benalla and the alpine towns of Bright, Mount Beauty and Dartmouth.
T
he municipal sewer pump station at Jordyn Terrace in Wangaratta receives very challenging wastewater containing a large quantity of sanitary items, and other fibrous waste objects, that cause “ragging” of the pumps. This resulted in pumps having to be lifted and unblocked twice or three times every week. In July 2016, North East Water became the first water business in Australia to install Xylem’s Flygt Concertor system with the aim of resolving this issue and delivering clog-free pumping to the Jordyn Terrace wastewater pump station. Since the installation, station managers have reported no blockages or clogging issues at the station, as well as a cleaner station with less visible material in the sump.
The challenge
Jordyn Terrace in Wangaratta, North East Victoria, is located within a busy residential area and close to a retirement village. The pumping station receives very challenging wastewater, including personal sanitary products and towelling, which caused the pumps to clog a number of times a week. This frequent clogging required operations and maintenance staff to travel to the site to remove the blockage up to three times a week. “Regular clogging of the pump station was a serious issue for us,” said Grant Waite, Manager Assets and Operations, North East Water. “As a result, operation and maintenance staff had to leave their daily work schedules to travel to the pump station, unclog the pump, and get the station up and running again. In addition to manpower, a maintenance crane truck was needed to perform the pump lifts which meant it had to be taken away from other projects, which added further expense to the repair job.”
New integrated clog-free technology
In July 2016, North East Water agreed to have Flygt Concertor installed at the Jordyn Terrace pump station in order to resolve the chronic clogging experienced. The team had high hopes for this new system, as it combines Flygt’s well-known self-cleaning hydraulics, Adaptive-N, as well as intelligent functionalities like pump cleaning. This function activates when a clogging instance is detected, and starts operating the impeller at different speeds and directions to remove the debris. Its efficiency has been proven in many applications all over the world and, together with other functions that ensure trouble-free pumping, offers a new level of reliability. After installing the Flygt Concertor system, clogging issues
at the Jordyn Terrace wastewater treatment plant were completely eliminated. “We have found Xylem’s Flygt equipment to be of excellent quality so we were happy to trial the new wastewater pumping system. The trial pump we received is still running in our station and so far we haven’t had one single case of clogging,” Mr Waite said.
Peace of mind in the long run
Concertor’s short-term results in Jordyn Terrace were certainly a relief for the station’s operators, but their main concern was to find a sustainable solution that can bring peace of mind in the long run. This is where the system’s flexibility played an important role. One of its main hardware elements, the pump impeller, is offered in three different materials, to adapt to different conditions: Flygt’s hard-iron, duplex stainless steel and stainless steel. A high chrome alloy, Flygt Hard-Iron™ is five times more wear resistant than duplex stainless steel.* In accelerated wear tests, Hard-Iron kept working efficiently and showed minimal wear after pumping water with a very high concentration of extremely abrasive particles. This durability and reliability saves customers time and money. Mr Waite said, “The Hard-Iron™ impeller will ensure that the current pump performance is maintained for extended periods. In an application like this, with wastewater that contains a high level of non-biological solids, it is the best option.”
Compact design and more functionality
Flygt Concertor is proof that new technologies with sophisticated integrated intelligence for wastewater pumping do not require more components or complexities, rather Concertor is user friendly and simple to install, commission and operate. “Since Flygt Concertor has been installed we haven’t experienced any clogging issues at the station, which is a dramatic improvement to how the station’s old pumps had been running. The new wastewater pumping system has also had a positive impact on the local community – less visits to the station by large maintenance trucks and personnel. Station managers have also reported that the sump is cleaner as a result,” said Mr Waite. *Hard-Iron™ is a high-strength alloy containing 25 per cent chromium and 3 per cent carbon. During the solidification process, the chromium and carbon transform into very hard carbides. This makes Hard-Iron™ highly resistant to abrasive wear and erosion-corrosion.
For more information, visit Flygt.com/one-ultimate-system.
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pump industry | Autumn 2017 | Issue 19
www.pumpindustry.com.au
SECTION HEADING
NEW
CONCERTOR™
PUMPING SYSTEM WITH
INTEGRATED
INTELLIGENCE
WORLD’S FIRST WASTEWATER PUMPING SYSTEM WITH INTEGRATED INTELLIGENCE This revolutionary system delivers optimal performance while reducing your total cost of ownership. It also offers unparalleled flexibility and simplicity on a whole new level. You might even say it thinks for itself. We invite you to enter a new era in wastewater pumping with Flygt Concertor. Witness the official unveiling of Flygt Concertor at Ozwater’17, Australia’s International Water Conference & Exhibition in Sydney, 16th - 18th May 2017. One powerful solution. Unlimited possibilities.
www.xylem.com/pumping www.pumpindustry.com.au
pump industry | Autumn 2017 | Issue 19
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WATER & WASTEWATER
LESSONS LEARNT from the Alfred Street PUMP STATION UPGRADE A major pump upgrade to the City of Logan’s largest wastewater pump station, involving 3D laser surveying and the reuse of existing pump station components, has won an industry award for its innovative design and cost-savings measures.
T
he Alfred Street Pump Station, located at Slacks Creek in Logan City, has operated since 1984, taking wastewater from properties to the Loganholme Wastewater Treatment Plant for processing. A $7.7 million project to upgrade the pump station and reduce the risk of wastewater overflows was completed by the Logan Water Infrastructure Alliance – a public and private sector enterprise comprising Logan City Council, Downer, Cardno, and WSP | Parsons Brinckerhoff. The success of the upgrade was recognised when the project won the 2016 Institute of Public Works Engineering Australasia Queensland (IPWEAQ) Excellence Award in the water, wastewater and drought management category. Principal Water Engineer Anthony Domanti led the design of project over several years and said that correctly selecting the new dry-mounted pumps was an important element during the design development of the project. “The new pumps selected for the project were KSB Amarex KRT-K, 500kW (dry-mounted) pumps with a single duty point of 1,175 L/s at 35m,” Mr Domanti said. Mr Domanti said these pumps were selected based on certain criteria, including the ability to use the existing overhead bridge crane, and the ability to pump to separate discharge points. “Upgrading the existing overhead crane at the pump station would be expensive and probably require the existing building roof to be raised, further adding to costs. “Originally the Alfred Street Pump Station site was connected to a set of rising mains before discharging to the Loganholme Wastewater Treatment Plant. However, following a master planning review of the Logan North wastewater catchment, a new $50 million rising main (7km x DN1200) was constructed on a different alignment,” Mr Domanti said. The new rising main is usually operated by SPS69 (one of two pump stations on site at Alfred Street complex), but the new pumps installed at SPS02 (the other pump station on site which was substantially upgraded) had to be able to operate effectively via this new conveyance direction. The original pumps that were replaced were Thompsons, Kelly & Lewis 600/700 VS wastewater pumps. These were driven via a line shaft from two speed motors mounted at the mezzanine level.
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pump industry | Autumn 2017 | Issue 19
The dry well prior to the upgrade.
Reduce, reuse, re-purpose The Logan Water Infrastructure Alliance (LoganWIA) decided to reuse existing pump station components in the project, saving $1 million. Mr Domanti said the aim of this was to ensure value for money and reduce the impacts of major construction. “LoganWIA adopted an asset management strategy to extend the operational life of the Alfred Street Pump Station. During detailed planning and design of the upgrade, the team identified several opportunities to re-purpose existing pump station components,” Mr Domanti said. These opportunities included reusing the existing electricity supply including site transformers, substation compound and standby generator; maintenance of the existing bridge crane; the optimisation of existing buildings; and avoiding significant modifications to the pump station roof and overhead crane system (influencing pump selection). The project also avoided the construction of a new electrical control building by reusing an existing structure. Other aspects of the pump station were also upgraded, including a new switchboard room which was built utilising existing space within the SPS02 building. “This offered a significant reduction in new cable supply compared to providing a new structure elsewhere on site,” Mr Domanti said.
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WATER & WASTEWATER This also allowed the provision of current industry-standard facilities. Operations and maintenance personnel are no longer exposed to a potential arcing fault hazard and the asset now operates reliably. “All mains cables were routed outside the building to avoid cable penetrations between the machinery hall and the new control room, which further minimised the risk of corrosive gas affecting the electrical system,” Mr Domanti said.
Utilising 3D surveying Mr Domanti said a key construction challenge during the project involved the safe removal of the existing steel framework system. A construction hazard assessment (HAZCON) was undertaken, which addressed the construction risks and sequencing of works. Following the HAZCON, the existing steel framework system was able to be removed by using a knuckle boom spider elevated work platform (EWP). “The key features of the machine were its small footprint, it reaches 15m in height, and the turret, which rotates 359 degrees, thereby achieving full access to the upper section of the dry well,” Mr Domanti said. In the end, the implementation of the EWP was five times cheaper than using conventional scaffolding. Due to the limited as-constructed information available, 3D laser surveying was used to design the new pump arrangements, and understand potential operational issues and prevent them from occurring. “Use of this technology for brownfield sites is more costeffective than manual measurement processes which are error prone and require a greater length of time to complete,” Mr Domanti said. The reliable 3D survey was used for all aspects of design development, such as confirming the exact pipework lengths, obtaining difficult-to-reach measurements and ensuring safety
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The first pump installed in the upgrade.
pump industry | Autumn 2017 | Issue 19
37
WATER & WASTEWATER in design obligations were met. “It was also used extensively to develop a safe demolition sequence associated with removing the pump line shaft framework system, and associated platforms,” Mr Domanti said.
What can other contractors learn? Mr Domanti said the innovative design and construction methods and the challenges of this project taught him several lessons that he now shares with young engineers and other project teams. The top six things he took away from the Alfred Street Pump Station upgrade include: 1. 3D laser surveying is an effective tool that enables designers, constructors and operators to better understand and eliminate safety risks 2. Overseas-produced fittings may be incorrectly labelled as being in accordance with Australian standards and need to be checked for this reason 3. Allow for as much pipework connection flexibility as possible to accommodate for potential misalignments 4. Recognise that tolerances are a part of the manufacturing process and their impacts must be considered during the design phase 5. It is beneficial when the pump supplier replicates (as close as possible) site conditions when performing factory acceptance tests 6. Suction specific speed is a key parameter for selecting high flow pumps Mr Domanti said the upgrade was a career-defining project for him, as well as those involved from Logan City Council, Downer, WSP | Parsons Brinckerhoff, and Cardno. “It is appreciated when your team receives an industry award. It’s like a ‘thank you’ for all the effort, long hours and innovation that goes with meeting the challenges of a project like this.” Installing the switchboard.
Clean Water. Yes! Sulzer introduces high-efficiency pumping solutions for Clean Water applications
Committed to providing efficient solutions across the entire water life cycle, Sulzer is proud to introduce a range of pumping solutions for Clean Water applications. This range is the result of years of expertise and experience in fluid handling, and embodies everything you’ve come to rely on us for.
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Our Clean Water pumping solutions feature state-of-the-art design, robust construction and efficient hydraulics for high operational uptime and energy savings. And all of them are backed by the Sulzer assurance of quality and dependability.
Sulzer Australia Pty Ltd Phone 03-9775 0522 jonathan.fullford@sulzer.com www.sulzer.com
To learn more about our Clean Water range of pumps meet us at Ozwater 2017, stand N23, or visit sulzer.com/cleanwater
pump industry | Autumn 2017 | Issue 19
www.pumpindustry.com.au
HD – Heavy Duty Series The proven aerator solution
HD series HDP100 gearbox
The HDP series consists of a range of heavy duty parallel helical reducers that feature advanced designs and robust build quality to ensure trouble free and quiet operation in all water treatment applications. The nodular cast iron housing ensures robustness even in the harshest of applications, whilst the strict assembly tolerances and fully ground gears provide an extremely quiet and vibration free operation. With over 100 years of gearbox assembly knowledge, local stock holdings, dedicated HD application engineers, 24 hour service and an extensive list of aerator application references, Bonfiglioli can provide you with a complete Heavy Duty aerator drive solution.
www.bonfiglioli.com.au Branches Australia Wide PH: 1300 656 757
Technical Key Characteristics Series: Size: Torque Ratings: Reduction Ratio: Input Options:
HDP parallel helical 14 sizes available 4,650Nm - 194,050Nm 7.1 - 534.5 High Speed shaft, IEC close coupled. Output Shaft Options: solid shaft + rigid flange, hollow keyed, shrink disc. Options: Mechanical and motor driven forced Lubrication systems, cooling systems, oil level sensors, heavy duty output bearings, drywell, taconite seals, rigid output mounting flange.
IRRIGATION
Irrigation inno WINNING Ian Hamono inspecting his maize crop grown on subsurface drip irrigation.
In Victoria’s Goulburn Valley, two innovative farmers have revolutionised the irrigation and pumping systems on their property, significantly reducing water usage per hectare of land, and widening the range of crops they can produce. In recognition of their efforts, they were awarded first place in the Irrigation District Water Users category of the 2016 State Rural Water Awards.
I
n 2008, when farmers Ian and Mary Hamono first purchased their farm in Cooma, Victoria, the land had previously been used for growing tomatoes and lacked a permanent irrigation system, the tomato growers having employed short term, removable irrigation infrastructure. In the midst of the Millennium Drought, water prices were high and the Hamonos knew they couldn’t take unlimited, reliable water supply for granted. “At the time I purchased this farm water prices were really expensive,” Ian Hamono told Pump Industry. “We were in the middle of a drought, and the long-term projection was the water prices were going to be expensive, and there was going to be a shortfall of water. I was really looking for an efficient way of irrigating my summer crops into the future.” So the couple began to research and plan an efficient, effective irrigation system that would maximise yield for each unit of water used, keep costs down, and see them well into the future. Now in 2017, they have state-of-the-art irrigation systems, including a 160-hectare subsurface drip irrigation system, installed on the property, and are reaping the benefits of their investment.
Installing an innovative irrigation system The new irrigation system was eight years in the making and encompassed a three-stage project. For each stage Ian and Mary Hamono exchanged water entitlements in return for government investment in on-farm efficiency improvements through the Australian Government’s $626 million On-Farm Irrigation Efficiency Program. This program aims to assist irrigators in the southern connected system of the Murray–Darling Basin to modernise their on-farm irrigation infrastructure while returning water savings to the environment. But before installation works could begin, the Hamonos had to undertake significant planning and research to identify the ideal irrigation infrastructure for their intended applications. “It was really a matter of going out and talking to others
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pump industry | Autumn 2017 | Issue 19
that had done it,” said Mr Hamono. “Talking to suppliers and equipment manufacturers about the latest technologies and trends. And I wanted to install something that was not only suitable today, but was going to be there in the future.” Every minute detail had to be considered in order to design the most effective systems. “We had to consider tape spacing, what sort of emitter application rates were required. What sort of filtration, what pumps,” said Ian Hamono. “There’s a whole range of factors. What sort of control system. What sort of valve. How to control field valves. There are old traditional hydraulic systems, then multi-wire systems, two-wire systems, and there’s radio. It was really a matter of working through all those sorts of technologies.” Once the planning was complete, on-ground installation works could begin. The on-farm works have included pump installation, channel construction, laser grading, establishing recycle dams, subsurface irrigation, and the installation of a centre pivot. “The first subsurface system that I installed we did in two parts, 60 hectares each year for two years,” said Mr Hamono. “The latest system that I’ve just finished installing, that was done over one season.” “I installed a recycle system,” he said. “That was the first grant that I got, it enabled me then to install pumps on that recycled system, so that I could install a subsurface drip irrigation. “I got a grant for the installation of centre pivot irrigation. I also got a couple of grants to upgrade some of the other parts of my property into high-flow flood irrigation. That was primarily done so that I could irrigate winter crops, to start them off in the autumn, and to finish them off in the spring, so that I basically reduced the risk of crop failure on those winter crops.”
Pumping water for efficient irrigation The Hamonos’ farm now has a highly efficient and effective irrigation system in place, powered by an array of pumps,
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IRRIGATION
vation reaps a HARVEST allowing them to grow a wide range of crops all year round. “I grow summer and winter crops,” said Ian Hamono. “Winter crops are cereals, canola, soya beans, whatever grows basically, on a rotation. In summer all of the area that I’ve upgraded predominantly goes to corn.” The irrigation system includes specially developed drip tape with a longer life expectancy, as well as a filter system to the pressurised pipe network that removes all fragments from the water, preventing blockages. The filter system is also capable of back flushing at lower pressure, putting less strain on the pumping system. “I’ve really got three different portfolios,” said Mr Hamono. “I’ve got some flood irrigation, which is the traditional way that people have irrigated here for decades. “I’ve got a centre pivot irrigator that covers about 65 hectares. Then I’ve got about 160 hectares of subsurface drip irrigation.
“They’re all pressurised systems, the subsurface drip irrigation pumps out of a dam. Basically, there are two systems, both pump out of dams. The water is then filtered, distributed in a main, distributed to a number of in-field valves that are controlled by a central processor unit that’s in the pump shed. It basically runs automatically. As for the drip lines, some are spaced a metre apart, some others are spaced a metre and a half apart, depending on what I’m growing on that country. “The first system that I installed was installed by a company in Shepparton called Water Dynamics. The centre pivot irrigator was installed by Eagle i Machinery at Finley. The newest drip system that I’m installing is being installed by Water Plus Irrigation in Shepparton.” The new irrigation systems couldn’t run without an array of pumps and valves to move and direct the water to where it’s needed.
Innovation leads to great inventions. The home built drip tape installation machine made by Ian.
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pump industry | Autumn 2017 | Issue 19
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IRRIGATION “On the largest system that I’ve got, I’ve got two 55 kilowatt three-phase electric motors that supply water to ten pod disk filters. From there the water is conveyed via 375mm main line to a series of in-field valves,” said Mr Hamono. “There are 27 of them on my large system. Those 27 valves supply about four and a half hectare blocks. Those field valves also have an inline disk filter on them, so that in the case that there’s a filter failure on the main filter, or some debris gets past it, it’s collected in the field valves, so that there is no chance of any debris getting into the drip tapes, and blocking the emitters. “Those field valves are controlled by a little computer system that’s in the main pump shed. That control system also controls fertigation – just how much fertiliser I inject in the system at any time. It also controls the flushing of the main filter. It controls the field valves to tell them in what sequence to come on, or to turn on and turn off.”
Harvesting the benefits The new irrigation systems have provided increased yield, significantly decreased labour input, and greater efficiencies – resulting in increased income for the farmers. “Comparisons of water usage on the
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Aqseptence Group - Summer - Half Page (PRINT).indd 1
different types of irrigation systems have shown on average water savings of about 1.5ML/ha with subsurface drip irrigation,” Mr Hamono said. “We’re also recording an increased yield of about one to two tonnes per hectare and we can irrigate more land. “It eliminates the need for channels, structures, check banks and surface drains, allowing me to increase the total amount of land available for irrigation by about 3.5 per cent.” However, Mr Hamono said that
pump industry | Autumn 2017 | Issue 19
possibly the most significant benefit was increased flexibility in irrigation practices, including the ability to apply small amounts of water to finalise crops when full irrigations are not required. “This system allows us to apply the right amount of water at the right time,” he said. “I can basically match water application to crop needs.” “I know now with my corn plants over summer, on a week-to-week basis, how much water they need for growth, and I can add to that the evaporation I expect
13/12/2016 1:50:17 PM
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IRRIGATION
given the climatic conditions we’ve got. Then I can apply whatever irrigation water is needed at that stage too.”
Setting an example of best practice While winning in the state category of the 2016 Rural Water Awards was a nice bonus, the Hamonos consider themselves to have just been “doing what needs to be done”. “I really didn’t do this for any accolades or awards or recognition, or anything like that,” said Mr Hamono.
“Having said that, it’s a terrific award, it’s a great achievement. It’s always good to showcase what the industry can do, and also provide some sort of leadership or inspiration for other people in the industry.” The Hamonos hope that the success of their irrigation overhaul can inspire other irrigation end users to consider overhauling their own irrigation systems to reap similar benefits. “Today, more and more farmers are adopting subsurface drip irrigation in
the Goulburn Valley as they identify with its benefits and best practices,” said Mr Hamono. “I’ve already had a couple of groups of people who have come past and called in to have a look at what I do, and how I do it. “Some of them are already doing it themselves, while others are contemplating it. Yes, it’s been good in that regard, there’s no doubt about that. It does show what can be done,” he said.
CALL 1300 789 466 WHEN PUMP KNOWLEDGE MATTERS
KELAIR PUMPS AUSTRALIA Searching for the most energy and cost efficient pumps for your applications? With our extensive range of pumps, first class customer service and ongoing comprehensive support, Kelair Pumps are second to none when it comes to your industry needs. Call us today! • Food & Beverage • Water & Wastewater • Irrigation • Power
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INDUSTRIAL PUMPS | BUILDING AND FIRE | ENVIRONMENTAL | SERVICE NSW | VIC | TAS | QLD | WA
pump industry | Autumn 2017 | Issue 19
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IRRIGATION
ENERGY SAVING AT A MUNDUBBERA CITRUS FARM In this Queensland Farmers Federation case study, a 100-hectare citrus farm in the Mundubbera region installed variable speed controls and a solar photovoltaic system as part of an irrigation upgrade that saw a 54 per cent saving in energy.
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pump industry | Autumn 2017 | Issue 19
www.pumpindustry.com.au
IRRIGATION
T
he farm sources water for irrigation from an underground aquifer. Citrus trees are irrigated using sprinklers beside each tree, and the areas are divided into zones with water supply controlled by an irrigation management system, which can be adjusted according to the season and weather conditions. The farm uses drip and micro irrigation, and submersible pumps. Electricity consumption onsite is driven mainly by the irrigation pumping, packaging operations, and refrigeration cold rooms, which are used from April to October. The irrigation system comprises: • Two 45kW bore pumps that supply water to the irrigation system and are located 66m below ground level • A third smaller bore pump of 5.5kW used to supply water to the packing shed and controlled by a variable speed drive (VSD) An energy audit of the site evaluated the installation of variable speed controls and a solar photovoltaic (PV) system. Of the energy-saving opportunities evaluated, two initiatives were identified, which the owner has since implemented, along with other measures to realise energy savings of greater than 50 per cent and a payback period of approximately 4.8 years. The energy audit included recommendations to install VSDs on the two 45kW irrigation pumps, that were run with the discharge throttled to provide the correct pressure to the irrigation sprinklers. Therefore, there was an opportunity to reduce energy use by slowing down the pumps using VSDs as an alternative to throttling. In fact, the farm replaced the two 45kW pumps with 37kW pumps, further adding to savings when combined with the VSDs. Another initiative recommended was to install a 30kW solar PV system on the packing shed to offset a large amount of the site’s energy usage during the day, and to review the tariff pricing structure for the pump electricity accounts to realise savings of over $1900 per annum. The owner subsequently implemented the VSDs on the two bore pumps and replaced high bay lighting and fluorescent tubes in the packing shed with new energy efficient LEDs. The owner also installed an 82.8kW solar PV system on the packing shed, reducing the number of points of supply to maximise the benefit received from electricity generated. The farmer said implementation of these energy-saving initiatives resulted in energy consumption avoidance of over 170MWh during the baseline season. This equated to energy savings of 82kWh per tonne of fruit production. The farmer indicated it was helpful to have the information needed to make informed decisions and said, “Once I had all the information, we went ahead with implementing the recommendations. Before installing our variable speed drives, we had to irrigate all three blocks to get rid of the pressure. Now we can just do one or two as required.” The project was part of the Irrigators Energy Savers Program, funded by the Queensland Department of Agriculture and Fisheries.
FORECAST SAVINGS IN SITE OPERATING COSTS Existing system
Upgraded system
Reduction in operating costs
Annual operating cost
$69,016
$27,513
-
Cost to implement
-
$200,000
-
Operating costs for first 3 years
$345,080
$337,565
$7515
Annual pump operating cost for years 4 to 10
$69,016
$27,513
$41,503
Total pumping costs for 10 years
$690,160
$475,130
$215,030
This case study was originally published by Queensland Farmers Federation. To view more irrigation and energy saving case studies, visit www.qff.org.au/energysavers.
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pump industry | Autumn 2017 | Issue 19
45
SEALS
Why don’t
GOOD SEALS WEAR OUT? by Bill McNally, McNally Institute
We know that a mechanical seal is supposed to run until the carbon wears down, but our experience shows us this never happens with the original equipment seal that came installed in the pump. We buy an expensive new mechanical seal and that one doesn’t wear out either. So was the new seal a waste of money?
N
ot really. Here you are doing something that appears logical, you are trying to solve the seal problem by purchasing a different seal, but that’s like trying to get a good paint job on an automobile by buying a good brand of paint. If you wanted to get a good paint job on an automobile you would have to do four things: Prepare the body (metal repair, rust removal, sanding, masking etc); buy a good brand of paint (all paint is not the same); apply the paint correctly (with exactly the right
46
amount of air pressure, no drips or runs and frequent sanding between primer and finish coats); and take care of the paint after it has been applied (keep it washed, waxed and garaged). If you did those four things correctly, how long can a paint job last on an automobile? Obviously for years. Step outside and watch the cars go by and you will see evidence of people that are not doing those four things. In fact, it is so rare that when we see an older car that looks good, we stare at it. Achieving a good seal life also
pump industry | Autumn 2017 | Issue 19
involves four steps. They should be obvious, but let’s look at them anyway. 1. Prepare the pump for the seal – that’s the body work 2. Purchase a good seal – the good paint 3. Install the seal correctly – apply the paint correctly 4. Apply the correct environmental control if necessary (and it probably is) – also wash and wax We will look at each of these subjects in detail and hopefully begin to increase the life of our mechanical seals to the point where most of them wear out.
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SEALS This information relates to centrifugal pumps but can also apply to just about any kind of rotating equipment, including mixers and agitators.
Prepare the pump for the seal To prepare you should do an alignment between the pump and driver, using a laser aligner. A “C” or “D” frame adapter is an even better choice. Next, you dynamically balance the rotating assembly, which can be done using most vibration analysis equipment, but check with your supplier if you do not have the program. You must make sure the shaft is not bent and that you rotate it between centres. It’s a good idea to avoid shaft sleeves, as a solid shaft is less likely to deflect and is much better for a mechanical seal, and try to reduce pipe strain wherever possible. Use a “centre line” design pump if the product temperature is greater than 100°C, as this will reduce some pipe strain problems at the pump. Also, use pumps with a low shaft length to diameter ratio. This is extremely important with intermittent service pumps. Use an oversize stuffing box, avoid tapered designs, and give the seal lots of room. Try to get the stuffing box face as square to the shaft as possible, which can be done using facing tools, and reduce the vibration by using any techniques you know. It’s essential that you do not let the pump cavitate, as the seal faces will bounce open and possibly become damaged. Water hammer can also occur if power is lost to the pump while it is running, so take preventative action to avoid these problems. There are a few things that need to be checked when preparing the pump for the seal, including; that the mass of the pump/motor pedestal is at least five times the mass of the hardware sitting on it; that there are ten diameters of pipe between the pump suction and the first elbow; and that the base plate is level and grouted in place. Keep the open impeller adjusted to lessen vibration and internal recirculation problems, make sure the bearings have the proper amount of lubrication, and that water and solids are not penetrating into the bearing cavity. You should also replace the grease or lip seals with labyrinth or face seals. Make sure to avoid discharge recirculation lines connected to the stuffing box, in most instances suction recirculation will be better. If the pump has wear rings, ensure you also check
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their clearance. The final things to do when preparing the pump are to make sure the wetted parts of the pump are manufactured from corrosion-resistant materials, as cleaners and solvents in the lines sometimes cause problems that the designer never anticipated. Then seal off any air that might be leaking into the suction side of the pump and remove any that might be trapped in the volute.
Purchase a good seal Use hydraulically balanced designs that seal both pressure and vacuum and if you are going to use an elastomer in the seal, try to use an o-ring. These are the best shape for lots of reasons, but don’t let anyone spring load the o-ring or it will not flex or roll as it should. You should also use non-fretting seal designs as shaft fretting is a major cause of premature seal failure. Stationary seals (where the springs don’t rotate with the shaft) are better than rotating seals (the springs rotate) for sealing fugitive emissions and any other fluids. If the seal has small springs, keep them out of the fluid or they will clog easily. There are plenty of seal designs that have this non-clogging feature. A wide hard face is excellent for the radial movement we see in mixer applications and those seals that are physically positioned a long way from the bearings. You will also need some sort of vibration damping for high temperature metal bellows seals because they lack the elastomer that normally performs that function. Use designs that keep the sealing fluid at the seal outside diameter, or centrifugal force will throw solids into the lapped faces and restrict their movement when the carbon wears. You should also use unfilled carbons for the seal faces as they are the best kind and the cost is not excessive. Also, be sure you can identify all seal materials because it is impossible to troubleshoot a “mystery material”. Do not let the supplier tell you that his material is proprietary, and if that is their attitude, find another supplier or manufacturer, otherwise you deserve all the problems you are going to have. Try to keep elastomers away from the seal face. The elastomer is the one part of the seal that is the most sensitive to heat, and the temperature is hottest at the faces. Any dangerous or expensive product should also be sealed with dual seals. Be sure the hydraulic balance is in both directions or you are gambling that one of the faces might open in a pressure
reversal or surge. Lastly, if the design has a carbon pressed into a metal holder, be sure the carbon was pressed and not “shrunk in”. Pressed carbon will shear to conform to irregularities in the metal holder, helping to keep the lapped faces flat.
Install the seal correctly Cartridge seals are the only design that makes sense if you want to make impeller adjustments, and they are a lot easier to install because you do not need a print, or to take any measurements to get the correct face load. Cartridge dual seals should have a pumping ring built in and you should use buffer fluid (lower pressure) between the seals whenever possible to avoid product dilution problems. Avoid any type of oil as a buffer fluid because of oil’s low specific heat and poor conductivity. When installing, keep the seal as close to the bearings as possible. There is usually room to move the seal out of the stuffing box and then use the stuffing box area for a support bushing to help stabilise the rotating shaft. Depending upon the application, you will have to decide if this support bushing has to be retained axially. Split seals also make sense in just about any application that does not require dual seals or fugitive emission sealing (leakage measured in parts per million). Split seals are the only design you should use on double-ended pumps, otherwise you will have to replace both seals when only one seal has failed. They also allow you to change seals without having to do a realignment with the pump driver. Do not lubricate seal faces at installation, and keep solids off the lapped faces. If there is a protective coating on the seal faces be sure to remove it prior to installation. If it’s a rubber bellows seal, they require a special lubricant that will cause the bellows to stick to the shaft. It is normally a petroleum-based fluid, but you can check with your supplier to be sure. Rubber bellows seals also require a shaft finish of no better than 40RMS, or the rubber will have difficulty sticking to the shaft. Lastly, when installing in a vertical application, be sure to vent the stuffing box at the seal faces. You may have to install this vent if the pump manufacturer never provided it. Many cartridge seals have a vent built in that you can connect to the pump suction or some other low pressure point in the system.
pump industry | Autumn 2017 | Issue 19
47
SEALS
Take care of the seal The last step in achieving a good seal life is to continually take care of it. Seals prefer to be sealing a cool, clean, lubricating liquid, and while we seldom have one of those to seal, maybe you can apply an environmental control in the stuffing box area to change your product into one. If you are using a jacketed stuffing box, be sure the jacket is clean. Condensate or steam are the best fluids to circulate through the jacket. Try installing a carbon bushing in the end of the stuffing box to act as a thermal barrier that will help to stabilise the stuffing box temperature. Flushing is the ultimate environmental control as it causes product dilution, but if you are using the correct seal you won’t need much flush. Four or five gallons per hour (notice I said hour not minute) should be enough for that type of seal. You should also keep the fluid moving in the stuffing box to prevent a buildup of heat. Suction recirculation will remove solids that are heavier than the product you are sealing. Since that is the most common slurry condition, use suction recirculation as your standard. Also, learn where not to use it. Discharge recirculation will allow you to raise the pressure in the stuffing box to prevent a fluid from vaporizing between the lapped faces. Try not to aim the recirculation line at the lapped faces, it could injure them. If you are using a metal bellows the recirculation line can act as a sandblaster and cut the thin bellows plates. If the product is too hot, cool the stuffing box area. It is important to remember that these environmental controls are often more important when the pump is stopped because soak temperatures and shutdown cooling can change the stuffing box temperature drastically, causing the product to change state. Dangerous products will need an API. type gland if you elect
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pump industry | Autumn 2017 | Issue 19
not to use dual seals. The disaster bushing that is part of the API. configuration will protect the seal from physical damage if you should lose a bearing when the pump is running. Ensure that the API connections are made correctly. It is easy to mix up the four ports and get the flush or recirculation line into the quench port. Try not to put too much steam or water through the quench connection or it will get into the bearing case. Leakage out the drain connection is often perceived as a seal failure by operators. Be sure they know the difference.
Implementing these seal tips Does anyone ever do all of these four things? Unfortunately not. If we did, 85 or 90 per cent of our seals would be wearing out, rather than the ten or 15 percent that do. The prematurely failed seal with plenty of carbon face left continues to be the rule. The most common excuse we hear to explain our lack of good seal life is that there is never time to do it right, followed by the cliché, “But there is always time to fix it.” Most of us do one or two of the necessary steps and experience an increase in our seal life. There is nothing wrong with an increase in seal life, but that is a long way from wearing out seals. Think about it for a minute. If the seal is lasting a year, how big can the problem be? The temperature cannot be too high or the pressure too severe. If that were true it wouldn’t take a year to fail the seal. The product can’t be too dirty for the same reason. We often find the problem is as simple as a seal design that is fretting the shaft, causing a leak path through the damaged sleeve or shaft. Other times we find that the flush that is used to clean the lines once a year is the culprit, and no one is changing the seal materials to reflect this threat to the seal components.
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SEALS | PARTNER SOLUTIONS
John Crane marks 100-year anniversary T
oday, a century after the Crane Packing Company launched in Chicago, Illinois, John Crane is a global leader in solutions for process industries– and still makes enough of the company’s original products every year to nearly reach the moon. “Our longevity is a testament to our people and our service-minded culture,” says John Donatiello, VP of Global End User Sales and Service. “We help our customers stay ahead of change.” While today the company is the market leader in mechanical seals for pumps and compressors, it built its early success on packing and gasketing products patented by engineer and co-founder John Crane. His flexible, lubricated metallic packing sealed voids in cylinders, valves and other equipment to prevent leaking. By the mid-1930s, an estimated 25 million automotive motor water pumps used Crane Packing materials.
In 1968, John Crane was awarded a patent for spiral groove technology, leading a shift from contacting to non-contacting shaft seals over the next three decades. The innovative non-contacting technology delivers lower operating costs, higher reliability, and improved safety, and is today gaining recognition as a low-emission technology solution to help address climate change concerns. Over the years, the company has developed dozens of revolutionary products and processes, including the first automotive mechanical seal; the end face, elastomer bellows shaft seal; seals for high-pressure and corrosive applications; and non-contacting technology for pumps handling environmentally hazardous liquids. “We’re celebrating 100 years of innovation,” says Joe Haas, VP of Engineering. “But we’re also working on the next breakthroughs
for industry, in areas like additive manufacturing, materials development using nanoparticles, and Sense™ – a predictive diagnostics platform for the industrial Internet of Things.” John Crane supplies engineered products and services to process industries including oil and gas, chemical, power, pharmaceutical and general industry. The company designs, manufactures and services products including mechanical seals, couplings, bearings, and filtration systems. Mr Donatiello says, “Customers see us as problem solvers. We help them keep their equipment up and running, meet environmental and safety requirements, and operate more reliably and cost efficiently, to meet today and tomorrow’s challenges.” The company continues to make packing and gasketing materials – including nearly 240,000 miles of braided packing a year.
For sales and support, call H.E Brehaut Pty Ltd. Australia's Amarillo experts since 1982. Phone (03) 9873 8744, or email sales@hebco.com.au
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pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
IS YOUR DIESEL PUMP Tests of irrigation pumps across NSW commonly show that many are not performing adequately due to incorrect pump selection or wear. The NSW Department of Primary Industries explains how you can measure the running costs and pump efficiency of diesel-engine-powered irrigation pumps to determine if they are performing properly.
P
oor pump performance results in increased pumping costs, and can also reduce productivity as the pump is not delivering the correct amount of water to the crop. Therefore, testing your pump for water delivery and energy efficiency is essential to find out if it’s performing how it should.
Pump efficiency
Pump efficiency is a measure of how well a pump converts diesel fuel to useful work moving water. The aim of careful pump selection and regular maintenance is to have the pump performing as efficiently as possible, because this produces the lowest running costs. Pump efficiency of 70 per cent to 85 per cent should be achievable in most circumstances. An acceptable minimum for a centrifugal irrigation pump is 65 per cent, and 75 per cent for a turbine pump. An efficiency figure below these indicates that either the wrong pump was chosen for the job, or the pump is worn and needs repair. The key to containing your pumping costs is to regularly monitor your energy usage and check on any significant change that suggests pump maintenance is needed.
quick checks from time to time to see if anything has changed, and you can estimate if the cost of repair is justified.
A. What is the pumping cost?
To work out the cost of pumping, you need to measure the fuel used and the water pumped. The fuel in litres (L) of diesel used to pump one megalitre (ML) of water is calculated from these figures.
Step 1: Measure the fuel used To obtain a fairly accurate idea of consumption, the fuel used for an entire irrigation should be measured. If you have fuel flow meters, you can work this out from the meter readings. If not, it can be done by starting with a full fuel tank and measuring how much is needed to refill the tank after irrigating, or by taking dipstick readings before and after irrigating.
Test procedure
There are two stages to testing the performance of your pump. The first stage is to work out how much fuel is used to pump a megalitre of water. The information required is the amount of fuel used and the volume of water pumped. If you know how much you are charged for fuel, the cost of pumping can then be readily calculated. The second stage is to work out the pump efficiency. The information required for this is the fuel consumption and the total dynamic head. The efficiency can then be roughly calculated and compared to the manufacturer’s specifications. Both stages are explained below in a series of nine steps. When these steps are completed, you can perform
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From this data you can calculate the fuel used per hour.
irrigation set up the same, the energy consumption is now higher, you know straightaway something has changed and you should investigate further. When comparing figures, be sure they are from the same operating setup, that is, the pump operating at the same revs, valves or gates opened the same amount, irrigation system in the same position, with the same number of sprinklers, and so on.
Step 2: Measure the flow rate (Q) The flow rate of your irrigation system (Q) is the volume or quantity of water pumped in a certain time – for example, litres per second (L/s) or litres per hour (L/h). Flow rate is obtained by taking readings from your water meter at the pump over, say, half an hour and dividing the volume pumped (litres (L), kilolitres (kL), or megalitres (ML)) by the time.
Flow rate = (final meter reading – start meter reading) x (60 ÷ measured time) = (7.12685 – 6.94835) x (60 ÷ 35) = 0.1785 x 1.7143 = 0.306 ML/h = 306 000 L/h
This calculation, performed regularly over a season or across seasons, will be a useful check on general fuel consumption. If you find that, with the pumping water level the same and with the
pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
COSTING YOU MONEY? Step 3: Calculate the fuel per megalitre pumped From its fuel usage and flow rate, the litres per megalitre (L/ML) for your pump can be calculated.
Calculating this figure a couple of times over a season or between seasons allows you to check your pump’s performance. If the value changes, you should look for the reason.
Step 4: Calculate the pumping cost To calculate the variable cost of pumping, you need to know the cost per litre of diesel. If diesel costs $1.10 per litre on-farm: Pumping cost = L/ML × cost = 88.2 × 1.10 = $97.02/ML See Table 1 below for a list of typical pumping costs.
B. How efficiently is the pump operating?
not only be with the pump: the engine may need some attention. A fairly accurate estimate of the overall pressure or total dynamic head is the pressure at the pump discharge plus the height from the water level to the centre line of the pump (the suction lift) and suction losses plus the height from the centreline to the pressure gauge, if this distance is more than one metre (this figure is an estimate because there are many variables which are difficult to measure). After working out your pump’s duty and efficiency, you can then find your pump’s duty point on the manufacturer’s performance curves, and read the efficiency at which the pump was designed to operate. The two efficiency figures can then be compared to see if there is room for improvement and therefore possibly a reduction in costs. For surface irrigation systems, skip Step 5 below. An adequate estimate of total dynamic head for surface systems is the vertical height in metres from source water level to the end of the discharge pipe, or, if the discharge is submerged, to the height of the water above the discharge, that is, water level
to water level, plus suction losses due to friction.
Step 5: Determining total head a. Measure the discharge (or delivery) head
This is the pressure read from the gauge fitted at the pump when the system is at full operating pressure. This reading needs to be converted to equivalent metres of head. Tip: New pumps usually have a pressure gauge installed but they often suffer physical damage quickly. A better method is to fit an access point on the delivery side of the pump where you can temporarily install a pressure gauge whenever you want to take a reading. The gauge can be easily detached when not needed. A change in the pump operating pressure through the season or across seasons, when irrigating the same block or shift, immediately tells you something has changed. A sudden reduction usually indicates a new leak or a blockage on the suction side; a gradual reduction usually indicates wear of the impeller or sprinkler nozzles; and an increase usually suggests a blockage somewhere in the system downstream of the pressure gauge. Pressure can be thought of as
The flow rate and pressure or head that a pump is supplying is called the duty or duty point. Pump efficiency varies over the range of possible duties for any specific pump. You can work out the approximate efficiency of your diesel-powered pump from the following information: the fuel per ML, the specific fuel consumption of the engine, and the overall pressure, or total dynamic head (H), of the system. Note: As this method includes both pump efficiency and engine efficiency, it can only be a guide. We are assuming that the engine is in good running condition. If the results are very different from those expected, the problem may
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pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
equivalent to a pipe of water of a certain height in metres. This is referred to as “head” (H). At sea level, the pressure at the bottom of a pipe of water 10 metres high is about 100 kilopascals (kPa).
If your pressure gauge reads only in psi, convert to kPa by multiplying by 6.9.
b. Suction head Suction head is the distance between the centre line of the pump and the source water level, plus losses in the suction pipe if the pump is positioned above the water level. Typical suction head figures for centrifugal pumps are three to five metres. Most problems with pumps positioned above the water level occur in the suction line, so ensure everything is right. Common problems include blocked inlet or foot-valve or strainer, air leaking in through joints or rust holes, pipe diameter too small, pipe damaged or crushed, suction height too great, or air trapped at the connection to the pump. Turbine and axial flow pumps must be submerged to operate, so they usually do not have any suction head.
Another useful figure that can now be calculated is the pumping cost per ML per metre of head. This allows a meaningful comparison between pump stations. Pumping cost per ML per metre head = cost ($/ML) ÷ TH (m) = $97.02 ÷ 51 = $1.90/ML/m head To read steps six to nine and find out about the other factors that affect cost and pump efficiency head to https:// www.pumpindustry.com.au/is-yourdiesel-pump-costing-you-money/ Acknowledgements Agfact E5.12, August 2004, Peter Smith, Irrigation Officer, Tamworth
The NSW Department of Primary Industries publishes fact sheets on pumps and irrigation systems. To view other fact sheets in this series or for more information visit http://www. dpi.nsw.gov.au/content/ agriculture/resources/water/ irrigation/systems
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pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES | PARTNER SOLUTIONS
HATZ for diesel HATZ Diesel Australia is one of the major suppliers of air-cooled industrial diesel engines in Australia and New Zealand.
O
ur parent company in Germany has been manufacturing engines for over 130 years and has developed into being a specialist for diesel engines rated up to 62KW. The basis of all activities is the development and production of high-quality and rugged diesel engines. Our customers around the globe value the performance and reliability of our products. The full range of the HATZ heavy duty diesel engines are only manufactured by our parent company in Germany under stringent quality control to ensure reliability and durability. A new generation of HATZ water-cooled and turbocharged diesel engines have now complemented the existing air-cooled range of engines, extending the HATZ product portfolio with the H-series. Starting with the 4H50TI and 4H50TIC water-cooled fourcylinder models, HATZ is relying on common-rail technology, turbocharger, and external exhaust gas recirculation. The new HATZ 4H50TI & 4H50TIC engines excel as compact, lightweight and robust in design. Setting new
standards in the performance class up to 62kW. This engine is equipped with a BOSCH common-rail system for excellent fuel efficiency. Other benefits of these engines are their light weight, compactness, high torque and low vibration. For over 30 years, HATZ Diesel Australia has supported the Australian market by providing quality products, unmatched spare parts supply, and the best service support anyone could ask for. The HATZ diesel engines are truly heavy duty industrial units designed for construction equipment, irrigation pumps, travelling irrigators ,and generating sets. Regardless of whether your requirement is water pumps for irrigation plants or emergency power generators for complete building complexes, HATZ has an engine for you. Thanks to their air-cooling and rugged construction, HATZ engines can be used everywhere, even in the most adverse conditions. For specification brochures, technical information or a more comprehensive look at HATZ Diesel Australia, please feel free to visit our website located at www.hatz.com.au
If you would like to discuss your application, please contact the HATZ sales team for assistance on 1300 796 900.
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MOTORS, ENGINES & DRIVES | PARTNER SOLUTIONS
Serious power for serious pumping, now ready to go
N
ow Kubota Australia is helping you pump up your efficiency even further. Its smart diesel power packs deliver a turnkey pumping solution that gives you higher power availability, increased operational efficiency and reduced assembly time, every time. You can now get your preassembled Kubota Power Pack delivered to your door, fully equipped for easy operation straight off the bat. Featuring world-class components, each power pack comes complete with radiator and guarding, coolant tank, muffler, fuel filter, air cleaner, temperature switch, engine feet, and electric lift. Kubota Diesel Power Packs are designed to save you significant time and money – there’s no need to waste time waiting for your dealer to build your pump to your specs, or assemble the kit yourself. Everything’s done for you – just position, flick the switch, and put it to work.
Australia’s #1 selling diesel engine in its class, reimagined For almost 40 years, Kubota Tractor Australia has engineered agricultural, construction, and power equipment to excel in Australia’s tough and diverse conditions. So, it’s probably no surprise its preassembled diesel power packs pack some serious punch. After all, they feature Kubota’s renowned large output three and four-cylinder engines – the ultimate in performance, reliability and durability. And that means less talk, more action. You’ll see a significant reduction in downtime and an increase in productivity, whatever work you want your power pack to
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pump industry | Autumn 2017 | Issue 19
do – from mining, oil and gas, to water, food and chemicals, plastics, paper and pulp. Kubota Diesel Power Packs are also available in engines ranging from 68-95hp – the ideal solution for powering irrigation systems and pumping stations, hassle-free. Take advantage of Kubota’s extensive Australia-wide service support network and two-year/2000-hour factory warranty to make your power pack one of the most reliable preassembled engine solutions available on the market.
How it works Kubota’s specially trained fitters assemble your power pack at the company’s Melbourne warehouse, after which it is application tested and approved by Kubota engineers to ensure it meets strict guidelines for our tough Australian conditions. Then it’s delivered to your door, ready to go. Easy! Your preassembled pack will include: • Kubota’s two-year/2000-hour factory warranty • Built from the ground up using world-class components • Local assembly, and delivery to your door, saving installation time and costs • Protective crating to protect the assembled engine in transport • Optional additions (such as deep sea engine controls) allow easy controller operation Get a more convenient, dependable and safe pumping solution today with Kubota Diesel Power Packs – the new benchmark for pumping applications worldwide.
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ssing . ans, pressors,
MOTORS, ENGINES & DRIVES
More drive, less work – motor, pump and fan efficiency
MOTOr, PuMP AND FAN EFFIcIENcy – u6 Eco-efficiency resources for the food processing industry
An electric motor uses four to 10 times its purchase price in electricity annually.¹ When More drive,a less work choosing motor it is essential to consider the operating cost as well as the capital cost. High efficiency motors can cost up to 40 per cent more than standard motors, however, An electric motor uses four to 10 times its purchase price in electricity annually. the payback can be less than two years, due to the energy savings. Here, motor and When choosing a motor it is essential to consider the operating cost as well as the capital cost. efficiencies are discussed as part of the Queensland Government Ecoefficiency for pump High efficiency motors can cost up to 40 per cent more than standard motors, however, the Queensland Manufacturers project. payback can be less than two years, due to the energy savings. 1
Table 1: Payback periods for purchasing high efficiency motors² Table 1: Payback periods for purchasing high efficiency motors2 Motor rating
Efficiency (%) Hours of operation per year Purchase price ($) Annual operating cost ($) Payback on premium
High efficiency 11 kW
Standard 11 kW
High efficiency 45 kW
92 89 6,000 6,000 $922 $877 $7,176 $7,458 Less than 2 months
Standard 45 kW
95 93 6,000 6,000 $2,390 $1,680 $28,541 $29,004 Less than 18 months
Assumptions: Pole 4 and average energy costs per year (10 cents/kWh)
Assumptions: Pole 4 and average energy costs per year Instead of rewinding motors, consider replacing them with energy efficient motors. Often motors (10 cents/kWh). are described as ‘high’, ‘super’ or ‘premium’. However, to be considered energy efficient, motors must meet the Australian Minimum Energy Performance Standards (MEPS). In April 2006, Instead of rewinding motors, consider replacing them the Australian efficiency levels (AS/NZS 1359 5:2004) were increased so the previous ‘high with energy-efficient motors. Often motors described efficiency’ standards are now standard and a new more stringent levelare has been created. The new“high”, level is targeted to reduce losses by 15 per cent, compared 2001 MEPS.3 as “super” orenergy “premium”. However, to tobetheconsidered
energy-efficient, motors must meet the Australian Minimum The Australian Department of Environment, Water, Heritage and the Arts – Motor Solutions Energy Performance Standards (MEPS). Online provides free downloadable software programs to assist businesses compare new or existing motors 2006, based onthe purchase price, efficiency, life cycle costs, noise(AS/NZS and greenhouse In April Australian efficiency levels 1359 emissions. For more information visit: 5:2004) were increased so the previous “high efficiency” www.environment.gov.au/settlements/energyefficiency/motors standards are now standard, and a new more stringent level Use the correct size motor was created. Avoid purchasing motors to cater for future productionenergy increases losses or to override The new oversized level was targeted to reduce byload 15 fluctuations. Table 2 on the following page illustrates the energy losses and associated costs of per cent, compared to the 2001 MEPS.³ an oversized motor.
Use a correctly sized motor
1 Green House Office, 2003, Motor Solutions Online – Selecting the Best Motor and Equipment, www.environment.gov.au/settlements/energyefficiency/motors/reference/r2.html 2 Teco Australia, 2003, Premium Efficiency Motors MAX-E2 Information Brochure www.teco.com.au 3 Group Instrumentation, 2008, Sustainability Matters - Towards a New Age of Electric Motor Efficiencies www.sustainabilitymatters.net.au/feature_article/article.asp?item=1700
Avoid purchasing oversized motors to cater for future production increases or to override load fluctuations. Table 2 illustrates the energy losses and associated costs of an oversized motor. Table 2: Cost comparison for an oversized motor⁴ 4 Table 2: Cost comparison for an oversized motor Motor size Annual energy use (kWh) Annual energy cost Annual energy savings
110 kW (68% loaded)
75 kW (sized to match needs) 427,500 $42,750
627,000 $62,700
$19,950
Assumptions: Operating 6000 hours/year, electricity costs 10 cents/kWh
Variable speed drives on oversized motors or for motors dealing with variable loads
Assumptions: Operating 6000 hours/year, electricity costs 10 Variable speed drives (VSDs) reduce energy consumption by adjusting the motor speed to cents/kWh. continually match the load of the equipment such as pumps, fans and compressors.
financial viability of installing|aAutumn VSD depends on the| motor application and operating hours. pump industry 2017 Issue 19 56 The VSDs tend to be most economical on large motors. They also enable ‘soft starting’ to prevent the electrical system overloading, which drops the voltage and affects other equipment.
5
Variable speed drives on oversized motors or for motors dealing with variable loads Variable speed drives (VSDs) reduce energy consumption by adjusting the motor speed to continually match the load of the equipment, such as pumps, fans and compressors. The financial viability of installing a VSD depends on the motor application and operating hours. VSDs tend to be most economical on large motors. They also enable “soft starting” to prevent the electrical system overloading, which drops the voltage and affects other equipment.⁵ Energy consumed by fans and pumps is proportional to the cube of the motor speed. If a VSD reduced the speed by 20 per cent, the power consumed would drop by 49 per cent.⁶
Multiple speed motors or multiple smaller motors Where a variable speed drive is too expensive, or the motor is so oversized that the variable speed controller would operate at very low speeds, reducing the useful life of motors and other equipment, consider one of the following: • Using a multi-speed motor that can operate at a number of different speeds • Installing several smaller motors with controls that switch on only enough motors to meet the demand
Keep motors well maintained⁷ • Keep motors clean of dirt and grease, especially fans on fan-cooled motors • Excessive vibration may be a sign of motor misalignment • Make sure no connections or wires are loose or damaged • Check motor bearings
Power factor correction Induction motors, magnetic ballasts and transformers require two types of power: • Active power – produces work or heat and is expressed in kilowatts • Reactive power – generates magnetic fields and is expressed as kilovolts-amps reactive (kVARs)
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Power factor correction Induction motors, magnetic ballasts and transformers require two types of power:
MOTORS, ENGINES & DRIVES
• Active power – produces work or heat and is expressed in kilowatts • Reactive power – generates magnetic fields and is expressed as kilovolts-amps reactive (kVArs) Total power is the vector sum of these two powers and is expansion. Pumps are also often oversized to cater for gradual Total power is vector sum of these two powers and is measured in increases kilovolts-amps (kVA). measured in the kilovolts-amps (kVA). in pipe flow resistance, due to roughness increases Power factor is the ratio of active power to total power or scaling. A pump that is oversized will have an operating head Power is the as ratio of activebetween power to total and(perfect is expressed as a number zero andthan the plant’s requirements, and and isfactor expressed a number zero power and one and/or flow between rate far greater one (perfect figure below demonstrates this graphically. score). Thescore). figureThe below demonstrates this graphically. will need constant throttling. Similarly, an oversized fan will For example: waste energy unnecessarily. For example: Active power=100 kW
The benefits of correct pump sizing
t To
For example, a food processing plant requires 1,500 tonnes of refrigeration during three months in summer but only 425 tonnes for the remaining nine months. The process uses two Power factor = reactive chilled water pumps operating at 13,411m3 /h (149kW each) 100/142 = 0.70 power=100 kW that are both used in summer but two-thirds of the flow rate is bypassed during the remaining nine months. By replacing one of the pumps with a new 5,504m3/h (37kW) pump designed to have the same discharge head but requiring This indicates that only 70 per cent of the current provided by the electrical utilityand is being used to the older pump in the summer, the only 37kW running only This indicates that only 70 per cent of the current provided plant would save 790,520 kWh a year or $79,052 (based on 10c produce useful work. by the electrical utility is being used to produce useful work. per kWh).9 al
po
we
r=
14
2
A kV
4
uS Office of Technologies Energy Efficiency and renewable Energy, 2004, Motor Master +4.0 Software, Motors inIndustrial food processing Well-designed and sized pipework www1.eere.energy.gov/femp/industrial/printable_versions/industrial_resources.html
Plants that operate with a low power factor require
5 Sustainability Victoria, resource Smart Business- Ac Variable Speed Drives www.seav.vic.gov.au/manufacturing/ Friction losses can be reduced by reducing the number of the power company to feed much more power into the sustainable_manufacturing/resource.asp?action=show_resource&resourcetype=2&resourceid=31 bends and valves in pipework. It is also important to ensure 6 distribution uS Department of Energy, Facilitiesits An Energy, Environmental, and Economic resource Guide for system so2001, the Green plantFederal can operate equipment the diameter of the pipework is not too small, thereby creating Federal Facility Managers Designers - 5.7.1 High Efficiency Motors www1.eere.energy.gov/femp/pdfs/29267-0.pdf and appliances. Powerand companies in other states of Australia additional load on the pump, motor and fans. In some cases 7 uS Department of Energy, 2001, 5.7.1 High Efficiency Motors.
usually charge an additional fee to food processing plants with poor power factors (e.g. 0.6) to capture costs not reflected by the electrical (kWh) meter. While Queensland power charges are based only on active power consumption, this is likely to change in the future. Poor power factors cause extra current flows, increase the chances of cables overheating, reduce equipment reliability, increase supply costs, and result in additional greenhouse gas emissions. Power suppliers or consultants can assist in power factor correction options which include: • Power factor correction capacitors designed to provide reactive current • Automatic power correction equipment or banks of capacitors that are switched on and off-line depending on the power factor • Replacing oversized motors that are lightly loaded, or idling, with smaller motors • Installing high power factor lighting and electronic equipment Pumps are often not run at their optimal design efficiency, as dampers, throttling and pressure relief valves and bypass systems restrict flow.
A unit of energy saved at the pump or fan saves 3.3 units at the motor.⁸ Improving the efficiency of pumps and fans will not only save energy but will also reduce maintenance, extend the life of the equipment, and reduce noise.
Careful pump, fan, motor and pipework selection Avoid oversizing fans or pumps Pumps and fans are often oversized due to uncertainty of the plant’s requirements or to accommodate future
the type of material used in pipework can also reduce friction losses.
Trim impellers on oversized pumps The impeller can be trimmed if a pump is continuously throttled to 10 per cent less than its design flow rate or the bypass valves are continually open, indicating excess flow. Trimming involves machining the impeller to reduce its diameter, which reduces the amount of energy it imparts to the pumped fluid.
Operate pumps and fans only when required Automatic controls can be used to limit the operation of pumps and fans to only when needed.
Close the loop on liquid-seal vacuum pumps Pumps such as liquid-ring pumps use water as a sealing and cooling medium. Some uses for vacuum pumps in food processing plants include dryers, packing machines and evaporative coolers. The water is typically sent to a drain. Recirculating water, or closing the loop, on this once-through use can save significant amounts of water and reduce wastewater volumes. If the water cannot be recirculated, investigate the possibility of collecting the water for other purposes such as cleaning. Alternatively, consider mechanical seals that do not require sealing water. Cost savings of more than 50 per cent can be achieved from the reduced water and energy usage.¹⁰
For more information on improving energy efficiency for pumps and motors, visit www.ecoefficiency.com.au.
Footnotes: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Green House Office, 2003, Motor Solutions Online – Selecting the Best Motor and Equipment Teco Australia, 2003, Premium Efficiency Motors MAX-E2 Information Brochure Group Instrumentation, 2008, Sustainability Matters–Towards a New Age of Electric Motor Efficiencies US Office of Industrial Technologies Energy Efficiency and Renewable Energy, 2004, Motor Master +4.0 Software Sustainability Victoria, Resource Smart Business - AC Variable Speed Drives US Department of Energy, 2001, Green Federal Facilities An Energy, Environmental, and Economic Resource Guide for Federal Facility Managers and Designers - 5.7.1 High Efficiency Motors US Department of Energy, 2001, 5.7.1 High Efficiency Motors NSW Department of Energy, Utilities and Sustainability, Energy Saving Manual Section 12: Pumps and Fans US Department of Energy, 2005, Industrial Technologies Program – Energy Tips Pumping Systems Sydney Water, 2004, Water, Money and the Environment – Liquid Ring Vacuum Pumps
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pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
VSD INSTALLATIO GOLD COA In this Queensland Farmers Federation case study, Gold Coast Tiger Prawns (GCTP), one of Australia’s largest black tiger prawn farming operations, installed variable speed drives and power factor correction equipment to achieve a 19 per cent saving in energy.
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pump industry | Autumn 2017 | Issue 19
W www.pioneerpump.com
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MOTORS, ENGINES & DRIVES
N OPTIMISES AST PRAWN FARM G
CTP is based in rural Woongoolba in the northern Gold Coast region and has an annual production capacity of around 1,000 tonnes. Electricity use is dominated by a large number of motors ranging in size from 0.37kW up to 55kW. These motors drive pumps for transferring water, paddle wheels to aerate the ponds, and conveyor belts in the processing and sorting factory. In 2015, GCTP discovered that network electricity tariffs were going to change to include a kVA demand charge. This demand charge would increase the cost of electricity for the operation. In response, GCTP engaged Energy Correction Options to review its electricity costs. Two areas were identified with potential for savings: • The installation of variable speed drive (VSD) motors • The installation of power factor correction (PFC) equipment Investigations revealed the power factor (PF) across various electricity grid connection points at maximum demand was dropping to near 0.8. The general requirement is for the PF to be 0.9 or better. Capacitor banks totalling 775kVAr were installed at seven locations where high voltage power was distributed and stepped down for use across the property. The PFC panels were fitted with visible external alarms to alert farm operators if the units tripped and went into bypass mode so a service call could be arranged.
GCTP also upgraded a number of motors with VSDs, focusing on the motors with variable flow requirements. The largest VSDs were installed on the 55kW harvesting pumps which extract water and prawns from ponds for processing. The VSDs allowed the pumps to maintain a constant water level in the collection drains without the need for stopping and starting which causes wear and tear on motors. PF was improved at maximum demand to up to 0.98. This resulted in a reduction of up to 340kVA or approximately 20 per cent of total kVA, and delivered electricity cost savings of up to $3,400 per month in demand charges. A number of much smaller VSDs were also installed in motors attached to conveyor belts in the processing plant. These motors ranged in size from 0.37kW up to 1.5kW. The VSDs allowed the belt speed to be adjusted during sorting and inspection according to the volume of prawns being processed at the time. The slow startup experienced with VSDs also reduced belt strain. By upgrading their motors with VSDs, GCTP improved the performance of their operation, reduced wear and tear on their equipment, and delivered electricity cost savings. GCTP recognised the energy savings and financial benefits made possible by switching to variable speed pumps and installing PFC equipment, and made the decision to implement energy-efficient systems.
This case study was originally published by Queensland Farmers Federation. To view more irrigation and energy saving case studies, visit www.qff.org.au/energysavers.
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DELIVERING PUMPING SOLUTIONS pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
Optimising pumping usi by Troy Leyden, Operations Engineer, Fitzroy River Water
I
n practice, a supervisory control and data acquisition (SCADA) package can be used to trend the power consumed in kilowatts (kW) divided by the flow rate in megalitres per hour (ML/h) to give a useful result for real-time comparison. That term is referred to in this article as energy density (ED), and is expressed in kilowatt hours per megalitre (kWh/ML) pumped. Furthermore, the ED for a given duty can be readily calculated or supplied by a pump manufacturer, but what about across the range of flow rates? Or even comparing pumps across a range of flow rates? Typically, the design duty includes various contingencies to ensure a pump with sufficient capacity for the design life of the pump station is chosen. For a municipal water provider, these contingencies may include factors such as forecast connection increases, seasonal demand variations, and possibly also fire fighting capacity. For the majority of the life of the pump this demand will not be required, so the pump could be turned off, or, if a VSD has been installed, it could be slowed down. If a VSD has not been installed there is no possibility to review the actual ED, so how can the potential benefit of a VSD be reviewed? For centrifugal pumps, one method is the following mathematical model that can be utilised with a spreadsheet program such as Microsoft Excel. Information required: • The pump curve in the form of a quadratic (second order polynomial) equation. Any order polynomial equation can be used, but quadratics seem to fit reasonably well, so for this example that will be the form utilised. »» Spreadsheeting programs allow a bunch of data points from the pump curve to be inputted, and the program will give the equation of the line of best fit, most likely in the form of y=ax2+bx+c. Ensure that the pump head (H1) is the y-axis and flow rate (Q1) is the x-axis. This will give the pump curve in the form H₁=aQ₁2+bQ1+c. • The pump power curve, usually also found on the pump curve graph. For this example, a linear equation will be
60
used. Again, any order polynomial can be adapted. »» Typically a linear equation is denoted as y=mx+c, but to avoid confusion, d will take the place of m, and e will be used instead of c to give y=dx+e. Make sure the x-axis is in the same units as were used for the pump curve, and the equation should look something like P₁=dQ₁+e. • The system curve. This can be in the form of an equation, or it can be observed flow rates in one column and the associated system head required in a second column. »» The system curve is presented using Q2 for flow rate and H2 as the system head at the flow rate Q2. »» Make sure the units for Q and H for both the pump curve and the system curve are the same or the equations presented will not work. Once the required data has been obtained, equations 1, 2, and 3 (shown later) can be calculated and a table such as Table 1 can be generated. A graph of the results is also shown in Figure 2.
Analysing the data What does that chunk of data tell us? Well, the minimum ED is at 80L/s, so there would be no benefit running the pump any slower than 68.3 per cent, or somewhere in the vicinity of 34.2Hz, based on 50Hz being what the full speed pump curve was based on. It also tells us that if the pump is run at 120L/s all day instead of 240L/s for half a day, that we will save more than 40 per cent of the energy to pump the same volume. So, the three main equations required are: Equation 1:
Equation 2:
pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
 ng variable speed drives It is well known that a variable speed drive (VSD) can be used to reduce energy consumption by slowing down a pump instead of throttling a valve to deliver the desired flow rate. But what savings could be achieved if a VSD was installed? If a VSD has already been installed, under what conditions does slowing down a pump actually increase the energy consumption?
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pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
per cent at the design duty to 62 per cent, which is reflected in the increase in ED at this flow rate. Besides excessive energy consumption, running the pump at this flow rate could be causing excessive wear, potentially leading to premature maintenance tasks being required.
Conclusion VSDs are increasingly becoming commonplace. The cost of the VSD has reduced so much in recent years that the energy savings in as little as a year may cover the cost of the unit. Unfortunately, they also lend themselves to allowing pumps to be operated outside their range of application.
Pump Curve (Does not intentionally relate to any existing pump) 90
500
80
450 400
70
y = -8E-05x2 + 1E-04x + 75
60
350 300
50
250
40
200
30
150
y = 0.7x + 27
20
100
10 0
Pump Power (kW)
Which may seem a bit daunting, but once the equations are entered correctly, they can be copied and modified as required for different pumps and systems. Care needs to be taken when reviewing the results to ensure the pump, motor and VSD are all within their application range. Also, the results are the theoretical pump power, and do not take into consideration any other losses that will cause increased energy consumption. The results, when correct, are an indication only of the flow rate that will offer the optimal ED for a given pump in a given system, any discrepancies will cause the results to be inaccurate, and the results are not always replicated in practice as the theory suggests they should be. But it is a modelling tool that can be very useful nonetheless. It can be seen that the potential benefits are best for systems with high dynamic losses (see Figure 3). While that might justify the expense of a VSD, the best long-term strategy to reduce
energy consumption may be to reduce the dynamic losses. For systems with high static head compared to dynamic head losses, the benefits of slowing the pump may not be as great. But performing this analysis will indicate the point where pumping at a slower flow rate not only consumes more energy, but is also no longer within the application range of the pump. Figure 4 shows such a system, and it can be seen that while there is a degree of benefit to slowing the pump down during periods of low demand, there is a risk of slowing down too much. At 50L/s the pump efficiency has fallen from 85
Head (m) / Pump Efficiency (%)
Equation 3:
Full Speed Pump Curve BEP at Full Speed Efficiency at Full Speed Power at Full Speed Poly. (Full Speed Pump Curve) Linear (Power at Full Speed)
50 0
50
100
150
200
250
300
350
0
Flow Rate (L/s)
Figure 1. Pump Curve used for these examples.
System Curve
Equation 1
Equation 2
(Q2*H2*9.81)/P
Equation 3
Q2 (L/s)
Q2 (ML/h)
H2 (m)
n2 (%)
P2 (kW)
Eff2 (%)
ED (kWh/ML)
0
0.00
30.0
63.2%
6.8
0.0%
N/A
20
0.07
30.3
63.6%
12.6
47.2%
174.9
40
0.14
31.1
64.5%
18.9
64.5%
131.4
60
0.22
32.5
66.1%
26.2
73.1%
121.2
80
0.29
34.5
68.3%
34.7
77.9%
120.6
100
0.36
37.0
71.0%
45.0
80.8%
124.9
120
0.43
40.1
74.2%
57.2
82.5%
132.4
140
0.50
43.8
77.7%
71.9
83.6%
142.6
160
0.58
48.0
81.6%
89.4
84.2%
155.1
180
0.65
52.7
85.9%
110.0
84.6%
169.8
200
0.72
58.1
90.4%
134.3
84.9%
186.5
220
0.79
64.0
95.1%
162.5
85.0%
205.1
240
0.86
70.4
100.0%
195.0
85.0%
225.7
Table 1. System 2, 30m static head design duty 240L/s at 70.4m.
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pump industry | Autumn 2017 | Issue 19
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MOTORS, ENGINES & DRIVES
By using the supplied equations and a moderate investment of time to get them working, a useful engineering tool can be made. Care needs to be taken when interpreting the results produced, and the results need to be viewed as an indication only of the pump performance at the given duty. However, by reviewing pump performance across a range of flow rates, there is the potential to reduce energy consumption and increase pump life through operational changes. Not a bad investment.
System 2 - 30m Static Head, Design Duty 240 L/s @70.4m 350
80
70
300
60
40 150 30
0
50
150
200
250
300
350
System 3 - 60m Static Head, Design Duty 240 L/s @70.4m
70
200 40 150 30
Pump Curve at Full Speed
60
System 1 Curve
50
Energy Density
300
200 40 150 30
100
20
150
200
250
300
350
Flow Rate (L/s)
0
Energy Density
50
10
0
System 1 Curve
100
20
50
10
Pump Curve at Full Speed
250 Energy Density (kWh/ML)
50
Energy Density (kWh/ML)
250
Head (m)
60
350
80
300
100
0
Figure 2.
70
Head (m)
100
Flow Rate (L/s)
350
50
Energy Density
50
10
System 1 - No Static Head, Design Duty 240 L/s @70.4m
0
System 2 Curve
100
20
80
0
Energy Density (kWh/ML)
Head (m)
200
0
Pump Curve at Full Speed
250
50
0
50
100
150
200
250
300
350
0
Flow Rate (L/s)
Figure 3.
Figure 4.
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pump industry | Autumn 2017 | Issue 19
63
PUMP PIONEERS
Kevin Wilson Kevin Wilson has had a long and successful career in the Australian pump industry. Since joining FN Bethune at the age of 20, Kevin has worked at Kelly & Lewis, BTR Australia, and the Weir Group, and is now the Secretary of the PIA. Here, Kevin reflects on his rapid career progression, the changes he’s witnessed in the industry and the memorable mentors he’s had. Kevin Wilson.
Starting out in the industry My life in the pump industry began in 1965 when, at the age of 20 and studying Mechanical Engineering at Preston Technical College, I joined FN Bethune as a Tool and Jig Design Draftsman – working under the guiding eye of Bert Webster, the manufacturing manager. They were a strength in the industry at the time as they were a member of the Clyde group of companies and produced a wide range of pump products including Pomona Turbines, Aurora Centrifugal pumps and Morris Slurry pumps. I didn’t realise it at the time, but it was at Bethune that I came to know several people who would go on to play a significant role in both my working and personal life, including Robert (Bob) Moore, who was the General Manager; Newton Reyment, the Financial Controller and Company Secretary; and Geoff Daniels, the Draftsman.
Weapons and drills in the army At the time, the Federal Government had just introduced a two-year National Service program and I needed to obtain a role to support my engineering education. This would help me secure a future career if I was conscripted. Bethune advertised and I got the job. As it happened, my number did come out of the barrel and I began a two-year stint in the Australian Army in April 1966. During this time, my education included the use of weapons and drills, and a posting with the engineers, where I learnt construction and demolition skills. When I returned, I rejoined Bethune in
64
April 1968 and continued in my role as a Design Draftsman during the day, with frequent stints in the pump test bay, alongside Barry Stevens, at night.
Rapid career progression In late 1970, I left FN Bethune and joined Kelly & Lewis (K&L) as a Design Draftsman. The company’s general manager at the time was Bob Moore, and here I designed structural steel for the influent pumping station at Carrum. This was a major project won by K&L from the Melbourne and Metropolitan Board of Works (MMBW) and the first of several large and successful projects undertaken by K&L during the eleven years I worked with them. My career with K&L developed quickly and I became a Contract Engineer and successfully managed several large turnkey projects, including another for the MMBW - the North Road Pumping Station. This turned out to be a very profitable project and its success helped my career progression as I was appointed Contracts Manager. Shortly after, I was made Projects Manager, responsible for tendering and contract-managing all large works undertaken by the company. Then I was promoted to General Sales Manager. After eleven years at K&L, I was approached by Alan Jackson to join him at BTR Australia as General Manager of their engineering businesses. This appointment required that I relocate, so in August 1981 my family and I moved to Sydney.
pump industry | Autumn 2017 | Issue 19
Working exclusively in the pump industry I remained with BTR for almost seven years, during which time the company grew exponentially and acquired many large Australian organisations including Nylex and Borg Warner. My role was demanding and required extensive travel and long hours working across many disciplines. In 1988, an opportunity arose for me to take on a new role working exclusively in the pump industry. I accepted a position with the Weir Group as the Managing Director of Weir Engineering – a subsidiary of the Weir Group based in Glasgow, UK. My brief was to grow the business, and it was a role I had been well prepared for thanks to my time with BTR. One of our greatest achievements during my period with Weir was to work with the UK management to acquire the worldwide operations of Warman International, the most renowned manufacturer of slurry pumps for the mining and mineral processing industry.
Significant industry developments The pump industry has undergone massive changes since I joined it in the mid 1960s. The old, traditional businesses such as K&L, Harland Engineering, Ajax Pumps, and many others no longer exist as standalone entities. Multinationals have consumed some, while others have restructured, merged or closed down.
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PUMP PIONEERS
Kevin with his wife Glenda.
From a negative perspective, the demise of local manufacturing began in the late 60s when the Federal Government initiated tariff reductions for imported goods, cumulating over time with the ultimate free trade agreements, and this has all but killed off the Australian manufacturing industry. However, on a more positive note, there has been the introduction of CAD and CNC machinery, improved and more efficient pump designs, access to international markets, and increased international competition – in some case the integration of Australian entities with multinational corporations.
Memorable mentors I can honestly say my career in the pump industry has been a joy and brought me many happy and memorable moments, the most significant being the numerous lifelong friendships I have made with like-minded people in Australia and around the world. Without a doubt, the most influential person in my career has been Bob Moore. Bob was inspiring and supportive, and even when he was at the pinnacle of his career he would always have time for a kind and encouraging word. Another memorable personality was Newton Reyment, the Financial Controller at Bethune. He worked from an office on the ground floor of the administrative building, when I was located on the opposite side of the building. Newton had a loud and raucous laugh that resonated
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Kevin and his grandson Gus on the ride on mower.
throughout the building, ensuring he was a well-known identity within the company. I hardly knew Newton when I worked at Bethune, as he was among the gods and I was a lowly draftsman. At K&L, Newton resurfaced again in the UK working with Bob Moore. Again, he was lost from my career as it moved onward and upward at BTR and then Weir. Halfway through my time with Weir, I learnt that the young accountant who was wooing my daughter Jillian was none other than Newton’s son – I was flabbergasted. I soon got to know him extremely well, and we enjoyed the odd glass of wine and reminisced about our intertwining careers. Furthermore, Ken Willcock, Alan Jackson, Sir Ronald Garrick, and John Hood were all highly regarded professionals in their respective fields, and each one helped me in some way to hone my skills in the pump industry.
Advice for the next generation This industry has been a part of my working life for over 50 years and has provided me with great learning experiences, a myriad of technical and commercial challenges, and a wealth of colleagues and friends. All these things have ensured that I enjoyed a very happy and rewarding career. My advice to young people in the industry is that they should obtain an appropriate qualification, seek employment with one of the major industry players, work hard to prove themselves, and continue to learn. Never stop learning and take all the
opportunities that are presented to you. With the population of the world expanding, it goes without saying that the need for pump products will continue to grow. The challenge is to find the niche that bests suits your skills and go for it.
From pumps to B&B The demands of working in a multinational company with 24-houra-day activities, and facilities in many countries, came with a heavy workload and continuous travel commitments. While I enjoyed a wonderful career, by 2003 I was ready to retire and take on something completely different. With my wife Glenda, we retired to the Mid-North Coast of New South Wales and built a B&B on a ten-acre parkland. We remain here today and enjoy hosting people from around the world. However, despite being retired, I haven’t lost contact with the industry. Since 2003, I have managed the operations of the PIA as their secretary. I’ve remained in close contact with many colleagues, and as the new breed takes over I am making a whole new circle of eccentric pump industry friends. With these two commitments, it does not leave much spare time, but in our free moments we also enjoy travelling and visiting our children and their families. For a spot of leisure, we enjoy a stroll on one of our region’s pristine and secluded beaches, or a drive in the rainforests – it’s a tough life!
pump industry | Autumn 2017 | Issue 19
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PUMP HANDBOOK
SELECTING AND AP positive displacement The PIA’s Australian Pump Technical Handbook is a cornerstone text for the Australian pump industry and, in our opinion, a must have for anyone who deals with pumps on a regular basis. In this ongoing series, we feature abridged chapters from the classic book to showcase the various areas covered and to reacquaint readers with the technical aspects of pumps. In this issue, we go into detail regarding selecting and applying different types of positive displacement pumps.
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PUMP HANDBOOK
PPLYING pumps (PART 1)
W
hile economic considerations often mean that centrifugal pumps are used for applications handling low viscosity, clean fluids or very high flow rates, there are many applications where the specific requirements of the fluid or process make positive displacement pumps the first choice. Circumstances where positive displacement pumps are often used include: • Low flow, medium to high head applications – in such applications positive displacement pumps can be substantially more efficient than centrifugal pumps • Medium to very high viscosity fluids • Low flow slurries (soft or hard solids, abrasive or non-abrasive depending on the type of positive displacement pump) • Where near constant flow rate is required regardless of pressure conditions, without the need for complex flow control systems • Where a moderate to high efficiency needs to be maintained over a wide range of flows and/or pressures • Where self-priming is an advantage – most positive displacement pumps have a much better priming capability than self-priming centrifugal pumps • Where liquids contain entrained gases • Where shear-sensitive liquids must be pumped with minimal damage • Where flow direction needs to be reversed for process or flushing reasons • Where large soft solids need to be pumped with minimal damage • Where solids content is very high and liquid content is low
Reciprocating piston and plunger pumps A reciprocating positive displacement pump is one in which a plunger or piston displaces a given volume of fluid with each stroke. The plunger or piston is contained in a liquid cylinder and to pump the liquid, the plunger or piston must be moved. When the plunger or piston is moved out of the cylinder the pressure is reduced, allowing fluid to flow into the cylinder through the suction valves. Then the plunger or piston moves back into the cylinder and the fluid is pressurised and exits via the discharge valves. This part of a reciprocating pump is called the “fluid end”. At what is known as the “drive end”, reciprocating piston and plunger pumps usually use crankshafts, connecting rods, and crossheads to provide reciprocating motion to either single or double-acting pistons or single-acting plungers. Pistons are equipped with sliding seals to limit pumped liquid slip past the piston, and both types of pump are fitted with stationary seals to stop leakage into the reciprocating mechanism. Inlet and outlet valves control fluid flow into and out of the cylinder. Single cylinder pumps are used rarely, due to high discharge pulsations. Triplex, quintuplex, septuplex (three, five and seven cylinders) are much more common because they provide much lower pulsations. Standard seal and valve construction is generally limited to relatively clean fluids, but the pumps can usually be provided with abrasion-resistant seals, valves, liners or plungers to reduce wear in applications containing abrasive solids. Some designs are also engineered to minimise downtime when replacing worn components. Piston pumps are usually limited to discharge pressures of around 100bar, while plunger pumps are commonly suitable for 700bar but are also readily available for ultra high pressures to 2,750bar. Within the pressure range where both piston and plunger pumps are available, piston pumps are usually easier and less costly to maintain. Capacities range up to 100L/sec for piston pumps and 315L/sec for plunger pumps. Many of the lower-cost general-purpose designs are made for stock in standard cost-effective materials for general clean non-corrosive liquid applications. Engineered designs are available in a wide range of materials to cover a wide range of corrosive and abrasive liquids.
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pump industry | Autumn 2017 | Issue 19
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PUMP HANDBOOK
Selection of reciprocating piston and plunger pumps The selection process for a piston or plunger pump is usually relatively simple. For clean, low viscosity fluids all that is required is that: • The pump manufacturer’s maximum fluid end pressure is not exceeded • The pump manufacturer’s maximum speed is not exceeded • The duty suction conditions are within the selected pump’s NPSHR needs • The fluid end materials are compatible with the fluid pumped The size of the pump is usually selected from a table showing the maximum speed, flow and pressure for each size/model. Once the size/model is selected, the pump speed for a specific capacity is usually calculated. For applications where the pumped fluid is viscous and/or has entrained solids, additional considerations must be taken into account. These include the type of inlet and outlet valves that are most suitable, and that the power rating of the pump’s drive end is not exceeded. For these duties it is recommended that the end user work in close cooperation with their pump supplier.
Characteristics of reciprocating piston and plunger pumps Like most positive displacement pumps, piston and plunger pumps are basically constant volume machines where flow rates are independent of pressure. Flow control is usually obtained by varying the pump operating speed. Drive end assemblies are designed for a maximum power rating and can be fitted with a range of fluid ends to provide low flow, high pressure or high flow, low pressure. Advantages: • Deliver fluid at high pressure (i.e. high discharge head) • Self-priming (however, this can be strictly limited due to the configuration of the suction valves, and in many cases a high acceleration head, so that to prevent cavitation a booster pump is required on the pump suction) • High efficiency Disadvantages: • Give a pulsing flow • Close fitting moving parts cause maintenance problems
• Viscous liquids can cause suction problems • Expensive outside mass-produced low power pumps
Common applications for reciprocating piston and plunger pumps Common applications for standard designs include: • General pressure wash • High-pressure cleaning • Heavy vehicle washing • Sewer jetting • Misting for temperature or humidity control • Dust suppression Common applications for engineered designs: • Drilling mud • Reverse osmosis • De-scaling • Water jet cutting • Chemical injection • Crude oil transfer • Mine dewatering • Ore pipeline transport (slurry version)
Air-operated diaphragm pumps Air-operated diaphragm pumps are made by many manufacturers with a range of standard materials, diaphragm, and valve types that allow a wide range of applications. Air-operated diaphragm pumps usually have two diaphragm pumping chambers with diaphragms connected by a push rod and actuated by compressed air. Each chamber has inlet and outlet check valves which are usually ball or flap type, and connected by inlet and outlet manifolds. Actuation of the diaphragms is controlled by an air distribution valve. Some types of air valves require oil-lubricated compressed air but others are made to be operated by non-lubricated air. When the left diaphragm is pressurised outward, the connecting rod pulls the right diaphragm inward on a suction stroke, which fills the left chamber with fluid. Liquid enters the pump at the suction manifold, moves through an open suction check valve and fills the chamber. As the air distribution valve directs pressurised air to the left of the diaphragm, the diaphragm is pushed outward forcing liquid from the left outer chamber. Discharged liquid moves from the chamber, through an
open discharge check valve, and exits the pump at the discharge manifold. The position of the discharge port can be at the top, the bottom or the side. At the end of the cycle, the air distribution valve automatically shifts the air pressure to the opposite diaphragm, initiating another cycle.
Selection of air-operated diaphragm pumps The selection of air-operated diaphragm pumps is usually determined by the fluid capacity and pressure required by the application, and from a performance curve, the air pressure needed to meet these conditions. Air-operated diaphragm pumps range up to 100mm discharge size with capacities to 100m3/h and heads up to around 9bar.
Characteristics of air-operated diaphragm pumps Due to their sealless construction and the many different materials from which diaphragms, valves or the pump body can be made, air-operated diaphragm pumps can be used in a wide range of applications, including those where leakage can be hazardous, or where the fluid is corrosive or contains moderate amounts of abrasive or sensitive solids. Self-priming and dry-running capabilities, in addition to ease of capacity control are also important in many applications. Pressure relief valves are not necessary since the maximum discharge pressure is limited by the pressure of the compressed air supply. Air-operated diaphragm pumps are also portable and easy to set up. However, air-operated diaphragm pumps may be unsuitable for applications where overall energy consumption is an important factor, as the air compression and expansion cycle in inherently inefficient.
Common applications for airoperated diaphragm pumps Common applications for air-operated diaphragm pumps include: • Chemical transfer – acids, solvents, resins, latex • Food transfer – ice cream, sauces • Tanker and drum unloading • Contaminated bilge and pump pumping • Clay slurries • Polymer
Further information and detailed diagrams, equations and schematics can be found in the Australian Pump Technical Handbook, available from the PIA website. In the next edition of Pump Industry, we continue our explorations into the selection and application of different types of positive displacement pump.
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PUMP SCHOOL
Air-operated diaphragm pumps In this edition of “pump school” we look at the principles of operation for air-operated diaphragm pumps. Basic design features Most diaphragm pumps (in this example we are using Sandpiper) are driven by compressed air. The directional air distribution valve and pilot valve, referred to as the “air end”, are located in the centre section of the pump. Liquid moves through two manifolds and outer chambers of the pump, referred to as the “wet end”. Generally, check valves are located at the top and bottom of each outer chamber or on a common manifold. The two outer chambers are connected by suction and discharge manifolds. The pumps are self-priming.
No-lube air distribution valve During operation, the air distribution valve controls alternate pressurising of one diaphragm, then the other. The valve automatically transfers air pressure to the opposite chamber after each stroke. This provides alternating suction and discharge strokes, as the diaphragms move in parallel paths. Sandpiper air valves require no lubrication. This is the preferred mode of operation as clean, dry air will enhance pump performance.
Diaphragms Flexible diaphragms are clamped at their outer perimeters, between the inner and outer chambers. The diaphragms are connected at their movable centres by a rod.
Check valves As fluid moves through the pump, check valves open and close. This allows each outer chamber to alternately fill and discharge. The check valves respond to differential pressures. Ball-type check valves can pass small particles.
The pumping cycle As the air distribution valve directs pressurised air to the left diaphragm, the diaphragm is pushed outward. This is a discharge stroke, which forces liquid from the left outer chamber. Discharged liquid moves from the chamber, through an open discharge check valve, and exits the pump at the discharge manifold. The position of the discharge port can be top, bottom or side. As the left diaphragm is pressurised outward, the connecting rod pulls the right diaphragm inward on a suction stroke, which fills the right chamber with fluid. Liquid enters the pump at the suction manifold, moves through an open suction check valve and fills the chamber. At the end of the cycle, the air distribution valve automatically shifts the air pressure to the opposite diaphragm, initiating another pumping cycle.
Article courtesy of Kelair Pumps Australia “When Pump Knowledge Matters” Phone: 1300 789 466 or visit www.kelairpumps.com.au www.pumpindustry.com.au
pump industry | Autumn 2017 | Issue 19
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TECHNICAL
Meeting the system needs by Ray Hardee, Chief Engineer, Engineered Software
In this article, we will look at a wastewater collection system consisting of a pump, collection and destination tanks, and the interconnecting piping. In this system, water is pumped from a collection tank to the destination tank and a pump is required to overcome the change in static head caused by the change in liquid level in the tanks and the piping head loss in the interconnecting piping. We will outline the tasks that must be performed when selecting the system equipment needed to meet the system design requirements. This process can be followed when designing a new system or modifying existing systems undergoing major changes from the initial design.
Determine the system requirements Every piping system is designed to meet a specific need. The first step is to determine the process fluid and the system’s design flow rate. Since this is a municipal waste collection system, the process fluid is water at 15°C. The system is designed for a maximum flow rate of 90m3/ hr. Figure 1 shows the collection and destination tank elevations and working levels. From this information we can start the design process. As always, we will look at selecting the various elements making up the system. The process elements In our example the two tanks and interconnecting piping comprise the process elements. The collection tank serves as the inlet boundary, and the destination tank serves as the outlet boundary. The physical layout determines the location of each tank, along with the working level of fluid in each tank. The difference in the liquid level and pressures between the two system boundaries represent the system static head that must be overcome. The process fluid and its operating temperature determines the pipe material to be used. The working pressure of the process fluid is used to determine the required pipe wall thickness. The system design flow rate along with the pipe material and wall thickness is needed to determine the pipe diameter. The operational requirements of the system determine the number and type of valves and fittings required for each pipeline so the resulting system can be efficiently operated and maintained. Once the pipeline design requirements are determined, the dynamic head loss for the interconnecting piping can be calculated for the design flow rate. The control elements In this system, control elements are used to operate the pump and turn the pump off when not needed. This can be accomplished by a manually operated on/off switch or automated controls so the system can meet its design goals. In this system, level switches in the collection tank are used to control the pump.
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The pump elements With the system’s process and control elements determined, the designer can select the pump elements. Since this is a municipal waste collection system, the customer has determined to use a submersible centrifugal pump. With the system’s design flow rate and the total head requirements needed by the process and control elements, a pump can be selected using available pump selection software to meet the system’s design requirements.
What’s missing? The method outlined above is commonly used when designing process systems. Based on the capital cost or special operating requirements, additional steps may be required to size specific elements. In my experience, each of the basic elements are handled by specific groups. Process engineers focus on the process elements and system operation. The mechanical group focuses on pumps, the electrical group focuses on motors and electronic variable frequency drives on the pump elements. The controls group focuses on the system instrumentation and control equipment needed to monitor and control the system. If one does not consider the interaction of the various elements on the total system, the design can result in increased operating and maintenance costs. System operation In our example system, the system flow rate was based on a maximum inlet flow rate of 90m3/hr into the collection tank. Based upon the customer’s operating experience, the maximum inflow to the collecting tank occurs for approximately one per cent of the system’s total operating hours. The normal flow rate into the collection system of 45m3/hr occurs approximately 65 per cent of the annual operating hours. During off-peak hours, the rate into the collection system is 20m3/hr, which occurs approximately 33 per cent of the annual operating hours. Selecting the pump to handle the maximum possible inflow into the collection tank ensures the tank will never overflow regardless of initial liquid level. With these further details of the system operating conditions, one can look
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TECHNICAL
Sample waste transfer pump system DestinationTank Pipe 2 Ø: 100 mm
El: 120 m Level: 5 m
Collection Tank El: 100 m Level: 3 m
Pipe 1 Ø: 100 mm
Wastewater Pump Op: Flow @ 90 m/h
Figure 1 – This example system is made of pump elements, process elements, and control elements. We will see how all these elements work together to meet the system design requirements.
for ways to improve the design to minimise operating and maintenance costs.
Ways to improve the system design The pump elements There are a variety of pump options that can be employed to improve the system design. Instead of selecting a single 90m3/hr pump to operate all the time, you could use two 45m3/hr pumps operating in parallel when maximum flow is needed. For the remainder of the year, a single 45m3/hr can meet the system’s requirements. Purchasing two smaller pumps will cost more than a single larger pump, resulting in an increase in capital cost. Furthermore, operating a single 45m3/hr pump increases the number of hours a pump must run in a year, however, the primary pump in operation can be optimised around the 45m3/hr design point. By analysing both single pump and parallel pump configurations using system simulation software, you can easily calculate the power required at each of the operating conditions (maximum inflow, normal flow, and off-peak flow). The system model can also account for the efficiencies gained from continuous operation around the best efficiency point, ensure minimum flow limits are not violated, and NPSH is maintained. From the pump power in each operating condition and the per cent of operation for each condition annually, a detailed operating cost calculation will determine the extent of the energy savings available. Further analysis with time simulation will allow evaluation of the cycling required in each of the configurations, and its impact on the pump’s operating point. This evaluation can provide some insight into potential maintenance issues due to continuous, sub-optimal pump operation. Even though the smaller pump takes twice as long to pump down the collection tank and is likely to incur higher capital costs, the total system is likely to consume less power when running and incur less maintenance.
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The process elements Looking at the dynamic head loss in the system, increasing the pipe diameter reduces the fluid velocity in the pipelines, resulting in a reduction in dynamic head. Increasing the pipe diameter results in an increase in the capital cost, but will reduce the system lifetime operating costs. A cost comparison can be easily conducted to determine the extent of the savings. An additional benefit occurs if the system capacity will be increased in the future. In looking at the example system, the system’s static head accounts for much of the pumping requirements. If possible, relocating the tank’s base elevation or adjusting the tank liquid operating level to reduce the system’s static head will also minimise the pump’s head requirement. The control elements The system is controlled using level switches in the collection tank. On a high liquid level, the wastewater pump is turned on. The pump continues to operate until the tank liquid level reaches the low level, at which time the pump is turned off. One way to improve the system is to replace the on/off level switches with a level controller. Since flow rate in the system varies from 20m3/hr to 90m3/hr, a variable speed drive can be connected to the level controller. The pump speed is then automatically adjusted to maintain a consistent level in the collection tank. The extra capital cost of the level controller could easily reduce the total lifetime cost for system operation. For analysis of this system design change, you will need a tool which can account for time-dependent inputs and control logic. This type of simulation over time will allow for the assessment of pump cycling as well as pump power.
Conclusion By understanding the interaction of the various elements in a piping system, one can consider options for reducing a system’s lifetime cost. Since these design options can be easily evaluated using a system simulation program, optimising around the full set of system requirements can pay a huge dividend in reducing total system costs.
pump industry | Autumn 2017 | Issue 19
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Editorial schedule
Action Aquatics........................................ 33
Aqseptence Group.................................. 42
Deadline: 2 June 2017
Also featuring
ABB Australia............................................ 13
Angus Flexible Pipelines....................... 3, 23
WINTER 2017
MAIN FEATURE
ADVERTISERS’ INDEX
ASM Pumps............................................... 8
Mining Coal seam gas Wastewater Recycling
Aussie Pumps........................................... 48 Barron - Auma Australia........................ 7 Bonfiglioli Transmission........................ 39 Brown Brothers Engineers.................... 59 Brown Brothers/Layne Bowler............ 20 Caprari Pumps Australia ..................... 37
SPRING 2017
DEUTZ Australia ...................................... 1
Deadline: 22 September 2017
EMT............................................................... 63
MAIN FEATURE
Energy efficiency
Also featuring
Fire Power generation Smart pumps
Plus the 2018 Industry Capability Guide
Franklin Electric....................................... 10 HATZ Diesel............................................... 53 HE Brehaut (Hebco)................................ 49 Hydro Innovations ................................. 19 Irrigation Australia.................................. IBC John Crane Australia.............................. 49 Kelair Pumps Australia........................... 43
SUMMER 2018
KSB Australia ........................................... 17
Deadline: 1 December 2017 MAIN FEATURE
Kubota......................................................... 55
Oil & Gas
LK Diesel Service ................................... 52 Masterflow Solutions............................. 9
Also featuring
State of Industry survey Valves Training
PCM Group Australia ............................ 32 Pentair Southern Cross......................... 11 Pioneer Pump............................................ 58 Pump Industry Australia........................ 21
AUTUMN 2018
SEEPEX Australia ................................... 18
Deadline: TBA
Shakti Pumps............................................ 25
MAIN FEATURE
Water
Also featuring
Seals Motors & drives Food Irrigation
Sulzer Australia ....................................... 38 United Pumps Australia......................... 27 Viega............................................................. IFC Watson-Marlow Bredel Pumps............ 6 WEG Australia ......................................... 14 Welling & Crossley ................................. 29
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pump industry | Autumn 2017 | Issue 19
Xylem........................................................... 35 Zetco Valves.............................................. OBC
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LEADING THE INDUSTRY TOWARDS A SUSTAINABLE FUTURE THROUGH TRAINING & CERTIFICATIONS
IRRIGATION PUMPS WORKSHOP (2 DAYS) Irrigation Australia operates Irrigation Training Australia (ITA), a Registered Training Organisation (RTO) providing a range of industry related training courses and workshops that contribute towards nationally accredited qualifications including Cert II, Cert III, Cert IV in Irrigation.
WORKSHOP OVERVIEW Learn the process of operating and maintaining irrigation pumping systems and be issued with a statement of attainment for the nationally recognised competency AHCIRG410A Select and Manage Pumping Systems for Irrigation. This workshop is designed for anyone working in the irrigation industry whether that be in retail, irrigation pump system design including selection & supply, irrigation pump system installation, commissioning, monitoring and operation.
LEARNING OUTCOMES DETERMINING SYSTEM REQUIREMENTS TYPES OF IRRIGATION SYSTEMS IRRIGATION AND PUMPING SYSTEM REQUIREMENTS HYDRAULICS OF IRRIGATION SYSTEMS INCLUDING FRICTION CALCULATIONS UNDERSTANDING PUMP CURVES
CAVITATION AND NPSH PUMP SELECTION CONTROL AND PROTECTION SYSTEMS INSTALLATION AND COMMISSIONING OF IRRIGATION PUMPS MAINTENANCE AND TROUBLESHOOTING OF IRRIGATION PUMPS TESTING PUMP PERFORMANCE
UPCOMING IRRIGATION PUMPS WORKSHOPS:
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10-11 AUGUST 2017 13-14 SEPTEMBER 2017 12-13 OCTOBER 2017
SA QLD Shepparton Region, VIC
COMPETENCIES AHCIRG410A - Select and Manage Pumping Systems for Irrigation.
IRRIGATION AUSTRALIA PROVIDES A RANGE OF INDUSTRY WORKSHOPS: Centre Pivot Lateral Move (2 days) Meter Validation and Installation (2 days) “New” Irrigation Essentials School (6 day residential) Introduction to Irrigation (2 days)
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12/56 Church Ave Mascot | +61 (02) 8335 4000 info@irrigation.org.au
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WaterMarked has valves, Zetco you covered
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