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MPTSee the Value ofMechanical Seal

Energy Audits

How to Save a DyingSeptic System

Internal Gear Pumps inIndustrial OperationsProviding Solutions for the Worldwide Pump Industry

www.modernpumpingtoday.com

Modern Pumping Today®

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CONTENTS

www.modernpumpingtoday.comP.O. Box 660197 | Birmingham, Alabama 35266


No part of this publication may be reproduced or transmitted in any form or by anymeans, electronic or mechanical, including photocopy, recording, or any informationstorage-and-retrieval system without permission in writing from the publisher. Theviews expressed by those not on the staff of Modern Pumping Today, or who arenot specifically employed by Highlands Publications, Inc., are purely their own. AllIndustry News material has either been submitted by the subject company or pulleddirectly from their corporate website, which is assumed to be cleared forrelease. Comments and submissions are welcome, and can be submitted to jay@modernpump ingtoday.com.

For information about advertising, call

205.795.0245

14

CHRIS GARMON

CFO

DONNA CAMPBELL

VP, Editorial

TIM GARMON

CEO/President

RUSSELL HADDOCK

COO/Publisher

www.highlandspublications.com312 Lorna Square | Birmingham, Alabama 35216

T: 866.251.1777 | F: 205.824.9796

@ModPumpMag

JEFF FLETCHER Publisher

[email protected]

J. CAMPBELL Editor

[email protected]

MICHELLE SEGREST Editorial Consultant

SCOTT GORDON Art Director

[email protected]

LISA AVERY Assistant Art [email protected]

TONYA BROWNING Associate Publisher

[email protected]

DAVID MARLOW Account Executive

[email protected]

INGRID BERKY Admin Assistant

MPT

EDITORIAL ADVISORY BOARD:

Terry Bell Product Manager, Baldor Electric Company

Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting

Robert G. Havrin Director of Technology, Centrisys Corporation

Michael Mancini Consultant and Trainer, Mancini Consulting Services

John M. Roach Engineering Manager for New Product Development, Trebor International,Inc.: A Unit of IDEX

Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt

Frank Knowles Smith III Executive Vice President, Blacoh Surge Control

Greg Towsley Director of Regulatory and Technical Affairs, Grundfos

Trey Walters, P.E. President, Applied Flow Technology

32

28

A NOTE ON THIS ISSUE:

Very soon many of us will welcome small visitors to our

doorsteps bearing the familiar greeting “trick or treat,” butfor process pump users—especially those at refineries

and petrochemical plants—one trick they are on watch for

throughout the year is energy loss due to mechanical seal performance. To that end, we’re proud to offer a treat in this

issue: The first instal lment of a four-part series by Tom Groveand Heinz Bloch on the value of mechanical seal energy audits.

With new performance regulations soon taking hold across the

industry, the need for energy efficiency—and monitoring that

efficiency—has never been greater.

Another treat: This issue’s “Pumping Trends” features

a conversation with Aaron Zahn, the president and CEO

of Florida-based NuTerra. His company has a compelling vision to transform thewastewater and organic waste industry in response to the growing global water crisis.

In a relatively short time, NuTerra has been able to deliver an impressive 100 percent

success rate on a lifecycle basis for its client facilities.

Finally, I’d like to extend a thank you to all of the people who stopped by the MPT

booths at the recent TPS and WEFTEC shows. It was a pleasure seeing both familiar

and new faces of our friends and partners in the pump industry.

J. Campbell, Edito r

Modern Pumping Today

http://www.mpt.com/http://www.mpt.com/http://www.mpt.com/https://www.linkedin.com/company/modern-pumping-todayhttps://www.facebook.com/Modern-Pumping-Today-262372740522483/https://twitter.com/ModPumpMaghttp://www.mpt.com/http://www.mpt.com/http://www.mpt.com/

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INDUSTRY NEWS

TRADE SHOW PROFILE

CASE STUDIES

WATER & WASTEWATER SOLUTIONS

MAINTENANCE SOLUTIONS

PUMP SOLUTIONS

DEWATERING SOLUTIONS

MOTOR SOLUTIONS

POWER GENERATION SOLUTIONS

PROCESSING SOLUTIONS

VALVES & CONTROLS SOLUTIONS

SEALING SOLUTIONS

MODERN PUMPING PRODUCTS

PUMPING TRENDS

14 From Fresh to Frozen... Fast

16 Electrical Signature Analysis

12 POWER-GEN INTERNATIONAL 2015

6

52 Featured Product Release: GRIFFCO VALVE Y-Strainers for Chemical-Feed Systems

20 North Las Vegas Wastewater TreatmentPlant Upgraded

22 Peach Lake Finds a Solution fora Dying Septic System

Part 1 of 2

28 Root Cause Analysis: The Justification Game Part 2 of 2

30 Reliability Starts from the Ground Up

32 The Benefits of Internal Gear Pumpsin Industrial Operations

Part 1 of 2

36 Copper Mine Quadruples Pump Wear Life

40 Reliable Energy Is Looking Up Down Under

56 The Growth of Big Green

46 Mechanical Seal Energy Auditsand Their Value

Part 1 of 4

44 Managing Assets, Saving Time

42 Minimizing Leaks and Environmental Hazardsfor Fluid Transfer

38 Turning Away from Tradition

OCTOBER 2015

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6 | October 2015 | Modern Pumping Today www.modernpumpingtoday.com

I N D U S T R Y N E W S

RELIABILITY CONCEPTS PURCHASES

ALIGNMENT SUPPLIES, INC.

Michael Olszewski, president of Reliability Concepts

based in Michigan is pleased to announce that RC has

recently purchased Alignment Supplies, Inc. based in

Maumee, Ohio. Alignment Supplies has been a provider of

machinery laser alignment and measurement equipment

for almost thirty years. This experience in distribution,

sales, and customer service, along with Reliability

Concept's expertise in the full spectrum of predictive

technologies and broader product line offering will

provide customers with a complete resource for al l of their

predictive, corrective, and preventive maintenance needs.

With this acquisit ion, Alignment Suppl ies, Inc. will now

be offering the Hamar Laser Instrument Stealth Series™

line of Laser Shaft Alignment systems. Stealth Series™

shaft alignment systems offer a full suite of features and

capabilities to meet the most demanding of alignment

scenarios.

Alignment Supplies, Inc. has off icia lly become the US

Master Distributor for the innovative B.A.T. Belt Alignment

Tool®. With national reach, the collective effort of our

merged resources will broadcast the proven concept of

the fast, Dual-Cross Firing Laser technology, which slashes

belt alignment time by 75 percent and eliminates errors

inherent with single laser and puck target systems.

GE’S WATER BUSINESS TO ACQUIRE

NETHERLANDS-BASED IMT SOLUTIONS

GE announced that it has agreed to acquire IMT Solutions,

a private Netherlands-based manufacturer of ultrafiltration

and microfiltration membranes for water treatment. With

IMT’s ultrafiltration membrane technology, GE will be

expanding and complementing its existing ZeeWeed

advanced ultrafiltration hollow-fiber membrane portfolio.

The acquisition of IMT will enhance GE’s water treatment

product offer ings and further GE’s commitment to

excellence in water treatment. GE will use its global reach

to take IMT’s membrane technology, integrate it with its own

and proliferate it across the world.

“Over the past twenty years, the ZeeWeed family has

grown and evolved to become the vast, industry leading

ultrafiltration membrane portfolio it is today. GE is

committed to continued technology advancements and

growth in water reuse, wastewater, and tough-to-treat

water technologies. The acquisition of IMT Solutions and its

polyethersulphone membranes will complement our current

offerings and offers terrific opportunities for further growth,”

says Heiner Markhoff, president and CEO—water and

process technologies for GE Power & Water.

Our technologies have great synergy and together will

be able to reach a broader market,” says Nico Marsman,

general manager, IMT Solutions.

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Modern Pumping Today | October 2015 | 9www.modernpumpingtoday.com

KSB ANNOUNCES NEW FOUNDRY

AT GIW INDUSTRIES INC.

GIW Industries Inc., the leader in the design, manufacture,

and application of heavy-duty centrifugal slurry pumps,

announces its foundry grand opening. The foundry is part

of a large expansion that includes a new distribution center,

additional heat-treat and casting cleaning facilities, CNC

machines, and an assembly center.

This expansion is one of the largest in the company’s

history and is the biggest project ever undertaken by GIW,

a fully owned subsidiary of KSB. The foundry construction

and related expansion projects are just the f irst phase in a

path of cont inuous investment for the company. Phase one

included the new foundry, which features 72-foot ceilings

and is about the size of a football field. These new facilities

will more than triple GIW’s current manufacturing capability.

Long term, this expansion will give GIW and KSB a

significant advantage in the mining market. The investment

will allow for better handling of the sizeable castings

needed by GIW’s customers; some produced by GIW

can weigh well over 40,000 pounds and are bigger than a

cement truck. This expansion will allow GIW to keep up with

current market demand and to be able to quickly adapt to

support future growth.

SMITH STEPS DOWN FROM VAL-MATIC

Val-Matic announces the retirement of Vice President of

Sales and Marketing Carl W. Smith. After a thirty-two-year

career with Val-Matic Valve and Manufacturing Corp., Carl

W. Smith wil l retire form the company on March 31, 2016.

Over his tenure, Mr. Smith opened new markets for

Val-Matic across the globe in international sales and later

became National Sales Manager. As Vice President of

Sales and Marketing he helped launch several new valve

products and buil t a successfu l representat ive network in

the water and wastewater industry. He also represented

Val-Matic for many years as a member and board member

of several industry organizations inc luding Water and Sewer

Distributors of America (WASDA), Water and Wastewater

Equipment Manufacturers Association (WWEMA) and the

American Water Works Association (AWWA).

President and CEO, Ted Makowan says, “Throughout

his career, Carl Smith has demonstrated an enduring

commitment to our Company and its mission to provide

quality products and service to our customers. His servicehas been important to the success of Val-Matic.”

CASHCO NAMES NEW VICE PRESIDENT

OF OPERATIONS

As par t of i ts plan for growth and future succession, Cashco,

Inc. recently promoted Darrin Vanderbilt to the position

of Vice President of Operations. Although Vanderbilt most

recently served as Engineering Services Manager, he has

assumed a number of responsibilities since joining Cashco

fulltime in 2005 as engineering lab manager. Ironically, his

history with the company goes back even further to when he

worked as an intern for Cashco, after growing up in nearby

Brookville, Kansas.

“Darrin has proven to be able to adapt to change quickly

and incorporate process improvements to both improve

the quality of our products and provide his group with the

proper tools to do the tasks easier and more eff icient ly,”

says Clint Rogers, president of Cashco, Inc. “With this

new position, all of manufacturing will now operate under

Darrin’s direction, while Quality Control will continue to

report directly to me in order to provide the checks and

balances ISO requires.”

Since returning to the area a decade ago, Vanderbilt has

since built a home for his family near his own boyhood

home in Brookville, where he and his wife, along with two

sons, manage to keep busy with school activities and sports.

DANFOSS

PARTICIPATES

IN SECOND

WHITE HOUSE

INDUSTRY LEADER

ROUNDTABLE

Danfoss participated

in an industry leader

roundtable hosted by

the White House to

reduce greenhouse

gas emissions from

hydrofluorocarbons

(HFCs).

Danfoss North

Amer ica President John Galyen provided an update on

the company’s ongoing commitment to a Codes and

Standards Task Force, which is helping address major

barriers in broad adoption of mildly f lammable, low-GWP

refrigerants. Galyen noted what the Task Force has already

accomplished and what it hopes to accomplish over the

next twelve months.

Additionally, Danfoss announced a mul ti-mill ion dollar

investment in a new Application and Development Testing

Center to increase the amount of available laboratory

capacity to help air conditioning and refrigeration

equipment manufacturers prepare to meet both energy

efficiency and refrigerant regulations, as part of the

company’s commitment to the adoption of low-GWPrefrigerants.

Other par ticipants included leading executives

from refrigeration and air conditioning equipment and

component manufacturers, refrigerant producers and

industry associations in a roundtable briefing of senior

White House off icia ls, including Depar tment of Energy

Secretary Ernest Moniz and Environmental Protection

Agency Administrator Gina McCarthy. The event was

moderated by Assistant to the President and Senior Advisor

Brian Deese, who oversees climate, conservation, and

energy policy.

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I N D U S T R Y N E W S

XYLEM’S GOULDS WATER TECHNOLOGY

FACTORY SCHOOL RELEASES Q4

TRAINING SCHEDULE

Goulds Water Technology announces its 2015 four th quarter

Factory School schedule for in-person and online training.

Live in-person training sessions are available at the

educational facili ty in Seneca Falls, New York. Classes

provide hands-on training in water systems, variablefrequency drives, wastewater and commercial applications.

This training is designed to provide attendees with

extensive, firsthand experience in the Campbell Education

Center laboratory.

The Commercial/Industrial Pump Product and Application

seminar will take place October 26 through 29, and the

Advanced Pumps and Drives Operations course will occur

November 9 through 12. Note that the latter course requires

participants to possess a minimum f ive years’ experience

with pumps and drives.

Online training is also available. These seminars provide

users with up-to-date product information, troubleshooting

support and industry knowledge. Training can be accessed

from anywhere with an Internet connection, and courses

are offered once per quarter to ensure availability for each

topic.

For a complete list of online courses, or to register for in-

person training, visit goulds.com/factory-school.

ENDRESS+HAUSER INTRODUCES CA80AM

AMMONIA ANALYZER

Endress+Hauser introduces the Liquiline System CA8AM

ammonium analyzer for monitoring critical control points

in water and resource reclamation facilities. The CA80AM

analyzer and its sample preparation systems provide an

automated approach to process control and regulatory

compliance.

To keep discharges at permitted levels and to avoid

penalties, managers of water t reatment and other

resource recovery facilities need accurate and reliable

measurements in their nutrient monitor ing systems. The

Liquiline CA80AM colorimetric analyzer provides these

measurements by using the standard indophenol blue

method, which is compliant to ISO 7150-1, DIN 38406-

5 and GB 7481-87 standards. The CA80AM analyzer

also provides data storage and retrieval using on-

board logbooks to allow continuous documentation for

reporting to regulatory agencies.

Multiple communications methods—including

EtherNet/IP, Modbus, Ethernet and an integrated web

server—allow the analyzer to be integrated into any

control system. The integrated web server allows a user

to remotely analyze process disturbances and decide

on required measures quickly, all through any web

browser. ◆

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T R A D E S H O W P R O F I L E

Power-Gen

International is

the world's largest

power generat ion event

focusing on the industry's

latest innovations,

technical trends, and

business strategies.

Presenting a broad

range of qualified power

professionals with the power to purchase, Power-Gen

International is the place not only to assess the direction

of the industry’s future but also to get business done

today! Throughout its history, Power-Gen International

has provided a global meeting space for the innovations,

ideas, and solutions that shape the industry now and in

the future.

THE PLACE TO BE

With a record-set ting

expected attendance of

more than 22,000 power

professionals from more

than ninety countries and

a show floor comprised of

more than 1,400 exhibiting

companies, there's no other

place to be for education,

networking, and new business development that the 2015

meeting of Power-Gen International. Attendees will hear

from more than 200 of the industry’s top speakers and

have access to more than fifty educational conference

sessions.

Events at Power-Gen International 2015 will also include

multiple Competitive Power College courses, networking

POWER-GEN

INTERNATIONAL 2015The industry comes together to charge into the future

POWER-GEN 2015 AT A GLANCE

Where: Las Vegas Convention Center,

Las Vegas, Nevada

When: December 8–10, 2015

Website: www.power-gen.com

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events, technical tours, as well as

online conference proceedings.

Power-Gen’s wide array of

offerings draws professionals from

myriad specialty fields, including

electric utilities, fuel suppliers,

independent power producers,

architects and engineers, original

equipment manufacturers, power

industry consultants, power plant

designers, equipment inspection

and repair specialists, construction

contractors, maintenance service

providers, and many, many more.

WOMEN IN POWER

LUNCHEON

A luncheon hosted by the Women

in Power committee that features

the 2015 Woman of the Year and

finalists. The Power-Gen Women

in Power committee selects a

Woman of the Year each year to

serve as a role model to inspire

young women to pursue careers in

energy. Luncheon attendees will

have the opportunity to network

with women in the power industry

and learn about the career paths

of some of the most successful

women in the industry. The winner

of the Power-Gen 2015 Woman of

the Year Award will be announced

during the Awards Gala on

Monday, December 7 at 6:30 pm.

AN INDUSTRY UNITED:

POWER GENERATION WEEK

Covering every aspect of the

power generation industry, Power-

Gen International, Nuclear Power

International, Renewable Energy

World Conference and Expo

North America, Coal-Gen, and

GenForum converge in 2015 toform Power Generation Week.

Benefit from five days packed

with pre-conference workshops,

technical tours, more than seventy

conference sessions, panel

discussions, three exhibition days

,and multiple networking events.

This unique collaboration provides

attendees with the chance to

access nearly every facet of the

market—all under one roof. ◆

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C A S E S T U D I E S

From Fresh to

Frozen… Fast

Pinguin Foods is a leading, international processor of

harvest fresh vegetables priding itself on delivering

fresh to frozen produce that are tasty, healthy, and

of the highest quality. Pinguin is an independent division

of the major European Food Group, Greenyard Foods,

which processes over 440,000 tons of product annually

over eleven production

sites. However, moving

food from fresh to frozen

requires solids handling

that is reliable, efficient,

and fast. Hidrostal Ltd.,

the UK distributor for

the major Swiss pump

manufacturer, has

provided an international

processor of fresh to

frozen vegetables with

the perfect pump for

passing peas.

MOVING FROM FIELD TO FORK

At Pinguin’s site in Boston Lincolnshire, the company

utilizes a field to fork approach that encompasses the

washing, de-stoning, separation, blanching, and freezing

of raw vegetables. Hidrostal’s “F” type pumps, ideally

suited for food processing, are employed to transfer the

field harvested peas

directly with the use

of recycled mains

water as the motive

media.

Pea season

typically runs from

June unti l August

where the produce

is being transferred

at a rate of up to

11 tons per hour

per line during this

period. The process

Hidrostal’s “F” pump passes peas for Pinguin

By Lucy Ogden, Hidrostal Ltd.

“Hidrostal’s pumps have proved

extremely reliable with minimal

maintenance required. They

need to be reliable otherwise

production stops.” —Barry Cooper,

Pinguin engineering stores manager

Pinguin’s food processing involves washing, de-stoning, separation, blanching, andfreezing of raw vegetables.

Pea processing at Pinguin

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involves peas picked fresh from the

fields which are then put through

an ongoing process to remove, silt,

stones, soil, and loose pods and

skins before entering the blanching

and freezing process.

KEEP IT MOVING, KEEP IT CLEAN

This solution allows the vegetable

produce to be pumped and piped

to its destination in favor of an

open belt conveyor system, which

under these open environment

circumstances would be susceptible

to contamination, debris, and product

loss. In addition it has the added

benefit of allowing Pinguin to retain

the main road through its premises

and not affect the traffic and transport

of product across its yard.

The Hidrostal pumped option was

selected due to its proven ability

to handle and transfer delicate

product with zero damage due to its

low velocity and low shear design

hydraulics while retaining optimum

efficiency and maximum energy

saving.

MORE THAN JUST PEAS

After pea season the same pumps

are then used to transfer cauliflower

and broccoli florets with the same

level of output and accuracy. These

pumps are critical to the successful

continuation of the entire production

cycle.

Both the client and the manufacturer

are delighted that their pumps

have functioned so well for Pinguin

and ensured the safe and speedy

processing of peas from production to

our plates. ◆

For more than thir ty years, Hidrostal

Ltd. has been at the forefront of

designing and delivering innovative

pump solutions that deliver real

benefits to business. For more

information, contact Lucy Ogden

at Hidrostal Ltd . via email at lucy.

[email protected] or visit

www.hidrostal.co.u k.

http://greatsouthernpump.com.com/http://naglepumps.com/http://gusher.com/mailto:[email protected]://www.acousticalsurfaces.com/

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Electrical SignatureAnalysis

Originally put into operation in 1999, Pump

Station P-19A supplies drinking water to

the City of Henderson, which is the second

largest city in Nevada. Serving a population well

over 270,000 people, P-19A is one of the most

critical potable pump stations operated by the city.

The pump station originally utilized three pumps

when its operation began, but in 2006, two more

vertical pumps were installed in the pump station

(Pumps 1 and 5).

CAUSE FOR CONCERN

In 2006, the pump size was increased, but the motor

horsepower remained the same. The motors have a

service factor of 1.15 and often exceed 105 percent

of nameplate full -load amperage (FLA). Although

this is within the capabilities of the motors, they

operate at near maximum output.

In November 2014, vibration analysis was

performed as par t of the plant’s Predict ive

Maintenance Program. While those test results

suggested the possibility of early bearing

degradation in Motor 5, the rotor bar passing

frequency was within range

The vibration summary concluded that systemswere operating within acceptable l imits and that

no maintenance actions needed to be taken at

that time.

Two months later, in January 2015, Motor

5 exhibited signs of overheating; reaching

temperatures that exceeded 320 degrees Fahrenheit

(160 degrees Celsius). Although the other pumps

did not show any symptoms similar to that of Motor

5, the maintenance team took action and initiated an

in-house investigation of all five pump motors using

their predictive maintenance equipment.

As performed on vertical turbine pumpmotors in municipal application

By William Kruger, All-Test Pro, LLC,

and Alex Panattoni, City of Henderson Dept. of Utility Services Electrical Section

The All-Test Pro 31 troubleshoots start-up and quality controlof AC/DC electrical motors, generators, or transformers.

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COMPREHENSIVE TESTING

TO PREVENT MOTOR FAILURE

The in-house maintenance team utilized their hand-held

All-Test Pro 31™ and All-Test IV Pro™. These high-tech

instruments, which are used for de-energized testing, are

designed to detect potential winding faults and provide

indications of rotor problems.

First, they used both the All-Test Pro 31™ and All-Test

IV Pro™ to perform winding tests and confirm that the

windings were in good condition.

Then they used this equipment to conduct ‘insulation

to ground’ tests to prove the insulation was not grounded.

Next, they performed a rotor inductance test, which

measures the inductance of all three phases of a motor

at different individual rotor positions. During the test, the

rotor is positioned at exact intervals, as seen in the picture

to the r ight.

The City of Henderson performed an extensive rotor

test—taking readings every 5 degrees of shaft rotation

using the All-Test IV Pro™—only then did indications show

an issue with both Pump 1 and Pump 5.

While the tests indicated the poss ibility of a rotor

problem, the results didn’t show the problem def initively.

Technicians knew the current was modulating and put a

time trace on it, but needed to do more extensive testing.

At the main tenance team’s request, a third-par ty

specialist went to the pump station to perform vibration

analysis. When the vibration analysis did not indicate

Vertical Turbine Pump Info

GPM 7400

# of Stages 5

Size 20x20 GHC-5

Suction Size 20-inches

RPM 1200 All-Test P ro 31™ for init ial tests Rotor Tested at 5-degree Intervals All-Test IV Pro™ for initial test

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any electrical faults (pole pass

frequency sidebanding) in the

associated vibration FFT signatures

the decision was made to bring in

technical support from ALL-TEST

Pro to perform additional testing.

An All-Test Pro technician

went to the pump station

in January to perform

an Electrical Signature

Analysis. Electr ical

Signature Analysis is a

diagnostic technology

that uses the motors

supply voltage and

operating current to

identify existing and

developing faults in the

entire motor system. To

perform the Electrical

Signature Analysis, he

brought with him the All-

Test Pro On-Line II™. The

ATPOL II™ is an energized

motor testing tool which,

when in ESA mode,

evaluates the condition of

incoming power, the control

circuit, the motor itself ,

and the driven load. Kruger

requested that MVA data be

taken simultaneously while the

Electrical Signature Analysis wasbeing performed.

ELECTRICAL SIGNATURE

ANALYSIS REVEALS BROKEN

ROTOR BARS

During the energized motor tests,

data was taken at different times;

first shortly after star t-up, then

again after the pump had been

running. Of significance was the

large change in rotor speed with a

very small change in motor load.

The rotor was running considerably

below name plate; after running

about thir ty minutes, the rotor

speed was 1171 rpm. This was

also confirmed by an independent

tach system provided by the third-

par ty who performed the vibration

analysis. While the results of the

vibration analysis did not show any

indications of rotor problems, the

speed and the ESA data taken with

the ATPOL II™ indicated that several

rotor bars were broken.

Rotor bars are solid continuous

bars that run through the rotor’s

steel laminations, which are

spaced to allow air f low to cool

the rotor. Once the maintenance

team received the report from the

Electrical Signature Analysis, which

showed severe indications of rotor

bar issues (Pump 1 had a severity

rating of 6 out of 7 and Pump 5 had

a severity rating of 7 out of 7), they

pulled Motor 5 and found that 30

percent of the rotor bars were in fact

broken.

REBUILDING THE ROTOR WITH

DIFFERENT METALLURGY

After discussing the issues with

the motor manufacturer and a third par ty motor repair company, the

maintenance team chose to have

both Motor 1 and Motor 5 rebuilt

with copper rotor bars. Pumps 2,

3, and 4 had copper rotor bars and

did not have the same issues as

Pumps 1 and 5. The original rotor

bars in Pump 1 and Pump 5 had

been made of aluminum. This was

believed to be the root cause of the

problem.

ALL-TEST PRO On-Line II

ESA Data from ATPOL II™

Pump 1 Pump 5

Pump Speed: 1183 RPM 1175 RPM

Demand Power: 738.98 HP 726.96 HP

Load: 100.7% 99.1%

Output Load: 507.95 KW 495 KW

Severity Rating: 6 out of 7 7 out of 7 Rotor bar breaks all occurred in the middle three rowsof laminations.

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W A T E R & W A S T E W A T E R S O L U T I O N S

North Las VegasWastewater TreatmentPlant Upgraded

Located within the greater Las Vegas metropolitan area,

North Las Vegas, Nevada, also sits in the majestic

Mojave Desert, which means that how the city treats

and manages its water supply is of premium concern. The

upgraded water reclamation MBR facility, one of the largest

in the United States, treats the municipal wastewater for more

than 300,000 of North Las Vegas’s residents and processes up

to 25 million gallons of wastewater per day.

MAKING THE LEAP

Earlier this year, GE provided the city with its high-

performance LEAPmbr membrane bioreactor (MBR)

technology for an upgrade to the city’s wastewater treatment

plant. By using GE’s LEAPmbr system, the c ity will reduce

its energy and maintenance costs including an estimated 29

percent reduction in membrane scour energy costs.

With GE’s LEAPmbr and ZeeWeed 500 membranes, the

newly upgraded facility can more efficiently treat the city’s

wastewater. Historically, the city of North Las Vegas relied on

the city of Las Vegas to treat its wastewater, but in 2012, North

Las Vegas built its own plant using GE ZeeWeed membranes

and MBR technology. The city then upgraded the facility with

LEAPmbr technology three years later to provide the same

treatment capacity and highly treated water quality while

reducing energy and maintenance costs and increasing

productivi ty.

SAVING GREEN BY GOING GREEN

“Environmental and economic concerns led us to upgrade our

wastewater treatment plant with GE’s LEAPmbr technology,

which provided us with a more energy-efficient and cost-

effective way to operate our facility,” says Dave Commons,

water reclamation facility administrator for North Las Vegas.

“The retrofit will give us a 29 percent energy reduction on

membrane aeration and will save more than $100,000 per year

in energy and maintenance costs.”

GE’s LEAPmbr technology providesreduced energy and maintenance costs

By GE Power & Water

Increased Surface AreaZeeWeed Module

Simplified Aeration Piping

No Air Cycling Valves

OptimizedTank Design Increased

ZeeWeedProductivity Lower Energy LEAPmbr

Aeration Technol ogyReduced Blower Size

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GE’s LEAPmbr aeration technology

provides optimal energy usage by

reducing membrane air scour costs

along with essentially eliminating

cyclic valve maintenance. In addition,

the plant’s advanced SCADA system

allows the city of North Las Vegas to

have minimal staffing at the plant and

the wastewater treatment facility can be

controlled remotely.

“LEAPmbr is our latest innovation

in membrane technology and

upgrading to it gives the city of Nor th

Las Vegas a more cost-effective and

energy-efficient method of aeration.

Additionally, LEAPmbr improves water

quality, increases water treatment

capacity and offers the lowest life

cycle costs available from any MBR

technology,” says Yuvbir Singh, general

manager, engineered systems—

water and process technologies for

GE Power & Water.

RETROFIT KITS PROTECT INITIAL

INVESTMENTS

Specifically for the project, GE

retrofitted the existing membrane

cassettes by supplying LEAPmbr retrofit

kits. This allowed the plant to take

advantage of the lower air and energy

requirements while continuing to get

the full lifecycle operation out of the

originally installed membranes.

LEAPmbr builds on tweny-five years

of experience to deliver the most

advanced MBR solution to date. At the

core of LEAPmbr is GE’s ZeeWeed 500

membrane, an advanced ultrafiltration

technology that separates solids,

bacteria and viruses from water or

wastewater. GE’s ZeeWeed ultrafiltration

membranes offer an unmatched

combination of performance, energy

efficiency, durability, ease of operation

and reliability. More than 1,000 plants

worldwide use this technology to

produce superior quality water.◆

LEAPmbr Technologyenables the City ofNorth Las Vegas tooperate the plantmore efficiently,

while increasing productivity.

GE Power & Water provides customers

with a broad array of power generation,

energy delivery and water process

technologies to solve their challenges

locally. Power & Water works in all

areas of the energy industry including

renewable resources such as wind

and solar; biogas and alternative

fuels; and coal, oil, natural gas and

nuclear energy. The business also

develops advanced technologies tohelp solve the world’s most complex

challenges related to water availability

and quality. Follow GE Power & Water

and GE’s water business on Twitter

@GE_PowerWater and @GE_Water.

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Peach Lake Finds aSolution for a DyingSeptic System

It only took a few generations and

several hundred dying septic

systems to age an idyllic vacation

spot like Peach Lake.

A CLOSER LOOK

AT PEACH LAKE

Fed for millennia by fresh flowing

springs—with no creeks or rivers

for drainage—a basin eventually

matured into a 1.5-mile long and half-

mile wide aquatic paradise originally

named Pechquenakonck by the

Kitawonks, a Mohegan group.

Around the dawn of World War I ,

vacation homes star ted to occupy the

pristine shoreline of what pioneer

Dutch farmers first named Peach

Pond; later, Peach Lake. Inevitably,

water quality deteriorated as the

reservoir's spring intake was

supplemented by wastewater flushed

from these summer bungalows

and cabins, equipped with septic

systems that only have a normal life

expectancy of ten to forty years.

By the 1990s, the problem of

wastewater—mostly during the peak

Memorial Day to Labor Day period—

was aggravated by the arrival of full-

time residents who were upgrading

once simple seasonal properties

in lakeside communities like North

Salem and Southeast into pleasant

abodes with additional bathrooms,

washing machines and dishwashers.

"Most of the people are here

year-round but we do have the 20

to 30 percent that are there in the

summer months," says Warren Lucas,

supervisor of the Town of North

Salem. "These communities grew

Part 1 of 2

By Joseph Harmes

Peach Lake is a quiet, private lake located in Putnam and Westchester counties in New York, about a ninety minute commute from Grand Central Terminal. Single-family homessurround the lake, consisting of both seasonal and full-time residents.

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up around the lake back in the 20s

and 30s and at this point we have in

some cases the second or third home

rebuilt on these properties."

Young families purchasing their

first houses, retirees and even work

day commuters to Grand Central

Terminal about ninety minutes away

further pushed Peach Lake's fragile

ecology to the brink.

THE PUSH TO IMPROVE

WATER QUALITY

A campaign to improve the water

quality of Peach Lake began over

forty years ago and gained traction

when the Citizens Statewide Lake

Assessment Program (CSLAP),

a volunteer lake monitoring and

education program, began sampling

Peach Lake's water in 1999.

Over the next decade, the project

found the "recreational suitability

of the lake to be unfavorable" and

"'slightly' to 'substantially' impacted

for most recreational uses" like

swimming and boating as failing

septic systems had a negative impact

on water quality.

CSLAP's reports noted "High

coliform counts (resulting in

occasional beach closures), along

with algal blooms and excessive

aquatic weed growth strangled

areas near the shores. The aquatic

growth may also depress dissolved

oxygen in the lake to the point where

the fishery may also be affected"

and storm events frequently led to

fish kills.

A wastewater study showing

eutrophication (an excess of nutrients

such as nitrates and phosphates) led

to Peach Lake's inclusion on New

York State's List of Impaired Waters.The situation was fully addressed in

2010 when a new sewage treatment

system was designed to replace the

area's 470 deteriorated septic tanks.

LOOKING FOR CAUSES

. . . AND SOLUTIONS

Engineers blamed the septic

failure on multiple origins. Scores

were situated too close to streams,

drainage ditches or the lake. Leach

fields at many properties were sized

to the original summer cottages and

not adequate for the additions or

newer homes; current regulations

require 5 feet between the septic tank

and groundwater. Significant numbers

failed percolation tests due to poor

soil conditions and shallow bedrock.

Executing the 2010 plan would be

no easy task as it required the input,

cooperation and approval of 1,000

citizens and four lake association

boards; the formation of sewer districts

which included inter-municipal

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projects, planners needed to win close coordination and

cooperation from homeowners for property visits, maps,

surveys, deed preparation, easement negotiations/

acquisitions and construction observation on private

proper ty.

Seemingly the biggest concern of residents was that

an adequate sewer system might increase the density of

homes or create condo development. It was agreed that

only existing land surveys would be acknowledged with

the caveat each home could be expanded or replaced

with one new structure.

North Salem and Southeast were divided into two

separate State Environmental Quality Reviews for

efficiency and less complication given the size and

impact of the project.

"I have 74 percent of the homes (360)," says Nor th

Salem's Lucas. "Southeast has 26 percent (120)."

The sewage treatment facility is owned in a 74-26

par tnership between the two towns.

In order to pamper local sentiment, the head works

and micro-filtration facilities of the Peach Lake Sewer

Treatment Plant (a small, mostly-automated facility

designed to process 170,000 gallons per day) are

housed in red and white buildings camouflaged to

mimic the ubiquitous horse barns synonymous with the

pastoral landscape. Alar m pane ls are located on the ou tside of t he home to a ler t the homeowner or ser vice

person about a problem.

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A LOOK AHEAD

Two sewer proposals were considered:

A gravity/low-pressure hybrid with

eight pump stations and a low-pressure

sewer system employing grinder

pumps at each home (or, where

housing is dense, a duplex pump

serving multiple dwellings). Next

month, we’ll conclude this case study

by exploring Peach Lake’s decision

and the benefits they discovered. ◆

With corporate headquarters in

New York and regional off ices

and distribution throughout the

industrial ized world, Environment

One Corporation (E/One) is a

manufacturer and provider of

products and services for the disposalof residential sanitary waste and

utility systems for the protection and

performance optimization of electric

utility assets. For more information,

visit www.eone.com.

E/One grinder pump stations (shown) can be buried on small lots. Only a few inches of green lid are visible to thehomeowner.

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M A I N T E N A N C E S O L U T I O N S

Root Cause Analysis:The JustificationGame

In last month’s introductory article,

we discussed some of the barriers

to selling not only the concept of

Root Cause Analysis (RCA) but also

the recommendations generated

as a result of these analyses. We

also laid the framework for making

better predictions by generating

and accessing better data—namely

predicting our Mean Time between

Failure (MTBF) and Mean Time to

Restore (MTTR) earlier and, therefore,

implementing a fix faster.

Given this background, let’s

explore how we can now justify

conducting a RCA and implementing

the recommendations as a result of

the analysis. By and far, conducting

a true RCA is viewed as luxury not a

necessity. Think about the objections

we hear when we offer the idea of

gathering RCA teams. What follows

is a list of common objections to RCA

accompanied by rational justifications

that any manager can employ.

OBJECTION: WE DO NOT HAVE

TIME TO DO RCA

We do not have t ime to do RCA

because we are so busy firefighting

that we do not have time to analyze

why the fires are occurring in the

first place or how to prevent their

recurrence. If this paradigm is

permitted to exist, then the conclusion

is that the best we can do is sharpen

our response time and accept that

the fires are a cost of doing business.

How much money is being accepted

as the cost of doing business? Hint,

how much is your maintenance

budget worth?


THE MONEY TO BACK A RCA

EFFORT

Maintenance budgets are pr imarily

developed to respond to failures that

are expected to occur. Man-hours

and materials are assigned and

budgeted. Therefore, if it is in the

budget, it is not a failure because we

have compensated for it. It is a cost

of doing business. This does not have

Part 2 of 2

By Robert J. Latino, Reliability Center, Inc.

See Part 1 onmodernpumpingtoday.com

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to be the case. Just as with safety, we

should have a zero tolerance policy

with failure. We should question

why the things in the budget are

acceptable and look at how to

eliminate failure.

Secondly, when failures occur that

are compensated for in the budget,

they oftentimes affect production

hours in terms of downtime. The cost

of a failure should be measured by the

man-hour dollars + material dollars

+ the lost production dollars. This is

a true measure of how much is lost,

and subsequently, how much is to be

gained. Just because a $50 bearing

fails, does not mean that it did not

cause $50,000 in lost production.


THE RESOURCES TO CONDUCT

RCA

However, it does seem that we

always have the resources to fix the

problems that occur daily. If we were

to support a RCA effort, the reactive

work would decrease over time,

as many problems would not exist

anymore. This would free up the time

of the people that we have as reactors,

and better utilize them in proactive

activities such as RCA, predictive

maintenance, etc.

OBJECTION: IMPROVEMENT

WORK CAN WAIT UNTIL

RESOURCES ARE AVAILABLE

If this is the prevailing attitude,

pack up your RCA bags because

these resources will never be made

available. This is where management

support is a must. We must make

accommodations in our work order

systems to effectively implement RCA

recommendations through assigningthem a higher priority. If this is not

done, then they are “back burner”

items and will likely never get done.

This will have resulted in a lot of work

on behalf of the RCA team and a lot of

cost in their wages while they were on

these teams. The larger impact will be

on the morale of the team, as they put

their best effort forward and no one

listened. This is where the program-

of-the-month paradigm originates.

THE VALUE OF THE INTANGIBLES

In the world of RCA, we must learn

the value of the intangibles and their

effect on the tangible world. This all

revolves around the dollar and all

aspects of the organizational system

are interdependent to optimize profits.

Here is a list of such intangibles:

• Lost profit opportunities —the

cost of a lost downtime hour on

the spot market at that time.

• World class analytical skills —

investing in our people’s skills

makes them better decision

makers and problem solvers. This

allows them to do things once

and do them right. How much

does it cost to replicate the same

activity over and over again?

• Teamwork —when people

work on RCA teams, they gain

an appreciation for how other

departments perceive given

situations. When this occurs, it

affects future decision making

because they tend to take into

consideration why people do

what they do. This empathy

results in a more synergistic

operation and a more educated

workforce.

• Morale —research shows that

failure rates tend to be higher

in organizations that have poor

morale. Why? Because when

our workforce feels alienated

their focus is distracted with the

emotional baggage they carry.

This distraction causes errors in

decision making which lead to

physical failures. By allowing theworkforce to demonstrate their

knowledge of how the process

works and to solve problems

utilizing their experience, their

morale is improved along with

their ownership over their work.

How much is this worth to the

organization?

These are just a few of the intangible

benefits of conducting RCA. Although

the returns from the tangibles alone

are self-justifying, imagine if we were

able to focus the creativity of the

workforce towards the betterment

of the organization. Remember, we

cannot do what we cannot imagine! ◆

Robert J. Latino is CEO of Reliability

Center, Inc. Mr. Latino is a practitioner

of root cause analysis in the field with

his clientele as well as an educator.

Mr. Latino is an author of RCI's Root

Cause Analysis Methods© training and

co-author of Basic Failure Analysis

Methods© workshop. Mr. Latino

has been published in numerous

trade magazines on the topic of root

cause analysis as well as a frequent

speaker on the topic at trade shows

and conferences. His most recent publication is titled "Root Cause

Analysis—Improving Performance

for Bottom Line Results." He can

be contacted at 804.458.0645 or

[email protected].

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M A I N T E N A N C E S O L U T I O N S

Reliability Startsfrom the Ground Up

A solid foundation is a proven way to increase the mean

time between planned maintenance for most types

of rotating equipment. Pump bases and foundations

constructed of polymer concrete provide many benefits

over their cast and fabricated metal counterpar ts. Often

referred to as a poly, granite, or mineral cast baseplate, this

material is a special combination of well-defined grain size

aggregates bound to a thermoset epoxy or vinyl ester resin.

Manufactured in a controlled environment during a transfer

molding process, these materials can be cast to precision

tolerances while offering the high mechanical properties

suitable for most industrial applications.

VIBRATION DAMPING

The polymeric matrix of the material provides damping

ratios 20-30 times greater per identical geometry than steel

or cast iron materials. Rotating equipment is often associated

with its stability under the inf luence of various disturbances

and polymer bases can effectively minimize vibrations

without the need to increase the mass size of the component.

PRECISION MOUNTING

Cast mounting surfaces are typically flat within 0.002 inches

per feet, which reduces soft -foot and speeds alignment.

Threaded insert holes are typically cast in place or

located with a CNC machine to insure precise location and perpendicular ity, which eliminates bolt bound conditions

often occurring with inexpensive metal bases. Difficult

to machine features can easily be cast in place. Thermal

expansion rates of most polymer concrete formulations are

considerably less than cast iron and maintain the consistent

alignment of equipment in a wider range of operating

conditions.

CORROSION RESISTANCE

Advanced resin systems along with inert natural aggregates

provide excellent protection from many fluids that would

otherwise require an expensive alloy or corrode standard

cast iron or steel. Polymer concrete systems eliminate the

need for additional protective coatings or periodic upkeep

and maintenance activities.

FASTER INSTALLATION

Polymer concrete baseplates will not twist, bend, or

diaphragm like most metal designs. This eliminates the need

for time-consuming field adjustment dur ing installation. Most

designs also incorporate threaded leveling inserts along with

a bottom surface ready for adhesion to grouting material

without modification or special preparation. Bases can either

be stilt mounted or grouted in place like a conventional

hollow design.

Outlining the benefits of polymerconcrete baseplates

By Scott Sapita, BaseTek, LLC

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Grouting a polymer concrete

baseplate requires considerably less

labor and mater ial. Grout volumes

are greatly reduced resulting in less

material and labor to pour. Greater

skill is often required in grouting a

hollow steel frame to insure all voids

are eliminated as grout is intended

to be in 100 percent contact with

the underside surface for proper

performance and vibration damping.

Since the solid pre-cast polymer

concrete base will maintain structural

integrity without requiring grout,

many potential installation errors can

be easily avoided. Stilt mounting a

polymer concrete assembly takes

advantage of the structural stability of

the mounting surface while allowing

the equipment to react to the forces

and moments of the piping system.

PROVEN RELIABILITY

In addition, polymer concrete mater ials

offer low levels of heat conduction,

act as an excellent electrical insulator,

are non-magnetic, and resist water

absorption. Mechanical properties

are suitable for most indoor-outdoor

environments found in the process

industries.

The proven reliability of polymer

concrete baseplates for rotating

equipment is rapidly expanding as the

features above continue to add benefit

for applications of most every shape

and size. By combining a consistently

flat, vibration damping structure that is

easy to install and maintain, polymer

concrete baseplates will continue to

be the choice of Reliability Personnel

worldwide. ◆

Scott Sapita is co-founder and

managing partner of BaseTek, LLC

in Middlefield, Ohio. Scott has over

twenty-eight years of experience

in the rotating equipment market

including product design, product

management and industrial sales. He

carries a BS in marketing from the

University of Dayton. Contact him at

[email protected].

MPT


WANT

TO

READ

MORE

Visit www.ModernPumpingToday.com today!

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SURVEYING THE OPTIONS

Industrial manufacturers have a wide

range of pump options to choose

from when outfitting their facilities.

There are also a number of factors

that go into their choice of pumping

technology. Operational reliability

and being able to meet very specific

fluid-handling requirements are

among the most important. With

manufacturing operations governed

by operating budgets and expenses,

equipment acquisition costs and

subsequent maintenance are also

primary concerns.

This article will illustrate that while

all pumping technologies can have

their positive points in industrial-

manufacturing operations,

positive displacement internal

gear pumps can offer the precise

and consistent transfer of highly

demanding fluids—in this case,

dangerous chemicals—that is

critical in creating a reliable,

efficient, cost-effective, and safe

pumping system.

No acid, polymer, resin, or caustic has the same handling characteristics, which makes pump versatility a primary concern for chemical processors. Maag G Ser ies Internal GearPumps overcome many handling concerns by featuring a method of operation that can successfully and safely transfer fluids of differing viscosities and chemical makeups.

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P U M P S O L U T I O N S

THE CHALLENGE OF

CHEMICAL PROCESSING AND

MANUFACTURE

Chemical processing and manufacture

is one of the most complex industrial

operations in the world. In fact, the

chemical-manufacturing process is so

intricate that there are several “unit

operations” within the process, from

cracking, distillation and evaporation,

to gas absorption, scrubbing and

solvent extraction, among others.

Within that family of unit operations,

one touches every stage of the

manufacturing process and stands out

above the others in its importance:

fluid transfer. Often over-simplified

as transporting fluid from one point

to another, fluid transfer in chemical

manufacturing is so much more.

Fluid transfer is a spectrum of

applications, with responsibilities

all along the chemical-production

chain. For example, thin or viscous

raw materials can be transferred

to storage tanks or blending and

mixing tanks. Final formulations can

be transferred to holding tanks, and

finished products can be loaded

into IBCs for delivery or consumer

packaging.

In many cases, chemical-

manufacturing processes require the

use of dangerous chemicals, such

as strong acids, caustics, solvents,

resins, and polymers. Despite their

inherent danger, these substances

are necessary for the manufacture

of thousands of consumer goods or

facilitate other industrial processes.

The challenge for users of these

dangerous chemicals is to construct,

handle, and transfer them in a

reliable way.

A LOOK AHEAD

Next month, we’ll take a closer lookat the benefits positive displacement

internal gear pumps have continually

offered pump users seeking reliability

and cost-effectiveness when handling

raw materials and f inished products—

with a specific breakdown of Maag’s

own G Series Internal Gear Pumps. ◆

Chrishelle Rogers is the global gear pump product manager for Maag

Industrial Pumps, Grand Terrace,

California, and PSG®, Oakbrook

Terrace, Illinois. Ms. Rogers can

be reached at 909.222.1309 or

[email protected].

Maag Industrial Pumps is a leading

brand of internal gear and screw

pumps and a product brand of PSG, a

Dover company. For more information

on Maag Industrial Pumps or PSG,

visit to www.psgdover.com.

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D E W A T E R I N G S O L U T I O N S

Copper mining involves working with some of the

harshest materials in the world. As a result, mining

companies must carefully monitor wear of their

slurry pumps and schedule frequent shutdowns to replace

worn parts. The cost of this maintenance goes far beyond

just the price of parts; downtime and lost revenue can run

into hundreds of thousands of dollars.

SEVERE WEAR RAISING COSTS

KSB's subsidiary, GIW Industries Inc., has produced

success at a South American copper mine.The GIW ®

Minerals product solution quadrupled pump wear life and

created dramatic savings for the mine's tailing pumping

operations. The South American company had struggled

for years to reduce maintenance downtime in its tailings

operations.

Tailings—the material left over after the valuable metal

has been extracted—consist of very fine par ticles that are

highly abrasive in slurry. The material was wearing out

pumps more quickly than other equipment in the tailings

line, increasing the frequency of downtime. They were

having such severe wear that they were repairing the

tailings pumps every 400 to 450 hours.

When considering replacement par ts, manpower, and

revenue lost due to downtime, the costs the copper mine

was facing on a regular basis were staggering. They

desperately needed a solution for more efficient operations.

FINDING A BETTER WAY

GIW offered the South American copper mine the answer.

An LSA centrifugal slurry pump was installed in a tail ings

booster application where GIW's exclusive Enduraclad™

material was applied to the new suction liner.

With the application of this new material, the miningcompany has been able to extend wear life up to 2,000

hours and also improved wear life of other related pump

par ts. This success comes from years of hard work and

innovation from GIW's team of hydraulic and metallurgical

engineers.

Copper MineQuadruples PumpWear LifeGIW Enduraclad™ increasesoperations from 450 hours to 2,000

By Ronnie Willis, GIW Industries

Enduraclad Liner at 550 HoursMetal Liner at 450 HoursLSA centrifugal slurry pump

SIDE-BY-SIDE COMPARISON

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When Enduraclad made its debut

in 2009, its uses were limited. It was

only applied to suction liners and

increased wear life up to three times.

But since then, its capabilities have

expanded to allow coating on other

essential parts and enables it to

provide even greater longevity for

GIW pumps.

GETTING YOUR

MONEY’S WORTH

Although Enduraclad-bonded parts

might be more expensive, they are

well worth the price. They will cost

more than uncoated par ts, such as

suction liners, buy end-users save on

costs by using fewer par ts, reducing

maintenance costs, and not suffering

the downtime revenue loss. To remove

and replace the parts on one of these

pumps requires two to four people

working with tools and lifting devices

for 6 to 8 hours. So the longer a

company can keep the pump running

with nobody touching it, the more

operational costs they will save.

Economy is just one of the things

GIW values and tries to deliver to

its customers. Users are seeking

par tners concerned with their best

interest, who are not just developing

these really specialized materials and processes and charging higher prices.

GIW is continually looking for ways to

reduce the cost of materials to provide

a product that serves customers'

needs and fits their budgets.

CONTINUOUS IMPROVEMENT

IS A MUST

GIW is constantly looking at new

materials and processes that

can improve pump wear life for

customers like the South American

copper mine. Metallurgical experts

are already testing new cladding

materials that will last even longer

than the current ones, and there may

be even greater improvements

in the future with enhanced

Enduraclad material. GIW believes

solutions that add value to their

products will meet and exceed

their customers’ expectations for

continuous improvement. ◆

Ronnie Willis is senior product

manager of new materials at GIW

Industries, Inc., a full subsidiary of

KSB. Through the GIW ® Minerals

product brand, KSB strives to be an

innovative partner that provides you

with the best and longest wearing

slurry solutions. We are your par tner,

today and in the future. For more

information, visit www.ksb.com.

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M O T O R S O L U T I O N S

Turning Awayfrom Tradition

Companies around the world

have come to rely on screw

conveyor drive systems for

reliable drive solutions to meet the

demands of transporting bulk material.

For these critical applications, open,

two-way communication between

OEMs and end-users is essential to

help drive customers with an accurate

assessment of each individual

application. To understand the

demands of industry, a manufacturer’s

goal should be to provide users with a

drive assembly that will reliably serve

the needs of a plant for many years to

come.

For example, NORD’s screw

conveyor packages, with their rugged

output seal and innovative CEMA

drive-shaft, are designed for reliable

performance in screw conveyor

applications. Some of the industries

that rely on screw conveyors include

agriculture; oil and gas; chemicals

process ing and handling; stone, g lass,

and concrete, food products, and

wastewater treatment.

BUILDING A MORE RELIABLE

DRIVE ASSEMBLY

NORD's industry leading ratio range

allows for the elimination of external

rotating components such as V- or

synchronous-belt drives. Eliminating

the belt drive results in a safer and

more reliable drive assembly. By

combining high quality gearing with

a leak free design, NORD delivers

reliable transmission of power to the

driven shaft.

Depending on the type of conveyor,

different applications can see

significant benefits right away. For

example, shaftless screw conveyors

have proven ideal for handling sticky

and sluggish bulk materials and are

equally well-suited for material with

high moisture content.

In addition, screw feeders and live

bottom conveyors incorporate either

a single or multiple gearbox design

and provide a means of moving a

wide variety of material from bins or

hoppers at a constant and controlled

rate of flow. This type of conveyor is

one of the most accurate and efficient

to meter bulk materials. Lastly, vertical

screw conveyors are ideal for elevating

dry to semi-f luid materials from

free-flowing to sluggish at very steep

inclines and are totally enclosed for

dust and vapor-tight requirements.

THE ALTERNATIVE TO

TRADITIONAL SCREW

CONVEYOR DRIVES

The NORD Screw Conveyor Package

offers a compact and cost effective

alternative to traditional screw

conveyor drives. Closely stepped

speed reduction ratios combined

with a directly coupled gearmotor or

NEMA C-face input design eliminates

the need for top motor mounts,

pulleys, belts, or guards. Minimizing

parts and eliminating the belted input

systems provides for easier system

maintenance, increased reliability,

NORD screw conveyor drive proves itselfcompact, reliable, and cost-effective

By Alie Foy, NORD Gear Corporation

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and superior drive performance.

NORD screw conveyor drive options

feature a UNICASE™ reducer housing,

Quadrilip™ reducer shaft sealing and

optional high capacity output bearings

with CEMA standard flange mounting

and CEMA drive shafts ranging from

1-1/2 to 3-7/16 inches.

The Screw Conveyor Package

(SCP) design is available for both

CLINCHER™ Parallel Shaft gear units

and Helical-Bevel Right Angle gear

units. The CEMA flange assembly

offers superior protection against

unwanted debris with its dual Viton™

gap seals (0.03 inch gap) on either

side of the grease filled felt packing

seal. Drive shaft material evacuation

por ts in the flange help protect the

drive system from debris. A slight lead

taper on the reducer shaft provides for

easy mounting and removal, allowing

for some screw pipe misalignment and

reduced bearing loads.

BENEFITS FOR END-USERS

For end-users, the NORD Screw

Conveyor Package offers many

benefits even beyond the reduced

cost, from the large ratio range to

direct drive motor options (Integral

or C-face). Fur thermore, there is no

belt maintenance or belt guarding

required. The advanced design means

reduced parts, higher reliability, and

space savings while also providing

higher efficiency and more direct

torque transfer. More than just an

alternative to tradition, the NORD

Screw Conveyor Package is a

step beyond. ◆

Alie Foy is marketing specialist for

NORD Gear Corporation and can be

reached at [email protected]. As a

privately-held, family owned company,

Nord believes in the long term with

a global perspective—providing a

broad range of products, the highestquality standards in mechanical and

electronic technologies, continued

reinvestment into production,

and a global presence. For more

information, visit www.nord.com.

Clincher SCP Unit Helical-Bevel SCP Unit

Torque Capacity Up to 53,100 lb-in Up to 42,480 lb-in

Power Range 0.16 – 60 horsepower 0.16– 30 horsepower

Ratio Range 4.32:1 – 1,585.08:1 8.09:1 – 4,246.38:1

Output Speed 1.0 – 405 rpm 0.41 – 216 rpm

Efficiency Up to 97% efficient Up to 95% efficient

CEMA Drive Shaft Sizes 1-1/2, 2, 2-7/16, 3, 3-7/16 inches 1-1/2, 2, 2-7/16, 3, 3-7/16 inches

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Woolpert Discipline Director Kirk McClurkin and Project Manager SteveSchwabe discuss the software implementation with ActewAGL’s MarkChenery and Chris Kelly at ActewAGL offices.

Phase Manager Jamie Munro and Market Director Dave Feuer work in amakeshift office in the Woolpert team’s apar tment in Australia.

Institute of Asset Management (IAM) cer tification, with thirteen

professionals cer tif ied.

“In Australia, as in Europe, the IAM standards are very highly

regarded, but most U.S. companies have been late to that party,”

said Feuer, who is IAM certified. “We were pleased that AAD

came to America to get support with its overall asset management

program, knowing we adhere to these elevated international

standards.”

LOOKING OUT FOR CUSTOMERS

The bulk of the work on this project is complete, but Woolpert

continues to support AAD by evaluating ideas on their issue log,

scoping, and developing system enhancements, and additionally

delivering the advanced functionality the AAD-user community

needs to meet its operating requirements. ◆

Woolpert delivers value to clients by strategically blending engineering

excellence with leading-edge technology and geospatial applications.

Woolpert’s mission is to help i ts clients progress—and become more

progressive. For over 100 years and with more than 25 off ices across

the United States, Woolpert serves the needs of federal, state, and local

governments; private and public companies and universities; energy and

transportation departments; and the United States Armed Forces. For

more information, visit www.woolpert.com or call 937.531.1258.

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P R O C E S S I N G S O L U T I O N S

Minimizing Leaksand EnvironmentalHazards for FluidTransfer

Transporting and securing

hazardous material

while also minimizing its

exposure are the twin goals o f any

processing engineer. Many of the

fluids transferred during chemical

processing can be corrosive to

equipment or dangerous to operating

staff. And although well-maintained

connections in the piping or pumping

system is a must, Ingersoll Rand

has introduced a product that thinks

outside the box by putting a pumping

system inside the box: the ARO

Station.

REDUCING LEAKS AND FUMES

The ARO Station is a customized

solution that houses an ARO pumpand piping in a durable housing in

order to reduce leaks and fumes

during chemical transfer from one

container to another. Standing

independently from a truck, the ARO

Station helps operators comply with

changing environmental regulations,

while enhancing operator safety.

ARO understands the importance

of transporting and securing

hazardous material and minimizing

its exposure. The risks with chemical

handling are a daily reality and the

ARO Station was designed to protect

operators as well as the environment

during the transfer of these materials.

DIFFERENT PUMPING OPTIONS

The ARO Station can accommodate

three different size pumps, the

1 inch, 1-½ inch, or 2 inch Expert

Series Pumps (EXP) ARO diaphragm

pump. With the capability to pump

material from 1,320 to 7,900 gallons

per hour, the ARO Station can be

calibrated to pump the appropriate

quantity for each application. Use of

the ARO Station increases the safety

of chemical installations during the

ARO Station provides a safe solution

for processing needs

By Fausto Lotti, ARO Fluid Management

One of two sizes of the Exper t Series Pumps (EXP) ARO diaphragm pump can be placed inside the ARO Station.

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unloading process by reducing risks

of water hammer that occur during

the pressurization of the tanks.

A leak detector that communicates

possible leakage, helping to minimize

air pollution and risk from fumes.

• A heater to prevent freezing in

extreme situations.

• An alarm that monitors the level of

liquid in the tank and whether the

system is running dry.

IMPERVIOUS TO CORROSION

Made of high-density polyethylene,

the ARO Station is impervious

to corrosion, and features a drip

collection tray that can hold up to 52

gallons of fluid. The ARO Station can

be used as a free-standing pump

solution or it can be equipped with

wheels for mobility. Compact and

ready for use, the ARO Station is a

standardized skid size thus reducing

integration costs.

MAKING SUCCESS FLOW

Ingersoll Rand introduced the ARO

Station pumping system at the 2015

ACHEMA tradeshow in Frankfurt,Germany, to an enthusiastic crowd

of professionals in the compressed

air and gas systems and services,

power tools, f luid management, and

material handling equipment industry.

Ingersoll Rand product experts

interacted with attendees, answering

questions and demonstrating the

details of how the new closed

pumping system could benef it their

facilities and operations. ◆

Fausto Lotti is marketing leader for ARO Fluid Management. ARO is a leading worldwide

manufacturer of fluid handling products expertly engineered to deliver performance and

serviceability, enabling customers to achieve the best total cost of ownership. For eighty-

five years ARO has been helping customers solve their most complex fluid handling

challenges to keep their business moving. For more information, contact 800.495.0276 or

[email protected].

"The risks with

chemical handling

are a daily

reality and the

ARO Station wasdesigned for

protection."

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V A LV E S & C O N T R O L S S O L U T I O N S

Managing Assets,Saving Time

A cross a range of industries

connected to oil and gas

or water and wastewater,

companies are experiencing a

worrisome trend. As a great number of

long-time technical experts retire, they

are not being replaced by an equal

number of younger skill workers.

However, companies’ requirements

to manage assets dispersed over

large areas has not diminished, and

Schneider Electric has recognized

the growing need for integrated and

automated control systems that today’s

workforce can operate reliably and

efficiently.

SAVING ENGINEERS TIME

Schneider Electric’s new open and

scalable software for telemetry and

remote SCADA applications, SCADA

Expert ClearSCADA, controls budgets

throughout each project, captures

relevant and reliable data from remote

and challenging locations,

and also minimizes

system security r isks.This software improves

the user experience

with better maintenance

tools, improved data

accessibility, and enhanced

security in telemetry

and remote SCADA

applications.

Cementing its position

as a global specialist

in energy management

and automation, Schneider Electric,

has also announced the release of

StruxureWare, an add-on to SCADA

Expert ClearSCADA that continues

to improve on the user experience

and provide functionality based

on customers’ needs. Template

expressions save engineers time

during implementation; alarm

summaries help pinpoint maintenance

issues faster, and the seamless

integration with a tier-2 historian

facilitates data accessibility across the

entire enterprise.

EXPANSIVE FUNCTIONALITY,

REDUCED OPERATING COSTS

These functionalities are part of a

software platform that is designed

to lower the overall operating costs

of remote assets while providing a

complete, comprehensive overview of

site operations. Other features include:

• Enhanced WebX user interface–

Process information is available

anytime, anywhere through any

device with HTML5 cross-browser

support for trends, alarm lists,

event lists, and queries.

• Extended integration of telemetry

hardware–Enhanced integration

with the Realflo software, a flow

measurement application, now

including support for Realflo

Liquids 6.91, plus native support

for well-known third-party flow

computers via a new oil and gas

EFM Driver suite.

• Increased system security–A

substantial increase in security

features includes enhanced

user account security, auditing

of the system security through

a dedicated security event

list and dedicated security

logging queries.

By providing remoteconfiguration capabilities

and collecting data from

multiple ClearSCADA

systems into a central

enterprise repository,

ClearSCADA software

helps reduce costs

while providing

crucial, business-

relevant data across all

operational levels.

StruxureWare SCADA Expert ClearSCADAsoftware fills the market’s need

By Brad Shaw, Schneider Electric

EcoStruxure Web Services-ready, SCADA Expert ClearSCADA seamlessly integrates products and systems from the Sch neider E lectr ic busin ess segments.

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SCADA EXPERT CLEARSCADA

The SCADA Expert ClearSCADA

system foundation is built using open

standards, naturally providing industr y-

leading integration with external

business and IT systems. Critical

infrastructure management business

systems, including GIS and ERP,

can share data with SCADA Expert

ClearSCADA using open SQL ODBC

and OLE-DB standards. Interchanging

data with a wide range of controllers

and PLCs, and other process systems

can be done seamlessly using

extensive OPC interfaces. SCADA

Expert ClearSCADA client and server

API fac ili ties provide ult imate flexibili ty

using the latest in OLE and .NET

software technologies.

All SCADA Expert ClearSCADA

facilities can securely interoperate

with business and IT systems to turn

asset and infrastructure SCADA data

into valuable business information.

Additionally, SCADA Expert

ClearSCADA is EcoStr

Documents

Modern Pumping - 102015