WINTER 2017
ISSUE 20
pumpindustry Celebrating
the operators:
from wastewater treatment plants to mine sites
5
YEARS OF
pumpindustry
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PUMP INDUSTRY
President’s welcome H 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 Ken Kugler Executive Officer – Standards Life Member Ron Astall - Councillor United Pumps Australia Ashley White – Councillor Davey Pumps Peter Passalacqua – Councillor Grundfos
eading into winter, it’s amazing how fast the year is going. For Pump Industry Australia, it’s another blur of the months. The PIA committee is focusing on ways to provide opportunities for development and training for our members. We look to provide training and facilitate discussion on all current topics for the industry. As such, please be in touch if there are any topics you’d like to see visited by your PIA committee. Last quarter, the PIA proudly held a How to get the best out of your pumps seminar. This covered topics including international pump standards and pump testing, motor MEPS improvements, performance measurement and condition monitoring for improved operational reliability, and scheduled maintenance. As PIA President, I was pleased to receive positive feedback following the presentations, and the seminar was well received. A similar offering will be made for our Western Australian colleagues in Perth on August 10. The PIA’s Installation and Commissioning course was held on May 24 at Link Pumps in Melbourne, with another to follow in Brisbane in September. Our PIA Technical Meetings are open to all members and their guests, catering for those new to the pumps game, through to industry icons with decades under their belts.
We invite you to attend for updates to technology and practices, and the opportunity to network among peers. Upcoming PIA Technical Meetings will be held in Melbourne on July 12, and in Perth on August 8. The PIA has supported Fire Australia again in May 2017, taking the opportunity to outline compliance issues on AS 2941 and the PIA pumpset checklist. PIA’s formal arrangement with Irrigation Australia was signed in April. From my perspective, the work between the two associations will benefit all members. Finishing up with a thought, I sat in on a pump training course recently, and it was refreshing to see the trainer get back to the basics of pumping principles. It was interesting for me to see that choosing the pumps is not all about using a selection program. Similar to a pilot of an aircraft, he or she can simulate the conditions on the computer – but in reality they still need to know how to fly a plane and remedy issues along the way for smooth operation. We need to have an understanding of how to select pumps, and manually understand pumping systems. Here’s to pumping. Dave Alexander President, Pump Industry Australia
David Brooks – Councillor Flowserve FSD Jamie Dixon – Councillor White International
2
pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
CONTENTS WINTER 2017
ISSUE 20
pumpindustry Celebrating the operators:
from wastewater treatment plants to mine sites
5
YEARS OF
pumpindustry
Cover image shows Daniel Partridge, WIOA's South Australian Operator of the Year, at work at one of SA Water’s wastewater treatment plants.
3,719 1 October 2016 – 31 March 2017
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 Senior Associate Editor: Jessica Dickers Contributing Editor: Michelle Goldsmith Journalist: Lauren Cella Marketing Director: Amanda Kennedy Marketing Consultant: Aaron White Marketing Associate: Mathew Walker Production and Customer Service: Titian Bartlau Senior Designer: Alejandro Molano Designer: Jacqueline Buckmaster ISSN: 2201-0270
NEWS Woodman Point WTP upgrade reaches milestone......................6 Hells Gate feasibility study lead announced................................8 Contract awarded for sewer pump station..................................9 HVAC&R industry to thrive under Federal Budget.................... 10 Pump upgrade for Poruma and Warraber Islands..................... 11 Major upgrade of Victor Harbor sewer network complete...... 11 PIA NEWS Creating opportunities in a challenging market...................... 12 Upcoming PIA events ................................................................ 14 It was five years ago today......................................................... 16 PIA MEMBER NEWS The new self cleaning sump game changer ............................. 19 INDUSTRY NEWS Debunking myths: performance facts about mechanical joining.................................................. 20 Here comes the story of the Shurricane................................... 22 Kubota Dedicated to supporting customer innovation........... 24 Powerful pumps that save money – and energy ...................... 26 Let’s focus on quality................................................................. 28 Tackling the challenge of sewage bypass................................. 30 Successful future with new generation diesel engines............ 32 Working with suppliers you can trust........................................ 33
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.
pumpindustry
WASTEWATER Wastewater efficiency improvements win big...... 34 Eliminating constant sewage spills....................... 38 Upgrading for healthy waterways and safe communities........................ 40 Submersible wastewater pump and motor testing – Part 1.......................... 44 Harvesting stormwater from Lake Caroline......... 46 MINING Sizing pump discharge piping............................... 48 Flexible risers for mine dewatering operations..... 52
REGULARS President’s welcome..................2 Ask an expert: What sort of progressive cavity pumps are best suited to mining applications?......54
COAL SEAM GAS Project Ruby: Expanding operations in the Surat Basin............................... 56 Johnson Screens® Pump Guard Screens............. 60
Pump school:
PUMP HANDBOOK Selecting and applying positive displacement pumps (Part 2).................. 66
Technical
PUMP PIONEERS Ted Beesley.......................................................... 70
www.pumpindustry.com.au
When to use a positive displacement pump....................... 74
Specifying heavy duty pumps for critical industries......... 62
Editorial schedule.....................76 Advertisers’ index....................76
pump industry | Winter 2017 | Issue 20
5
NEWS
Woodman Point WTP
upgrade reaches milestone W ater Corporation’s upgrades to its Woodman Point Wastewater Treatment Plant have reached a milestone with its first major concrete pour of 360 cubic meters. That’s the equivalent of 360,000 litres of water – which is more than the average Perth household uses in one year. Water Corporation General Manager Asset Delivery, Mark Leathersich, said Henderson based company Civmec carried out the work as part of its joint venture with Black and Veatch Australia, forming the WP180 Alliance. “Around 60 locally sourced trucks poured the concrete over an eight hour
period on Tuesday, marking a major milestone in the project to upgrade the Woodman Point Wastewater Treatment Plant,” Mr Leathersich said. “The concrete will form the base of one of eight tanks being built at the plant. Each of these tanks will have the capacity of 11 million litres, and will be 50m in diameter and six metres high. “The tanks are Secondary Sedimentation Tanks and are a vital part of the wastewater treatment process. The tanks are where treated wastewater undergoes further settlement and clarification, which then produces final treated wastewater.
“We are pleased to work with our locally based contractor on the upgrade, with about 200 jobs being created when construction is at its peak.” The Woodman Point Wastewater Treatment Plant is the largest plant in Western Australia. Water Corporation is upgrading the plant’s capacity to 180 million litres a day to cater for future growth in the region. When the upgrade is completed in late 2019, the plant will treat wastewater from 900,000 people who live south of the Swan River.
THE NEXT GENERATION OF SOLARPAK
6
pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
Nobody extends wear life like we do. You’ve probably heard about the innovation and progress LaserBond is achieving in surface engineering technology. We apply new surfaces to worn parts so they work literally better than new. And brand new parts can also be treated so they last a lot longer. Customers enjoy longer wear life, fewer shutdowns for component replacement, and better workplace health and safety control. Our laser-applied coatings typically at least double the life of a part. The new ‘laser cell’ in our SA engineering facility will have the highest-power laser beam used for laser cladding in the Southern Hemisphere. We already operate the three most powerful lasers in this industry in Australia. These are supported by many other processes and technologies, such as HP HVOF, all supported by our own well-equipped metallographic
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NEWS
Hells Gate feasibility study lead announced T
ownsville Enterprise Limited (TEL) has appointed the lead for the Hells Gate Dam and Irrigation Scheme Feasibility Study in the Upper Burdekin catchment of Northern Queensland. SMEC will lead the 12-month study to determine the dam’s engineering, environmental and economic feasibility. The Hells Gate Dam project has been in discussion since 1938 and has been the subject of a number of investigations in the 1970s through to 2014. This study will produce the first fully investigated feasibility into the dam and irrigation scheme, and is a precursor to attracting investment for the construction of a multi-billion dollar project over the coming ten years. The project has nation building significance in that it will double
the irrigated agriculture capacity of Northern Australia, and has attracted funding from the National Water Infrastructure Development Fund. SMEC will lead a team of local businesses to complete the feasibility study into the one million mega litre dam and 100,000 hectare irrigation scheme. TEL CEO, Patricia O’Callaghan, said, “It is very important to be able to engage local content, that was a key part of the criteria. “The company (SMEC) will use local expertise wherever possible.” SMEC Regional Manager, Graeme Pollock, said the company was proud to be leading a consortium of local businesses. “We have specifically partnered with leading local businesses to not only achieve the project objectives
but provide high-level expertise in areas such as cropping analysis, water resource modelling, environmental assessments and economic analysis, which will be key to achieving the project,” Mr Pollock said. Project scope of work includes: water resource and cropping assessments; agronomy and field studies on soil conditions; concept engineering of Hells Gate Dam, Big Rocks Weir, irrigation infrastructure, power supply, road and associated infrastructure and water delivery to the City of Townsville; ecology and environmental assessment; stakeholder relations and economic assessments.
RELIABLE OPERATION SEEPEX progressive cavity pumps from product group N operate reliably and efficiently, have service-friendly components and save on costs. Product group N pumps are ideal for conveying thin to highly viscous liquids with or without solids for a variety of applications from mining and wastewater treatment to food and beverage.
8
BENEFITS Minimal pulsation, uniform flow Low running costs High self-priming capabilities even with a mixture of liquid and air/gas Numerous installation options Reversible rotation and flow Contact our experts now, to experience these benefits yourself.
pump industry | Winter 2017 | Issue 20
SEEPEX Australia Pty. Ltd. info.au@seepex.com www.seepex.com
www.pumpindustry.com.au
NEWS
Contract awarded for
sewer pump station
C
entral Highlands Water (CHW) has awarded the contract to construct a new sewer pump station and wet weather detention storage facility in Ballarat, Victoria. Jaydo Construction will build the new facilities which are expected to be completed by the end of 2017. CHW Board Director, Rachel Thomson, said that CHW continues to focus on the performance and lifetime of its infrastructure networks, ensuring the liveability and wellbeing of customers, and enabling the region to achieve its potential for economic development. “This major sewer project continues our successful collaboration with the City of Ballarat, with the new facility to
ensure that the ongoing development in the Ballarat West Urban Growth Zone (BWUGZ) and new residential developments, including Lucas Estate, Carngham Road and Alfredton West precincts, can be accommodated and managed,” Ms Thomson said. “The new facility provides capacity for 5800 residential lots, and has a back-up generator for continual power supply. “The key benefits of the new facility will also support the management of flows during a one in five year rainfall event, provide capacity for future growth and development, and optimises the wastewater treatment plant and our investment into the region’s wastewater services.”
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pump industry | Winter 2017 | Issue 20
9
NEWS
HVAC&R industry to thrive under Federal Budget
A
ccording to the Australian Institute of Refrigeration, Air Conditioning and Heating (AIRAH), the new Federal Budget offers considerable value for the HVAC&R industry. AIRAH Chief Executive, Tony Gleeson, said the government’s plan to spend $75 billion on key infrastructure projects over ten years offers plenty for Australia in general, and the HVAC&R industry in particular. “A Budget focused on rail, road and airport spending is obviously a boon for the construction sector, and for trade opportunities,” Mr Gleeson said. “As an integral component of the industries that assemble our built environment and also provides health and comfort, the HVAC&R industry will benefit too. “And with the establishment of the Skilling Australians Fund, the HVAC&R trade sector is getting quite a leg-up, which we tentatively support while
we await more detail. The Industry Specialist Mentoring for Australian Apprentices program, which has had $60 million set aside for it, is another excellent initiative.” Mr Gleeson said the government’s $1 billion National Housing Infrastructure Facility to remove impediments to developing new homes is one of a number of positive elements included in the Budget. Another was the establishment of a $10 billion National Rail Program to create better connectivity and productivity. “We also applaud the directive for researchers to engage more closely with industry than has occurred in the past,” Mr Gleeson said. “Indeed, we are already seeing this happen, where academics have come down from their ivory towers and actively engaging with industry and with AIRAH itself to kick-start some fantastic initiatives. This will help Australia build
ACTION AQUATICS HAVE JUST CHANGED THE GAME
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Evaporation, condensation, fungus, mould, sodium, chlorine and bromine combine forces to create corrosion problems in pool facility environments.
skills and capability for the jobs and industries of the future.” Mr Gleeson said it’s disappointing that, pending various policy reviews that are in progress, the Federal Budget appears to defer new funding for policy responding to climate change. As participants in some of those reviews, AIRAH will continue to voice the view that it’s important to reduce Australia’s greenhouse gas emissions via the adoption of appropriate refrigerants, and through resilient design. “Although there are some very admirable elements in the 2017–18 Federal Budget, the Institute will continue to talk to those in power about those things important to us and our members,” Mr Gleeson said. “We will continue to be the leading independent voice for our industry on resilience, sustainability, compliance, innovation, and the transition to low-GWP refrigerants.”
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Action Aquatics Dehumidifier Range Technical Specifications Specification
C-250
C-350
C-500
C-600
C-800
C-1000
C-1200
C-1500
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
14100
17625
21150
29375
35250
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
4500
5500
5500
6200
7100
7800
6700
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
O
C-1800
7200
WE HAVE AUSTrAlIA COVErED www.acTionaquatics.com.au/mfdh
Optional units Optional pool heating unit capacity (kW)
55
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
77
110
*Test standard: Dry bulb temperature of 30 C and Relative humidity of 80% O
10
110
PH +61 7 3051 5861 FAX +61 7 3806 4528
**Specifications subject to change at manufacturer’s discretion
pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
NEWS
Pump upgrade for Poruma and Warraber Islands
Major upgrade of Victor Harbor sewer network complete
T
S
he Queensland Government is investing in priority water infrastructure upgrades on Poruma and Warraber Islands, with the replacement of water supply booster pumps to ensure continued reliability. Minister for Local Government, and Aboriginal and Torres Strait Islander Partnerships, Mark Furner, said $142,000 had been delivered through the Local Government Grants and Subsidies Program for new water supply booster pumps. “The islands’ existing booster pumps have served their communities well, but are due for replacement to ensure the continued reliability of drinking water supplies for local residents,” Mr Furner said. “Once installed the new pumps’ inbuilt smart design will enable Torres Strait Regional Council to adjust water pressure on both Poruma and Warraber Islands to meet demand during periods of increased water usage.” The new water transport systems include three vertical multistage pumps with computer assisted control panels. Torres Strait Island Regional Council Mayor, Fred Gela, said the project will meet the future needs of the community. “This is obviously vital infrastructure to sustain our communities, and the upgrades mean we will also have greater capacity to conserve water when needed,” Mr Gela said. Installation is expected to be completed by the end of June 2017.
A Water has completed a $9.8 million upgrade of Victor Harbor’s sewer network, which will help cater for new residential and community developments. Work began in late 2016 and involved the installation of approximately six kilometres of underground sewer mains and three new pump stations. Minister for Water and the River Murray, Ian Hunter, said, “It’s vital that we continue to support the community’s needs into the future by facilitating residential and business growth, and accommodating a fluctuating tourist population. “The upgrade will improve the network’s reliability and environmental performance, including helping to reduce the potential for overflows.” The project supported 28 full time jobs during its delivery, using local contractors and suppliers who worked with the Ngarrindjeri community to provide employment for indigenous workers. The project has substantially increased the capacity of the local sewer network, which currently services more than 10,000 people and can double during peak tourist periods. The upgraded infrastructure will help to accommodate increased flow from the recently completed Fleurieu Regional Aquatic Centre, a new medical centre and residential care facility in the town. Construction of the new sewer infrastructure was completed in May 2017.
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pump industry | Winter 2017 | Issue 20
11
PIA NEWS
CREATING OPP in a challenging by Keith Sanders, PIA Councillor and Life Member
A
ustralia represents a relatively small market for industrial and commercial pumping equipment, and yet pump products are coming under increasing focus from governments to make a contribution to reducing the greenhouse gases generated by their use in a wide variety of applications. Based on information available to the industry from Ibis World, the demand for pumping equipment in Australia is around $3 billion per annum. 2015 was a tough year for most players in the market, while 2016 was somewhat better. Growth is not expected to exceed 1 per cent in the next couple
12
of years, so there will be plenty of competition for the business that is available. The share of imported product over locally produced pumps is steadily PERIOD
increasing, and this trend is likely to continue. Despite the lower value of the Australian dollar, exports are also down on previous years, so the industry has some difficult issues to grapple with.
REVENUE ($MIL)
IMPORTS ($MIL)
EXPORTS ($MIL)
TOTAL DEMAND ($MIL)
2014-15
1291.7
1925.6
354.6
2862.5
2015-16
1283.9
1756.3
361.4
2678.8
2016-17
1305.8
1944.8
358.8
2891.8
2017-18
1324.6
1995.3
365.8
2954.1
(Source: IbisWorld Report 2017)
pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
PIA NEWS
PORTUNITIES market While these figures do not exactly align with PIA's coverage of the market, the trends are relatively consistent with the association’s assessment of the overall size of the pump market and rates of growth reported by members. Energy efficiency is also a major challenge for the pump industry. There is already legislation covering pumps used in pools and spas – a system of star ratings has been developed that both Australian and overseas manufacturers need to comply with at the consumer product level. There are also moves being made to legislate for the more efficient use of pumping equipment in industrial applications, although this is not yet well developed. Under the banner of the Emissions Reduction Fund, the Department of Environment & Energy is drafting proposals for Industrial Equipment Upgrade legislation and pumps are included in this, with PIA making a contribution to the early discussions. However progress is slow and the political landscape is constantly changing. In addition, work is continuing with submissions to the Australian Building Codes Board (ABCB), covering possible amendments in the National Construction Code (NCC) for next year. The principal areas of interest will be pumps for HVAC systems and Fixed Fire Protections systems. While not a major player in either of these sectors, PIA is working with AIRAH and FPAA in an effort to define strategies that reduce energy consumption and strengthen compliance to specifications already operating in these sectors. With this level of uncertainty, it is not surprising that there is no major investment in pump manufacturing activities, and one can expect to see further rationalisation in the years ahead. What this will mean to service levels and supply lead-times is hard to predict, but it is not looking good for local production of pumps. The new
www.pumpindustry.com.au
While members of the Australian pump industry are continuing to operate in a challenging environment, the PIA is actively involved in sourcing new opportunities for the industry - and training members of the industry so that they are in the best position to take advantage of opportunities as they arise.
pump industry | Winter 2017 | Issue 20
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PIA NEWS
UPCOMING PIA EVENTS TECHNICAL MEETING 8 August, 4.30pm Flowserve Offices, Perth WA
HOW TO GET THE BEST OUT OF YOUR PUMPS 10 August, 9am-5pm AMC Jakovich Function Centre 4 McGrath Road, Henderson WA 6166
For more information, or to book your spot at either of these events, contact Keith Sanders on 03 5981 2680 or 0421 323 123.
potential is likely to be in better pumping systems, with reduced operating costs by improved design, lower power consumption and better performance monitoring of equipment already installed in the field. So, what are the strategies for growth? It’s not an easy issue to deal with. It really requires a close look at the business model being employed by companies and identifying where the competitive advantage exists for that particular business. One obvious advantage is that Australian businesses are closer to the customer and should have a detailed local knowledge of customer preferences, local legislation, OH&S requirements and even the climatic conditions that apply to various plant sites around Australia. This really means an investment in know-how, and leads to identifying opportunities for education and training of key personnel about the particular applications that prevail in the local market.
What PIA is doing to help In an effort to support members, PIA has increased its involvement in providing seminars and training programs directly aimed at improving the skill level of people operating in the industry. In the first six months of 2017, the Association organised a series of events aimed at improving the level of expertise of people in the field and also providing improved links to other organisations with similar objectives who need to communicate effectively with customers in specific market sectors. By sharing knowledge on emerging technologies, the influence that can be brought to bear on government will increase and better decisions can be made to support local industry. Specifically, PIA has introduced
14
a program to train engineers and technicians in preferred installation and commissioning procedures. The initial start-up of rotating equipment requires a careful and thorough inspection and testing program to ensure the equipment is put into service in the most favourable conditions. At this stage several courses have been run in Melbourne and Sydney, with a future course planned for Brisbane in September this year. These courses are open to members and non-members and can provide invaluable opportunities for both supplier and customer to understand the importance of the installation and commissioning process, as well as any corrective action that may be necessary to ensure optimum operating reliability through the life of the equipment. New pump station design or even the upgrading of an existing station needs to be undertaken with the most accurate information on future demand. This is not an easy task as projections need to be made many years ahead and stations are often developed in stages, so that the initial stage is complete and in operation before any expansion is contemplated. There needs to be objective data available about the current demand and how reliable the equipment has been in service. Condition monitoring is becoming increasingly important from this perspective, and a number of PIA members offer services that can measure, record and analyse existing pump operations to provide accurate information. Better information means better decisions and cost effective solutions should result. With this in mind, PIA organised a one day seminar at the Bruce County
pump industry | Winter 2017 | Issue 20
Conference Centre in Melbourne on 24 April. A group of experienced engineers presented a series of papers to outline the scope of equipment and services for pump users to consider. Entitled How to get the best out of your pump, the seminar attracted a good audience and the feedback from participants was excellent. This has encouraged PIA to run a similar program in Perth in August and it will again be open to members and non-members. We believe by sharing this knowledge, there will be a better understanding within the industry. The seminar opened with a review of international pump standards, focusing on work that has been done in Europe and USA, delivered by Ron Astall, Ken Kugler and Keith Sanders from PIA. Ken and Ron also combined to look at rotodynamic pump performance testing and make comparisons between the expectations of accuracy in both the works test environment and actual site conditions. Later, Keith Sanders reviewed ANSI/ HI 9.6.5 – which offers pump monitoring and failure detection techniques for rotodynamic (centrifugal and vertical) pumps. Participants then heard from Malcolm Robertson from Robertson Technology about the thermodynamic method of determining pump performance including a case study in a site situation. The seminar also included papers from the supply side with a presentation from Nasir Akolawaha of KSB Australia on sensors and protection methods for submersible sewage pumps. PIA invited Spiro Fkiaras from WEG to give everyone an update on the latest MEPS regulations for electric motors and this was most interesting. To complete the program, Josh Pinto of Endress & Hauser
www.pumpindustry.com.au
PIA NEWS
INSTALLATION & COMMISSIONING COURSE 23 August, 8am-5pm Link Pumps 4 Ponting Street, Williamstown VIC 3016
spoke on process instrumentation and Praveen Salian outlined the remote online condition monitoring services available from SKF. These papers outlined the latest trends in the industry and should help users to design pump stations to capture important data on performance and equipment condition over time. Following the success of this seminar, PIA intends to present a very similar program to pump users and suppliers in Perth. This will take place on Thursday 10 August at the AMC Jakovich Centre
in Henderson. Bookings can be made on the PIA website. Not everyone can spare a full day in their busy week, so PIA also has a series of shorter programs that can be presented at technical meetings, either organised by the association itself or provided to other organisations with whom PIA has some sort of reciprocal arrangement. PIA is happy to discuss such possibilities with anyone who wishes to consider working with us. Current programs are featured on the PIA website – head to www.pumps.asn.au.
Australian pump companies have a long history of being leaders in hydraulic technology and it is important for this expertise to be maintained. PIA is keen to share this expertise with customers, particularly when operational problems are causing concern. A problem shared is a problem halved.
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wastewater treatment needs. From our world class basket strainers to our valves and actuation, our industry-leading products are ideally suited for the vast range of requirements for multiple applications in water and wastewater treatment systems. We understand the precise requirements for water and wastewater treatment systems and are committed to offering solutions that will keep your systems working right for years to come. For more information, please contact us at sales@flowcontrol.net.au or call 0468 486 798. See us also at Hayward is a registered trademark of Hayward Industries, Inc. © 2016 Hayward Industries, Inc.
32050_Hayward_HalfPgAdHorz_PumpIndustry.indd www.pumpindustry.com.au
• • • • • • •
CHEMICAL DOSING / DILUTION REVERSE OSMOSIS DESALINATION MEMBRANE SYSTEMS NEUTRALIZATION PROCESS MEDIA FILTRATION CHEMICAL TRANSFER / HANDLING
Thermoplastic Valves | Actuation & Controls | Strainers | Filters | Instrumentation | Pumps | Bulkhead Fittings & Tank Accessories
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pump industry | Winter 2017 | Issue 20
15
PIA NEWS
IT WAS FIVE YEARS AGO TODAY… by Chris Bland, Publisher and Editor, Pump Industry
It was sometime before 2012 when I first had the idea of a pump magazine. I’d worked on various titles serving industries like water, oil & gas, energy and infrastructure, and one of the most common themes I kept coming across was pumps. Whatever the industry, people needed pumps and used pumps. But if they wanted to get information about the pump industry, or communicate with pump users, there was no single channel they could use – and thus the idea for a dedicated pump magazine was born.
A
fter researching the industry I came across the PIA, so one of the first steps was to get in touch with them. When I explained the concept, they were a little wary and uncertain whether it would work. When I explained there was no charge to them, they were pretty enthusiastic! The next step was to get in touch with the PIA members. Over the course of a month in July 2012 I tried to call pretty much every PIA member to pick their brains. A lot were pretty uncertain about whether the concept would work, but the key message that kept coming up was to make sure it went to, and was
ISSUE 1
OCTOBER 2012
ISSUE 2
“As an active member of the PIA, supporting their new magazine was fundamental. Having a magazine specific for the pump industry was going to be a significant resource for the industry and five years later, it continues to be one. “Sharing our knowledge through writing articles every edition, informing readers about new products, showcasing our abilities and continuing our reputation as a key player in the pump industry have all been benefits of being involved in the magazine. “The magazine covers all levels of industry, from the Pump School to the technical articles and the project articles, there is something of interest to read in every edition. Being directed at the pump industry, every edition is a key read at all levels in our organisation.” Vickie Thomsen, National Marketing Manager, Brown Brothers Engineers Australia
read by, the end-users and specifiers of pumps across all industries. The PIA membership itself consisted
FEBRUARY 2013
pumpindustry pumpindustry
ISSUE 3
MAY 2013
pumpindustry
Australia’s
FEATURES: • Import & export update • Fire pump standards • Water industry advocate • History: Bob Moore interview
Pumping
LNG & CSG
BEST NEW
ISSUE 4
pumpindustry
Australia’s
Australia’s
Number 1
Motors
services pump selection
& drives
in the HVAC industry
NOVEMBER 2013
pumpindustry Power station
pumps
Local manufacturing under the pump
ENERGY EFFICIENCY
Features
Efficiency
Valve
Control
ch
un
La
MAY 2015
ue
fugitive emissions
Iss
pumpindustry
ISSUE 12
AUGUST 2015
pumpindustry
getting the best out of your pump systems
ISSUE 13
pumpindustry Fire protection at the front line
Reassessing lifetime lubricated sealed bearings
The underground network
COOLING BRISBANE
November 2015
Why energy efficiency matters Storage the key to new hydro project
Dr Pump’s top tips for reliability
Dewatering the Roy Hill Mine Optimised wastewater pumping Diagnosing motor issues
PLUS exclusive Industry Capability Guide
2016
Your guide to the industry’s leading providers in 2016 OIL & GAS
pump industry | Winter 2017 | Issue 20
ISSUE 14
Irrigation pump selection Instrumentation, control & monitoring Fire pump standards
SUMMER 2016
pumpindustry
ISSUE 15
AUTUMN 2016
pumpindustry
Everything you need to know about valves
State of the Industry:
changes ahead for 2016
The dos and don’ts of
pumping fuel oil
Irrigation’s fruitful harvest Improving efficiency in HVAC Choosing the right
PUMP INDUSTRY CAPABILITY GUIDE
ALSO FEATURING:
Features
Industrial fans Food and beverage Wastewater pump stations
Reliability
Repetitive pump failure: the unnecessary evil
16
Mining
Inside Sydney Water: in-depth interview
Energy
ISSUE 5
Pump Source
Pump Source
Building Seals or sealless pumps?
ISSUE 11
AUGUST 2013
Number 1
Trade Magazine
FEATURES: • Industry training • Understanding pump curves • NSISP Project Manager interview
mainly of pump manufacturers and suppliers, so we had to look more broadly to build our audience. Armed
WASTEWATER
MINING HVAC
MANUFACTURING
mechanical seal
Seeing the forest for the trees:
tips for system reliability
www.pumpindustry.com.au
PIA NEWS
with the advice of the members, who told me that we needed reliability engineers, rotating equipment engineers, hydraulic systems engineers, hydraulic consultants, building managers and maintenance supervisors reading the magazine, we set about researching every mine, oil & gas plant, power plant, council, wastewater treatment plant, major building and even every irrigation store in the country. At these places, we found the relevant people that should be reading the magazine, and built our audience from there. We worked on not just getting our magazine to the right people, but also on ensuring they actually read it by investing in creating content that is relevant to them. We spoke to a representative sample of people to find the key issues they were interested in and made sure that we based the content of the magazine around their interests – not just the interests of the pump suppliers. One of the common themes that came up in these conversations was the fact these people had often studied pumps a long time ago, and now dealt with pumps along with a wide variety of other pieces of equipment in their daily lives. As a result, they were keen to see content centred around technical basics and other primers, to help refresh their knowledge. From day one, this has always been a key theme of the magazine,
ISSUE 6
FEBRUARY 2014
“SEEPEX Australia began operations around the same time as Pump Industry magazine. I was introduced to Chris Bland by a former work colleague and after speaking with Chris it became obvious that the magazine was a good platform for helping SEEPEX to establish our direct presence here. “We often receive enquiries from previously unknown contacts as a direct result of our magazine advertisements and editorials. The subscribers to Pump Industry magazine appear to be made up largely from our targeted potential customer base. “What I love about the magazine is the variety of articles and editorials, and also the ability to access both online and hard-copy versions.” Peter Vila, Managing Director, SEEPEX Australia
and the daily tracking and research we conduct into reader behaviour shows that this content is, and always has been, among the most popular featured in our magazine and website. We were very pleased to have an audience of over 2,600 from the very first issue, and have since seen our print circulation climb over 4,000. We also launched the magazine online from the start, building a strong audience with the newsletter and website from day one. Now, in 2017, we reach at least 22,000 people each quarter across our print, digital and social channels. In 2014 the PIA celebrated 50 years and it was a particular joy to be able to publish a supplement in the magazine covering this history. After its publication, I was surprised and pleased to hear from Bob Pullen, who let me know that he had actually published his own Pump Journal in 1968. He was kind enough to share some original editions and I was amazed by the quality of the
ISSUE 7
production, particularly given the lack of technological resources that we take for granted today in the world of magazine production. In 2015 we continued to expand the range of offerings and launched the first Pump Industry Capability Guide, an annual publication and integrated website to help better inform pump end-users about the offerings of Australia’s many innovative pump suppliers. “Hydro Innovations wanted an advertising platform that accessed potential customers across a broad spectrum of end users. Pump Industry seemed as though it could deliver on this front. “We have had plenty of customers point to the fact that they saw something in the magazine that showed them that our product could be of benefit to them. “It is a good quality magazine with well written and pertinent articles.” Sanja Kandic, Media Specialist, Hydro Innovations
MAY 2014
pumpindustry
pumpindustry
Slurry pumping
Retrofits increase
ISSUE 10
pumpindustry The road ahead:
State of the Industry forecast
building efficiency
Industrial valve market outlook
STATE OF
THE
INDUSTRY
ISSUE 16
Features
Features
Repair & maintenance Valves Product liability LNG
Environmental water Mechanical seals Peristaltic pumps Reliability engineering
WINTER 2016
pumpindustry
ISSUE 17
SPRING 2016
pumpindustry
FEBRUARY 2015
Performance prediction for slurry pumps What is the purpose of minimum flow?
ISSUE 18
SUMMER 2017
pumpindustry
ISSUE 19
AUTUMN 2017
WINTER 2017
ISSUE 20
pumpindustry pumpindustry Celebrating Lessons learnt
Dewatering
mines for safer
communities Pumps versus wet wipes
How to choose a VSD
The pumps A new wave of power generation Controlling a
Switching on to
energy efficiency
Mine pumping
no longer a drag
piping system
Ten questions
you should ask when purchasing a control valve
Sydney Water invests in
infrastructure
SECTION
OIL & GAS
i HVAC
PLUS exclusive Industry Capability Guide
IRRIGATION WASTEWATER
WASTEWATER IRRIGATION
PUMP INDUSTRY CAPABILITY GUIDE
HVAC
i
MINING
Your guide to the industry’s leading providers in 2017
that drive oil and gas
MANUFACTURING
MINING
Powering future submarines
from a major pump station upgrade
2017
OIL & GAS
MANUFACTURING
www.pumpi
ndustry.com
.au/directo
Make pumps great again Our industry survey highlights what needs to be done
Is your diesel pump costing you money?
Tips for irrigators More drive, less work – making motors more efficient
the operators:
from wastewater treatment plants to mine sites
5
YEARS OF
pumpindustry
Why good seals don’t wear out
ry
1
www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
17
PIA NEWS
“It was the intrepid Chris Bland who made the initial move that started Pump Industry – he contacted the PIA with his plan for a pump magazine, and wanted to know if PIA would support it. We were impressed by his ideas and vision and to be honest felt that we had nothing to lose and everything to gain. There really was a synergy from the beginning and PIA have been thrilled by the coverage and the quality of the magazine. I recall (perhaps the devil made me do it) introducing Chris at a PIA function as ‘Bland by name, but not by nature’, which on reflection was a bit cheeky but I think the analogy is pretty true. “Pump Industry is seen by PIA as a high quality platform for the Australian pump industry, not just in Australia but overseas as well. I was personally surprised to see a copy of Pump Industry on an engineer’s desk at a New Zealand oil refinery. The engineer in question ragged me about it being ‘my’ magazine due to my editorial role and photo, being PIA president at that time. That aside, he said it was the only pump related magazine that he would normally read from cover to cover because the articles were good and not just recycled product advertorials as is often the case in trade related publications. We are receiving similar feedback locally. The PIA is also impressed by the way Pump Industry has accurately reported PIA initiatives and events. “What I personally enjoy about the magazine is the fact that there is always a good technical article to read, and I also get to read about other players in the Australian market and some of the personalities. Ron Astall, PIA Immediate Past President and Sales & Contracts Manager at United Pumps Australia
Is your DAF System costing you $$$? Advantages: No compressor No complicated controls Reduce energy cost Reduce maintenance cost No air saturation vessel
Over the past few years we’ve also expanded our offerings and now act as a full marketing agency for a number of companies in the industry, helping manage their marketing and create unique content, custom newsletters, social campaigns, websites and more. In recognition of the PIA and the industry’s long history, we decided to feature a “Pump Pioneer” interview in each edition. Over the years we’ve spoken to life members and other industry stalwarts about their life and their career in pumps. I was particularly pleased to be able to meet and interview industry legends like Bob Moore and Antony Grage in our early editions, both of whom have sadly since passed away. In the past five years, Monkey Media has launched a number of new magazines in areas like utilities and infrastructure, but as our first publication, Pump Industry always holds a special place in our hearts. I want to thank all of the PIA members and executive for their support over the past five years, and in particular Keith Sanders and Ron Astall. Here’s to another five and many more beyond!
An EDUR Multiphase (DAF) pump replaces your Compressor, Air Saturation Vessel and existing Pump. Create the same (or better) micro-bubbles without the complicated and maintenance intensive system.
HydroInnovations.com.au 02 9898 1800 sales@HydroInnovations.com.au
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pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
PIA MEMBER NEWS | PARTNER SOLUTIONS
The new self cleaning sump
GAME CHANGER Gorman-Rupp and leading designer Yves Givron have developed what is said to be the Fourth Generation wet well called the Self Cleaning Sump (SCS).
D
esigned for use with self-priming Gorman-Rupp pumps, the SCS keeps the fluid in the system moving and maximises self cleaning. The total concept has been designed to eliminate blockages caused by the build-up of rags and stringy materials, sediment build-up in the sump, fat and grease build-up, and air entrainment. It is also designed to reduce energy consumption, reduce gases and odours, eliminate the need for “well washing”, greatly reduce blockages in the pump, as well as reduce maintenance and civil costs.
The design concept The premise is simple: keep the liquid moving for as long as possible. Do the majority of the pumping at a liquid level that produces the best cleaning effect, keep non-pumping times short, and use equipment that is reliable, safe, easy to access, and easy to maintain. The complete system consists of: • A Gorman-Rupp self priming packaged pump station with VFD controls • A short sloping collector pipe in HDPE (which replaces the conventional concrete wet well) • A modified maintenance/manhole (with sloping bottom to direct flow into the SCS) • An operating procedure designed to clean solids out with every cycle The mode of operation is an
www.pumpindustry.com.au
important component in the design philosophy. The pump starts at the “on level” at full speed to maximise re-priming lift (minimising re-prime time). It slows down at the “regulation level.” At this level, the velocity is at its highest to transport solid matter, including silt, fats and grease and stringy material. The VFD controls maintain this level (by speeding the pump up or slowing it down) for between three and five minutes. If the pre-set minimum speed is able to lower the level, or if the pre-set regulation level time limit has been reached, the pump will speed back up to maximum speed, pumping down to the “off level” to empty the SCS. This faster speed is designed for maximum self cleaning to remove as much silt, fat and stringy materials as possible. If there is a longer than acceptable delay between the next pumping cycle, the pump will cut-in prior, reaching the normal “on level” so that solids do not get a chance to settle out. This mode of operation is designed to keep solids moving and minimise the chance of silt build-up or stringy materials “balling” or “matting” together. All self cleaning sumps need to be paired with above ground self priming pumps. Gorman-Rupp’s Ultra V Series or Super T Series sewage pumps are
most suitable. Gorman-Rupp has been at the cutting edge of this technology for over 50 years and offers the most advanced pumping equipment for reliability, maintenance, non-clogging and un-clogging. The SCS concept in conjunction with a Gorman-Rupp packaged pump station can improve many of the issues confronting sewage pump station designers and asset owners. This new approach can reduce blockages, reduce odours, reduce air entrainment, reduce energy costs, reduce maintenance costs and reduce construction costs. It can also greatly improve operator safety. For more information call Hydro Innovations on 02 9898 1800 or visit www.hydroinnovations.com.au.
pump industry | Winter 2017 | Issue 20
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INDUSTRY NEWS | PARTNER SOLUTIONS
DEBUNKING MYTHS: PERFORMANCE FACTS ABOUT MECHANICAL JOINING
A new mechanical joining solution from Victaulic offers outstanding performance capabilities for high density polyethylene pipes.
In response to this trend, Victaulic, the world’s leading producer of mechanical pipe joining solutions, has developed the Refuse-to-Fuse™ system, a mechanical joint for HDPE piping. Strong and durable, the solution is changing the way we think about fusion practices. For years, butt fusion and electrofusion have been considered the top joining methods for HDPE piping. There are common misconceptions about the performance capabilities of fusion; until now, it has been widely accepted as the easiest, most efficient method for joining HDPE pipe. But a new mechanical joining solution from Victaulic is now changing the landscape. Here are the top myths about the performance of fusion compared to mechanical joining.
Myth one: fusing is faster
H
igh density polyethylene (HDPE) is lightweight, corrosionresistant, flexible, long-lasting and economical, so it’s an ideal material for underground buried and outdoor exposed pipelines. While HDPE poly has been available for over 50 years, recent adoption of the piping material is quickly replacing steel, concrete and ductile iron piping. It is the fastest-growing piping material in civil works and water transport infrastructure applications, with adoption expected to increase by 5 per cent per year.
The Refuse-to-Fuse system cuts crew downtime on-site so you can finish projects ahead of schedule. It can be installed up to ten times faster than fusing, while providing a consistent joint every time. Through the simple act of tightening two bolts and nuts, there is no need for expensive fusing equipment, power sources or certified fusion installers. There’s also no need to spend time heating and cooling pipe ends. Finally, without the need for complex equipment, mechanical joints can be quickly installed in tighter spaces and places that traditional fusing gear can’t reach.
Myth two: fusing is stronger Refuse-to-Fuse products meet or exceed HDPE pressure ratings. That means an HDPE pipe is likely to fail under pressure before a properly installed Refuse-to-Fuse joint. So you can push, pull and drag your pipe like any fused solution. The solution is specifically designed with strength and durability in mind and meets other common job site requirements, such as allowable tensile load and minimum bend radius.
Myth three: mechanical joints can’t be buried Victaulic mechanical joints for HDPE pipe are designed for buried services, and are perfect for underground civil works and water transport infrastructure applications. With a range of industry-accepted coatings, the Refuse-to-Fuse system is protected from the harsh underground environment.
Myth four: mechanical solutions are expensive While fusing may require hundreds of thousands of dollars-worth of equipment – depending on the size range of the project – the Refuse-toFuse solution eliminates the need for capital purchase and maintenance of these tools. Plus, because mechanical joining is faster and easier to install, projects can save on labour costs with fewer man hours required and no need for specially-certified workers. Overall, comparative studies of mechanical and fused projects have shown the Refuseto-Fuse solution to be a competitively priced option.
For more information, contact Victaulic on 1300 742 842 or email vicaust@victaulic.com. Visit the Victaulic team at the 2017 Victorian WIOA Exhibition at stand number 6 for live demonstrations and more.
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pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
INDUSTRY NEWS | PARTNER SOLUTIONS
HERE COMES THE STORY
OF THE SHURRICANE Ebara has rethought the hydraulic design used in multistage pumps. Utilising the latest in computational fluid dynamics and design, followed by rigorous testing, Ebara has developed a unique impeller design that offers solutions and value to the customer – the Shurricane.
T
he imbalance of forces acting on the front and rear shrouds of a conventional impeller results in axial thrust. This thrust load is compounding in multistage pumps, and has to be allowed for in the pump design. For pumps with conventional impellers, the existing solutions include having a thrust bearing built in the pump, or to use a special motor fitted with a larger thrust bearing. Both are costly and can be complicated. Another solution has been to simply have a smaller diameter back shroud to reduce the thrust. Ebara has rethought the hydraulic design used in multistage pumps. Utilising the latest in computational fluid dynamics and design, followed by rigorous testing, Ebara has developed a unique impeller design that offers solutions and value to the customer. The optimised shape of the Shurricane maintains high efficiencies and very significantly reduces the axial thrust – meaning that any standard IEC motor can be used and bearing life is improved.
strict technical evaluation criteria and control programs that involve the whole manufacturing process.
Suitable for a range of applications The range of Ebara vertical multistage pumps are suitable for a wide range of applications, in the industrial, commercial and agricultural fields. They can be used at water treatment plants (for reverse osmosis and filtration), for the pumping of hot or cold water for HVAC systems, for the pumping or boosting of water in general, and in boiler feed, irrigation and fire fighting systems. The pumps can be coupled with any motor, anywhere. Optional materials are part of the unique hydraulic design, and there are optional connections for customers to consider.
Built like a Katana A Katana is a traditional Japanese product manufactured with care and precision. Only years of experience can give the necessary capacity to build a masterpiece. This is what Ebara does with its pumps. The result of over 100 years of Japanese experience in pump design and manufacturing, their pumps offer high quality performance, reliability, and cutting-edge technology. Ebara’s vertical multistage pumps are manufactured in Italy to the highest standards of quality, and achieve reliable operating performance by means of
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pump industry | Winter 2017 | Issue 20
Product features Innovative hydraulic solutions • Commercial motors can be fitted to all of the pump models without any modifications thanks to low pump axial thrust load • Long life of the motor bearing • Patent Application Energy saving • High pump efficiency with MEI (minimum efficiency index) > 0.7 • Fitted with high efficiency motors • Suitable for use with Variable Frequency Drives for further energy savings Piping connection options • Various types of connections are available to best suit different installation requirements • The external dimensions are to the industry standard, and are interchangeable with most other brands. Easy maintenance • The cartridge type shaft seal is able to be replaced without disassembling the motor bracket • The spacer coupling allows easy maintenance without having to remove heavy motors 5.5 kW & above. Smart plug solutions • Air ventilation plug • Water filling & sensor plug • Commercial sensor fitting • Tappings for suction and discharge pressure, and/or drain
www.pumpindustry.com.au
NEW VERTICAL MULTISTAGE PUMPS FROM EBARA ™ The optimised shape of the new Shurricane impeller
Japanese Technology since 1912 and very significantly reduces maintains high efficiencies
™
the axial thrust – meaning that any standard IEC motor can be used, and bearing life is improved.
In Ebara’s new EVMS vertical multistage pumps Any motor Anywhere
Cutting edge technology
n
IEC standard motors
Spacer coupling (5.5 kW & above)
Cartridge mechanical seals
Unique impeller design greatly reduces thrust
(to EN12756)
Optional materials
Axial thrust with conventional Impeller
Japanese technology
Unique hydraulic design
Made in Italy
Optional connections
www.ebara.com.au
EBARA PUMPS AUSTRALIA PTY. LTD. 7 Holloway Drive Bayswater, VIC. 3153 Ph: 03 9761 3033
sales@ebara.com.au
www.ebara.com.au
Looking ahead, going beyond expectations
INDUSTRY NEWS | PARTNER SOLUTIONS
Kubota Dedicated to supporting customer innovation For almost 40 years Kubota Australia has been supporting its customers in agriculture, construction and power equipment.
W
orking hand in hand with manufacturers to design and test new product innovations, Kubota is even more relevant to customers’ needs. Kubota Australia’s Engineering department offers full engine application testing to assist original equipment manufacturers (OEMs) all round the world develop stronger products. Working with Kubota means working closely with the team from concept through to production to match an engine to your exact specifications. The team delivers comprehensive application testing across key product areas, including heat balance, vibration, safety and maintenance. This ensures each engine is matched perfectly with the product it powers without compromising engine emissions, safety, output, reliability or serviceability. Kubota’s ability to adapt engines to an extensive range of applications is legendary. It uses its rich expertise to design and optimise engines that are resolutely fit for purpose – and the company is continuously developing its industrial engines to boost productivity, improve performance and better meet your specific application requirements.
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pump industry | Winter 2017 | Issue 20
Take for example Spitwater Australia, which uses Kubota’s engineering support during its testing phase. “We fit custom-built, application-specific Kubota OC engines to our diesel pressure washers,” said Spitwater Managing Director, Andrea Martinotti. “And when we bring our two great brands together, the product pretty much sells itself. “People prefer to buy brands they know and trust. It just makes good business sense,” he added. Put simply, a Kubota engine does the job it’s built for perfectly. It’s highly durable yet light and compact. It gives maximum fuel efficiency while minimising noise and vibration. Engine life is enhanced and – more importantly – is outstandingly reliable, year in, year out. Customers also have the added peace of mind knowing Kubota’s Worldwide Service Network gives you timely service for engine supply, service requests, parts supply and warranty issues – great news if you export finished products overseas. Boost customer satisfaction and confidence today. Partner with Kubota to drive innovation in your business now.
www.pumpindustry.com.au
POWER PERFORMANCE STRAIGHT OUT OF THE BOX! REDUCE YOUR DOWNTIME & POWER UP YOUR PRODUCTIVITY Kubota’s large output three & four-cylinder power packs provide the ultimate in performance, reliability and durability. Built with world class components and backed by the support of a national dealer network for service and spare parts. Designed to save you significant time and money – there’s no need to waste time waiting for your dealer to build up a pump to your specs, or assemble the kit yourself.
Everything is done for you... just position, flick the switch and put it to work!
Call now for low finance rates & your nearest dealer
AUSTRALIA WIDE 1300 582 582
kubota.com.au
INDUSTRY NEWS | PARTNER SOLUTIONS
POWERFUL PUMPS THAT SAVE MONEY – AND ENERGY One of the biggest challenges facing the world today is enhancing energy efficiency – but there are a number of simple solutions that can make the task much easier.
O
ne such solution is Shakti’s new range of state-of-the-art solar pumps. The pumps are based on fabricated technology and are used to supply water efficiently and effectively.
Why solar pumps? Solar pumps are energy efficient and offer many benefits to users. Some of these include: • They can provide more discharge than ordinary pumps • They can be used in rural areas, as they do not require electricity or other fuels like diesel to run smoothly • They can provide relief from interrupting electric supply or load sharing • In avoiding electricity usage, users avoid rate hikes and supply issues,
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and save on their electricity bill • They reduce carbon emissions • Electric pumps can be damaged due to fluctuations in electricity voltage - solar pumps avoid this problem entirely • Solar pumps do not require a high torque Solar panels generate the energy used to drive a solar pump. Improvements in solar panel technology mean that they are more efficient than ever. In particular, improvements in the tempered glass used in each panel improve their capability, enhancing durability and ensuring optimum function at all times. Every customer is after a quality product which performs as promised. The latest solar pumps can work from
pump industry | Winter 2017 | Issue 20
dusk until dawn, and now, thanks to battery technology, they can even work when sunlight is not available. Solar pumps are well equipped to handle the needs of customers with large water requirements – hence they are particularly useful for customers looking to irrigate large areas of land. For Shakti, the needs of the customer are always the first priority. Solarpowered pumps are affordably priced, and they come with the added benefits of helping to reduce electricity bills for users – making them a win-win option for many. With more than 50,000 pump sets installed worldwide, Shakti Solar Pumps is pleased to be able to offer customers a proven, energy efficient solution for their water pumping needs.
www.pumpindustry.com.au
INDUSTRY NEWS | PARTNER SOLUTIONS
LET’S FOCUS ON QUALITY The world is getting smaller, competition is becoming fiercer and budgets are shrinking. In today’s global environment, it is easy to cut costs by buying cheaper, but inexpensive can sometimes mean ultimately more expensive.
T
he old saying that “you get what you pay for” rings true in most day-to-day situations, however for engineers, the dollars saved on that cheaper system component in the design phase can sometimes lead to significant increases in repair, maintenance and service costs shortly after commissioning. A company’s reputation can be impacted by such decisions. We are all looking at budgets, focusing on the dollars and cents. Let’s take a step back to look at the big picture, sharpen our focus on quality. The smallest items in a system such as hoses, couplings and expansion joints can have a significant impact on productivity and efficiency. They can also cause the biggest headaches if they continuously fail under normal working conditions. However, it is often the case that these low-cost items are the components which are price driven and considered a commodity item. Flexible bellows have a lasting impact on a system’s performance. Choosing the right expansion joint that will go the distance will reduce the need for continual maintenance. Elaflex Pacific have expansion joints (flexible rubber bellows) for almost every industry and application. With sizes from DN25 to DN4200, these German-made expansion joints can handle the most demanding operating environments, from freezing arctic climates to power station
28
engine rooms, and carry an excellent reputation for quality and reliability. Most recently, Elaflex have also released a new type of rubber expansion joint, the ERV-BR. It is specifically designed for abrasive media such as sludges, slurries, solid / liquid mixtures and emulsions. All Elaflex ERV expansion joints are available with a range of mating flanges and accessories. They are also certified by most leading industry bodies and authorities including DNV-GL, Lloyd’s Register and Bureau Veritas. It is often thought that a hose is just a hose, and again it is treated as a simple commodity. With an ever increasing
focus on standards and compliance, the type of hose selected can affect the media purity, as well as the lifetime and safety of a system. The exclusive Elaflex-ContiTech range of rubber hoses boasts a coverage of up to 98 per cent of all fluids. Ongoing experience within the global chemical, food, aviation, pharmaceutical, and mining industries, among others, has allowed companies to see the value in buying quality products. It is easy to promise quality at the time of purchase. With ELAFLEX hoses, couplings and expansion joints, "the proof is in the pudding".
Elaflex has been providing high quality engineering solutions since 1923. With an ever growing range of products to meet internationally recognised standards, Elaflex prides itself as a company focused on quality. For more information about the range of products, visit www.elaflex.com.au or email info@elaflex.com.au
pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
Many options, quick choice.
Perfect
Durable
Dependable
Quality Refuelling Equipment from the Specialist
ERV-BR : Rubber Expansion Joint for abrasive Media
Premium Class : Chemical Hoses to EN 12115
ELAFLEX PACIFIC, a daughter company of ELAFLEX Hamburg in Germany, is the supplier of the Elaflex product range: ZVA nozzles, rubber hoses, couplings and ERV expansion joints along with MannTek Dry Disconnect Couplings in the Pacific region, including Australia, New Zealand and the Pacific Islands. The ELAFLEX ERV-BR, rubber expansion joint has been created specifically for abrasive media and is perfectly suited to the aggressive nature of sludge dewatering, mineral processing and the transfer of many types of slurries. Our online configurator is the perfect tool to get a fast and efficient overview of the product you require. Try it at http://ervconfigurator.elaflex.com.au/ ELAFLEX PACIFIC PTY LTD Ph. +61 2 8058 9258 · info@elaflex.com.au · www.elaflex.com.au
INDUSTRY NEWS | PARTNER SOLUTIONS
TACKLING THE CHALLENGE OF SEWAGE BYPASS A new 8-inch submersible pump has been released by Tsurumi that is ideal for the temporary bypass of sewage during sewer reconstruction work. The pump offers a maximum head of 26.5m, coupled with a maximum flow of 5,700lpm and its slim design enables it to fit into a standard manhole.
C
alled the KRSU series, the new pump will be introduced to the Australian market by exclusive Tsurumi distributors, Australian Pump Industries. “The pump’s unique 546mm diameter means it can operate in the deep, confined spaces of a conventional manhole,” said Aussie Pumps’ Tsurumi Divisional Manager, Neil Bennett. The unit offers a semi-vortex impeller and a large solids passage of 56mm to prevent foreign matter clogging. The top mounted discharge and side flow design ensures efficient motor cooling, even when operating at low water levels. Sewer pipes deteriorate with age and can be damaged during nearby construction or earthworks. During repairs and replacement of these pipes the sewage must be safely diverted to prevent the health issues for workers and the neighbouring community. Conventional sewage bypass pumps are engine driven and struggle to lift
fluids beyond depths of 7m. Tsurumi’s KRSU submersible pump not only fits in the deep, limited confines of a manhole, but it provides a maximum head in excess of 25m. The pump is powered by a heavyduty 22kW, three-phase DOL dry-type induction motor. The 4-pole motor, running at 1450rpm, provides loads of torque and allows for long, trouble-free life. The new KRSU pump features Tsurumi’s unique anti-wicking block for the cable entry. This watertight cable entry, with strain-relief device, prevents water incursion due to capillary action, in the event of the power cable being damaged or the end submerged. Tsurumi protects the motor from water incursion from the pump chamber with their unique dual double-silicon carbide mechanical seals. These seals are located in an oil-chamber away from abrasive particles pumped media. Additionally, a patented oil lifter in the
oil chamber forcibly supplies lubricating oil to the seal surfaces. A motor protection device, in the form of a circle thermal protector, is built into the motor housing. It cuts power to the motor circuit if excessive heat builds up or an over-current condition occurs. Australian Pump expects that the submersible will replace engine drive sewer bypass pumps, because of its ability to lift sewage from a depth of 25m. Further information on the Aussie Pump Tsurumi KRSU pump is readily available from Australian Pump Industries or Aussie Pump Industrial Dealers throughout Australia or www. aussiepumps.com.au.
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
ABB Australia Pty Limited Tel. 1800 222 435 E-mail: abb.dodge.sales@au.abb.com
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pump industry | Winter 2017 | Issue 20
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When it comes to
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Zetco specialises in WaterMarked manual isolation valves including ball, gate, globe, check valves and YÂ strainers in DZR brass, bronze and stainless steel.
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pump industry | Winter 2017 | Issue 20
31
INDUSTRY NEWS | PARTNER SOLUTIONS
SUCCESSFUL FUTURE WITH NEW GENERATION DIESEL ENGINES HATZ Diesel Australia has released a new generation of water-cooled and turbocharged diesel engines to complement its existing air-cooled range of engines.
H
ATZ is one of the major suppliers of air-cooled industrial diesel engines in Australia and New Zealand, and its parent company in Germany has been manufacturing engines for over 130 years, developing into a specialist for diesel engines rated up to 62kW. This new engine family extends the HATZ product portfolio with the H-series, allowing customers to choose the best diesel engine for their needs from six families and over 20 different models between 2-62kW. Complementing the recently
released 4H50TI and 4H50TIC 4-cylinder engine models, is the upcoming 3H50TI and 3H50TIC 3-cylinder versions. HATZ is relying on common-rail technology, turbocharger and external exhaust gas recirculation. This new range of engines excels as a compact, lightweight and robust 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 lightweight, 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 any one could ask for. Manufactured under stringent quality control to ensure reliability and
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32
M - Series
Air-Cooled Heavy Duty - 1 cylinder
62kW Max
pump industry | Winter 2017 | Issue 20
C A S E ,
durability, 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 its 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 its new 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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PIA MEMBER NEWS | PARTNER SOLUTIONS
WORKING WITH SUPPLIERS YOU CAN TRUST Credentials, credibility, credence – these words all stem from the latin credere – to believe or trust.
I
n this world of shifting corporate sands and faceless multinationals, you need to know what you can believe, and who you can trust. Kessler Couplings & Engineering Supplies’ (KCES) credentials in relation to pipe couplings are impeccable. Wolf Kessler, founder and director, comes from Austria, where he qualified as a mechanical engineer. He was the applications engineer at the original Swiss manufacturers before emigrating to Australia, and KCES was their exclusive Australia/NZ distributor for twelve years. KCES is now proud to announce a new exclusive distributorship
with another quality European manufacturer, UNI-Couplings of the Netherlands. Relatively new to Australia, UNI-Couplings have been sold overseas in markets as diverse as shipbuilding and district heating. They also have a highly distinguished pedigree, coming from the stable of United Pipeline Products (UPP). UPP have produced pipe joints and repair clamps under various wellknown brands for nearly 30 years and are certified to ISO 9001 and ISO 14001. Many in the international oil, gas and offshore industries will know Huwa, Hegawa and Romacon/ Petro. Despite its global presence, UPP is a hands-on, family-owned group which stands behind its products, and places enormous value on excellence
and quality in both product and service. UNI-Couplings are the most technically advanced, wellmanufactured pipe couplings on the market, developed in and for the 21st century. They are manufactured and tested to stringent specifications in UPP’s own in-house manufacturing facilities in the Netherlands, and the quality of their design and build is instantly recognisable. They have the usual approvals, and are available in the range and variety you would expect. KCES is the local pipe couplings specialist you can trust, offering technical expertise, extensive stock, excellent service and great value. KCES and UNI-Couplings – credentials you can trust.
For more information, contact KCES on +61 3 9728 3973, or visit www.kces.com.au
Pipeline Installation, Modification + Repair Easy + Quick Installation Light, Modern, Efficient OHS Advantages No Hot Work Permit No Heavy/Specialist Equipment Required Innovative design Most technologically advanced pipe coupling on the market Superior European quality Designed and fully manufactured in The Netherlands
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Trusted Applications Advice for 20+ Years Unsurpassed Product Knowledge Unrivalled Specialist Technical Expertise One-Stop Shop for Project Consultancy Partnership and Sales Personal + Responsive Service WE Care about YOUR Business Australian Owned
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CALL KCES ON +61 3 9728 3973 FOR A NO-OBLIGATION CHAT ABOUT UNI-COUPLINGS – THE BETTER CHOICE www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
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WASTEWATER
WASTEWATER
IMPROVEMEN Ensuring wastewater treatment plants operate efficiently and reliably is an important task that operational staff undertake. In a move to recognise the excellent performance, initiative and attention to detail of operational staff, the Water Industry Operators Association (WIOA) has awarded its inaugural South Australian Operator of the Year Award to SA Water’s Hahndorf Wastewater Treatment Plant Operator, Daniel Partridge, for his work to reduce hazards and boost efficiency across several sites.
The Murray Bridge Wastewater Treatment Plant.
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pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
WASTEWATER
EFFICIENCY
NTS WIN BIG
www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
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WASTEWATER
The Bolivar Wastewater Treatment Plant.
M
r Partridge has been with SA Water for eight years and works across several sites providing wastewater processing for communities around Murray Bridge, Mannum, Hahndorf, Stirling, Lobethal, Gumeracha and Angaston. SA Water’s Senior Manager of Production and Treatment, Lisa Hannant, said winning this award was great recognition of Mr Partridge’s skills as an operator. "Daniel is a high performer and his achievements have made a real difference to our business and customers throughout the Adelaide Hills and Murraylands," Ms Hannant said. "We’re fortunate at SA Water to have highly skilled, dedicated people working to provide vital services for communities throughout South Australia.” Mr Partridge said it was a great achievement and honour to represent South Australia as the WIOA Water Industry Operator of the Year. “Winning the award has given me an opportunity, which I otherwise wouldn’t have had, to learn from operators from all across Australia and New Zealand,” Mr Partridge said.
Reducing hazards and boosting efficiency Mr Partridge was nominated by SA Water and competed against seven other South Australian operators to take out the honour for his work in reducing the number of hazards, and boosting efficiencies at wastewater treatment plants in the Adelaide Hills and at Murray Bridge. He was prompted to make changes by SA Water’s safety culture program, Mate Watch, which is a behavioural based safety program that encourages employees to look for hazards/potential risks and come up with solutions. It also includes modelling good behaviour.
36
“When a suction hose attached to our Kelly & Lewis three-inch pump, was used to clean our contact tank, the grate had to be removed. I noticed that taking away this grate created a fall risk for employees into the 3m deep tank. I was keen to make this cleaning job safer, so I 2016 WIOA South Australia Operator of the Year, came up with the solution to adapt Daniel Partridge from SA Water. scaffolding to fit over the handrails around the tank. This eliminates the the time taken for this task from one potential for an employee to fall into the hour to just 15 minutes.” tank when the grate is removed,” said Mr Learning from facilities in New Partridge. Zealand “The second hazard concerned the As part of the award, Mr Partridge process for changing over the mixers in travelled to New Zealand in May where the bottom of our reactors. Employees he attended the Wellness in Operations at our plant were required to disconnect Conference in Queenstown, and visited a cable holder from the top of a winch, local wastewater facilities to learn from around 2.4m off the ground. Due to the their processes. height of the winch, workers had to either “Before visiting New Zealand, I hadn’t use a ladder or step on the handrail to previously seen a wastewater process reach the cable holder, risking a fall. To fix which dries out dewatered sludge from this problem, I worked as part of a team a centrifuge in a 100m-long glass house. and we decided to put in a piece of chain When compared with conventional which lowered the cable clip. systems, this is really efficient taking the “This made it easy to reach without a total solids yield from 20 per cent up to ladder or using the handrail, eliminating 85-95 per cent,” Mr Partridge said. the fall risk for workers.” “It was interesting to see that a Mr Partridge also wanted to improve variable speed drive (VSD) can be efficiency, and identified a number of incorporated into the pump motor on areas where changes could be made. certain pumps to monitor torque. When “Heathfield Wastewater Treatment torque increases due to ‘ragging up’ Plant experienced higher than average (i.e. a pump becoming clogged with inflows during the wet winter of 2016. non-flushable items) the VSD stops Aluminium sulphate is used to remove the pump, then reverses it to clear the phosphorous from wastewater, and at blockage.” Heathfield we used flow-paced dosing Mr Partridge said he is also keen to of aluminium sulphate during highly improve how the turbidity wet rack variable flow periods,” he said. lines at SA Water plants are managed, a “I identified an opportunity to process he was able to learn more about improve efficiency within the aluminium in New Zealand. sulphate dosing system, by changing “A wet rack is where water is pumped from a flow-paced to a fixed dose to be analysed for turbidity – a key test system. This reduced chemical use at for water quality. Fortunately as part of the plant. I also suggested using a larger the tour we were able to visit a number front-end loader to transfer biosolids of water and wastewater treatment into our transport container – reducing
pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
WASTEWATER plants which have wet racks to get ideas. I have taken details of several pumps that supply water to wet racks with a view to trialling some of these over the next few months,” he said. “I also learned that the water catchment environment is quite different on New Zealand’s South Island compared to South Australia. In my home state, raw water from our catchment areas requires filtration barriers and treatment because it contains contaminants that enter the water from the environment. By contrast, some water processed at the South Island’s water treatment plants is pure enough to be pumped straight from the bore to the customer without any treatment.”
Selecting the right pump for the job According to Mr Partridge, when it comes to choosing pumps for wastewater facilities, reliability, the right size and power efficiency are some of the key factors. “Reliability is a key factor, and getting the right pump for the right job is a must. This involves making sure you have the correct size of pump and the pump has capacity to handle increased demand into the future. With many wastewater treatment plants looking to improve their carbon footprint and
electricity costs on the rise, the power efficiency of pumps is also an important consideration,” Mr Partridge said. “Energy efficiency of pumps is vitally important when deciding which pump to purchase. It’s possible to make major savings in energy costs just by selecting the right pump for the job. It also pays to pick a pump that has the extra capacity to only run during off-peak periods, or when the spot price for electricity is reasonable.” Maintenance also plays an important role in ensuring pumps are running efficiently. “We categorise our pumps into different levels of servicing depending on the value of the pump, the task of the pump, and the availability/reliability we require from the pump,” Mr Partridge said. “Our pump categorisation system is important for our plant operations, because it allows us to tailor highly effective servicing schedules for our pumps and plan for pump replacement needs. “I think it’s important for operators to develop an in-depth and current knowledge of pump products on the market. It’s vital to get the right pump that is durable and can achieve the required flows rates and pressures for the job you need it do.”
Daniel Partridge at work at one of SA Water’s wastewater treatment plants.
Uncompromising Blockage Protection As the rags and solids in wastewater increase, you need innovation that keeps pumping stations problem-free. The submersible sewage pump type ABS XFP from Sulzer, with its versatile range of Contrablock Plus impellers, is insurance against downtime that’s easy to acquire. The impellers’ superior rag handling and minimum free solids passage of 75 mm mean you spend far less time on troublesome pumping stations. Switching from an existing pump is easy, and you save energy immediately with the XFP’s premium-efficiency IE3 submersible motor – which Sulzer pioneered and provides as standard. For more innovation in wastewater collection, visit www.sulzer.com
www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
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WASTEWATER
Eliminating constant
SEWAGE SPILLS Xylem’s new system solves constant clogging issues at a pump station located at a university’s residences.
O
perators of a wastewater pumping station at Sultan Qaboos University in Oman were facing serious clogging issues, having to frequently lift the station’s pump and manually remove waste solids and grease build-up. Furthermore, as the station couldn’t handle the flow during peak hours, it was not unusual to have overflows that would reach the adjacent roads. In an effort to solve these issues, the university agreed to install and trial Flygt Concertor, a new wastewater pumping system with integrated intelligence designed to ensure clean wet wells, clog-free operation and drastically reduce unplanned vacuum cleaning call-outs. The trial was planned to last for four months, but after the first number of weeks the difference in performance and efficiency was remarkable. Flygt Concertor not only kept the pump and sump continuously clean, but it also completely eliminated the common sewage spills during peak flows.
Clogging issues at the university Sultan Qaboos University, located in the Muscat region of Oman, houses approximately 16,000 students. Both the student and staff population has steadily increased during the last number of years, and the university’s administration is focused
on finding efficient and sustainable solutions for all their services. In September 2015, the operators of a pump station located at one of the student residences agreed to install and trial Xylem’s new wastewater pumping system, Flygt Concertor, in an effort to solve serious clogging issues as well as frequent overflows caused by peak flows. The positive results were clear as early as during the first week of the trial. Before installing Flygt Concertor, operators had to frequently lift the pump up to remove waste solids caught in the impeller. With Xylem’s new wastewater pumping system, the pump clogging was completely eliminated. Furthermore, the cleaning of the sump, which previously required the services of a sewage vacuum truck to manually remove accumulated grease and sediment, dramatically improved. “We had to call the vacuum truck once a month and have them manually remove sediment and grease. “This is now a thing of the past – with Flygt Concertor this hasn’t been a problem and we have saved both time and money,” said Ramesh Rathinavel, Senior Mechanical Engineer at Sultan Qaboos University. As Xylem’s wastewater pumping system with integrated intelligence
automatically adapts to pumping conditions to deliver optimal pumping performance, overflows in the vicinity of the pump station have also been eliminated. “The Flygt pumping system is managing the peak flow without any problem and has eliminated the flooding issues,” said Mr Ramesh.
Compact and energy efficient wastewater pumping system On top of the benefits delivered by Flygt Concertor’s pump and sump cleaning functions, the system’s compact design allowed it to easily fit into the existing station at Sultan Qaboos University. Concertor’s system design results in compact control cabinets as traditional components (such as motor protection, starters, variable frequency drives and climate control equipment) are either not required or built into the pump. This reduces the size of the control cabinet and at the same time enables more monitoring functionalities. Mr Ramesh added, “Overall our experience with Flygt Concertor has been very positive – the pumping system has been operating trouble free since it was installed. We no longer have to contend with clogging, break-downs or overflows. On top of that our energy bill has decreased.”
For more information, head to www.flygt.com/one-ultimate-system.com
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pump industry | Winter 2017 | Issue 20
www.pumpindustry.com.au
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. See Flygt Concertor for yourself at the 80th Victorian Water Industry Operators Conference & Exhibition in Bendigo, 6th & 7th September 2017. One powerful solution. Unlimited possibilities.
www.xylem.com/pumping
WASTEWATER
UPGRADING FOR HEALTHY WATERWAYS
AND SAFE COMMUNITIES Earlier this year, Unitywater announced that it would undertake a major upgrade of its Kawana Sewage Treatment Plant (STP), one of their key sewage treatment facilities. The upgrade will not only expand the plant’s capacity, it will also incorporate Unitywater’s first waste-to-energy facility.
A
s one of Unitywater’s largest facilities, the Kawana STP plays an important role in keeping coastal waterways healthy, serving Sunshine Coast communities from Pelican Waters to Buddina. As the population of the Sunshine Coast grows, the volume of sewage treated by the Kawana STP will continue to increase from its present rate of 20 million litres a day. The upgrade to the facility will allow it to continue to provide high treatment standards as it handles increased sewage loads.
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In addition to population growth, Unitywater has identified the Kawana STP as the future central sewage treatment plant for the Sunshine Coast. Areas such as South Buderim, Chancellor Park and Sippy Downs, which are currently connected to the Maroochydore STP, are planned to be serviced by the Kawana STP in the near future. Looking to the long term, Unitywater is considering the requirement for treating sewage on the Sunshine Coast and believes that Kawana STP may ultimately need to treat the sewage for
pump industry | Winter 2017 | Issue 20
an equivalent of 600,000 people – over six times its current capacity.
Building for the future Simon Taylor, Executive Manager Infrastructure Planning and Capital Delivery at Unitywater, said that the upgrade is focused on ensuring Unitywater has the infrastructure to cater for future population growth. “We are investing $73.9 million to upgrade the Kawana sewage treatment plant (STP) which will significantly increase its current capacity, from 90,000 people to
www.pumpindustry.com.au
WASTEWATER 150,000 people. Further investment planned over the coming decades will ensure that we keep ahead of the increasing population.” Engineering group Monadelphous won the contract for the project and started construction recently, with the upgrade expected to be completed by December 2018. The new plant will incorporate sewage treatment technology that means the current site can accommodate a larger plant as it expands over the long term. “The upgrade will incorporate a biotechnical process that requires less infrastructure to be built,” said Mr Taylor. “The moving bed biofilm reactor (MBBR) process is a type of wastewater treatment where small plastic pieces known as ‘carriers’ are used to grow special bacteria, which then consume the impurities from incoming sewage.” This technology requires less space than other treatment processes as the bacteria can be concentrated into a smaller area. “As part of the upgrades, we will be installing an anaerobic digester where bacteria turn sewage into methanerich biogas,” said Mr Taylor. ”We are currently undertaking a feasibility study to determine the best way to optimise that gas and turn it into energy. In this
way, we have the potential to cut our electricity bills at Kawana STP.” Transporting liquids and gases from one part of the plant to another is a very important part of the overall process and the plant will contain a wide range of new pumps to help with this.
Selecting the right pumps According to Mr Taylor, from the outset of the project design process, Unitywater provided a detailed specification for pumping systems to Monadelphous. With their design and technology partners, Monadelphous will
complete the procurement, installation, and testing of pumps on site as part of the upgrade. EPC Manager Kawana STP K150 Upgrade Project Jason Keating from Monadelphous said “On site at Kawana there are a wide variety of pumping applications including water, sewage, sludge, oil and grease, sand and grit and chemicals and, as a result, we have selected a range of pumping types including helical rotary load pumps, centrifugal pumps to best suit requirements.
ACCELERATED EVAPORATION
EFFECTIVE POND LEVEL REDUCTION · · · ·
Remote monitoring
Atmospheric intelligence module Water droplets <100UM
16 head atomises 438 m3/day
PHONE (08) 8118 6460 ace@adlcontrol.com.au www.adelaidecontrolengineering.com www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
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WASTEWATER
“Monadelphous has worked in water infrastructure for over 10 years, and we’ve worked with these types of pumps on previous projects – so we’re confident of their capabilities and reliability. “In accordance with Unitywater’s mandated equipment list requirements, Monadelphous has sourced pumps from local Australian agents with a known history for reliability and local support provision.” For Unitywater, the pump selection process begins with several key factors in mind: reliable operation, minimal downtime, reduced maintenance, longevity, efficient operation, and capital cost. “Unitywater uses a whole-of-life analysis when selecting pumps so that we find the right balance between the upfront costs and entire running costs of the pumps,” said Mr Taylor. For Monadelphous, the focus is on ensuring they comply with Unitywater’s detailed specifications and processing condition
42
requirements, while also factoring in total lifecycle cost of the pump (including purchase and maintenance costs) and energy efficiency. For Unitywater, energy efficiency is an important consideration. “Electricity is one of the major costs when running a sewage treatment plant and we are very focused on reducing our total energy consumption,” said Mr Taylor. “Pumping fluids around the plant uses a significant amount of energy and while we are conscious of this, we also look at whole-of-life cost factors when choosing pumps.”
Making waste-to-energy work Unitywater is continuing to investigate the waste-to-energy component of the STP through a feasibility study being carried out over the last seven months with support from the Australian Renewable Energy Agency (ARENA). Prior to this, a series of scoping studies and pre-feasibility investigations had been undertaken. “The concept of recovering energy
pump industry | Winter 2017 | Issue 20
from waste is not new, however our concept looks at accepting multiple variable waste streams, in addition to sewage sludge,” said Mr Taylor. “These waste streams might include liquid organics such as fats, oils and greases from industry and businesses like restaurants and cafes. We believe that this additional feedstock might serve to improve the biogas production at smaller scale sewage treatment plants like Kawana, where traditionally sewage biosolids would be insufficient to economically sustain a cogeneration engine. “Through anaerobic co-digestion, the combination of the liquid organic wastes with the sewage sludge will serve to break down and produce extra biogas, which in our case is will be used to generate energy. “It’s really exciting to think that we can take this waste that would otherwise end up in landfill and turn it into renewable bioenergy to help power the sewage treatment plant.”
www.pumpindustry.com.au
WASTEWATER
HD â&#x20AC;&#x201C; 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.
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.
www.bonfiglioli.com.au Branches Australia Wide PH: 1300 656 757 www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
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WASTEWATER
Submersible wastewater pump and motor testing – Part 1 by Joe Evans, Pump Ed 101
All pumps should be tested regularly, but wastewater pumps are at the top of my list as they are especially susceptible to changing system conditions.
E
ven if a pump operates at BEP at start up, many conditions will change during the coming months and years. These include malfunctioning gate and check valves, partial blockages in the pipeline, air accumulation at a high point and new branches entering a force main, just to name a few. Clear water systems can face similar challenges but the content of the pumpage makes wastewater systems more vulnerable. These changes can have a major effect on the pump’s operating point on its H/Q curve. Submersible wastewater pumps can be even more of a problem since they are
out of sight and often out of mind. Wastewater pumps can be problematic when operated at off BEP conditions due to the size of their impellers. The large width, required for solids passage, increases the radial forces on higher head pumps. This leads to increased shaft deflection which will reduce seal, wear ring and bearing life. In addition to radial loading, operation to the left of BEP can give rise to damaging, suction and discharge recirculation cavitation. In order to encourage frequent testing, I developed two, simple submersible pump field test
spreadsheets for our customers. One uses a flow meter for flow measurement and allows plotting of multiple test points. The one we will review in this article uses a drawdown test to measure pump flow. Drawdown is still the most used procedure for measuring flow in smaller and remote lift stations. Figure 1 shows the pump test portion of the spreadsheet. The bottom right section is the drawdown test and the bottom left tests for TDH. The gray cells are the entered data and the yellow ones are the calculated data. The equations used for the calculations are shown to the right of the cells.
SUBMERSIBLE WASTEWATER PUMP FIELD TEST PROCEDURE (DRAW DOWN) Manufacturer / Model # / etc Job Name
Hydromatic S6L - 1750 RPM - 11.38 Trim Crap Creek Lift Station
Date:
8/13/2013
Witness
SJ Lee
Printing - Set to 75% of full size Entered Data Calculated Results
Motor Serial Number
123456
Liquid SG & Temp
1.0
Pump Serial Number
654321
Q Measurement
Drawdown (1’)
Time of Day
9:00 AM
Ambient Temperature
71°F
60°F
Vibration (in/sec peak to peak) ** See Instructions
Pump Head Test
Drawdown Flow Test**
Discharge Gauge to Waterline (ft)
10.0
Wet Well Diameter (Inches)
Discharge Gauge Head (ft)
51.0
Drawdown Distance (Inches)
144.0 12.0
Pipe Friction Pump to Gauge (ft)
5.0
Drawdown Time (Seconds)
32.0
Pump Suction Diameter (in)**
9.0
Wet Well Volume / ft (Gal)
845.5
6.0
Drawdown Volume (Gal)
Discharge Pipe ID (in)
845.5
Discharge Velocity (fps)
18.0
Discharge Velocity Head
5.0
Inflow Distance (Inches)
0.0
Suction Velocity (fps)
8.0
Inflow Time (Seconds)
0.0
Suction Velocity Head
1.0
Inflow Volume (Gal)
0.0
TDH (ft)
70.0
Flow Rate (GPM No Inflow)
Flow Rate (With Inflow)
1585.4
1585.4
Calculations: TDH = Hd + GW + F + Hvd - Hvs Hd = discharge gauge pressure (ft) GW = vertical distance between the gauge and wet well level F = friction in the discharge piping from pump to gauge Hvd = velocity head at the discharge gauge Hvs = velocity head at the pump suction Velocity (V) = (Q * 0.4085) / ID2 Q = flow rate (gpm) ID = pipe inner diameter 0.4085 = conversion constant Velocity Head (Hv) = V2 / 2g V = flow velocity g = gravitational constant
Figure 1
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pump industry | Winter 2017 | Issue 20
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WASTEWATER
We will begin with the drawdown analysis Usually a drawdown test measures the time required to remove one foot of water starting at the pump on level. The reason one foot is a preferred distance is that it provides for an ample time measurement and flow changes very little over a single foot. The distance can be measured with a laser device, a plumb bob or a rod with starting and ending markings. It is always best to shut off the invert once the pump start level is reached in order to obtain the greatest accuracy. If this cannot be done, choose a time during the day when inflow is minimal. As seen in Figure 1, entering the wet well diameter, drawdown distance and drawdown time is the only data needed if there is no inflow. The spreadsheet will calculate the wet volume per foot, the drawdown volume and the flow rate based upon that information. In this example, flow rate is 1585 GPM. If inflow occurred during the drawdown test, an inflow test can be performed immediately following drawdown. If inflow is small, a two to
three inch rise is all that is needed to calculate inflow. If an inflow test is performed, the inflow volume is used for the final GPM calculation. It is always best to perform two or three drawdown tests in order to obtain the most accurate results. Pump head is measured with a high quality pressure gauge at the pump start water level, immediately after pressure has stabilised. The total dynamic head (TDH) is calculated by taking into account the gauge to water level elevation, pipe friction from the pump discharge to gauge location and velocity head. Friction head loss is determined using a friction table. I considered calculating it but decided that a friction table for the proper piping material and fittings would provide a more accurate value. Discharge velocity head is calculated using the piping ID at the gauge location and the flow rate calculated during the drawdown test. As before, the equations used to calculate these values are shown to the right of the calculator. You have probably noticed that there is a cell for pump suction diameter and a calculation for
suction velocity head. There are some who believe that when a submersible pump incorporates an external “suction bell”, suction velocity head must be subtracted from the TDH calculation. If you belong to that group, enter the suction diameter in that cell. If you do not, enter a diameter large enough to reduce suction velocity head to zero. In our example a suction diameter of 9-inches results in a one foot velocity head at the suction. The discharge gauge reading was 51 feet but when the calculator takes into account the gauge to water level elevation, friction in the piping and the velocity heads, TDH is calculated at 70 feet. This particular pump tested at 1585 GPM at 70’ which is approximately 97 per cent of BEP flow. Wouldn’t it be nice if all pumps ran this close to BEP? In submersible wastewater pump and motor testing – Part 2, I will review the submersible motor testing portion of the spreadsheet. These tests will provide more pump hydraulic test results based upon motor performance and will also provide us with phase voltage and current unbalance calculations.
Joe Evans has been in the pump industry since 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
www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
45
WASTEWATER
Harvesting stormwater from Lake Caroline City West Water has recently completed construction of a wet well extraction system within Lake Caroline, for the irrigation of eight hectares of open spaces across Caroline Springs Town Centre Recreation Reserve and Catholic Regional College.
W
ater is delivered via 1100m of reticulation pipes connected to the extraction system, and the project is estimated to save up to 52 million litres of precious drinking water per year.
The pumps The wet well extraction system includes a Grundfos submersible pump with a horizontal discharge port. These particular pumps are specifically designed for the pressurised pumping of wastewater. City West Water Customer Compliance Officer Water Innovations Brock Tunnicliffe said the pump was also equipped with a grinder system, which grinds destructible solids into small pieces so that they can be led away through pipes of a relatively small diameter. “This was great for this particular application, as there were large amounts of leaves, dirt and sediment in the water being pumped,” said Mr Tunnicliffe. “Another benefit is that the pump does not have to run continuously to operate effectively. When switched to ‘auto’ mode, the pump will only activate when there is demand for water.”
The Benefits According to Mr Tunnicliffe, the Lake Caroline Stormwater Harvesting Project is a fantastic example of City West Water’s commitment to putting customers first by supporting thriving community spaces. “We have worked closely with the City of Melton to help the area of Caroline Springs reduce its reliance on potable water for irrigation, and to improve the quality of Melbourne’s waterways. “The project also boasts a water sensitive urban design, which is in-line with our commitment to the government’s Water for Victoria initiative. “The system will continue to operate no matter the climatic conditions, and will provide our customers with a communal space that they can enjoy all year round,” said Mr Tunnicliffe.
About Lake Caroline Lake Caroline is part of the Stony Hill Creek catchment area of approximately 1530 hectares, with 290 hectares of the total catchment contributing to flows into the Lake Caroline catchment. The catchment spans from Melton Highway in Hillside to Caroline Springs Blvd in Caroline Springs.
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WASTEWATER
The Lake Caroline pump system draws water from the pump wet well when the tanks have sufficient water for this to occur.
Pumps
Screen Filter
Under Ground Tank
Flow Meter
Level switch Under Ground Tank PLC
Wet Well Float Pressure Transducer
CRC Above Ground Tank PLC
Level switch Main Switchboard Lake
CRC PLC
Flow and field connections – located on the discharge of the pump set is the Siemens flow meter (FT01) which monitors all outgoing flows from the pump station. Harvested water has been connected to the following sportsgrounds Melton City council under-ground tanks and Catholic Regional College.
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DELIVERING PUMPING SOLUTIONS pump industry | Winter 2017 | Issue 20
47
MINING
Sizing pump discharge piping at a mine site by Ray Hardee, Chief Engineer, Engineering Software
Most of my articles are based on discussions with people at operating plants. This article is the result of a question asked at a Piping System Fundamentals course given at a customerâ&#x20AC;&#x2122;s site.
D
uring the training course, I start by identifying the elements used in every piping system (pump elements, process elements, and control elements) and how they work together to efficiently meet the systemâ&#x20AC;&#x2122;s objectives. We had just completed discussing the pump elements and starting the section on process elements. During our discussion on calculating the average fluid velocity and resulting head loss in a pipeline, one of the participants asked why we needed to calculate this information. He stated that he selected the pipe diameter to match the diameter of the pump discharge nozzle. I mentioned this approach results in oversized equipment and increases in pumping costs. To demonstrate, I suggested that we create an example on a system he was familiar with; in this case a dewatering system for an open pit mine.
Looking at the system Rainfall at the site could be intense and in many cases the mine would fill up with water to a point at which mining operations were forced to shut down. The pumping system was the choke point and determined the amount of down time. An optimal pumping system would have the ability to move a sufficient amount of water in order to keep the mine operating, even during storms. Figure 1 shows the dewatering system for his open pit mine.
All the rainwater falling into the mine flows by gravity to the mine sump. Here the dewatering pump moves the rain water through a 4km long pipe into the mill water collection tank. The attendee mentioned that the dewatering pump had a 150mm discharge nozzle; as a result a 150mm diameter pipe was selected for the discharge pipe. Using the manufacturer's supplied pump curve for the dewatering pump a computer model was created to simulate system operation. The simulation software calculated a flow rate through the system of 81.53m3/hr. We ran additional simulations using both a 200mm and 250mm pipe for the discharge pipe. Table 1 shows the results of the simulation: system flow rate, pump head and power draw, along with the pipe friction loss and fluid velocity for the different discharge pipe diameters. In reviewing table 1, we can see that increasing the diameter of the discharge pipe increases the flow rate through the system. Looking at the system with a 200mm discharge pipe, the flow rate more than doubles up to 167.5m3/hr with little effect on pump head, a small increase in pump power, but a significant increase in pump efficiency from 29.9 per cent to 55.8 per cent. Increasing the discharge pipe diameter to 250mm yielded even higher flow rates and better efficiency.
Figure 1. Customerâ&#x20AC;&#x2122;s mine dewatering system.
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MINING
The pump curve
Balancing the system energy
The key to understanding the system operation is the manufacturer’s supplied pump curve, shown in Figure 2. The pump curve uses test data for the supplied pump for a range of flow rates. This curve shows the operation of the installed pump with a 416mm impeller. The pump curve shows the pump head, efficiency and power consumption for the pump’s operating range, and uses water as the test fluid. The calculated flow rates based on the simulation in Table 1 have been superimposed on the pump curve for the 150mm, 200mm, and 250mm discharge pipe scenarios. As you can see from the curve, the head developed by the pump decreases as the flow rate through the pump increases.
It is important to know that the flow rate through the system is based on the interaction of the pump, process, and control elements. The flow rate is determined when head developed by the pump equals the head loss associated with the process and the control elements. Formula 1 shows the relationship between the energy supplied by the pump elements and how the process and control elements consume that energy:
hP ump = hP rocess + hControl
Discharge pipe
System flow
Pump head
Pump power
Pipe head loss
Velocity
Pump efficiency
mm
m3/hr
metres
kW
metres
m/sec
%
150*
81.53
55.45
41.2
35.44
1.22
29.9
200
167.5
55.02
44.76
35.02
1.44
55.8
250
296.9
53.19
57.48
33.19
1.62
74.7
Table 1. Simulation results for different discharge pipe diameters. *Original pipe diameter.
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49
MINING
Figure 2. The pump curve describes how the pump operates at various flow rates.
In looking at Table 1 then, we can see the pump head is equal to the pipe head loss along with the change in elevation between the mill tank level and the mine sump level (a constant 20 metres) which are considered process elements. The control for the system is a simple on/off switch hooked to a level control in the sump. This ensures the pump is running when water is present, but also that it doesn’t run dry. There is no head loss associated with the control element since it is an electrical switch. In the physical piping system “mother nature” balances flow rate through the system, so the results of Formula 1 are met. Calculating the balanced flow rate manually, however, is a more complex problem. It requires one to guess at a flow rate, calculate the resulting head loss for that guess, and, if Formula 1 is not met, then the guessed flow rate is adjusted until Formula 1 is balanced. A piping simulation program goes through the same process, and since the math is done by the computer, you can gain a better understanding of how the system works without all the tedium. Another member of the class asked why the manufacturers don’t increase the discharge nozzle size to better match the
recommended discharge pipe diameter. The answer to that question is based on cost. A pump is made of a casting, and using a larger discharge nozzle increase the pump weight and cost. Using a smaller discharge nozzle reduces the pump cost. A smaller nozzle results in a higher fluid velocity through the pump nozzle though. Since the length of the discharge nozzle is so short the head loss associated with the smaller nozzle is not that great.
Conclusion When attaching a pipe to a pump, make sure you do things right by sizing the discharge pipe to the desired system flow rate. It may be easy to assume that the manufacturer optimised this part of the system for you, however they do not necessarily know how the pump will be used. It is only through looking at how the all the elements of the system interact that the benefits of an analysis become clear. It is also important to weigh the analysis against the priorities of the system. In industrial processes the energy savings may be the cost driver, however in this scenario it was the ability to keep the mine operating and minimise downtime.
ABOUT THE AUTHOR Ray T Hardee, PE, is the Chief Engineer and a principle founder of Engineered Software Inc., creators of PIPE-FLO® and PUMP-FLO® software. The PIPE-FLO product line helps some of the largest companies across a variety of industries find hidden profit in the design and operation of their fluid piping systems through simulation software, modeling services, and training opportunities. Hardee is a member of the Hydraulics Institute, ASME Energy Assessment for Pumping Systems standards committee and ISO Pumping System Energy Assessment committee. Hardee’s publications include Piping System Fundamentals and contributions to HI’s Pump Life Cycle Cost and Optimizing Piping Systems.
He can be reached at SimGuyRay@eng-software.com
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PUMPING IRON ORE Goodwin Submersible Pumps are designed and precision engineered to endure in the most demanding environments.
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MINING
Flexible risers for mine dewatering operations Dewatering is a crucial part of the mining process, and its efficient management leads to major savings.
M
ines around the world save time, money and trouble by using Wellmaster flexible hose systems. Layflat hoses are especially recommended for mining activity where the surface equipment and pumps are constantly being moved. Wellmaster is the industry standard flexible rising main designed for use with electric submersible pumps in all types of groundwater borehole extraction and well monitoring operations. Over the past 30 years, the Wellmaster system has proven its performance in more than 70,000 installations worldwide. Instead of having to transport, handle and install steel pipe sections, the compact and lightweight Wellmaster flexible system, supplied in coiled layflat form, makes minimal demands on transport and handling resources. Pump removal for maintenance or repair is a quick and easy operation and can generally be achieved in hours, significantly reducing out of service hours for the well. Wellmaster is not only easy to use and store, but it is also highly resistant to all forms of microbiological attack, which deter internal scaling. As a result, Wellmaster is totally corrosion resistant. This means riser performance is unchanged throughout the life of the installation. With its built-in flexibility, Wellmaster swells under pressure, minimising friction-head loss and creating superior hydraulics, resulting in reduced power consumption and
52
improved riser efficiency. Installing Wellmaster is simple. The most common methods for installing Wellmaster are either using a crane, specialist trailer, or vehicle. Crane installations are preferred where the space surrounding the borehole is restricted, as the hose can be held vertically above the opening. Where overhead hazards may preclude the use of a crane, a special trailer might be preferred, as installation and retrieval can be completed without the need to suspend the hose. In remote locations, a simple vehicle installation allows deployment to take place at ground level using the Angus wellhead roller. Installations of up to 200m in a single length can be achieved using the Wellmaster system, or 400m using Angus joiner system. Wellmaster flexible rising main is the only flexible system to come with a software program, which enables users to validate hydraulic performance in advance of installation. By using
WellCalc, miners can select the correct diameter hose for boreholes, and thereby minimise operational delays, increase efficiency and save money. Further information on the installation and use of Wellmaster can be obtained from the Wellmaster installation manual, technical manual and WellCalc software. Installation courses are also available from Angus Flexible Pipelines, leading to certified installer status. The effectiveness of site water management can be greatly improved by the use of flexible rising mains to accurately control surface and groundwater in order to maximise the safety of the miners, the performance of the mine, and conservation of the environment. Known as â&#x20AC;&#x153;steel on a reelâ&#x20AC;?, Wellmaster offers exceptional strength and hydraulic efficiency as well as major cost savings and performance advantages over conventional rigid polyethylene, glass fibre, galvanised and steel pipes.
For more information, head to www.flexiblepipelines.co.uk
pump industry | Winter 2017 | Issue 20
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INDUST RY LEADIN G
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if installed by an Angus approved installer
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ASK AN EXPERT
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.
What sort of progressive cavity pumps are best suited to mining applications? Progressive cavity pumps (PCPs) are very common on mine sites throughout Australia. For these pumps, this particular market sector would be on par with water/wastewater as one of Australia’s most popular. To list in detail the various applications would take up this entire magazine issue, so instead I have summarised the typical applications and key benefits of this pump design.
Overview of mine types where PCPs are used in Australia: • • • • • • • • • • • •
Bauxite (also refined alumina) Coal Copper Gold Iron Ore Mineral Sands Nickel Shale Oil Tin Uranium Vanadium Zinc
Common applications for PCPs in mining: • • • • • • • • • • •
Transfer of mineral slurries Void back-filling applications Dosing of explosives Thickener underflow applications Centrifuge filling Chemical dosing Water treatment Cake transfer Leachate treatment Gland water supply Sludge feed to dewatering machines Typical transfer liquids include polymers, sludge, slurries, grout, various chemicals and clean and dirty water.
Mine dewatering applications for PCPs This is one of the most common areas where PCPs can be seen, usually installed on a transportable skid with collection tanks for incoming water, and generally incorporating some kind of solids separation to partially clean the muddy, high sediment mine water.
They are also used by countless suppliers of mining equipment and chemicals for: • • • • •
54
Decanters and centrifuges Tunnel drilling equipment Flocculants Chemical dosing Liquid explosives
pump industry | Winter 2017 | Issue 20
The difference between close-coupled and long-coupled PCPs.
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ASK AN EXPERT
The range of PCPs used for these applications have a long length, due to the pressure generation required for pumping to the surface from several hundred meters underground. There are several companies currently who specialise specifically within this application sector and occasionally there can be new design developments which may give significant benefits to the users of this product range. Keeping abreast of these developments can certainly pay significant dividends to mine operators. More detailed information on specific design developments can be requested via the contact details at the end of this article.
Cutaway view of a PCP.
Benefits of PCPs • • • • • • •
Self-priming Minimal pulsation Valve-less operation and flow control Reversible for back-flushing Flow proportional to speed No day to day maintenance required Versatile: can be installed horizontally or vertically and in virtually any position • Minimal flow rate variation even with changing pressures • Handle multiphase products (liquid and gas)
PCP on a rail car for a coal mine.
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
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pump industry | Winter 2017 | Issue 20
55
COAL SEAM GAS
PROJECT RUBY: Expanding operations in the Surat Basin With a moratorium on unconventional oil and gas exploration now in place in several Australian states and territories, there is a risk of reduced supply for customers and exports. However, in a move to secure gas supply, Queensland Gas Company (QGC) is continuing the sustainable development of gas fields in the state through Project Ruby.
Chris Finlayson (left) and Mitch Ingram (centre) at a gas well in the Surat Basin.
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COAL SEAM GAS
I
n March 2017, QGC, a Shell Australia joint venture, announced that it will be extending its operations in the Surat Basin with the drilling of up to 161 additional wells – a move that will enable further supply to both domestic customers and natural gas exports. The project, dubbed Project Ruby, expands on QGC’s operations in the Basin, and will underpin 350 new and existing jobs in regional Queensland during the 16 month construction period, and sustain QGC’s gas production as older wells decline.
local businesses have full, fair and reasonable opportunity to compete for QGC business. “Actively encouraging local procurement is one of the four objectives of our new Local Content Policy,” Mr Nunan said. “Businesses can now register their interest in working with us through our website free of charge. “These measures will help QGC build on its track record of creating opportunities for local business as we work to supply natural gas to businesses and homes in Australia and beyond.”
Keeping it local
Shell Chairman Andrew Smith said this latest project was the company’s way of continuing to supply gas into the east coast market whilst protecting valuable export jobs in regional Australia. “This is the next significant milestone for the QGC project and a further vote of confidence in Queensland’s onshore gas industry,” Mr Smith said. “We are proud to be investing in regional Queensland, where state and local government have had the vision to establish the rules for a gas industry that creates jobs and supports farmers by providing water, building new roads and paying taxes. “During construction the Queensland gas industry created more than 40,000 jobs, and even today after construction has been completed it employs 13,000 people. “Queensland has shown itself to be a leader in creating an onshore gas industry, creating valuable export jobs, and [this] announcement shows the industry is growing and creating more jobs.”
Since the project was announced, QGC has begun construction with a 2.2km upgrade to Wieambilla Road and 1.38km of upgrades to Ravens Road. The project area is part of QGC’s existing tenements in south-west Queensland with 17km of access tracks completed on these tenements, 20 well sites prepared for drilling, and 12 wells already drilled. Pumps will be used to extract water and gas from these wells, and then compress the gas to sales gas pressure for transport via high pressure pipelines. Local pump companies will be given the opportunity to supply the pumps required for Project Ruby, as per QGC’s supplier policy which was launched in 2016. By providing local pump suppliers with the opportunity to supply it with competitively priced products, it aims to support the long-term economic stability of the region. Tony Nunan, QGC Managing Director, said that the policy was the result of community feedback, and aims to ensure
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Ensuring gas supply for QLD
pump industry | Winter 2017 | Issue 20
57
COAL SEAM GAS
WE CAN PUMP ALMOST ANYTHING
• ISO Pumps • Vacuum pumps • Submersible Pumps • Self-Priming Pumps
FOR MORE INFORMATION VISIT WWW.SOUTHERNCROSS.PENTAIR.COM.AU
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COAL SEAM GAS
Meeting growing demand The Australian Petroleum Production and Exploration Association (APPEA) Queensland Director, Rhys Turner, said the start of Project Ruby was an important milestone for QGC and the Queensland gas industry. “The only way to meet growing demand for gas for our export and domestic markets is to increase supply,” Mr Turner said. “The Queensland gas industry is committed to supplying gas into the east coast market. This new project will help the industry to deliver on its commitment.”
Setting the right policies The gas industry’s commitment to continuing the supply of gas into the east coast market can be met, in part, due to the State Government introducing policy aimed at promoting the sustainable development of the industry. Such policy is important, as the tightening of gas supply, in part due to restrictions on exploration in other states and territories, will translate to higher gas prices. Queensland Minister for Natural Resources, Dr Anthony Lynham, said ongoing investment in Queensland’s $70 billion CSG-LNG industry, through projects such as Project Ruby, shows the policy settings are right. He said this is good news for gas supplies and jobs in Queensland, with studies showing that for every local person working directly in the CSG industry, a further three new indirect jobs are created within the Surat region.
QGC’s natural gas operations in Queensland’s Surat Basin supply gas to domestic and international customers.
PIONEER PUMP REVOLUTIONISED THE MINING AND QUARRYING PUMP INDUSTRY WHEN WE LAUNCHED THE PIONEER PRIME, HIGH EFFICIENCY SELF PRIMING PUMPS.
Whether our pumps are assessed on flow rates, pressures or efficiencies, Pioneer pumps offer their users world class performance including flows over 2300LPS, heads of over 26 bar (260m) all from pumps with a two year warranty.
Revolutionising mining pump performance.
Typical features of Pioneer pumps • Heavy duty construction including, high quality materials of construction • Oversized shaft and seal for high reliability in arduous conditions • Hard Face mechanical seals with Viton elastomers & SS hardware • Patented positive sealing priming equipment in full stainless steel • Low NPSHr impeller designs for exceptional suction lifts • Back pullout design allowing for ease of maintenance • 50cfm vacuum pump on all sizes of Pioneer Prime for the fastest priming • Ductile iron castings for extra long life on key parts such as casings • Impellers in CA6NM hardened stainless steels • Optional materials includes CD4MCU Duplex stainless steels • 17-4PH stainless steel shafts for corrosion and abrasion resistance • Auto-start and stop functionality on control panels • GSM pump and engine monitoring from anywhere in the world • Trailer or skids and Pontoons
Fully packaged sets including Mine Spec Skids, Pontoons, Trailers, sound attenuation, bunded Skids & double skin tanks, to MDG 15 Guide lines and to Tier IIII engines pending clients requirements. With well over 100 models of pumps and packaged pump sets to choose from Pioneer offer one of the largest range of electric motor or engine driven self priming dewatering pumps in the world.
Phone: 03 9988 1650 Fax: 03 9988 1666 Email: PPAUsales@pioneerpump.com www.pumpindustry.com.au
pump industry | Winter 2017 | Issue 20
59
COAL SEAM GAS | PARTNER SOLUTIONS
Johnson ® Screens Pump Guard Screens Screening challenges in your coal seam gas, mining, wastewater or recycling application? Johnson Screens® has you covered.
J
ohnson Screens® (a brand of the Aqseptence Group) continues to provide services including drafting, engineering design and manufacturing, delivering quality Australian-made products to various industries for solids and liquid separation. The company can now offer the most comprehensive and innovative range of screen surface media in the industry. Johnson Screens® can design and manufacture screen panels, whether it is with their revolutionary Vee-Wire® technology, polyurethane, rubber, perforated plate or hardened plate materials, or a combination of any of these to meet the challenges of the most difficult screening applications. During the design process, every aspect of the application is taken into consideration. This total custom approach to manufacturing offers many advantages to Johnson Screens’® customers in terms of safety, extended wear life, high efficiency, ease of maintenance and cost-effectiveness. Johnson Screens® manufacture a range of products ideal for the irrigation
industry, including bore pump inlet screens, pump suction screens, lowering spears, jetting spears, dewatering spears, sieve bend screens and complete rundown units, rotary units and Noggerath screw press equipment for larger volumes of primary screening of sand, grit and soil.
Johnson Screens® Pump Guard Screens Abrasion by sand can shorten pump life, but Johnson pump guard screens keep out fine sand particles, extending pump life, reducing downtime and increasing well production. Constructed out of stainless steel, these pump guard screens are corrosion resistant, lengthening the life of the screen.
Noggerath spiral sieves These are ranked among the best machines of their kind in the world. The liquid flows into the sieve basket, which is open on the inlet side. Solids with a larger diameter than the hole/gap width are retained. A continuous layer of solids is therefore formed on the surface of the screen, reducing free passage
through it and causing the level of the liquid upstream of the screen casing to rise. These sieves are ideal for organic waste recovery.
Sieve bends Johnson Screens® sieve bend screens are used in static sieves for either dewatering or classification. Slurry flows by gravity over an inclined screen surface. Screen Vee-Wires®, which are perpendicular to flow, slice away a layer of slurry. The Vee-Wires® can be as narrow as 0.5mm and up 12.7mm. Johnson Screens® fine Vee-Wires® create a sieve, which presents more edges to the flow for superior separation efficiency. The dewatering capability of the screen is determined by the percent of open area and tip of the wire. Vee-Wire® slot openings can be as narrow as 50µm with increments of 25µm allowing for more open area. Australasia and New Zealand regions are serviced from the Johnson Screens® manufacturing facility in Geebung, Brisbane.
For any enquiries, please email au.waterwell.water@aqseptence.com
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pump industry | Winter 2017 | Issue 20
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TECHNICAL
Specifying heavy duty pumps for critical industries by Ron Astall, PIA Immediate Past President and Sales & Contracts Manager, United Pumps
API 610 pumps are expensive, normally custom built and are often on a long delivery. So why would you specify an API 610 pump? Ron Astall explains why.
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hen is API 610/ISO 13709 a logical requirement, and how are these pumps different from ordinary centrifugal pumps? In this article, I will be discussing where this specification came from, why you might specify this standard, and how pumps to this standard differ from conventional centrifugal pumps. As ISO 13709 is identical to and is fundamentally an adoption of API 610, I will simply refer to the standard as API 610 for from now on.
CENTRIFUGAL PUMP STANDARDS • DIMENSIONAL & PERFORMANCE STANDARDS • Basic standards that set out dimensions and performance envelope • • • •
• CONSTRUCTIONAL STANDARDS • Stricter standards that outline properties such as »» Design stresses (API 610) »» Nozzle loads »» Min bearing life
ANSI B73.1 ISO 2858 DIN 24255 DIN24256
»» Shaft stiffness »» Baseline stiffness (API 610) • ANSI B73.1 • API 610 • ISO 5199
Figure 3. Comparison between various pump standards.
SIMPLIFIED COMPARISON
Figure 1. A BB3 style API 610 pumpset.
There are various exciting centrifugal pump standards that you may come across such as ISO 2858, DIN 24255, ANSI B73.1 and ISO 5199. These are great reading if you suffer from insomnia, so I have summarised the basics in Figure 3.
ISO 5199
ANSI B73.1
APl 610
Critical Speed Margin
10%
20%
20%
Basic Pressure Rating
16 Bar
19.5 Bar
40 Bar
17,500 (over allowable operating range)
17,500 (over allowable operating range)
25,000 at rated duty 16,000 worst case conditions
3mm/s
4.8mm/s
3mm/s
G6.3
G6.3
G2.5
50µm (over alllowable operating range)
130µm (over alllowable operating range)
50µm worst case Conditions
50µm
25µm
25µm
Grease
Grease
Oil lube
Per Annex B modified by materials & other factors
Similar to lSO 5199
Per Table 5 basic table values lower than ISO 5199, but no modifiication allowed. Option of s2 x Table 5 loads is commonly applied
Min Bearing Life (hrs -B10) Vibration (Horizontal Pumps) Balance Grade Shaft Deflection (at Seal Chamber face) Allowable Shaft Runout Lubrication
Nozzle Loads
Figure 2. Comparison between Din/ISO and an API pump.
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Figure 4. Simplified comparison of the key differences between the constructional standards.
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TECHNICAL
WHY END USERS SPECIFY API PUMPS (NOT ONLY OIL & GAS) • Dangerous liquids »» Hazardous »» Flammable • • • • •
»» Poisonous High temperatures High pressures Critical service High cost of pump failure Compulsory in oil & gas
Figure 5. Why end users specify API pumps.
KEY SPECIFICATION REQUIREMENTS • Pump design life of 25 years • Designed to run uninterrupted for three years • 40 Bar minimum design pressure • Oil lube bearings • 25,000hr L10 minimum bearing life • Renewable wear rings • Shaft rigidity: »» Maximum deflection 50 µm (0.002 in) at the seal faces • Tough vibration criteria • Material certification & testing • Performance tested Figure 6. Key specification requirements.
API 610 BASIC DESIGN PROPERTIES 6.1.1 Minimum service life of 20 years (excluding normal wear parts). Pumps to operate uninterrupted for a minimum of 3 years. 6.3.3 Pressure cases shall be designed to operate without leakage or internal contact while subject simultaneously to the MAWP and twice the allowable nozzle loads. 6.3.5 MAWP to be at least maximum discharge pressure plus 10% of maximum differential pressure. MAWP shall not be less than 4,000 kPag
6.3.7 Minimum corrosion allowance of 3mm 6.5 External nozzles are required to withstand the high nozzle loads (forces and moments) 6.8 Minimum Seal Chamber dimensions for better cooling, ease of installation of dual seals. 6.6.9 Shafts to be machined and finished so the TIR is not more than 25 µm (0.001 in)
6.3.7 Minimum corrosion allowance of 3mm
6.9.1.3 The shaft stiffness shall limit the total deflection under the most severe dynamic conditions (max impeller diameter, speed and fluid) to 5O µm (0.002 in) at the primary seal faces.
6.3.3 Pressure cases shall be designed to operate without leakage or internal contact while subject simultaneously to the MAWP and twice the allowable nozzle loads.
6.10.1 Bearing basic rating life L10, is to be at least 25,000 hours at rated conditions and at least 16,000 hours at maximum radial and axial loads and rated speed.
6.3.5 MAWP to be at least maximum discharge pressure plus 10% of maximum differential pressure. MAWP shall not be less than 4,000 kPag
7 .3.20 Strict design properties are placed on the baseplate. Table 13 (API 610 11th Edn) outlines the stiffness test acceptance criteria.
You can see that some are dimensional and performance envelope standards, while others are constructional; addressing reliability aspects. ANSI/ASME B73.1 covers both dimensional and constructional aspects. Some of the key differences between the constructional standards are shown in Figure 4. In practice, the major points of difference with API 610 are rigidity (nozzle loadings), extreme reliability requirements, and bearing life, noting that in practice API designers normally consider “worst case conditions” to be zero flow. The American Petroleum Institute (API) was founded in 1919 to cooperate with government in matters of national concern, to promote the general interests of the petroleum industry and, in particular, issue and maintain more than 500 standards and recommended practices for the petroleum industry. Today the world’s petroleum industry uses API standards as the mainstay of design and installation specifications for almost all operational equipment and plant. So, what exactly is API 610? It is primarily about centrifugal pump safety and integrity. API 610 is normally specified where the pumped product is dangerous, hot, high pressure, flammable, toxic and for critical services (see Figure 5). It is a tough specification, with a required pump design life of 25 years, and a requirement for uninterrupted operation for at least three years (see Figure 6). It is too ambitious to cover all the requirements of a 221 page standard in this article, but some of the basics are shown in Figure 7. Let’s look at one of these requirements in a little more detail. Nozzle loads and base plate rigidity were dramatically increased by the 6th edition of the standard, and are such that shaft deflection shall be negligible under the worst combination of nozzle loadings. This means that not only the pump itself has to be strong, but the baseplate as well (see Figure 8). Basically, you can park a large car on the pump nozzles, and the shaft must not move more than 0.178mm vertically or 0.076mm horizontally! A properly designed API 610 pump from the late 1980s onwards is recognisable by the massive mounting feet and strong base plate pedestals (see Figure 9).
Figure 7. API 610 basic design properties.
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TECHNICAL
NOZZLE LOADS AND BASEPLATE RIGIDITY Fx = 254 kg Fy= 209kg Fz = 317kg FR = 457kg Mx= 2300Nm My= 1180Nm Mz= 1760Nm MR= 3130Nm Fx = 254kg Fy= 209kg Fz = 317kg FR = 457kg Mx= 2300Nm My= 1180Nm Mz= 1760Nm MR= 3130Nm
WHAT DOES IT REALLY MEAN?
FOR 150mm (6'') NOZZLES MAXIMUM COUPLING DEFLECTION WITH ANY COMBINATION OF FORCES & MOMENTS: VERTICAL : 0.178mm (0.007'') LATERAL : 0.076mm (0.003'') MOST API 610 CUSTOMERS SPECIFY DOUBLE THESE LOADS
Figure 8.
API 610 has various pump type designations with coding “OH” for overhung pumps, “BB” for between bearings and “VS” for vertically suspended pumps. An overview of some of the most common types and what they look like is provided in Figure 10. As well as tough constructional requirements for the pumps, API 610 references API 682 (ISO 21049) for mechanical seals and their associated, often complex systems. Where the liquids are hot, dangerous and toxic, the sealing systems can sometimes rival or exceed the cost of the pumps. So why, and when would you specify an API 610 pump? The answer is ultimately pretty simple: when you have a dangerous, difficult or critical service and when safety and reliability are the highest priorities. Figure 9. Identifying an API 610 pump from the 1980s onwards.
Figure 10. Common types of API 610 pumps.
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PUMP HANDBOOK
SELECTING AND APPLYING
positive displacement pumps (PART 2) Metering pumps While various types of pumps can be used for dosing and metering purposes, special designs are available for applications requiring consistently accurate volumetric metering. These are reciprocating positive displacement pumps and are known as metering pumps. Metering pump output must be able to be varied within its operating range and the results of this adjustment must be repeatable. Various different metering pump designs are available to handle a wide range of flow rates, pressures and liquids. These pumps include diaphragm, plunger and plunger-diaphragm types, with further variations of design within each basic type for specific applications. All metering pumps consist of the following components: • Liquid end • Drive mechanism • Adjustment mechanism • Drive motor The major types of metering pumps include: • Mechanically actuated diaphragm/ plunger • Hydraulically actuated diaphragm • Electromagnetic (solenoid) diaphragm • Electronic diaphragm Generally, the operation of the various metering pump types is similar to that of the standard piston, plunger and diaphragm pumps that the metering versions were based on. The main operational differences relate to the various methods of capacity control,
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and the need to minimise the effects of pressure pulsations in order to maintain metering accuracy. Mechanically actuated diaphragm/ plunger In this type of metering pump a reciprocating connecting rod or cam, located within an oil bath lubricated gearbox, displaces a diaphragm or plunger over a given length within the pumping chamber. Via the hydraulic opening and closing of the internal inlet and outlet check valve, this accurately displaces a continuous injection of the liquid to the process, the amount of which can be adjusted either manually or automatically. Typically, these pumps are driven by AC motors. Plunger designs have a static seal on the plunger, which is subject to leakage and must not run dry. These designs are suitable for higher pressures. On the other hand, diaphragm designs are sealless, which can be very important when pumping hazardous or expensive fluids. These pumps are capable of running dry. Hydraulically actuated diaphragm This type of metering pump combines the benefits of the sealless construction of the mechanical diaphragm pump with the higher pressure capabilities of the plunger metering pump design. The diaphragm is hydraulically coupled to the plunger so that the plunger displaces oil within a cavity, which in turn displaces the diaphragm. This design requires a positive flooded suction and normally features an
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inbuilt pressure release valve for pump protection. Electromagnetic (solenoid) diaphragm In this metering pump design the diaphragm is displaced by energising/ de-energising the restricted movement of a plunger within a solenoid coil. The plunger is mechanically linked to a diaphragm that displaces the liquid volume on a noncontinuous (on/ off) principle. Capacity adjustment is achieved manually or by a range of direct automatic input signals. Electronic diaphragm Based on the same principles as the mechanically actuated metering pump, this design incorporates both manual and electronic control features similar to the electromagnetic metering pump by varying the “off period” of time of a single phase AC motor.
Selection of metering pumps Different types of metering pumps demand different approaches for selection. Simple low-cost off-theshelf solenoid pumps can generally be selected from tables in catalogues. However, more demanding applications are best referred to the manufacturer or distributor.
Characteristics of metering pumps After accuracy, one of the most important characteristics of metering pumps is capacity control. A metering pump’s capacity adjustment system should fulfil the following requirements: • Ease of operation
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PUMP HANDBOOK
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 continue our detailed look at selecting and applying different types of positive displacement pumps.
Flexible vane pumps are commonly used in the pharmaceutical industry.
• Adjustable while pump is in operation • Accurate repeatable settings • Maintain consistent output over a long period of time There are various types of capacity control, including manual, electrical and pneumatic. It is also important to note that no matter how well designed and manufactured the pump is, it may not give satisfactory service if it is not installed correctly. Careful consideration should be given to: • The pump location • Piping and accessories • Priming • Back pressure, relief and isolating valves • Suction strainers, pressure gauges, piping layout
Common applications for metering pumps Metering pumps are used to pump a wide range of chemicals in a diverse range of industries. The type used depends on many factors including duty cycle, required metering accuracy, and the nature of the liquids handled. Common applications include, but are not limited to: Light duty • Fertilisers and nutrients in farming and commercial nurseries Medium duty • Food and additives in food manufacturing, dairies and wineries • Dyes in the textile industry • Chemicals in municipal water and
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sewage treatment Heavy duty • Petrochemical industry • Pulp and paper manufacturing • Mining and mineral treatment
Vane pumps Vane pumps are available in a number of vane configurations including sliding vane, flexible vane, swinging vane, rolling vane and external vane. Each type of vane pump offers unique advantages. In one of the most common sliding vane designs, a rotor with radial slots is positioned off-centre in a housing bore. Vanes that fit closely in rotor slots slide in and out as the rotor turns. Vane action is aided by centrifugal force, hydraulic pressure, or pushrods. Pumping action is caused by the expanding and contracting volumes contained by the rotor, vanes and housing. Vanes are the main sealing element between the suction and discharge ports and are usually made of a non-metallic composite material. Rotor brushings run in the pumped liquid or rotors use roller bearings isolated by seals. Despite the different configurations, most vane pumps operate via the same general principle: 1. A slotted rotor is eccentrically supported in an eccentric cam. The rotor is located close to the wall of the cam so a crescent-shaped cavity is formed. The rotor is sealed into the cam by two side plates. Vanes or blades fit within the slots of the impeller. As the rotor rotates and
fluid enters the pump, centrifugal force, hydraulic pressure, and/or pushrods push the vanes to the walls of the housing. The tight seal among the vanes, rotor, cam, and side plate is key to the good suction characteristics common to the vane pumping principle. 2. As the rotation continues, the cavity volume increases, allowing fluid into the pumping chamber through holes in the cam. 3. As the rotor continues around, the vanes sweep the fluid to the opposite side of the crescent where it is discharged through the discharge holes of the cam as the cavity volume decreases. Fluid then exits the discharge port.
Characteristics of vane pumps While vane pumps can handle moderate viscosity fluids, engineered non-metallic vane materials make these pumps well suited to handle low viscosity, non-lubricating liquids such as LP gas, ammonia, solvents, alcohol, fuel oils, gasoline, and refrigerants. Vane pumps have no internal metal-to-metal contact and self compensate for wear, enabling them to maintain peak performance on these non-lubricating liquids. Efficiency drops quickly as viscosity increases above 200 centipoise, but they can be used up to about 10,000 centipoise. Vane pumps are noted for their dry priming, ease of maintenance, and good suction characteristics over the life of the pump. The pumps can usually handle
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PUMP HANDBOOK fluid temperatures from -32°C to 260°C and differential pressures to 15 bars (higher for hydraulic vane pumps).
Common applications for vane pumps Some common applications for vane pumps include: • Transport tanker services of petroleum products • Pumping fuels, lubricants and refrigeration coolants in the auto industry • Bulk transfer of LPG and ammonia • LPG cylinder filling • Aerosols and propellants • Alcohols and solvents • Refrigeration Flexible vane pumps The design of flexible vane pumps is much simpler than the sliding vane design. These pumps use a flexible (usually rubber) impeller instead of a separate rotor and sliding vanes, and a simple eccentric casing with a single inlet and outlet port instead of a double wall casing with holes in the cam. These pumps are usually only available in small sizes and for low heads. They create a very good vacuum but can only handle very small solids. A wide range of available casing and rotor materials, as well as many different elastomers for the flexible vane, mean these pumps can be used in a broad range of industries. The pumps are either belt-driven or direct-coupled to motors. Magnetic drives units are also available. Common applications for flexible vane pumps include: • Pumping engine cooling water • Marine bilge pumps • Food, beverage and pharmaceuticals • Chemicals and paints
polyamide reinforcing layers, thick walls, and are capable of handling differential pressures to 15 bars. Tube pumps use tubing with thinner walls and can generally handle pressures up to 4 bars. The stiff, reinforced walls of the hoses used in hose pumps mean greater force is needed to occlude the hose. This means a bigger pump and motor is required for a given flow rate for a hose pump compared to a tube pump. As a result the hose pump requires more power to run. In these higher pressure designs, the hose and the shoe mechanism operate in a glycerin bath to reduce friction on the hose and dissipate the heat caused by its compression. When operating a peristaltic pump, liquid is trapped between the shoes or rollers. As the shoes move across the hose, the hose is occluded, pushing the liquid along. The hose behind the shoe or roller recovers its shape, creating a vacuum and drawing more fluid in. Flow rate is determined by multiplying speed (rpm) by the volume of trapped liquid. The volume moved is consistent, even under a wide range of viscosities or densities. The flow rate is therefore directly proportional to the gearbox speed.
Selection of peristaltic pumps After selecting a suitable size for the flow pressure and duty condition (continuous or intermittent), speed and power can be read from a performance chart. However, hose life and materials are critical for the successful application. It is recommended that the final selection is done by the manufacturer or authorised representative.
Peristaltic pumps
Characteristics of peristaltic pumps
The term “peristaltic pumps” refers to hose or tube pumps. Although there are specific differences between hoses and tubing, these terms are generally used interchangeably. Peristaltic pumps are self-priming rotary positive displacement pumps that consist of three major parts: hose or tubing, housing, and rotor. The hose is located in the tubing bed between the rotor and housing. The rotor has a number of “rollers” or “shoes” attached to the external circumference. Generally hose pumps have
Essentially, the main wearing part of the pump is the hose. This is both a strength and a weakness. If properly and conservatively selected, the hose, and therefore the pump, will give long operating life between overhauls. But if care is not taken, hose life can be short. Hose life depends in a range of factors: • The amount of squeeze applied to the hose affects pumping performance and the hose life. More squeezing decreases the hose life dramatically, while less squeezing decreasing pumping efficiency, especially at high
pressures. Therefore, the amount of squeeze becomes an important design parameter. • Mechanical capability is a function of hose material and the number of times the hose is squeezed. Therefore, pump speed is a significant factor in hose life. • The hose needs to be elastomeric and maintain the circular cross section after millions of cycles of squeezing in the pump. Different hose materials have different mechanical flex lives. The most common hose material is natural rubber. • Chemical compatibility. As the pumped fluid only makes contact with the inside of the hose, the only compatibility to worry about in a peristaltic pump is that between the hose materials and the fluid. • The implications of temperature should also be considered. The normal rated temperature for hose pumps is 40°C. Normal maximum temperature is 80°C, subject to adjustments to either maximum pump speed or maximum discharge pressure. The key advantage of peristaltic pumps is the sealless design with no moving parts in the pumped fluid. Discharge pulsations are low, selfpriming is good, the pump can handle high viscosities, and capacity accuracy is maintained for good process control. The pumps can be run dry. Performance on high concentration, high SG abrasive slurries is good. Because of the requirement to keep running speed low, the pumps tend to be large and relatively expensive. Capacities generally range up to 90 m3/h with pressure 16 bars.
Common applications for peristaltic pumps Common applications for peristaltic pumps include, but are not limited to: • Mining slurry transfer • Thickener underflow • Reagent dosing • Wastewater containing fibrous materials, fillers, chemical residues • Sludge transfer • Filter press feed • Printing inks • Laboratory and pharmacy applications such as blood transfer and product dosing
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 pumps.
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PUMP PIONEERS
Ted Beesley Ted Beesley began his career as an accountant before joining his family’s pump company as an accountant/junior sales assistant. Since then Ted has had a long and successful career in pumps, working with companies such as Brown Brothers and Engineered Products Group (EPG), as well as running his own company, Pumpserv. Here, Ted reflects on his career in the industry and how the industry has changed. A family in pumps We originally came from Adelaide where dad was Manager of FR Mayfield electrical contractors. He took on a Kelly & Lewis agency to obtain work such as pumping stations on Mannum-Adelaide and Mannum-Whyalla pipelines. Kelly & Lewis poached dad from Mayfield in late 1960 and we moved to Sydney so dad could take up his role as NSW Manager. He left two years later and got involved with Sykes Pumps while manager for Coates Hire. He tried to convince Coates to start hiring out Sykes pumps but they weren’t interested, so he started KAB Projects.
From accounting to pumps I first joined the pump industry in September 1968. Originally, I studied accountancy at North Sydney Tech College. I worked for a chartered accountancy company for two years and as accountant to a plywood company. At 21, I was drafted into the army for National Service. I was fortunate to attend Officer Training School at Scheyville and graduated as a Second Lieutenant. I was posted as Stores Officer to 133 Signal Squadron at Kingswood in Western Sydney. This afforded me very good management experience as I was 2IC of the camp. After two years national service, the plywood company had changed hands so my father suggested I work for the family pump company, KAB Projects. I started there as accountant/junior sales. Our initial main products were Worthington pumps, Forrer sewage pumps, Grundfos
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pumps, and Sykes pumps. My father left KAB Projects a year later after attending a board meeting at Sykes Pumps UK. He returned to Australia as a Director of Sykes UK with the power to start Sykes Australia and teach Malcolm Cramb to take over as Manager once the business reached $3 million yearly turnover. This took three years. During those three years I did almost everything at KAB Projects, and each night sent a bag of questions home with mum, for dad, and she would bring back answers the next day. It was virtually a pump sales course by correspondence. I wished I could have been able to plug a computer into dad’s brain and download his pump knowledge.
Growing the market in New South Wales I was instrumental in getting Grundfos established in New South Wales as dad knew Ray Pank in Adelaide very well from their electrical days. We were sole New South Wales distributors for about 10 years then received a commission for all units sold in New South Wales for a few years more. Our factory was in Hornsby but we installed all over New South Wales, Queensland and Victoria. We started importing, with customs duty of 25 per cent (10 per cent developing countries), from Sakuragawa, Kirloskar, Vogel, Emu, SEEPEX, Roto, Hermetic-Lederle, Pompe-FBM, Apollo, Hidrostal, Gorator and more. This period saw intense training in pump application and sales.
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Starting a business In 1979, KAB Projects went into receivership so I bought the Sakuragawa Agency with assistance from contacts in Newcastle and traded on as Kabpro Sales. Part of the deal was I had to spend time in Newcastle and teach them about pumps. In 1985, I sold Kabpro Sales to Malcolm Thompson Pumps and stayed on as NSW Manager and Sakuragawa Product Manager for nine years. This was MTP’s first venture outside of Western Australia. We were essentially an importer of Varisco and Sakuragawa, but were also responsible for about 20 per cent of all Grundfos sales in New South Wales. We had a team of five external and four internal sales staff plus six in workshop and four in office. Malcolm Thompson brought in a new management team in 1994 and although they wanted me to stay I decided it was time to move on. So I returned to Pumpserv, a company started years previously by myself and Ron Maher, but by this time was owned by myself and my wife Melanie. This was the perfect platform for continuance, as many people were coming to me for pump assistance, and it just grew. We tried to get a Grundfos account but they would not grant one as their other distributors knew too many customers would flock back to me. I then approached Brown Brothers and started selling Lowara with good success.
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PUMP PIONEERS Brothers in June 2000 and told him he needed me. I worked as NSW State Manager for six years, and we had great success expanding the Lowara/Goulds/ Hydrovar products throughout New South Wales. In April 2006, I returned to manage Pumpserv, where my wife and son had done a great job, but Melanie wanted a break. During my absence they had commenced stainless steel base, manifold and shroud manufacturing, and this has continued to grow to the point where we are manufacturing for Franklin, Xylem, Aline, KSB, Hydro Innovations, DP Pumps, Grundfos, Skyline, Doyles, BKB, GT Water, and more.
A lifetime of contacts
An early photo of Ted with his daughter Heidi, wife Melanie and son Lincoln.
A hands-on pump career After three years I went back into the larger pump world as NSW Manager of Engineered Products Group (EPG). Melanie and our son Lincoln took over running Pumpserv.
Two years at EPG taught me I needed a more hands-on pump life, as looking after the four divisions at EPG left little time for customer contact, it was constant paperwork. I approached John Inkster at Brown
The pump industry has been very good to me, and has given me lifetime contacts. I really enjoy what I do, particularly more so now, as people come to me for answers. The industry has also given me contacts overseas which have helped greatly. I have worked with pretty much every pump company in Australia over the years and many overseas companies. They have all, in some way, contributed to my life. Without a doubt, my biggest mentor was my father. He provided me with a lot of pump knowledge, but
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 PIONEERS
It’s not just the pump industry which is doing this, but the personal contact between salesman and customer is being lost. One of my major complaints is when I ring a company for some quick answers only to be told everyone is in a meeting and someone will ring back later. I’m still heavily involved in the pump industry. Pumpserv has a good business in stainless steel base, manifold and system building, plus we re-sell many brands of pumps to irrigation, motor rewinders, and building services, as well as service work in golf courses, and power stations. Our claim to fame is the written knowledge we have of a vast range of pumping equipment, which is why people come to us for answers. We also import a range of air blowers (Hiblow from TTC Japan) for the septic tank and aquarium industries.
Imparting knowledge Ted and his wife Melanie in Venice.
more importantly, business ethics. He was what I now describe as one of the gentlemen of the pump industry.
A changing industry When I started in the pump industry it was essentially only selling Australian made products, but now it is virtually all imported, which is a great shame as we no longer have the engineering expertise that was so valuable to my learning. The most memorable moment of my career was my first business trip overseas in 1978. It really opened my eyes as to what was available in the world. I was away for seven weeks and visited Japan, Europe, England and India.
Since then, many trips (including Japan every two years) have consolidated this view that we need more knowledge. The most significant development I have seen is the loss of Australian manufacturing, but now, more importantly, the loss of sufficiently trained people in the industry. I’ve always sent new staff to training schools, where possible, and feel that doing this would benefit more people. Unfortunately, some larger multinationals are reverting to salespeople in a one-off location and these people do not necessarily fully understand what they are selling.
The biggest challenge for the pump industry is to get younger people involved. To do this some of us need to impart more knowledge so the industry can thrive. These young people need to absorb any knowledge on offer and attend meetings, training, trade shows, etc. But the best learning by far is at the site of the pump. One of my greatest pleasures in the pump industry is to see people who have worked for me advance themselves. I know that a small company is a stepping stone for many people and I am only too happy to help people advance. I have been criticised in the past for helping staff find a job stepping up the ladder, but I think it’s wrong not to help. These people have always appreciated it and helped me in the future. One
Specialising in custom design, manufacture, repair and service of centrifugal pumps for over 30 years •
UNITED PUMPS
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www.unitedpumps.com.au T: +61 3 9464 9500 31 Western Avenue, Sunshine Victoria 3020, Australia E: unitedpumps@unitedpumps.com.au
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pump industry | Winter 2017 | Issue 20
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PUMP PIONEERS
Three typical build jobs from Pumpserv.
thing I tell everybody who is looking for advancement is do not burn bridges behind you.
From pumps to golf My wife Melanie and I met before the National Service, but we got engaged and married while I was in the Army. We have been happily married for 49 years and have two children, Lincoln and Heidi. Melanie and I love travelling and are also keen golfers. We play regularly and are members of Avondale Golf Club. I played rugby for 21 years (from ages 16-37) for Lindfield Rugby Club and am now a life member of NSW Waratahs, so we also go to quite a few major rugby matches. We have also lived in our current house for 45 years and the garden is a credit to Melanie, while I enjoy the role of labouring assistant with mowing duties.
Typical build job from Pumpserv.
Lowara has an extensive range of pumps and pressure systems suitable for commercial buildings, homes, general industries, agriculture and irrigation. Reliable, high performance, quality materials, and the widespread Lowara support network make these pumps an ideal selection for your water supply requirements.
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Ph: 1300 4 BBENG www.brownbros.com.au
DELIVERING PUMPING SOLUTIONS pump industry | Winter 2017 | Issue 20
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PUMP SCHOOL
When to use a positive displacement pump The choice between a centrifugal and positive displacement pumps is not always apparent and cannot be made without a full understanding of the differences. The fundamental difference is that positive displacement pumps, with the exception of air operated diaphragm pumps, are basically constant volume machines where flowrates are independent of pressure. Flow is dependent only on shaft revolutions per minute.
T
he performance chart (Figure 1) illustrates this difference. The centrifugal has varying flow depending on pressure or head, whereas the PD pump has more or less constant flow regardless of pressure.
Viscosity impacts on pump performance in very different ways. Figure 2 shows how centrifugal pump performance reduces markedly as viscosity increases. It also shows that with a positive displacement pump, higher viscosity increases the flowrate. The reason for this is that slippage (flow back towards suction because of differential pressure) reduces with increased viscosity. The volumetric efficiency of positive displacement pumps increases with increased viscosity.
Figure 1.
Figure 2.
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pump industry | Winter 2017 | Issue 20
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PUMP SCHOOL
The pumps behave very differently when considering mechanical efficiency as well. By looking at the efficiency chart (Figure 3) you can see the impact of pressure changes on the pump’s efficiency. Changes in pressure have little effect on the PD pump but a dramatic one on the centrifugal.
Figure 3.
Another consideration is NPSHr. In a centrifugal the NPSHr varies as a function of flow, and flow is determined by the system resistance (total dynamic head). If the total head varies for any reason, the flow will change and NPSHr will also change as a consequence. In a PD pump NPSHr varies as a function of flow which is determined by speed. At a fixed speed the flow is constant irrespective of pressure and therefore NPSHr is constant. When comparing the two types of pumps, it is important to understand that a centrifugal pump has an ideal operating flowrate i.e. the flowrate at the best efficiency point. At flowrates other than best efficiency flowrate, other factors need to be considered. Radial loads (the load that applies a bending moment to the shaft) increases at all flowrates other than that at best efficiency. With a PD pump you can operate the pump on any point of the curve. In fact the volumetric efficiency actually improves at the high speed part of the curve. This is because the volumetric efficiency is affected by slip, which is essentially constant regardless of speed. At low speed, the percentage of slip in relation to volumetric displacement is higher than at high speed. The data presented in these charts is the actual data for a specific application. The centrifugal was picked at its best efficiency point (BEP) and the PD pump (internal gear) selected to match the flow, viscosity, and pressure. Different applications will have different curves and efficiencies. These curves are presented as an example of the type of
performance behavior between the two different principles. The most obvious reason to use a PD pump is when you have a high viscosity application. It is common knowledge that a centrifugal becomes very inefficient at even modest viscosity. The acceptable viscosity ranges for centrifugal pumps tends to be dependent on pump size. Published data is also variable in this area. We believe that acceptable viscosity limits for centrifugal pumps is as follows for nominal discharge pipe diameters: ≤ 50mm – up to 100 mm²/s ≤ 150mm – up to 250 mm²/s > 150mm – up to 400 mm²/s However, there are other reasons to select a PD pump over a centrifugal other than high viscosity. These can be summarised as follows: • A simple rule of thumb is that a PD pump should be selected where the smallest available centrifugal pump needs to operate at a flow less than 50 per cent of best efficiency flow. • PD pumps may be a more appropriate selection at low flow, high head applications. • A PD pump would be used on applications that have variable pressure conditions • The flowrate from centrifugal pumps will vary up and down the performance curve which can cause process problems. A PD pump will give near constant flow at constant rpm regardless of pressure fluctuations. That makes it possible to match the flow to the system process requirements. • Hence, PD pumps are ideal for constant flowrate applications. The desire to have constant flow is a reason that a PD pump is normally selected for metering or dosing applications. • Generally speaking centrifugal pumps tend to shear liquids more as speed is increased and the centrifugal is a high speed pump. This makes certain PD pump types better able to handle shear sensitive liquids. Shear rates in PD pumps vary by design, but some are low shear devices, especially at low speeds. It is important to contact the manufacturer for specific information on PD pump shear rates and application recommendations. • By their nature, many PD pumps are self-priming, unlike end suction or multistage centrifugal pumps i.e. PD pumps will operate on suction lift without the necessity for a foot valve or a priming chamber on pump suction. This capability can vary from pump to pump so manufacturers’ recommendations must be followed.
Article courtesy of Kelair Pumps Australia “When Pump Knowledge Matters” Phone: 1300 789 466 or visit www.kelairpumps.com.au
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pump industry | Winter 2017 | Issue 20
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ADVERTISERSâ&#x20AC;&#x2122; INDEX ABB Australia............................................ 30 Action Aquatics........................................ 10 Adelaide Control Engineering............. 41
SPRING 2017
AIMEX.......................................................... IBC
Deadline: 22 September 2017
Angus Flexible Pipelines....................... 53 Aqseptence Group.................................. 60
MAIN FEATURE
Energy efficiency
Also featuring
Smart pumps Training
Plus the 2018 Industry Capability Guide
ASM Pumps............................................... 9 Australian Pump Industries.................. 12 Automation Direct.................................. 61 Barron-Auma Australia.......................... 69 Blacoh Fluid Control............................... 13 Bonfiglioli Transmission........................ 43 Brown Brothers Engineers............... 47, 73
SUMMER 2018
Caprari Pumps Australia....................... 45
Deadline: 24 November 2017 MAIN FEATURE Also featuring
Deutz Australia......................................... 1
Oil & Gas State of Industry survey Valves Fire Power generation
Ebara Pumps Australia........................... 23 Elaflex Pacific............................................ 29 Franklin Electric....................................... 6 Goodwin Submersible Pumps............. 51 Green Process.......................................... IFC Hatz Diesel................................................. 32 Hayward Flow Control............................ 15
AUTUMN 2018
HE Brehaut (Hebco)................................ 71
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Hydro Australia......................................... 65
MAIN FEATURE
Water
Also featuring
Seals Motors & drives Food Irrigation
Hydro Innovations................................... 18 Kelair Pumps Australia........................... 49 KCES............................................................. 33 KSB Australia............................................ 11 Kubota......................................................... 25 Laserbond.................................................. 7 Pentair......................................................... 58
WINTER 2018
Pioneer Pump............................................ 59
Deadline: TBA
SEEPEX........................................................ 8 Shakti Pumps............................................ 27
MAIN FEATURE
Mining
Also featuring
Coal seam gas Wastewater Recycling
Sulzer Australia........................................ 37 United Pumps Australia......................... 72 Victaulic Australia .................................. 20 WEG Australia................................... 21, OBC Weir Minerals............................................ 3
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29 – 31 AUGUST 2017
ASIA-PACIFIC’S INTERNATIONAL MINING EXHIBITION
AIMEX WILL FEATURE: ▶ The largest showcase of suppliers both locally and internationally
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Asia-Pacific’s International Mining Exhibition Sydney Showground, Sydney Australia For more information visit aimex.com.au