- Email: [email protected]
Pigment plant saves with smaller pumps
PPLICATIONS
the drive motors. A further operational convenience was t h e fact t h a t t h e p u m p s can r u n d r y i n d e f i n i t e l y w i t h no a d v e r s e effects. No c o n c r e t e w o r k is r e q u i r e d o t h e r t h a n t h e u p p e r a n d lower b e a r i n g s -- t h e lower b e a r i n g is i s o l a t e d from t h e r a w sewage. M a i n t e n a n c e is r e l a t i v e l y minor, d u e t o t h e s i m p l i c i t y of t h e p u m p design. The screw p u m p s a r e s u i t a b l e for a wide variety of a p p l i c a t i o n s ; for simp l e i n d u s t r i a l a q u e o u s sludge a n d w a s t e water, a n d for lifting s l u r r i e s a n d o t h e r simil a r liquids.
Internalifl screw pumps can run dry indefinitely.
S e w a g e w o r k s get a lift I n c r e a s e d i n t e r e s t is b e i n g shown in t h e I n t e r n a i l i f t r a n g e of t o t a l l y enclosed screw p u m p s ,
says t h e supplier, W h e e l a b r a t o r E n g i n e e r e d Systems. Twin p u m p s were r e c e n t l y i n s t a l l e d at O r m i s t o n Sewage T r e a t m e n t W o r k s , UK. E a c h p u m p is c a p a b l e of lifting 91 l/ sec o f i n c o m i n g r a w sewage t h r o u g h a h e i g h t of 6 m, a t a n angle of 45 ° . Of several a d v a n t a g e s over centrifugal and conventional screw variants, t h e client was p a r t i c u l a r l y i m p r e s s e d by t h e high efficiency of t h e p u m p over a wide range of flows, d u e in p a r t to t h e twin s p e e d facility of
Contact: Wheelabrator Engineered Systems, Johnson House, Browells Lane, Feltham, Middlesex, TW13 7EQ, UK. Tel: + 4 4 181 893 7126; Fax: +44 181 893 7018.
[]
Pigment plant saves with smaller pumps
At t h e Ciba Pigments p l a n t in Paisley, Scotland, a new install a t i o n in t h e AZO p i g m e n t p r o d u c t i o n a r e a of p u m p s from Ingersoll-Dresser P u m p s (IDP), has greatly increased pump performance and provided a d r a m a t i c r e d u c t i o n in m a i n t e -
m
CEP and CPX pumps have increased pump performance at Ciba Pigments.
t
WORLD PUMPS NOVEMBER 1995
PPLICATIONS
n a n c e a n d w a t e r costs. The AZO p i g m e n t is used for p r i n t i n g inks, p a i n t s a n d plastics. The epoxy r e s i n CEP a n d stainless steel CPX p u m p s move p i g m e n t slurry a n d 5-10% Hcl or NaOH s o l u t i o n s , respectively. Potential savings alone on the costs t h a t were i n v o l v e d i n m a i n t a i n i n g the p u m p s now replaced by the IDP u n i t s are reported at £1000 p e r month. Both types of p u m p offer a r e d u c t i o n in size w i t h o u t compromising on flows. The power draw of the IDP p u m p s is m u c h lower t h a n their predecessors as they utilise 5.5-11.0 kW electric motors c o m p a r e d to the 15.018.5 kW motors used previously. As well as greatly reduced m a i n t e n a n c e a n d energy costs, f u r t h e r significant savings at Ciba P i g m e n t s have also res u l t e d from t h e m u c h lower volumes of w a t e r n e e d e d for sealing the m e c h a n i c a l seals. The single seal a r r a n g e m e n t for CPX p u m p s features a conical seal h o u s i n g allowing the l]llr
0
rlr'
p u m p s to flush themselves. The new 45 ° conically s h a p e d seal h o u s i n g was j o i n t l y developed w i t h l e a d i n g E u r o p e a n seal m a n u f a c t u r e r s . The vort e x - b r e a k i n g ribs w i t h i n t h e h o u s i n g e l i m i n a t e the p r o b l e m of v a p o u r or air collection at the seal a n d meet a p p l i c a t i o n s where quickly settling abrasives are present. The conical h o u s i n g can accommodate many different seal designs, i n c l u d i n g single, double, t a n d e m a n d cartridge types, offering u s e r flexibility to r e d u c e m a i n t e n a n c e a n d d o w n t i m e costs. The d o u b l e a n d t a n d e m seal a r r a n g e m e n t s s u p p o r t e d by a range of flush p a n s a n d auxiliary systems, are p a r t i c u l a r l y s u i t e d to severe a n d / o r e n v i r o n m e n t a l l y sensitive applications. The p e r f o r m a n c e of the sealing h o u s i n g allows the p u m p to be used w i t h o u t e x t e r n a l services for a w i d e v a r i e t y of liquids, with radial clearances sufficient for the seal a n d ade1[.
.
.
.
.
.
.
]
.]
q u a t e flow c o n d i t i o n s to remove heat effectively. As well as the control of v a p o u r build-up, the h o u s i n g can h a n d l e solids in suspension a n d is e a s i l y a d a p t e d to fit safety b a c k - u p devices. The previous set of p u m p s in the AZO area were the worst offenders in t e r m s of m a i n t e n a n c e costs. The old p u m p s suffered cont i n u o u s l y from cracked casings, worn impellers a n d seal failures, resulting in excessive d o w n t i m e a n d high m a i n t e n a n c e costs. T h e i r r e p l a c e m e n t with CPX p u m p s h a s d r a m a t i c a l l y red u c e d stock w i t h d r a w a l . The first CPX p u m p was installed a b o u t 18 m o n t h s ago a n d AZO engineers have not had to touch the u n i t since. The new CPX range of chemical process p u m p s from IDP is currently available in 19 sizes covering up to 100 m3/h a n d heads up to 80 m. The p u m p s have a hydraulic design t h a t provides high effi1
I
Hr. . . .
I
I
s=,,
maintaining flexibility throughout entire manufacturing process
"you name it, we'll manufacture it"
ProductionProgramme
TURBOSAN A.S.
Gumussuyu Cad. Hastane Yolu No, 1 L3 End suction pumps Maltepe 34020 TopkapHstanbul/TURKEY /3 Double suction pumps Phone: (+<~:]-212) 567 95 50 (10 Unes) [] Multi-stage pumps Fax: [+90-212) 612 47 41 [] Vertical, axial and mixed flow pumps [] Sewage pumps [] Submersiblesewage pumps [] Submersibleaxial and mixed flow pumps ArchernedJan screw pumps [] Chemical process pumps D Irrigation and sprinkler pumps [] Buflerfly valves Iq Check valves and dismantling pieces
ISO
~JuI II I ~ U U t I
412 Katsushika 2-Chome, Funabashi-City, Chiba, 273 Japan. Tel: 0474 3"7 2711; fax." 0474 37 3969.
2) Automatic Dewatering 3) Flameproof 4) Hot water
9001
WORLD PUMPS NOVEMBER 1995
r
PPLICATIONS
ciency c o u p l e d w i t h low NPSH. They f e a t u r e an o p e n impeller, p r o v i d i n g s u p e r i o r solids h a n d l i n g p e r f o r m a n c e , w h i c h is screwed d i r e c t l y t o t h e shaft. This a r r a n g e m e n t , a c c o r d i n g to IDP, e n s u r e s high s t r e n g t h a n d e l i m i n a t e s shaft e n d corrosion. The p u m p is s u p p l i e d in a range of m a t e r i a l s including Ductile Iron, Carbon Steel, 304L, 316L, D u p l e x a n d a selection of alloys. It is of the back pull-out type which facilitates i n t e r n a l maintenance, w i t h o u t first having a d e c o u p l e t h e whole p u m p from t h e process pipework. A 3 m m c o r r o s i o n a l l o w a n c e is available on all casings as are special long life m a t e r i a l s for severe applications.
Contact: Ingersoll-Dresser Pump Co., Marketing Services, PO Box 2, Chorley New Road, Horwich, Bolton, Lancs, BL6 6JN, UK. Tel: +44 1204 690690; Fax: + 44 1204 600368.
Peanut butter problem solved The i n t r o d u c t i o n of a hygienic Mono p u m p to deliver highly abrasive, p e a n u t b u t t e r h a s eradicated serious wear damage
which was causing frequent maintenance problems. F D u e r r & Sons Ltd, one of t h e UK's l e a d i n g p e a n u t b u t t e r m a n u f a c t u r e r s , p r e v i o u s l y used r o t a r y lobe p u m p s to t r a n s f e r t h e highly viscous a n d a b r a s i v e p e a n u t p a s t e from a g r i n d i n g mill to a r e f r i g e r a t i o n system p r i o r to bottling. With t h e r o t a r y lobe p u m p , b o t h t h e lobes a n d b o d y suffered c o n s i d e r a b l e w e a r d a m a g e in delivering t h e m i l l e d p e a n u t paste, which has a viscosity of 15 St a n d 1 . 8 6 S . G . As a r e s u l t of this s e r i o u s wear, t h e p u m p ' s i n t e r n a l c l e a r a n c e s bec a m e too great, l e a d i n g to loss of p r e s s u r e a n d p r o d u c t buildup. This c a u s e d t h e p e a n u t p a s t e to l o d g e in t h e p u m p a n d b u r n o n t o i n t e r n a l surfaces r e s u l t i n g in r e j e c t e d p r o d u c t . F D u e r r & Sons also h a d to carry out additional mainten a n c e r o u t i n e s to k e e p t h e pump operational. In a d d i t i o n t o high levels of hygiene and abrasion resistance, a key r e q u i r e m e n t was that the pump did not overheat during continuous operation. The p a s t e h a s to be p u m p e d a t a c o n s t a n t 85°C -- t h e temp e r a t u r e g e n e r a t e d by t h e friction of t h e milling p r o c e s s - to
keep it fluid. However, b e c a u s e t h e p e a n u t b u t t e r c o n t a i n s sugar, t o o m u c h h e a t can cause it to c a r a m e l i s e a n d burn. After analysis of a s a m p l e of the product, Mono recomm e n d e d a s t a i n l e s s steel p u m p f r o m i t s h y g i e n i c 'S' Range, specially d e s i g n e d for t h e food p r o c e s s i n g industry, with CIP facility to e n a b l e t h e p u m p to be easily c l e a n e d in situ on a daily basis. A gentle p u m p i n g action keeps component wear r a t e s low. The p u m p is o p e r a t e d a t a s p e e d of 16 r p m at a p r e s s u r e of 2 bar to deliver the peanut b u t t e r at a r a t e of 2.5 toO/hr. Like a l l ' S ' Range p u m p s , t h e model installed at F Duerr's p l a n t f e a t u r e s t h e Mono Flexishaft, w h i c h p r o v i d e s a single component link between the r o t a r y m o t i o n of t h e drive shaft a n d t h e eccentric m o t i o n of the helical rotor. The r e d u c e d n u m b e r of moving p a r t s in t h e drive train eliminates wear and m a k e s l u b r i c a t i o n unnecessary, r e d u c i n g t h e risk of p r o d u c t c o n t a m i n a t i o n -- a p a r t i c u l a r a d v a n t a g e in t h e food processing i n d u s t r y . The s i m p l i c i t y o f t h e F l e x i s h a f t drive, a n d c o n s e q u e n t l y t h e p u m p design, m e a n s t h a t t h e p u m p is easily dismantled and assembled w h e n r o u t i n e m a i n t e n a n c e is required. The hygienic design of t h e 'S' Range p u m p also h a s a selfd r a i n i n g e n d cover (to e n s u r e t h a t p r o d u c t o r cleaning fluid is n o t r e t a i n e d in t h e p u m p ) , food a p p r o v e d m a t e r i a l s , surface finish a n d stainless steel c o n t a c t surfaces. A single m e c h a n i c a l seal, d e v e l o p e d to m e e t hygiene r e q u i r e m e n t s , is located u n d e r the suction inlet to enable t h o r o u g h cleaning. A t Duerr's plant, which only closes down for m a i n t e n a n c e once a year, t h e p u m p o p e r a t e s at least 12 h o u r s a day, somet i m e s seven days a week, with a total daily output of over 19 000 kg of p e a n u t butter.
Contact: Mono Pumps, Martin Street, Audenshaw, Manchester, M34 5DQ, UK. Tel: +44 161 330 9000; Fax: +44 161 344 0727.
A hygienic Mono pump delivers highly viscous and abrasive peanut paste.
II
WORLD PUMPS NOVEMBER 1995
I
the drive motors. A further operational convenience was t h e fact t h a t t h e p u m p s can r u n d r y i n d e f i n i t e l y w i t h no a d v e r s e effects. No c o n c r e t e w o r k is r e q u i r e d o t h e r t h a n t h e u p p e r a n d lower b e a r i n g s -- t h e lower b e a r i n g is i s o l a t e d from t h e r a w sewage. M a i n t e n a n c e is r e l a t i v e l y minor, d u e t o t h e s i m p l i c i t y of t h e p u m p design. The screw p u m p s a r e s u i t a b l e for a wide variety of a p p l i c a t i o n s ; for simp l e i n d u s t r i a l a q u e o u s sludge a n d w a s t e water, a n d for lifting s l u r r i e s a n d o t h e r simil a r liquids.
Internalifl screw pumps can run dry indefinitely.
S e w a g e w o r k s get a lift I n c r e a s e d i n t e r e s t is b e i n g shown in t h e I n t e r n a i l i f t r a n g e of t o t a l l y enclosed screw p u m p s ,
says t h e supplier, W h e e l a b r a t o r E n g i n e e r e d Systems. Twin p u m p s were r e c e n t l y i n s t a l l e d at O r m i s t o n Sewage T r e a t m e n t W o r k s , UK. E a c h p u m p is c a p a b l e of lifting 91 l/ sec o f i n c o m i n g r a w sewage t h r o u g h a h e i g h t of 6 m, a t a n angle of 45 ° . Of several a d v a n t a g e s over centrifugal and conventional screw variants, t h e client was p a r t i c u l a r l y i m p r e s s e d by t h e high efficiency of t h e p u m p over a wide range of flows, d u e in p a r t to t h e twin s p e e d facility of
Contact: Wheelabrator Engineered Systems, Johnson House, Browells Lane, Feltham, Middlesex, TW13 7EQ, UK. Tel: + 4 4 181 893 7126; Fax: +44 181 893 7018.
[]
Pigment plant saves with smaller pumps
At t h e Ciba Pigments p l a n t in Paisley, Scotland, a new install a t i o n in t h e AZO p i g m e n t p r o d u c t i o n a r e a of p u m p s from Ingersoll-Dresser P u m p s (IDP), has greatly increased pump performance and provided a d r a m a t i c r e d u c t i o n in m a i n t e -
m
CEP and CPX pumps have increased pump performance at Ciba Pigments.
t
WORLD PUMPS NOVEMBER 1995
PPLICATIONS
n a n c e a n d w a t e r costs. The AZO p i g m e n t is used for p r i n t i n g inks, p a i n t s a n d plastics. The epoxy r e s i n CEP a n d stainless steel CPX p u m p s move p i g m e n t slurry a n d 5-10% Hcl or NaOH s o l u t i o n s , respectively. Potential savings alone on the costs t h a t were i n v o l v e d i n m a i n t a i n i n g the p u m p s now replaced by the IDP u n i t s are reported at £1000 p e r month. Both types of p u m p offer a r e d u c t i o n in size w i t h o u t compromising on flows. The power draw of the IDP p u m p s is m u c h lower t h a n their predecessors as they utilise 5.5-11.0 kW electric motors c o m p a r e d to the 15.018.5 kW motors used previously. As well as greatly reduced m a i n t e n a n c e a n d energy costs, f u r t h e r significant savings at Ciba P i g m e n t s have also res u l t e d from t h e m u c h lower volumes of w a t e r n e e d e d for sealing the m e c h a n i c a l seals. The single seal a r r a n g e m e n t for CPX p u m p s features a conical seal h o u s i n g allowing the l]llr
0
rlr'
p u m p s to flush themselves. The new 45 ° conically s h a p e d seal h o u s i n g was j o i n t l y developed w i t h l e a d i n g E u r o p e a n seal m a n u f a c t u r e r s . The vort e x - b r e a k i n g ribs w i t h i n t h e h o u s i n g e l i m i n a t e the p r o b l e m of v a p o u r or air collection at the seal a n d meet a p p l i c a t i o n s where quickly settling abrasives are present. The conical h o u s i n g can accommodate many different seal designs, i n c l u d i n g single, double, t a n d e m a n d cartridge types, offering u s e r flexibility to r e d u c e m a i n t e n a n c e a n d d o w n t i m e costs. The d o u b l e a n d t a n d e m seal a r r a n g e m e n t s s u p p o r t e d by a range of flush p a n s a n d auxiliary systems, are p a r t i c u l a r l y s u i t e d to severe a n d / o r e n v i r o n m e n t a l l y sensitive applications. The p e r f o r m a n c e of the sealing h o u s i n g allows the p u m p to be used w i t h o u t e x t e r n a l services for a w i d e v a r i e t y of liquids, with radial clearances sufficient for the seal a n d ade1[.
.
.
.
.
.
.
]
.]
q u a t e flow c o n d i t i o n s to remove heat effectively. As well as the control of v a p o u r build-up, the h o u s i n g can h a n d l e solids in suspension a n d is e a s i l y a d a p t e d to fit safety b a c k - u p devices. The previous set of p u m p s in the AZO area were the worst offenders in t e r m s of m a i n t e n a n c e costs. The old p u m p s suffered cont i n u o u s l y from cracked casings, worn impellers a n d seal failures, resulting in excessive d o w n t i m e a n d high m a i n t e n a n c e costs. T h e i r r e p l a c e m e n t with CPX p u m p s h a s d r a m a t i c a l l y red u c e d stock w i t h d r a w a l . The first CPX p u m p was installed a b o u t 18 m o n t h s ago a n d AZO engineers have not had to touch the u n i t since. The new CPX range of chemical process p u m p s from IDP is currently available in 19 sizes covering up to 100 m3/h a n d heads up to 80 m. The p u m p s have a hydraulic design t h a t provides high effi1
I
Hr. . . .
I
I
s=,,
maintaining flexibility throughout entire manufacturing process
"you name it, we'll manufacture it"
ProductionProgramme
TURBOSAN A.S.
Gumussuyu Cad. Hastane Yolu No, 1 L3 End suction pumps Maltepe 34020 TopkapHstanbul/TURKEY /3 Double suction pumps Phone: (+<~:]-212) 567 95 50 (10 Unes) [] Multi-stage pumps Fax: [+90-212) 612 47 41 [] Vertical, axial and mixed flow pumps [] Sewage pumps [] Submersiblesewage pumps [] Submersibleaxial and mixed flow pumps ArchernedJan screw pumps [] Chemical process pumps D Irrigation and sprinkler pumps [] Buflerfly valves Iq Check valves and dismantling pieces
ISO
~JuI II I ~ U U t I
412 Katsushika 2-Chome, Funabashi-City, Chiba, 273 Japan. Tel: 0474 3"7 2711; fax." 0474 37 3969.
2) Automatic Dewatering 3) Flameproof 4) Hot water
9001
WORLD PUMPS NOVEMBER 1995
r
PPLICATIONS
ciency c o u p l e d w i t h low NPSH. They f e a t u r e an o p e n impeller, p r o v i d i n g s u p e r i o r solids h a n d l i n g p e r f o r m a n c e , w h i c h is screwed d i r e c t l y t o t h e shaft. This a r r a n g e m e n t , a c c o r d i n g to IDP, e n s u r e s high s t r e n g t h a n d e l i m i n a t e s shaft e n d corrosion. The p u m p is s u p p l i e d in a range of m a t e r i a l s including Ductile Iron, Carbon Steel, 304L, 316L, D u p l e x a n d a selection of alloys. It is of the back pull-out type which facilitates i n t e r n a l maintenance, w i t h o u t first having a d e c o u p l e t h e whole p u m p from t h e process pipework. A 3 m m c o r r o s i o n a l l o w a n c e is available on all casings as are special long life m a t e r i a l s for severe applications.
Contact: Ingersoll-Dresser Pump Co., Marketing Services, PO Box 2, Chorley New Road, Horwich, Bolton, Lancs, BL6 6JN, UK. Tel: +44 1204 690690; Fax: + 44 1204 600368.
Peanut butter problem solved The i n t r o d u c t i o n of a hygienic Mono p u m p to deliver highly abrasive, p e a n u t b u t t e r h a s eradicated serious wear damage
which was causing frequent maintenance problems. F D u e r r & Sons Ltd, one of t h e UK's l e a d i n g p e a n u t b u t t e r m a n u f a c t u r e r s , p r e v i o u s l y used r o t a r y lobe p u m p s to t r a n s f e r t h e highly viscous a n d a b r a s i v e p e a n u t p a s t e from a g r i n d i n g mill to a r e f r i g e r a t i o n system p r i o r to bottling. With t h e r o t a r y lobe p u m p , b o t h t h e lobes a n d b o d y suffered c o n s i d e r a b l e w e a r d a m a g e in delivering t h e m i l l e d p e a n u t paste, which has a viscosity of 15 St a n d 1 . 8 6 S . G . As a r e s u l t of this s e r i o u s wear, t h e p u m p ' s i n t e r n a l c l e a r a n c e s bec a m e too great, l e a d i n g to loss of p r e s s u r e a n d p r o d u c t buildup. This c a u s e d t h e p e a n u t p a s t e to l o d g e in t h e p u m p a n d b u r n o n t o i n t e r n a l surfaces r e s u l t i n g in r e j e c t e d p r o d u c t . F D u e r r & Sons also h a d to carry out additional mainten a n c e r o u t i n e s to k e e p t h e pump operational. In a d d i t i o n t o high levels of hygiene and abrasion resistance, a key r e q u i r e m e n t was that the pump did not overheat during continuous operation. The p a s t e h a s to be p u m p e d a t a c o n s t a n t 85°C -- t h e temp e r a t u r e g e n e r a t e d by t h e friction of t h e milling p r o c e s s - to
keep it fluid. However, b e c a u s e t h e p e a n u t b u t t e r c o n t a i n s sugar, t o o m u c h h e a t can cause it to c a r a m e l i s e a n d burn. After analysis of a s a m p l e of the product, Mono recomm e n d e d a s t a i n l e s s steel p u m p f r o m i t s h y g i e n i c 'S' Range, specially d e s i g n e d for t h e food p r o c e s s i n g industry, with CIP facility to e n a b l e t h e p u m p to be easily c l e a n e d in situ on a daily basis. A gentle p u m p i n g action keeps component wear r a t e s low. The p u m p is o p e r a t e d a t a s p e e d of 16 r p m at a p r e s s u r e of 2 bar to deliver the peanut b u t t e r at a r a t e of 2.5 toO/hr. Like a l l ' S ' Range p u m p s , t h e model installed at F Duerr's p l a n t f e a t u r e s t h e Mono Flexishaft, w h i c h p r o v i d e s a single component link between the r o t a r y m o t i o n of t h e drive shaft a n d t h e eccentric m o t i o n of the helical rotor. The r e d u c e d n u m b e r of moving p a r t s in t h e drive train eliminates wear and m a k e s l u b r i c a t i o n unnecessary, r e d u c i n g t h e risk of p r o d u c t c o n t a m i n a t i o n -- a p a r t i c u l a r a d v a n t a g e in t h e food processing i n d u s t r y . The s i m p l i c i t y o f t h e F l e x i s h a f t drive, a n d c o n s e q u e n t l y t h e p u m p design, m e a n s t h a t t h e p u m p is easily dismantled and assembled w h e n r o u t i n e m a i n t e n a n c e is required. The hygienic design of t h e 'S' Range p u m p also h a s a selfd r a i n i n g e n d cover (to e n s u r e t h a t p r o d u c t o r cleaning fluid is n o t r e t a i n e d in t h e p u m p ) , food a p p r o v e d m a t e r i a l s , surface finish a n d stainless steel c o n t a c t surfaces. A single m e c h a n i c a l seal, d e v e l o p e d to m e e t hygiene r e q u i r e m e n t s , is located u n d e r the suction inlet to enable t h o r o u g h cleaning. A t Duerr's plant, which only closes down for m a i n t e n a n c e once a year, t h e p u m p o p e r a t e s at least 12 h o u r s a day, somet i m e s seven days a week, with a total daily output of over 19 000 kg of p e a n u t butter.
Contact: Mono Pumps, Martin Street, Audenshaw, Manchester, M34 5DQ, UK. Tel: +44 161 330 9000; Fax: +44 161 344 0727.
A hygienic Mono pump delivers highly viscous and abrasive peanut paste.
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WORLD PUMPS NOVEMBER 1995
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