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MPT
Wastewater Streams
MAY 2021
Face Down Flushables
Can Predictive Maintenance
Improve Pump Operations?
Smart Tech Optimizes
Modern Pumping Today ®
Moisture Measurement
Providing Solutions for the Worldwide Pump Industry
www.mptmag.com
MAY 2021
10
MPT
Modern Pumping Today ®
www.mptmag.com
P.O. Box 660197 | Birmingham, Alabama 35266
@modpumpmag
J. CAMPBELL Editor
20 28 jay@mptmag.com
TONYA BROWNING Vice President
tonya@mptmag.com
JEFF FLETCHER National Sales Manager
jeff@mptmag.com
LISA AVERY Art Director
CAMILLE BLACK Graphic Designer
SETH SAUNDERS Digital Media Specialist
INGRID BERKY Office Manager
A NOTE ON THIS ISSUE:
Welcome to the May edition of MPT! Electricity SUBSCRIPTIONS
plays a vital role in everyday life, powering For all changes, go to:
industrial and domestic equipment. However, MPTMAG.COM
coordinating generating capacity with Click the SUBSCRIPTIONS button
maintenance requirements is a delicate balancing in the main menu
act, and one that benefits from minimal downtime.
In this month’s Case Studies section (pg. 14), Alex
Edwards shows how Sulzer's combined resources
J. Campbell, Editor
and expertise delivered extended service life of
Modern Pumping Today
vital pumping assets at a power station.
Specialized physical vapor deposition (PVD) coatings are widely
recognized for the critical role they play in enhancing operational www.highlandspublications.com
performance and extending the life of parts across countless 312 Lorna Square | Birmingham, Alabama 35216
866.251.1777
manufacturing and industrial sectors. In our Maintenance & Reliability
section (pg. 24), Logan Walz of Oerlikon Balzers shares how some
TIM GARMON RUSSELL HADDOCK
specialized coatings manufacturers make a strong case that coatings CEO President
can significantly contribute to improving the environment as well.
CHRIS GARMON DONNA CAMPBELL
CFO Vice President, Editorial
EDITORIAL ADVISORY BOARD: TONYA BROWNING
Vice President
Terry Bell Product Manager, ABB
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting No part of this publication may be reproduced or transmitted in any form
or by any means, electronic or mechanical, including photocopy, recording,
Robert G. Havrin Director of Technology, Centrisys Corporation or any information storage-and-retrieval system without permission in
Michael Mancini Consultant and Trainer, Mancini Consulting Services writing from the publisher. The views expressed by those not on the
staff of Modern Pumping Today, or who are not specifically employed
John M. Roach Engineering Manager for New Product Development, Trebor International, by Highlands Publications, Inc., are purely their own. All Industry News
material has either been submitted by the subject company or pulled
Inc.: A Unit of IDEX directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt jay@mptmag.com.
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
CONTENTS 14
I N DU S T RY NE W S
What's happening in the industry.......................................... 6
T R A DE S HO W P RO FI L E
Offshore Technology Conference 2021...............................10
S W PA I N S I G H T
The New Normal.................................................................12
Submersible wastewater pumps and the challenge of “flushables”
CASE STUDIES
Framework Agreement Minimizes Repair Times.................14
Power station reduces downtime by using pre-approved supplier for maintenance
WAT E R & WA S T E WAT E R FO C US
Flood Defense Pumps Need High-quality Bearings.............18
Bedford Pumps and Thordon Bearings work wonders for English pumping station
M A I N T E N A N C E & RE L I A B I L I TY
Controlling Dangerous Dusts
in the Chemical Processing Industry...................................20 18
Part 1 of 2
Reducing Environmental Friction
with High-performance Coatings........................................24
The key to lower energy consumption, reduced emissions, and longer equipment life
PUMP SOLUTIONS
How Can Predictive Maintenance
Improve Pump Operations?.................................................28
Six points of preparedness for Industry 4.0
MOTOR SOLUTIONS 36
Modal Testing of Pump Bearing Housings...........................32
Resonance is more than critical speeds
SEALING SOLUTIONS
Smart Moisture Measurement Technology Continually
Optimizes Product and Process Quality...............................36
M O D E R N PU M P I N G P RO D UC T S
CRANE PUMPS & SYSTEMS
Envie3 Pump Motor.............................................................40
Cover image provided by SEEPEX, Inc.
INDUSTRY NEWS
ANUE WATER EXPANDS INTO NEW ENGLAND SPX FLOW TO ACQUIRE PHILADELPHIA MIXING
Anue Water Technologies announces that Russell Resources SOLUTIONS FOR CASH
Inc. is the exclusive new channel partner for the sales and SPX Flow has signed a definitive agreement to acquire
distribution of Anue’s eco-friendly product line throughout mixing solutions provider Philadelphia Mixing Solutions,
the six New England states of Connecticut, Massachusetts, Ltd. from Thunder Basin Corporation, an affiliate of Wind
Rhode Island, Vermont, New Hampshire, and Maine. River Holdings. The all-cash transaction valued at $65
According to Anue Water VP and General Manager Greg million is expected to close during the second quarter
Bock, “We are thrilled to have Russell Resources as our of 2021 and will be paid for with cash on hand.
exclusive channel partner throughout the six New England Upon completion of the transaction, SPX Flow will
states. The Russell team of process technology experts further bolster its position as an innovative provider
will introduce New England municipalities and industrial of essential products and process solutions that help
customers to eco-friendly systems that pay for themselves make the world safer, healthier, and more sustainable.
in operational savings within a couple of years.” This acquisition is in line with the SPX Flow’s focus
Russell Resources President Jim Russell declares, “We on strategic alignment combined with clear plans for
look forward to introducing New England wastewater value creation.
treatment customers to the FORSe and Phantom oxygen/ Based in Palmyra, Pennsylvania, Philadelphia Mixing
ozone injection systems with remote digital telemetry, Solutions employs approximately 150 people and
Anue Geomembrane covers with carbon-embedded filters generated nearly $50 million in revenue in 2020.
for odor control and the EnviroPrep well-washers for FOG The company has more than six decades of industry
control. During this pandemic, and coming out of it, New experience in multi-industry mixing products and
England wastewater customers want clean-tech solutions service, along with a reputation for world-class innovation,
that minimize labor and inputs into the environment.” technical support, testing, analysis, and field service,
Anue Water CEO Paul Turgeon adds, “We are which has led to a high-quality revenue base.
very pleased to have the Russell Resources team Marc Michael, president and CEO of SPX Flow, adds,
as our exclusive channel partners for the six New “The combination of these two great mixer businesses will
England states.” create new opportunities for synergy and growth.”
CUSTOMIZED
SUBMERSIBLE MOTORS
Sun-Star Electric, Inc.
is the worldwide distributor for Hitachi submersible motors. We
are also fully equipped to design and manufacture a custom
submersible motor for your specific project. Sun-Star’s signature
line of oil and water filled motors are built to meet your exact
requirements. Put our 40+ years of experience to work on your
next submersible motor project.
Sun-Star Electric, Inc. 888-SUN-STAR/800-782-9675
sales@sunstarusa.com www.sunstarusa.com
6 | May 2021 | Modern Pumping Today www.mptmag.com
W E BI NA R S
LEARNING FOR TODAY’S PUMP
INDUSTRY, AT YOUR FINGERTIPS
Whether your work focuses on water and wastewater, chemical
processing, or original equipment manufacturing, you need to stay up
to date with the latest training. MPT’s hosted webinars bring industry
experts from leading companies to your computer and offer professional
certificates for completion.
FOR MORE INFORMATION:
J. Campbell (jay@mptmag.com)
visit our website mptmag.com
INDUSTRY NEWS WOOLPERT SELECTED TO PROVIDE PRECIRIX PARTNERS WITH EVERGREEN TO EXPAND TOPOGRAPHIC MAP OF NIGERIA NORTH AMERICAN CLINICAL TRIAL SUPPLY Woolpert has been selected to collect, process, and Precirix, a clinical-stage biotechnology company deliver topographic mapping across more than one- developing novel radiopharmaceuticals in oncology, and quarter of Nigeria under a $4.4 million contract with the Evergreen Theragnostics, Inc., a radiopharmaceutical Ministry of Mines and Steel Development (MMSD). The contract manufacturer, have entered into an agreement project is part of the Mineral Sector Support for Economic whereby Evergreen will provide domestic manufacturing Diversification Project, also known as MinDiver, and is for Precirix's lead product candidate, CAM-H2, which funded by the World Bank. is being evaluated in a Phase I/II clinical trial targeting Woolpert will supply the labor, materials, and equipment HER2-positive metastatic breast and gastric cancer. needed to develop 340 complete topographic mapping "Establishing a strong manufacturing footprint in North sheets and corresponding Multinational Geospatial Co- America is an important step for Precirix to ensure reliable production Program (MGCP) data. The firm will provide clinical trial supply. We are very pleased to be working processed satellite imagery, digital elevation models, ground with Evergreen, a team with solid expertise and a proven truthing, feature extraction, and topographic map data. track record in radiopharmaceutical manufacturing," says Additionally, Woolpert has deployed a full-fledged, cloud- Ruth Devenyns, chief executive officer of Precirix. based enterprise geospatial data hosting platform coupled Evergreen will manufacture CAM-H2, an I-131 with multi-user virtual desktops through Microsoft Azure based radiopharmaceutical, at its new state-of-the-art and Woolpert’s raster service, Stream:Raster, to allow for facility in Springfield, New Jersey. Opening in 2021, the easily managed, cross-continental geospatial production. facility is located near Newark Liberty International Woolpert is coordinating this project through its Airport and within driving distance of John F. Kennedy Johannesburg office and has hired over fifteen additional International Airport. GIS positions at that site in support. The cloud-based "CAM-H2 is a very promising product with potential to infrastructure allows for a swift ramp up as new team significantly improve outcomes for patients with HER2- members join. This contract is underway and slated to be positive cancer,” adds James Cook, chief executive officer complete in April 2022. of Evergreen. ◆ 8 | May 2021 | Modern Pumping Today www.mptmag.com
T R A D E S H OW P R O F I L E
Offshore Technology
Conference 2021
Where energy professionals prepare for tomorrow
OTC 2021 AT A GLANCE
When: August 16-19, 2021
Where: NRG Park, Houston, Texas
Website: www.2021.otcnet.org
T
he Offshore Technology Conference (OTC) is
where energy professionals meet to exchange
ideas and opinions to advance scientific and
technical knowledge for offshore resources and
environmental matters. OTC’s flagship conference is OTC WELCOMES TEACHERS AND STUDENTS
held annually at NRG Park in Houston, Texas. Though The OTC Energy4me Teachers STEM Workshop welcomes
originally slated for earlier in the year, the OTC Board science teachers to this free, one-day workshop. Teachers
of Directors has chosen to postpone the 2021 event to receive hands-on training by qualified facilitators, listen to
August 16 through 19 due to the ongoing challenges a presentation from a prominent energy professional, and
presented by COVID-19 and out of the greatest care tour the OTC exhibit floor. Additionally, teachers receive a
for the health and safety of their partners, attendees, variety of free instructional materials to take back to their
exhibitors, staff, and community. classrooms. Teacher workshops include the following:
OTC is sponsored by thirteen industry organizations
and societies, who work cooperatively to develop • Oil and gas educational instruction
the technical program. OTC also has endorsing and • Free classroom materials provided
supporting organizations. Also, OTC has expanded • Qualifies for continuing education credits
technically and globally with the Arctic Technology • Classroom activities designed by the NEED project
Conference, OTC Brazil, and OTC Asia. Still, the • Substitute teacher reimbursement
Houston-based event remains a must-see learning and • Breakfast and lunch
networking experience for professionals throughout the • Guided tour of OTC exhibit floor
energy sector.
Additionally, the OTC Energy Challenge is a high school
TECHNICAL PROGRAM competition where teams work to solve a real-world
OTC brings together the technical and scientific energy challenge. All competing teams submitted a video
knowledge from offshore energy game-changers as and e-poster presentation to compete for a scholarship
they share best practices, technical innovations, and prize. Each team was supported by their teacher, or
emerging trends. The conference has a strong reputation “coach,” and assigned an industry mentor. Through
for a world-class technical program. Attendees can take this event, OTC and its sponsorship partners intend to
advantage of the opportunity to hear from scientists, challenge and inspire students by asking them to solve
engineers, researchers, and executive-level speakers real-world energy challenges, discover new technologies
on their progress in revolutionizing the ever-changing and innovations from the next generation of engineers
environment of offshore projects. No one will want to and scientists, inform students of the wide range of STEM
miss this opportunity to participate in four days of opportunities in the energy industry, and learn more about
learning, sharing, and networking. what drives and motivates young STEM students.
10 | May 2021 | Modern Pumping Today www.mptmag.comT R A D E S H OW P R O F I L E
OTC RECOGNIZES EXCELLENCE The Abu Dhabi National Oil Panorama has generated over a
OTC is also the traditional time Company (ADNOC) will be billion dollars in business value for
to recognize several award presented the OTC Distinguished the company over its three-year
winners for both individuals and Achievement Award in recognition life span.
institutions. Joe Fowler will be of its cutting-edge Panorama digital Finally, the Heritage Award will
honored with the Distinguished command center. Considered the be presented to Edward Heerema
Achievement Award for only global platform of its kind in in recognition of his long-term
Individuals for his extraordinary the oil and gas sector, Panorama continuous, distinguished service
technical leadership in risers and provides an AI-based analysis with in management and leadership of
pipelines, industrial leadership complete visibility of production offshore installation for the deepwater
and entrepreneurship, significant facilities. As a result, Panorama industry and Russell Hoshman for his
contributions in higher education, provides a unique advantage in long-term continuous, distinguished
and his substantial contributions to terms of data integration, speed, service in safety and environmental
the societies that organize OTC. and accessibility across operations. stewardship for the offshore industry. ◆
W E BI NA R S
LEARNING FOR TODAY’S PUMP
INDUSTRY, AT YOUR FINGERTIPS
Whether your work focuses on water and wastewater,
chemical processing, or original equipment manufacturing,
you need to stay up to date with the latest training. MPT’s
hosted webinars bring industry experts from leading
companies to your computer and offer professional
certificates for completion.
FOR MORE INFORMATION:
J. Campbell (jay@mptmag.com)
visit our website mptmag.com
www.mptmag.com Modern Pumping Today | May 2021| 11S W PA I N S I G H T
The New Normal
Submersible wastewater pumps and the
challenge of “flushables”
By SWPA Executive Director Adam Stolberg and Jeff Boling,
Ebara Pumps Americas Corporation
R
agging and clogging are persistent problems in Consumers may not think their individual use can harm
wastewater streams, which can cause backflows, a wastewater system, but how serious can ragging and
seal leaks, and motor or pump damage, not clogging become?
to mention costly downtime and repair expenses.
Consumer cleaning products labeled—or, in many cases, It only takes a few wipes or rags to clog a pump.
wrongly presumed to be—“flushable” only compound One person can cause the clog that completely shuts down
the issue. Since these products have proven so popular a pump station. Once the clogging starts, it affects the
and consumer behavior is unlikely to change, the burden hydraulics of the entire wastewater system. These
falls on wastewater treatment professionals and pump stoppages cause overflows that spill the waste out into the
manufacturers to ensure the stream flows steadily, even streets and into the public. These hazards go unnoticed to
when wet wipes, disposable mopheads, and the like the general public, who unfortunately do not understand
threaten to bring an entire wastewater system to a halt. what’s really in those flood waters their kids are playing in.
Below, SWPA Executive Director Adam Stolberg and Jeff The danger to public safety is real.
Boling of Ebara Pumps Americas Corporation discuss
how to take on this challenge. How widespread is this problem and what can our
industry do to combat it?
Not everything that consumers deem “flushable”
is suitable for a wastewater system. What are some All wastewater systems are victims to this modern waste
of the most common offenders and what dangers or “flushable” mentality. As an industry, we must do
do they pose? our best to educate consumers on the consequences
of disposing of trash and wipes into the collection
Wet wipes are the most common “flushable” systems. Positive changes start with education.
offender. Wet wipe advertising has made these Seeming inconsequential actions by consumers
products extremely popular. However, many of drive up wastewater transfer and treatment costs and
these wet wipes are not flushable. Product labels for negatively impact the environment. The costs often
most of these products define the misunderstood or have significant impacts on the budgets of both small
never-read guidelines. and large municipalities. These costs can result in
the delay of repairs and upgrades that are needed to
• No more than one wipe per flush. maintain everyday operations.
• Wet wipes should not be flushed if fats,
oils, and grease will also be present in your Have “shelter in place” and “work from home” orders
collections system. placed a new stressor on municipal systems?
Most consumers are unaware of what occurs after they Prior to the pandemic, municipalities experienced the
flush, which is the start of an elaborate journey through highest flow rates after 3pm and on weekends. During
the collection systems. The definition of “waste” is the pandemic schedules shifted and municipalities
changing every day including new changes resulting are seeing higher flow rates throughout the day.
from the COVID-19 pandemic, which brought new waste These municipalities are adding inventory to their pump
stream items such as masks, gloves, and other personal stock and adding labor support to cover the increased
protective materials. These items are littered across demand for hands-on coverage.
the landscape and will eventually make their way into a In addition to the changes in the waste stream,
collection system during a future rain event. these municipalities require skilled operators
12 | May 2021 | Modern Pumping Today www.mptmag.comS W PA I N S I G H T
MPT
to manage the collections
systems. Most municipalities rely
READ MORE
on trade shows conferences and
seminars to gain insights into
enhanced and new methods and
Modern Pumping Today ®
technologies. This training is crucial
Providing Solutions for the Worldwide Pump Industry
to operating efficiently and effectively. Visit www.mptmag.com
The COVID-19 pandemic has
delayed or cancelled most of these
events in 2020 and early 2021.
What are some of the options
municipalities are adopting to
face the new normal? This doesn’t
appear to welcome a one-size-fits-
all solution.
Their demands change daily
depending on rain events, school
schedules, and unscheduled
breakdowns or maintenance needs.
Some municipalities are choosing
to repair and unclog pumps as
needed, rather than investing in
new pumps or other technologies.
In other areas municipalities
are planning for the future and
choosing to upgrade lift stations with
new pump technology, trash baskets,
advanced controls, and many other
solutions. Each municipality, and
really each lift station, requires a
tailored approach.
Do you foresee this problem
growing? And, if so, where is
technology headed to prepare
for it?
Unfortunately, with the
new flushable products available
to the public, the impact on the
waste streams will likely never
subside. New solids-handling pump
technology will continue to be
developed to keep up with the
stringy waste demand. New
controls technologies will continue
to be developed to ensure that
the systems are being operated
as efficiently as possible. Through
organizations like SWPA, pump
manufacturers can play a vital role
in educating municipalities on
best practices for operating
their wastewater collection systems. ◆
www.mptmag.com Modern Pumping Today | May 2021| 13CASE STUDIES
Sulzer removed and
installed the pumps as part
of the project.
Framework
Agreement
Minimizes
Repair
Times
Power station reduces
downtime by using
pre-approved supplier
for maintenance
By Alex Edwards, Sulzer
W
orking through a framework agreement ensured
high quality repairs were delivered on time,
extending the service life of vital pumping
assets at a power station. Sulzer's combined resources
and expertise also delivered overhaul projects for high
voltage motors at the facility.
Electricity plays a vital role in everyday life, powering
industrial and domestic equipment. Meeting this demand
requires careful management of the assets involved in
producing electrical power. Coordinating generating
capacity with maintenance requirements is a delicate
balancing act, and one that benefits from minimal downtime.
QUALITY AND TIME OPTIMIZATION
The power generation industry appreciates the
advantages of high-quality workmanship in prolonging
asset performance and increasing reliability. One of
the procedures used to minimize delays and optimize
maintenance tasks is the framework agreement. This
establishes a short-list of suppliers that have shown they
meet the required standards for workmanship, health
and safety, as well as management procedures and
cost efficiency.
14 | May 2021 | Modern Pumping Today www.mptmag.comCASE STUDIES The boiler feed pump motor windings were reconfigured to extend its service life. Both motors were reinstalled by Sulzer's field technicians before being commissioned. As an approved supplier Sulzer can be asked to quote generating sites throughout the United Kingdom and now has for maintenance projects in the knowledge that they have a number of framework agreements that are managed by the already met the necessary criteria. This can reduce the service centers closest to the customers' sites. time to repair important assets and maintains the high standards of the generating plant. CASE STUDY: HIGH VOLTAGE PUMP Another example of time optimization is to remove large MOTOR OVERHAUL assets, such as pumps and motors from service and overhaul As the initial point of contact, the local service center them as part of a preventative maintenance strategy. Sulzer coordinates all of the assets and personnel required to has been involved in such projects with several power deliver the project through the comprehensive service www.mptmag.com Modern Pumping Today | May 2021| 15
CASE STUDIES
The boiler feed pump motor windings were Sulzer delivered a turnkey project including removal and installation.
reconfigured to extend its service life.
center network. A good example leads to create a new star point. This the service centers to review
is the recent overhaul of two high- will extend the service life of the stator progress or see firsthand any
voltage motors, one from a cooling winding by taking the in-rush current unforeseen developments that are
water pump and the other from a away from the phase coils, reducing uncovered during an inspection.
boiler feed pump. the stress on the windings and allows Through continuous communication
Both motors were disconnected the operator to start planning for a and a transparent repair process,
and removed from service by complete rewind in the future. customers receive an efficient and
engineers from the Avonmouth Having reinsulated and varnished cost-effective solution.
Service Center, which is located the new windings, the motor was Larmour concludes, "The final
close to the power station. The reassembled with new bearings result from this project has been
refurbishment work was completed and seals before the remainder very positive. Downtime has been
by the Southampton Service Center of the testing was completed. minimized and plans are in place to
with additional expertise provided by Both motors were shipped to the make further improvements during
engineers in Birmingham, where the power station and reinstalled by the next planned outage." ◆
motors would be finally tested before Sulzer's field technicians before
being returned to the customer. being commissioned.
In this case, the boiler feed pump Adrian Larmour, U.K. sales
motor had a history of high partial manager, large machines at
discharge readings in the windings Sulzer, comments, "Our framework Alex Edwards is marketing and
communications manager, rotating
and action was required to manage agreement with this customer was equipment services, for Sulzer.
the situation and extend the useful a great advantage because all the Sulzer is a global leader in fluid
life of the windings. This would terms and conditions have already engineering, specializing in pumping,
allow the power plant to plan for a been agreed. This saved time when agitation, mixing, separation, and
complete rewind at a later date and repairs were needed and also application technologies for fluids of
all types. Sulzer customers benefit
improve the reliability of the motor provided assurances of the quality from its commitment to innovation,
until that time arrived. and the procedures used to complete performance and quality and from its
the project." responsive network of 180 world-
EXTENDING SERVICE LIFE class production facilities and service
Sulzer suggested reconfiguring the EXPERTISE AND EFFICIENCY centers across the globe. For more
information, visit www.sulzer.com.
windings by breaking the star point As with any work that Sulzer carries
and connecting the original supply out, customers are invited to visit
16 | May 2021 | Modern Pumping Today www.mptmag.comOUR H100+ IS TURNING THE PUMP WORLD
UPSIDE DOWN
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1-800-891-2941 | sales.us@lselectricamerica.comWATER & WASTEWATER FOCUS
Flood Defense Pumps
Need High-quality
Bearings
Bedford Pumps and Thordon Bearings
work wonders for English pumping station
By Emma Gerard, Thordon Bearings Inc.
P
umps for flood defense must handle high-capacity lubricated SXL bearings, in a contract that marked the first
volumes and also be reliable in extreme conditions. application of a Thordon bearing in a Bedford pump.
Bedford Pumps Ltd., one of the world’s leading Alix Macdonald, engineering manager, Bedford Pumps,
manufacturers of high-capacity flood defense pumps, has says, “We have created a brand-new type of axial flow
selected Thordon Bearings water lubricated SXL bearings pump to offer better efficiency, better solids handling, and
for a new pump design developed for the Islington enhanced environmental protection compared to other
Pumping Station, in King’s Lynn, Norfolk, England. concrete casing pumps of comparable size.
This important project will see four fish-friendly land “We found the Thordon product to be the best solution
drainage and flood control pumps installed at the new for large diameter vertical shaft bearings. The water
253,605-gallons-per-minute capacity pumping station lubricated elastomeric polymer material allows the
which, when commissioned, will protect a 6,000-hectare impeller to run at much tighter tolerances, improving
area of low-lying fenland. overall efficiency, maintainability, and reliability.”
ENTER THE NEW PUMPING STATION THE SXL BEARING
The existing pumping station, built in 1959, had reached the Macdonald adds that “competitive pricing, high quality
end of its service life and will be demolished following the material and a long-life expectancy” were also important
construction of the new pumping station. Canadian based factors in the procurement decision.
Thordon Bearings, a pioneer in elastomeric polymer materials, “The material is very easy to use, and easy to machine.
supplied eight 7.9 inch inside diameter fully finished water And then when it comes to installation, we can freeze fit,
press fit, or bond fit, so there are some options there too.”
Axel Swanson, business development manager,
Thordon Bearings, says, “The SXL bearing is the market
ABOUT BEDFORD PUMPS
Bedford Pumps Ltd. is a flexible, highly experienced
British manufacturer of robust pumping plant for the
water, wastewater, flood control, and dock industries.
With pump ranges from typically 7,925 to 317,007
gallons per minute at heads between 9.8 and 328
feet, the pumps are designed for the most arduous
and demanding applications and the brand is
synonymous for efficiency, reliability, and longevity.
18 | May 2021 | Modern Pumping Today www.mptmag.comWATER & WASTEWATER FOCUS
leader in product lubricated
vertical pump bearings due to its
durability, resistance to abrasion,
shock loading and vibration.
Wear life and performance are
the biggest advantage to using
Thordon materials.”
FISH-FRIENDLY PUMPING
To achieve “fish-friendly” status, a
key requirement for pump station
owner Kings Lynn Internal Drainage
Board (IDB), Bedford Pumps
designed a 63,401-gallon-per-minute
pump capable of allowing fish,
migratory eels, and other marine life
to pass through unencumbered.
A complementary intake was also
designed which offers significant
advantages over a standard ANSI type Emma Gerard is marketing communications specialist for Thordon Bearings Inc. Thordon
10 intake, such as allowing the water Bearings designs and manufactures a complete range of journal bearing and seal systems
levels to be drawn down to half the for marine, clean power generation, pump, and other industrial markets. These products
minimum submergence when compared are built using Thordon proprietary non-metallic polymer materials that are lubricated with
water eliminating oil or grease usage, meaning zero risk of oil pollution to our rivers, lakes,
to the type 10 design. and oceans. Thordon systems and bearings are available worldwide through over seventy-
“This intake significantly reduces five agents and distributors. For more information, visit www.thordonbearings.com.
the pumping station’s footprint
and the deep excavations typically
required,” says Macdonald.
A UNIQUE, ECOLOGICALLY
SAFE PROJECT
Chris Simmons, sales manager,
Duwel Group, Thordon Bearings’ U.K.
distributor, which also provided front
end engineering assistance, says,
“As a new customer for Thordon
and Duwel, it is a privilege to be
involved not only in an important
flood defense project but also in
the development of a new range of
Bedford pumps. We are proud to have
supplied Thordon bearings to what is
a unique, ecologically safe pump. It
is an important project and important
piece of kit.”
Macdonald adds, “We will
definitely look at using Thordon’s
bearings in the future for similar
pumps. The workshop staff gave
Thordon SXL bearings a very high
rating based on how easy they were
to fit with dry ice.”
At full capacity, the Islington
Pumping Station will be capable of
pumping 369 billion gallons of water
per day. ◆
www.mptmag.com Modern Pumping Today | May 2021| 19MAINTENANCE & RELIABILITY
Controlling
Dangerous Dusts
in the Chemical
Processing Industry
Part 1 of 2
By David Steil, Camfil Air Pollution Control
E
ffectively controlling toxic and to protect their employees from equipment. Other fine chemical
combustible dust generated exposure to airborne dusts, as well as dusts can travel deep into the lungs,
in chemical processing National Fire Protection Association becoming embedded and causing
facilities is essential to protecting (NFPA) standards to provide a safe serious respiratory conditions such
employee health, maintaining working environment. as occupational asthma and even
product quality, and preventing lung cancer.
devastating explosions. This article OCCUPATIONAL EXPOSURE TO OSHA regulations govern employers
examines these dangers, applicable TOXIC DUSTS whose processes generate dust, and
regulatory guidelines, and how to Regular exposure to certain types the agency will issue citations and
use a high-efficiency dust collector of chemical dust particles can be fines for lack of compliance. Under
to keep workers safe and facilities hazardous and irritate the eyes and OSHA, companies must control
in compliance. skin. Such conditions can cause toxic chemical dust emissions into
health problems for workers and the indoor workplace atmosphere
DUST HAZARDS IN THE may require treatment and protective to comply with the established
CHEMICAL PROCESSING permissible exposure limit (PEL)
INDUSTRY for workers. If no legal limits are
Controlling toxic and combustible applicable, then the company
dust is a common yet serious is required to define in writing,
challenge in the chemical processing implement, and measure its own
industry. Everyday processes like environmental safety plan to comply
mixing, conveying, and blending with the general duty clause.
create dangerous dusts that become
airborne, endanger air quality, and OSHA REGULATIONS
can create fire and explosion hazards. GOVERNING OCCUPATIONAL
Although each processing facility EXPOSURE
has unique dust issues based on OSHA 1910 is a broad, general
the raw materials used, they must standard that covers most
all comply with worker exposure industries. It is a comprehensive
limits, environmental regulations, and and complex standard with twenty
combustible dust standards. subsections. OSHA PELs include
Chemical processors must comply limits on airborne concentrations of
with Occupational Safety and Health Regular exposure to chemical dust particles can irritate
hazardous chemicals in the air for
Administration (OSHA) regulations the eyes, skin, and lungs. general industry in 1910.1000–Air
20 | May 2021 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITY
Contaminants. They are listed by with harmful dusts, fumes,
chemical name in Tables Z-1, Z-2, and mists, gases, smokes, sprays,
Z-3. Most OSHA PELs are eight-hour or vapors and coming into
time-weighted averages (TWAs), physical contact with these
although there are also ceiling dusts. It recommends accepted
and short-term exposure limits engineering control measures
(STELs). Many chemicals include to mitigate these risks as a first
a skin designation to warn against step before relying on PPE.
skin contact. • OSHA 1910:307: Hazardous
(classified) locations covers
• OSHA 1910.22: Walking- the requirements for electric
working surfaces is a equipment and wiring in
housekeeping standard locations where there is a risk of
that requires all places of fire or explosion because of the
employment, passageways, presence of flammable vapors,
storerooms, service rooms, and liquids or gases, or combustible
walking-working surfaces to be dusts or fibers.
clean, orderly, dry, sanitary, and Extracted air can be ducted to a dust collector located
free from hazards. This means Furthermore, the National outside of the processing plant.
that manufacturers must prevent Electrical Code (NEC) defines
dust from accumulating on hazardous location types, and many REDUCING WORKER EXPOSURE
these surfaces. chemical processing facilities are TO TOXIC DUST
• OSHA 1910.134: Personal Class II, where there is a sufficient The best way to reduce workers’
protective equipment (PPE) amount of combustible dust exposure to hazardous dusts is
requirements aim to minimize present in the air to be explosive or to install a dust collection system
occupational diseases caused ignitable under normal, everyday with high-efficiency primary and
by breathing air contaminated operating conditions. secondary cartridge-style filters. It is
www.mptmag.com Modern Pumping Today | May 2021| 21MAINTENANCE & RELIABILITY
OSHA: preferable to capture chemical fumes can be used to limit exposure and
COMBUSTIBLE and dust at their source to prevent cross-contamination of collected
CHEMICAL DUSTS them from expanding throughout material when performing filter and
the plant. This is accomplished by dust removal maintenance. Additional
Adipic acid
incorporating a hood or extraction features such as duct and equipment
Anthraquinone arm into the chemical process clean-out doors, stainless steel
Ascorbic acid machinery. Source capture is construction, safety after-filters (HEPA),
Calcium acetate extremely effective, and it requires the and FDA-compliant paint are also
Calcium stearate least energy and capital investment. commonly used with the air filtration
However, once they are captured, unit based on contaminant properties.
Carboxymethylcellulose
dust should be isolated from the
Dextrin rest of the facility and contained TYPES OF FILTERS AND
Lactose in a specific area. For example, a FILTRATION MEDIA
Lead stearate portioned area can be kept under Primary filter media should be
Methylcellulose Paraformaldehyde negative pressure. The extracted air selected for each application
Sodium ascorbate is either drawn directly into a local based on the dust particle size,
collector or ducted to a dust collector flow characteristics, quantity, and
Sodium stearate
located remotely. In some cases, the distribution. If the dust being collected
Sulfur filtered air can be safely returned is toxic and the primary filtration
back into the facility system does not use a HEPA filter, it is
to create a push- recommended that a secondary HEPA
pull airflow pattern filter be used downstream. Secondary
to improve the filters prevent hazardous dusts from
contaminant control. discharging to the atmosphere and
A chemical can be configured to prevent return
manufacturing air ducting contamination and the
facility may also associated costs of cleaning hazardous
require special options dust leakage.
or accessories to A wide, uniformly pleated filter
improve the safety allows the collected dust to release
and reliability of the from the filter, keeping the resistance
system. Bag-in/bag- lower through the filter for a longer
out filters and hopper period of time. When the pleats of the
discharge options filter media are tightly packed, the
reverse pulse cleaning system of
the dust collector will not eject
the dust that has settled in
between the pleats. Tightly
packed pleats increase
the resistance of the air
through the filters and
diminishes airflow, thus
shortening filter life.
There are two basic categories
of media commonly used in
pleated cartridge filters. The
choice is usually driven by dust
type, operating temperatures and
the level of moisture in the process:
• Nonwoven cellulosic blend
media is the most economical
choice for dry dust collection
applications at operating
HemiPleat® Gold Cone™
temperatures up to 160 degrees
cartridge filter. Fahrenheit (71 degrees Celsius).
22 | May 2021 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITY
• Synthetic polyester media dust from building up in the work
or polyester-silicon blend is environment, on electrical equipment
a lightweight, washable and other areas where dust
media that can handle can accumulate, such as
dry applications with false ceilings.
maximum operating These measures help to
temperatures ranging negate the risk of a primary
from 180 degrees and/or secondary explosion.
Fahrenheit (82 degrees The primary explosion is the
Celsius) up to 265 first point where an explosion
degrees Fahrenheit (129 occurs and is usually an isolated
degrees Celsius). These incident. A secondary explosion
filters are washable occurs when the primary
and can recover from a explosion pressure disturbs
moisture excursion, but the dust collected in the areas
they are not intended for mentioned above, creating a far
wet applications. more extensive and potentially
deadly explosion.
Standard and nanotechnology Dust collectors minimize the
filter media treated with a flame amount of combustible dust
retardant are recommended for that can collect on floors and
applications considered a fire risk. other surfaces, and they contain
Conductive or anti-static filters chemical dust in one area. But
may be used where conveyed the dust collectors themselves
dusts generate static charges that can be a fire or explosion
require dissipation. Cartridge hazard if they are designed
filters with anti-static media incorrectly or not equipped with
can also be used in explosive the proper explosion protection
dust applications, making it controls.
possible to conform to NFPA
requirements and lessen the A LOOK AHEAD
risk of ignition sources due to In next month’s conclusion,
static electricity charges. we’ll review the regulations
High-efficiency dust collection governing combustible dust—
systems also use self-cleaning from the NFPA, OSHA, and the
mechanisms that regularly pulse U.S. Chemical Safety Board—as well
dust off the filters, allowing units to where a spark or flame can ignite as look over techniques for mitigating
run longer between filter change- them, causing a fire or explosion. combustible dust and its exposure.
outs. When a layer of nanofibers Common ignition sources are kilns or Effectively controlling the dusts
is applied on top of the base filter a welding flame, but they also can be generated in chemical processing
media, it promotes surface loading of a lit match or cigarette. facilities is an essential life-saving
fine dust and prevents the dust from Good housekeeping and installing and legal obligation, so these points
penetrating deeply into the filter’s a well-designed dust collection will be of interest to anyone mindful
base media. This translates into system can prevent airborne of reducing hazardous dust. ◆
better dust release during cleaning
cycles and lower pressure drop
readings through the life of the filter.
COMBUSTIBLE DUST EXPLOSIONS Camfil Air Pollution Control is one of the world’s largest manufacturers of industrial dust,
mist, and fume collection equipment. As part of the global Camfil Group, we’re represented
A dust explosion occurs when on six continents and draw upon over five decades of experience and expertise to ensure
a confined and concentrated that our customers are kept safe and productive. Every manufacturing process creates
combustible dust cloud comes into some kind of dust, mist, or fume. These byproducts can be harmful to workers, and they
contact with an ignition source. can cause machinery to become less efficient. Camfil APC’s product range is designed
to keep your workforce safe and healthy, and ensure that your operations and processes
Many chemical dusts qualify as
remain as efficient as possible. For more information, visit www.camfilapc.com.
combustible dusts. These chemical
dusts can accumulate on surfaces,
www.mptmag.com Modern Pumping Today | May 2021| 23MAINTENANCE & RELIABILITY Reducing Environmental Friction with High-performance Coatings The key to lower energy consumption, reduced emissions, and longer equipment life By Logan Walz, Oerlikon Balzers 24 | May 2021 | Modern Pumping Today www.mptmag.com
MAINTENANCE & RELIABILITY
S
pecialized physical vapor contributor to improving the only a few micrometers to further
deposition (PVD) coatings environment. They not only point to harden the surface of these parts and
are widely recognized for the these environmental benefits but through mechanisms such as altering
critical role they perform in enhancing also to the enhancements they have the surface chemistry they can also
operational performance and extending made in their own coating equipment lower the coefficient of friction. As a
the life of parts across countless to operate more efficiently. In result, less energy is used and less
manufacturing and industrial sectors. addition, continued advancements emissions are generated.
Less understood is the value that in specialized PVD coatings are Carbon-based coatings such as
these coatings provide in reducing the also playing an important role in the diamond-like carbon coatings (DLC)
environmental impact of the industrial design of components for new and from specialized coatings formulators
processes where they are used. emerging green technologies. like Oerlikon Balzers, are even more
It starts with one of the primary durable. Produced mainly through
reasons to use PVD coatings in REDUCING FRICTION WITH plasma-assisted chemical vapor
the first place, which is to reduce SPECIALIZED COATINGS deposition (PACVD), these well
friction between mated parts to Reducing friction when mated adhering coatings provide a unique
improve performance. This can result components are in contact with combination of high hardness and
in direct energy savings and, by each other is critical, particularly in low friction coefficients.
extension, reduced CO 2 emissions. punishing environments where there Such coated components are
Because these coatings extend are high loads and high wear. Bearings, utilized for a variety of applications
the life of component parts that gears, rollers, and other precision including wind turbine shaft bearings
require frequent replacement, the components suffer from excessive wear, and planetary gears, stainless steel
raw materials, metals and energy surface fatigue, pitting, galling and cutting blades and piston pumps,
that are required to manufacture a corrosion which can also cause failure and sliding components across many
replacement part, are also saved. especially in high-load applications. industries. The coatings are also
In fact, some specialized coatings To prevent these issues from a proven technique for upgrading
manufacturers are making a strong occurring, specialized PVD coatings critical rotating parts in hydraulic
case that coatings are a significant are applied in thicknesses of typically drives, pumps, and valves.
www.mptmag.com Modern Pumping Today | May 2021| 25MAINTENANCE & RELIABILITY
Advanced, hydrogen-free DLC reductions translate into comparable higher performance, cleaner and
coatings provide even higher CO 2 reductions. smoother running machinery.
hardness along with a very low Similarly, in the automotive sector,
coefficient of friction. These DLC-coated valve and power train EXTENDING THE LIFE OF PARTS
coatings can be applied in the most components can reduce the friction SAVES ENERGY
demanding environments for high mean effective pressure (FMEP) The environmental benefit of high-
friction, wear, and contact areas by 10 percent. This translates to performance coatings is also realized
such as in hydraulic pump parts, a 2 percent reduction in fuel. A by how they extend the life of parts
mechanical seals, and high-pressure 20 percent reduction in FMEP and tools. When parts last longer they
valve components. Today, they are will generate a 5 percent fuel are replaced less frequently which
also playing an increasingly important consumption reduction. reduces the raw materials, metals, and
role in e-mobility applications. More stringent environmental energy it takes to manufacture them.
regulations and standards worldwide In the automotive sector, forming
SMALL EFFICIENCIES ADD UP are also causing industry to focus on tools are made from multi-ton pieces
Even small percentage gains in reducing their carbon footprint and of steel in the negative shape of a
energy savings can really add up in design greener products. car. Used to make millions of cars,
large scale industrial environments. Take large cargo ships as an the forming tools will degrade over
“Consider that a single percent gain example. Today operators need to time and require reworking. To
in efficiency for a 200-megawatt gas reduce the sulfur content of their ensure optimal performance and
turbine represents the equivalent fuel in order to be compliant with long life, they require polishing and a
power needed for 1,500 homes,” says current sulfur cap requirements. PVD coating application. In addition
Alessandro Zedda, chief technology With a cleaner fuel mandate, marine to saving energy by keeping the
officer at Oerlikon Balzers. engine manufacturers required a new forming tool in optimal condition,
Seemingly minor factors such as a fuel injection technology because additional energy is saved by less
smoother surface finish can improve clean fuels typically do not lubricate frequently moving equipment of this
fuel efficiency. In the aerospace as effectively as those with a higher size and weight to a separate location
and energy sectors, for example, sulfur content. to be repaired.
PVD erosion coatings are applied As a result, the coatings used in In the energy sector, applying
to compressor blades to protect diesel marine engines also needed a DLC coating to roller bearings
polished surfaces from degrading to be redesigned to ensure the new in wind turbines extends their life
over time. This can reduce fuel usage clean fuels will work well. Coatings and lowers maintenance expenses.
by up to 0.5 percent while promoting that meet this new requirement have Consider that changing one main
component longevity. These fuel become an enabler of more efficient, shaft bearing costs between $200-
300,000 in addition to the disruption
caused by taking the turbine off of
the grid.
ENABLING GREEN
TECHNOLOGY DEVELOPMENT
Beyond improving the efficiency and
carbon emissions of existing systems,
PVD coatings can be an enabler of
new green technologies in categories
such as fuel cells and high-power
energy density batteries.
“Within the fuel cell sector, we
are working with a client who
manufactures bipolar plates, a
key component in fuel cells,”
says Zedda. “Here the role for a
PVD coating will be to promote
conductivity while at the same time
resisting corrosion. Together these
attributes will promote the longevity
of the fuel cells extending their
environmental benefits.”
26 | May 2021 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITY
Zedda adds, “We are also working
with clients to apply PVD coatings
on some exciting and highly Oerlikon Balzers is one of the world’s leading suppliers of surface technologies that
innovative projects in high power significantly improve the performance and durability of precision components and
energy density batteries. As industry tools for the metal and plastics processing industries. For more information, email
balzers.components@oerlikon.com or visit www.oerlikon.com/balzers.
continues to develop environmentally
friendly innovations, there will be
more opportunities for coatings
to be engineered to support their
performance and overall life span.”
EFFICIENCIES IN COATING
APPLICATION GENERATE AN
ENVIRONMENTAL ROI
Further up the specialized coatings
supply chain, coatings manufacturers
themselves have examined their
processes for applying coatings
since it consumes both materials
and energy.
When the energy consumed to
produce coatings is compared to the
energy savings they generated in
their application, either through the
improved efficiency and longevity
of an engine or a cutting tool, an
“energy payback” or return on
investment is generated.
“We are constantly striving to
reduce the energy consumption of our
coating equipment,” says Zedda. “Our
new coaters consume 40 percent less
energy by using new more efficient
plasma sources. Multiply this saving
on every batch at all our coating
centers around the world and the
environmental benefit is huge.”
He adds, “While the impetus
to explore a new source was
environmentally-driven, it is also
in our customers’ economic best
interests because it reduces their
coating cost and shortens our
manufacturing cycle.”
Specialized coatings have an
important role to play in reducing
our environmental impact. Energy
consumption and carbon emissions
of manufacturing and operations
processes can be reduced
significantly. Thus, while industry
continues to use specialized coatings
for their ability to enhance operating
performance, the environmental
impact is an important value-add that
should not to be overlooked. ◆
www.mptmag.com Modern Pumping Today | May 2021| 27PUMP SOLUTIONS
How Can Predictive
Maintenance Improve
Pump Operations?
Six points of preparedness for Industry 4.0
By Emily Newton
T
oday, leaders in many industries are shifting towards could quickly turn into major problems. Some diagnostic
predictive maintenance rather than the traditional processes also record vibration signatures so technicians
approach, which typically requires having equipment can tell when a pump starts vibrating more, possibly
maintained on a schedule or only once problems result. signaling its impending malfunction.
Predictive maintenance involves using tools like Maybe you’re in a position to adopt predictive
specialized sensors and data interfaces to show maintenance but are still unsure if you’d see measurable
technicians the minor signs of worsened operations that benefits from it. Here are some specific ways predictive
28 | May 2021 | Modern Pumping Today www.mptmag.comPUMP SOLUTIONS
maintenance could directly support PROVIDING VALUABLE HELPING COMPANIES REMAIN
better pump operations. INFORMATION TO RESPONSIBLE COMPLIANT
PARTIES Professionals in numerous industries
ENSURING INTENDED As predictive maintenance has must follow regulations to satisfy the
PERFORMANCE become more widely utilized, appropriate regulatory bodies. For
Keeping pumps running smoothly there has been an increase in tools example, in the construction sector,
is important at all facilities that use that help companies capitalize the Occupational Safety and Health
them. However, it’s arguably crucial on it. Authorized users can log in Administration (OSHA) requires
when failures pose public health to specialized interfaces and see accommodating areas with at least
threats. Those problems can lead current conditions and historical 19 inches difference in elevation
to fines, damaged reputations, and data. Products that help companies by providing ladders or ramps
negative media attention while stay on top of maintaining equipment for workers.
putting people’s lives at risk. facilitate finding the causes of It also mandates creating
A pump failure at a treatment plant problems and taking the correct protective systems for trenches of
led to officials concluding that the actions to fix them. 5 feet or more. OSHA has extensive
problem caused a significant water This approach can also make requirements, so it’s no surprise that
supply safety risk. It took workers equipment last longer. For example, rules exist for concrete pumps, which
almost eight hours to detect the installing a sensor on a progressive construction workers often use.
issue. The matter deposited sludge cavity pump can prevent issues like One stipulation is that there must
particles into the water. It also made premature wear and decreased be pipe supports designed for 100
the liquid have elevated aluminum suction capabilities. When teams can percent overload on systems with
levels and look cloudy. immediately look at data that shows discharge pipes. One advantage of
If the team at that facility had taken how certain factors change over time, predictive maintenance is that it can
the Industry 4.0 approach of using it’s easier for them to know when help professionals become more aware
sensors to get immediate notifications problems might occur or identify of equipment as a whole. For example,
of faults, they could have avoided inefficient processes that could a technician may notice that a pump
this situation. reduce a pump’s lifespan. system does not comply with OSHA
www.mptmag.com Modern Pumping Today | May 2021| 29You can also read
