The Northwest of Russia literally flows with water. An area known for huge lakes and vast wetlands. Petrozavodsk is the capital, and the largest city, of the republic and most of the 300,000 inhabitants get their drinking water from the nearby Lake Onega. But some new settlements on the outskirts of the city have chosen another source. “We get our water supply from an aquafer, that covers most of southern Karelia. Three large pumps from Grundfos deliver water to our building complex with around 5,000 people,” explains Vitaliy Markov, General Manager of Drevlyanka Vlll – a part of Chistiy Gorod.

SP pump range

“When we had to decide whether to be on public water or invest in our owns wells, the most important factor was the cost. We could save half by having our own system,” says Vitaliy Markov, who lives in one of the flats himself.

Grundfos was chosen as the main supplier for the complete system – including SP and NB pumps, frequency converter, filtration, aeration and chlorification. Three huge 26 kW SP pumps (Fig.) deliver an average of 2,000 m³/day, but the pumps and disinfection system don’t run all the time. They normally work five days per week. Water for daily usage is taken from two huge storage tanks.

“Because of digitalization the total system is run by only two people, compared to other systems that require up to ten people. The single most important factor was the excellent energy efficiency in the system, that has resulted in significant savings,” says Rodion Andreev,  Manager of Vodokanal 3.

Best water in the area

According to the general manager of the building complex, the water quality is the best in Karelia. The water is natural and healthy.  Today people even talk about it in the city, when comparing to the water from the lake.

“We are spoiled with water in this area, but I often hear that new tenants are surprised how fresh and tasty our water is. It puts an extra flavor to our name Chistiy Gorod,” says Vitaliy Markov.

Room for expansion

Soon a new building complex will be erected. Drevlyanka Vl is in the making and will be finished in 2023/24. That means the demand for water from the underground river will increase over time. And to meet the rising demand a new well is in the planning.

“We will increase the capacity by 50 percent,” says Dmitriy Potashev, Sales Engineer from Grundfos. “Not only by drilling a new well, but also by increasing the flow in the existing installation. That will make this water utility the biggest and only of its kind in the whole of Karelia.”

A German energy supplier had initially used a geological horizon for gas storage, but then decided to extract crude oil from the same deposit. Therefore, a suitable extraction system had to be acquired for transporting the multi-phase mixture with a high gas content to the surface from 1,200 m below. Due to the extreme conditions, a special pump technology was required:

Netzsch developed a progressing cavity pump system with submersible drive. As all moving parts are positioned deep down in the well, there is also no risk of environmental impact from leaks at the surface.

The conditions on site presented high requirements for the pump design: as the medium is a multi-phase mixture with a very high gas content. Progressing cavity pumps, which are normally used in Central Europe until now, have been systems with above-ground drive. These units have a dynamic seal on the surface which has a significant disadvantage in case of extreme pressure increase on the intake side: the seal can become overloaded and trigger a blowout.

To exclude this risk, Netzsch decided on a progressing cavity pump which is driven underground – the ESPCP. The special feature of this pump is that the rotor-stator combination and the motor are sunk into the well. The motor is connected directly to the rotor via a short flexible rod. All radial and axial forces of the rotor are absorbed by a special underground bearing housing. In addition to this, the dynamic seal is also located in the 1,200 m deep well. This moved all critical components of the pumping solution below ground, precluding environmental impact from leaks above ground.

This new KSB app called ‘FlowManager’ can be used to operate and configure the PumpDrive 2 and PumpDrive 2 Eco variable speed systems. It can also be used to adjust the fixed speed of MyFlow Drive to the optimum operating point. The new KSB FlowManager app features all of the familiar basic functions from previous versions of the MyPump Drive app and supports both IOS and Android devices. It is available for download from the iTunes Store and Google Play Store free of charge.

The app’s main functions can be summarised under the terms operation and monitoring.

The app shows the current operating point and provides access to all key parameters, alerts and warnings as well as records of trends. It also has a commissioning wizard for open-loop control, discharge pressure control and differential pressure control. Selected parameter sets can be saved, managed and sent.

Furthermore, it features an additional parameter view that enables editing of drive parameters to adjust the pump system to system requirements. In combination with MyFlow Drive, the app enables subsequent adjustment of the pump’s operating point through virtual impeller trimming. This functionality can be used in the app with the help of a TAN entry. For a fee, operators can purchase a TAN list of 50 valid numbers.

Another new feature – the external Bluetooth gateway – allows wireless communication with the devices via smartphone, tablet or notebook. The gateway does not have to be built into the devices. Instead, it can be attached externally to the service interface of the devices. The gateway also has an additional interface for a mini-USB cable (for communication with a notebook or for charging the battery) as well as an “on-off” button for battery-saving operation or to switch between Bluetooth and USB mode. Two integrated status LEDs indicate the operating and battery modes.

SPX Flow Inc. Industrial and Energy (I&E) division and the Tapflo Group signed a major distribution agreement for Central and Eastern Europe including Austria and South Africa. The agreement starts with immediate effect and covers the Johnson Pump, Bran+Luebbe, Plenty, Lightnin, Airpel and GD Engineering brands. Upon signing Tapflo placed an initial stock order for 200 Johnson pumps.

From left to right: Krzysztof Doroszkiewicz Distribution Lead at Tapflo Group, Hakan Ekstrand COO at Tapflo Group, Börje Johansson owner of Taplflo Group, Emelie Johansson, Gerard Santema Emea Sales Director Industrial Pumps & Mixers at SPX Flow

“We are delighted to sign this agreement with the Tapflo Group who we consider to be a very strong partner in Central and Eastern Europe. I am confident that SPX Flow I&E will increase its customer base and market share in these important regions”, said Gerard Santema, SPX Flow, Emea Sales Director Industrial Pumps & Mixers.

“Tapflo has been in the business for over 30 years serving the general process industries. We have the experience, domain knowledge, languages and local presence to provide a level of service commensurate with that of SPX Flow I&E. I am confident that having so many well-known and respected brands in our range we will be able to expand our business and the services providing the highest levels of support to our customer base”, said Krzysztof Doroszkiewicz, Distribution Lead, Tapflo Group.

Slides assume the main job of generating the vacuum – more than 30,000 hours of durability were achieved using a new material

Whether slide bearings, sliders or mechanical seals – all these components are exposed to high loads on a daily basis and, therefore, wear out. With innovative materials, however, maintenance intervals and the service life of pumps and seals can be extended considerably, as evidenced by developments in carbon materials.

Selecting the right material determines the service life of machines, units, and systems. Conventional materials often reach their load capacity limits, especially in pumps and mechanical seals. Schunk Carbon Technology develops and produces materials for seal rings, slide bearings, and pump components made of carbon and silicon carbide. These innovative materials particularly excel in the areas of abrasion resistance, sliding capability, media resistance, and temperature resistance. Carbon in the form of graphite also has the characteristic property of self-lubrication. All in all, exactly the features required in demanding industrial environments. “In practice, their use leads to a significant increase in service life and extended service intervals,” says Thomas Kräuter, Sales Director of the Mechanical Carbon Industry at Schunk. It is not enough to simply replace a material; many years of expertise are required. Three current development projects demonstrate the path from material to functioning components, leading to new materials that considerably extend the service life of pumps, seals and the like.

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The new C-Series pumps have been specifically developed by Almatec to be a cost-effective alternative. The housing parts are tightened to each other via housing bolts. All of the C-Series’ bolts are tightened together against a diaphragm-sized ring on each side of the pump.

This design distributes the forces of the housing bolts onto the housing parts evenly, providing a consistent flow of forces that increases bolt torque and improves pump safety.

The design of C-Series pumps also ensures the suction and discharge ports are available as separate housing parts so that different connection versions are available for easy matching to existing installations. In addition, these pumps provide good suction head, and feature self-priming and dry run capabilities.

The C-Series features Almatec’s exclusive Perswing P air control system, which offers superior efficiency when comparing flow rate and air consumption needed that translates into lower energy costs. The C-Series also features no mechanical seals, drives or rotating parts that cause wear over time. All wear parts are compatible with other Almatec pumps.

C-Series pumps are available in three pump sizes – C 10 (3/8”), C 15 (1/2”) and C 25 (1”) – and achieve flow rates from 1.3 to 7 m³/h at a maximum discharge pressure of 7 bar (100 psig). The wetted housing parts of the C-Series are made of either abrasion-resistant polyethylene or chemically, almost universally resistant, PTFE. The material of the non-wetted center block is polyethylene or PE conductive. Additionally, C-Series pumps are available in versions that conform to Atex requirements according to the 2014/34/EU directive.

Salinen Austria AG is one of Europe’s leading salt suppliers. The company’s most important products include brine for the chemical industry, food, industrial and melting salt, and chemically pure salt for pharmaceuticals. Three sites (Bad Ischl, Hallstatt, Altaussee) produce more than 3 million cubic meter of brine. Because of this, Austria is one of the most important salt producers in Europe. Salinen Austria AG contracted with Altmayer Anlagentechnik to construct a system that would be used to transfer tailing piles from the brine purification process used in the production of evaporated salt into the caverns. The tailing piles from the brine purification process are to be used to pack the salt cavities that have been created.

Fig. 1

The method is, on the one hand, highly ecologically conscious in the sense of closed loop waste management, and, on the other hand, packing excavated caverns increases the stability of the underground works. The packing material is delivered by truck at a dry weight of approx. 70 % and unloaded into hoppers. Using walking floors and screw conveyors the packing material is conveyed into a mixing container. It is mixed with the brine removed from the mine to form a homogenous solution with approx. 30% dry matter.

A hydraulic, quadruple-action piston membrane pump (HMQ series- Fig. 1) pumps the packing material out of this hopper at an internal design pressure of 40 bar and a capacity of 6 to 45 m³/h into the mine via a pipeline that is about 2.5 km long. The mined caverns are then refilled with the packing material. Once the suspension has had time to settle in the caverns, the brine is pumped back up to the surface and is again used for mixing. In contrast to solids handling pumps, a piston membrane pump is ideally suited for abrasive, liquid media. For this reason, the HMQ is ideal for conveying the packing material in this application.

Due to the high salt content of the packing material, the suction and pressure lines, as well as the cone valve housing and pump housing, are made of stainless steel, so that the pump parts that come into contact with the product do not corrode.

Fig. 2

The integrated reversing valves are suited for use with the pumped medium and the process pressure. The reversing valves are installed in such a way that the medium’s direction of flow through the pump is “reversed” (Fig. 2). The normal direction of flow for piston membrane pumps is from bottom to top; in this case, the medium flows from top to bottom. The advantage gained through reversing valves is that the medium is pumped in the same direction of flow in which sedimentation may take place. This means that larger particles cannot lodge in the product valves and the membrane housings, and possible damage to the membrane can be avoided.

The HMQ pump uses an intelligent membrane pulsation damper (Fig. 3). The iMPD damper automatically adapts to changing operating pressures, providing low residual pulsation over the entire pressure range. The iMPD automatically adapts to the actual operating conditions through the use of a piston compressor.

Fig. 3

The performance range of Abel HMQ pumps goes up to 500 m³/h, for media up to 10.0 MPa. Main applications are

• Conveying suspensions
• Feeding filter presses
• Treating water
• Conveying ore and ash
• Desulphurisation of flue gas

KSB experts developed a special impeller for its Movitec multistage high-pressure pumps. This new impeller significantly improves these pumps’ suction characteristics (NPSH value).

It proves its worth particularly in applications with critical inlet conditions (e.g. boiler feed applications) as well as applications in which the pump is required to take in water from low-lying tanks or at higher temperatures. Under these conditions, a pressure drop in the intake area may cause cavitation to occur in the first pump stage. This can result in excessive wear of pump parts or motor bearings as well as a reduced service life of the pump due to damaged parts and an unbalanced hydraulic system.

The new impeller is offered as an alternative to the standard product.

When developing the new impeller, KSB’s design engineers went to great lengths to ensure it can be used with a number of Movitec variants without necessitating modifications to the outer pump casing.

The new impeller features a modified inlet diameter, vanes allowing a slightly diagonal throughflow and a newly designed stage casing, all of which serve to substantially improve the pump’s NPSH curve.

The multistage centrifugal pumps from the Movitec range are designed for handling fluids such as water, coolants, condensate and mineral oils. They are ideal for a wide variety of applications ranging from

• industrial boiler feed installations in steam circuits,
• recirculation and
• fire-fighting systems,
• cooling water circuits and
• washing plants to
• pressure boosting in general process applications.

Technical paper by Susanne Suttrop

Committed to their slogan – Coppenrath & Wiese – Where else can you get quality like this? –  the company has earned a reputation in the field of frozen desserts that has been solidly anchored in the consciousness of consumers for more than 40 years (Fig. 1). But a slogan alone is not enough to satisfy customers if not simultaneously associated with reliably high quality products. That is why the company insists not only on high quality, fresh ingredients and skilled, talented employees but advanced production processes as well.

With a daily production volume of 3.3 million rolls as well as more than 200,000 various tortes, failure of even one component can lead to significant financial losses. For this reason, the company’s expectations for high-quality production systems are just as high as the expectations of consumers for outstanding products.

Oven with pumps of the CTWH series on the baking line

At the Mettingen plant in northwestern Germany, Coppenrath & Wiese bakes in tunnel ovens measuring 3 m x 50 m (Fig. 2) that are heated largely by thermal oil. While reliable performance of thermal oil pumps was the company’s top priority, Coppenrath & Wiese also needed pumps that could meet the baking industy’s stringent requirements for quality and safety. Finally, the company was looking for a partner with skilled service and support capabilities, to continuously monitor the entire system, as well as provide annual maintenance and repairs as needed. The bakery selected centrifugal thermal oil pumps from Allweiler.

Reliability built right into production

With a variety of processes and production steps, the company needed several different temperatures, so they divided the heating system into three connected heating loops. These loops use two different pump types of various sizes that are specially constructed for pumping heat carrier liquids at temperatures as high as 400 °C.

A variety of sizes for optimal hydraulic dimensioning in various configurations are available according to the needs of the application- shown here the Allheat GP block inline series. Pumps with separately coupled motors and foot attachment on a base plate or directly coupled in block or inline versions with both vertical and horizontal installation options provide flexibility and ensure that the customer will have maximum operational efficiency and reliability for the entire system.

The heat transfer oil is first heated to 290 °C in a central boiler. This primary loop is the ideal use for a single-flow volute centrifugal pump of the CTWH series from Allweiler’s Allheat product family. With a mechanical seal that is lubricated by the pumped liquid, the pump can be used to circulate heat-transfer oils at temperatures as high as 400 °C in heat transfer plants and is characterized by extremely low efficiency losses.

As soon as the required temperature is achieved in the heating kettle, the oil is pumped to the ovens in a secondary loop. The secondary loop also uses pumps of the CTWH series, but in a smaller size.

The third and most important heating loop for good baking results connects directly to this loop. This tertiary loop utilizes mixers to properly regulate temperature as well as circulate the hot oil through the heat exchangers in the walls of the oven, resulting in uniform heating of the oven itself.

Operational safety without leaks a fundamental requirement

Due to the strict requirements of the food industry, a complete absence of leaks is essential in these production steps, necessitating the use of the CMIT series of the Allmag product family from Allweiler. These are magnetically-coupled single-stage volute centrifugal pumps with a hermetically sealed design that prevents all leaks. Their patented design principle also provides exceptionally high operational safety and reliability.

This is very important because if the fully automated process was interrupted by the failure of even one pump, the temperature in the stations would drop within a few minutes. Such a disturbance to the continuous and complex process would result in quality inconsistencies, forcing the company to destroy the products and suffer a significant loss.

But the Allweiler  pumps selected by Coppenrath & Wiese have fully met the company’s expectations for safety and quality in the plant’s production system. “Since their installation sixteen years ago, these pumps have been running with no disturbances and have proven to be highly reliable components,” according to Andreas Beckmann, director of the engineering department.

Committed to future performance

In order to ensure that this high level of operational safety continues into the future, Coppenrath & Wiese is supported by Allweiler’s PumpService program of technical expertise. Especially to minimize the service time the CMIT pumps offer design related advantages. These pumps used in the tertiary loop are characterized by unparalleled durability in continuous operation because the magnetic coupling eliminates all of parts that wear found in conventional designs.

Considering the fact that Coppenrath & Wiese must stop its production lines for maintenance and service, this built-in durability has a direct positive effect on the company’s bottom line. The discontinuation of some seasonal products necessitates the temporary stopping of a production line. But Coppenrath & Wiese can plan for these window of time with a high degree of accuracy, virtually eliminating unanticipated downtime during the high season that would affect the company financially.

Over the past decades, international technology Group Andritz has become a byword for highest quality and customized pump solutions and is now a preferred partner on a global scale. In the interests of its customers, the Pumps division does not set itself any limits with regard to size and flow rate in the development and manufacturing of tailor-made pumps. Thus, Andritz has been commissioned to supply the water intake pumps for China’s first privately managed and largest petrochemical plant.

During the first construction phase of the Zhoushan project, 14 vertical line shaft pumps provided by Andritz will also be installed and set up for operation.

The production of chemical products stemming from natural gas and suitable fractions of mineral oil gained importance during the Second World War. Due to a sudden lack of natural products such as rubber, artificial substitutes were needed instead. Once established as a substitute, the petrochemical industry and the derivatives it produces, such as polyester, ethanol or ethylene glycol used in antifreeze, became quite a significant area, encouraging China especially to invest in enlarging its production capacities.

To be built on the 6.25 sq. km Zhoushan Island off the eastern Chinese coast near the strategically important ports of Shanghai and Ningbo, the Zhoushan project is setting new standards in China. It is not only the country’s first energy installation to be built by a non-state investor, but will also be the biggest green petrochemical base in China after its completion. The cost of the project is estimated at around 25.44 billion US dollars. It is part of Beijing’s efforts to make the state-controlled energy sector more attractive to private investors. The first building phase of the oil refining and petrochemical complex has already been started. When the plant is completed, which is likely to be sometime in 2020, it will consist of two oil refineries producing 400,000 barrels per day and two ethylene plants producing 1.4 million tons a year.

Andritz offers a complete program of impeller shapes for all combinations of delivery rates and heads, according to specific speeds.

During this first phase, 14 vertical line shaft pumps provided by Andritz will also be installed and set up for operation. The decision to order the pumps from the international technology Group was made due to its extensive experience from over 165 years in the pumps business and its specifically high engineering competence as well as better life cycle costs overall. Thus, Andritz has become a preferred partner on a global scale for accommodating customers’ needs and providing the ideal pump solution. Beginning with R&D, continuing with design and manufacture to after-sales service, Andritz combines the entire value-added chain under one roof.

The pumps supplied are highly engineered hydraulic machines characterized by lowest energy consumption and efficiencies above the market average. They have been designed in accordance with customers’ and projects’ specific requirements. Installed in the production process as water intake pumps, the 14 vertical line shaft pumps have various properties depending on the medium to be transported. Especially the choice of material and suitable finishing are determining factors in functioning and stability of these pumps. Acting as water intake pumps, they are exposed to the aggressiveness of the salty sea water. Hence, these pumps are made of a special, highly resistant material – duplex steel. Processing of duplex steel requires extensive practice and know-how. Andritz has long-term experience in working with this special material.

Additionally, Andritz offers a complete program of impeller shapes for all combinations of delivery rates and heads, according to specific speeds. By varying the trailing edge, high-precision adjustments can be made to the desired duty points. Moreover, by using separately mounted, angle-adjustable impeller blades, it is possible to compensate any uncertainties in the system design. As a result, the efficiency can also be optimized or the duty point altered at a later stage. In this case, the angle of the impeller blade can still be adjusted manually to suit new conditions just before installation and start-up.

Sumit Mehrotra

Following its acquisition of Colfax’s Fluid Handling business in late 2017, Circor International Inc., a US public company with 1.1 billion USD revenue and over 4,000 employees worldwide is bringing together more than 40 renowned pumps and valves brands under one direction, including Allweiler, GmbH. The Industrial Group is Circor’s largest business segment, and Allweiler is the largest brand within that group.

Sumit Mehrotra, President of Circor Industrial Group, explained Allweiler’s special position within the group: “The fact that Circor, an American corporation, has moved the headquarters of our Industrial Group to Allweiler’s Radolfzell location in Germany, indicates just how important this acquisition and Europe are to us.” Mr. Mehrotra went on to explain to ∆ p the strategy behind the Allweiler acquisition, its importance to the business and the ways in which Circor Industrial customers will benefit:

“The Circor family is a collection of “century brands” providing highly engineered flow control solutions for critical and severe service applications. Our brands like Allweiler have history in flow excellence for over 150 years. We place a very high value on the traditions behind our brands and consider ourselves stewards of their future success. Our brands have stood the test of time, and we are building on this long legacy by innovating every day and serving our customers better than anyone else. Circor is our family name, and each of our brands retain their identities as their first names. In this respect, each one has a unique identity yet is part of the strong Circor family.”

“Circor makes a point of optimizing its leadership structures, market orientation and processes before we attempt larger acquisitions. So, we were well prepared to welcome Allweiler into our organization while simultaneously transforming the Circor business. The great thing about this acquisition is we move from being a provider of valves and related accessories to a broader flow control solution provider. Now, we can now offer not just products, but complete flow control solutions. We house the full spectrum of flow control technology under one roof – a wide range of pumps, valves, and accessories – to offer our customers complete solutions for their fluid handling needs.”

The Allweiler site in Radolfzell at the Lake Constance, Germany

“Acquiring Allweiler and the other Fluid Handling pump brands has enabled us to increase our revenues by over 75%. The Allweiler brand is the largest contributor to this increase, and its size alone makes Allweiler a critical part of our pump portfolio. The fact that we, as an American company, have moved the headquarters of our Industrial group to Allweiler’s Radolfzell location in Germany, indicates just how important this acquisition and Europe are to us. Radolfzell is the company’s largest manufacturing site with over 600 employees. Over 60% of the Industrial Group’s employees are based in Europe, and the European sites generate over 50% of the revenue for the Industrial Group. For all these reasons, Germany was an excellent choice for our group headquarters location. This is also a signal to all Allweiler customers that we are committed to this business and this region and intend to deepen the relationships with our customers in the tradition of Allweiler.”

“We also intend to utilize our Circor global network to give our customers completely new ways to do business with Allweiler. Many of our customers are active around the world and Circor is also a globally positioned, reliable partner. We have the resources to follow our customers to many key regions of the world and provide local support. In this way, we augment the global accessibility of our products and services with a strong regional focus. As a company, we can truly claim to play globally, but act locally! We speak our customers’ languages, understand their business requirements and, in most cases, we are present locally in their immediate neighborhood. This power of Circor, which now includes Allweiler, is found in the short inquiry reaction times and rapid and locally available service that is tied into a global network.”

“We are very excited about our acquisition of Allweiler as a part of the fluid handling business. Allweiler will have new opportunities to promote its outstanding products globally and supplement its competencies with the valve expertise of Circor.”

About Circor International

Circor (NYSE: CIR) designs and manufactures highly engineered products and sub-systems for some of the world’s most severe-service and mission-critical applications. Meeting the needs of the oil and gas, industrial, aerospace, defense, power generation, commercial & institutional facilities, and marine industry segments, we market our solutions through 650+ sales partners to 7,000+ customers in 100+ countries.

Established in 1999, our company is broadly organized into three segments: Aerospace & Defense, Energy, and Industrial. With sales and manufacturing facilities in the United States, Mexico, Canada, Italy, Germany, France, England, Netherlands, China, Morocco, United Arab Emirates, Malaysia, Singapore, and India, Circor has an established global presence with more than 4,000 employees worldwide.

About Allweiler

Allweiler GmbH is the European technology leader for centrifugal, propeller, screw and eccentric screw pumps, as well as complete pump systems. Founded in 1860, one of the oldest German pump manufacturers, Allweiler serves the shipbuilding, power generation and specialized industrial markets with an unparalleled product portfolio, expertise, personalized support onsite and commitment to customer needs. Allweiler pumps are precisely manufactured to specific applications and trusted for their high quality and reliability.

For the production of cosmetics and pharmaceutical products as well as for the processing of foodstuffs, a special thoroughness and cleanliness must be ensured to consumers. When using hygienic pumps, the operator expects besides a high system availability and low maintenance requirement an absolutely perfect hygienic and easy to clean design.

The B70V SanitaryPlus barrel pump has a one-piece joint-free drive shaft and is consistently without threads in the hydraulic area. Just a few components reduce the assembly and dismantling times for approx. 80 % as well significantly reduce the cleaning effort.

The B70V SanitaryPlus is the universal pump for container emptying in the food-, pharmaceutical- and cosmetics industry. The materials are in accordance with the applicable Regulations of FDA (Food and Drug Administration), USP (United States Pharmacopeia) and EC 1935/2004 and moreover the pump has an approval according to 3-A Sanitary Standard. Main benefits are as well

• Long operating times due to contamination-proof and sterile pump design
• Delivery volume proportional to speed
• Reversible conveying direction
• Continuous and low pulsation pumping, nearly independent from pressure and viscosity fluctuations
• Careful pumping of the product
• Stable pressure capacities
• Service-friendly
• Housing design, free of dead space for good flow properties
• Wetted surfaces with a polished finish prevent the accumulation of liquid and facilitate the cleaning

The new eccentric screw pump Lutz B70V SanitaryPlus was developed and designed for pumping liquid foodstuffs, pharmaceutical agents and cosmetic products from different vessels and containers. This new development strictly meets the constructive requirements of the hygienic design and is certified and approved according to the latest “3-A Sanitary Standards (3A 02-11)”. All parts coming into contact with the product are made of resistant stainless steel (1.4571/1.4404/1.4462), 3-A/FDA compliant plastics (PTFE) and elastomers (EPDM).

The entire design of this pump places hygienic features in the foreground: therefore, only manually detachable, non-threaded connections are used in the areas coming into contact with the medium. The design is almost free of dead space, thus microbiological problems caused by germs and bacteria are practically impossible. The Lutz B70V SanitaryPlus can be quickly and easily dismantled and re-assembled enabling a speedy and thorough cleaning and disinfection mechanically or by hand. All parts coming into contact with the liquid are easily accessible for inspection and service. Quickly detachable tri-clamp connections according to DIN 32676 avoid any contamination. This pump is the solution for application cases where the use of a CIP pump is technically impossible.

With a flow rate of 12 to 50 l/min and an operating pressure of max. 10 bar, the B70V SanitaryPlus hygienic pump is suitable for pumping thin-bodied to highly viscous media. The proven positive displacement principle allows a gentle product handling. Thanks to low pulsation and low shear effect, liquids with solid particles, such as small fruit pieces in the food- and beverage industry, can be pumped.

The chosen immersion depth and the small immersion tube diameter ensure that drums, IBC containers and other commercially available containers are emptied safely and almost completely without residue from the top. Various drive motors e.g. 3-phase motors with and without integrated frequency converter (B70V-H-D) and universal motors (B70V-H-SR) are available. The drive motor can be separated from the pump tube instantly thanks to the new quick action coupling or hand wheel. This allows you to go from one task to the other at any time.

The new 6 mm (1/4”) Velocity Series AODD pump offers a detachable mounting foot providing adaptable mounting capabilities. Thanks to this design, the Wilden Velocity Series pump can quickly and easily be reoriented by loosening a single screw.

This design provides the user with multiple mounting options while allowing the pump to perfectly fit into restricted spaces, a critical consideration for OEM systems and skids.

The pump’s design also eliminates the effects of torque decay and delivers improved dry suction lift at all operating parameters for better priming under a wide variety of system conditions. Additionally, Velocity Series pumps feature an interchangeable footprint with competitor and previous Wilden designs.

Velocity Series pumps come equipped with a simple air distribution system with only two moving parts that reduce the risk of downtime. Wilden Velocity Series pumps can handle suction lifts from 10-14 feet. These pumps are available in polypropylene and PVDF construction, as well as an Accu-Flo (solenoid) option. Additionally, Velocity Series elastomer options include PTFE and Wil-Flex.

The actual Top 10 posts on Δ p GLOBAL Online:

1. Netzsch: Downhole progressing cavity pump with submersible drive
2. SPX Flow strengthens ties with the Tapflo Group
3. Siemens: Pressure transmitters for remote commissioning of functional safety
4. AS-Schneider: Metal seated ball valves for up to 420 bar and 450 °C
5. Grundfos: Providing the best water in Karelia
6. Circor/Allweiler: “Play globally – but act locally”
7. Schunk: Technical Paper – High-performance carbon – the service life extender for pumps
8. KSB: Impeller improves suction characteristics in high-pressure pumps
9. Almatec: AODD pumps with a solid plastic design
10. KSB: New app simplifies pump operation

The actual Top 10 posts on  Δ p Online in German:

1. Carsten Krumm verlässt Wilo Vorstand
2. Grundfos: Einstufige Kreiselpumpen mit horizontal geteiltem Gehäuse
3. Sera eröffnet zwei neue Standorte
4. KSB: Neue App vereinfacht Pumpenbetrieb
5. Jung: Seminar zu Regenentwässerung, Versickerung und Überflutungsschutz
6. Auras: Kläranlagen von Schlämmen befreien
7. SKF/Spandau: Fachbeitrag – Pumpen für Kühlschmiermittelversorgung
8. Grundfos: 5 Jahre Garantie ab Inbetriebnahme
9. Grundfos White Paper: Von der analogen Pumpe zu digital-basierten Operations
10. KSB: Laufrad verbessert Saugverhalten in Hochdruckpumpen

Fig. 1 Analyzing vibration measurements on Omnitrend Center taken by Vibscanner 2.

It’s not a secret, that vibration on machines causes severe issues – not only on a long term perspective. Vibration, caused by any issue is the natural enemy of any rotating machine such as a pump. Due to the latest handheld high-speed data collector Vibscanner by Pruftechnik vibration of all kind on all kind of machine can be detected during the maintenance routine.

With the special software Omnitrend Center the measurement results of Vibscanner 2 (Fig. 1) can be analyzed deeply and used for an entire machine health program. But what measurements does the new high-speed data collector Vibscanner 2 deliver, how do you interpret these and how can you react on these measurements? Let us give you a quick kick-start into vibration analysis to help keep your pumps alive.

Fig. 2 The chart shows 4 zones of vibration severity ranging from good to unacceptable.
• Zone A – the vibration of newly commissioned machines would normally fall into this zone.
• Zone B – machines with vibration within this zone are normally considered acceptable.
• Zone C – machines with vibration in this zone are normally considered unsatisfactory for long term continuous operation. Machine may be operated for a limited period in this condition until a suitable opportunity arises for remedial operation. (It is advised to increase the frequency of vibration monitoring during this operating period.)
• Zone D – vibrations within this zone are normally considered to be of sufficient severity to cause damage to the machine.

Fault detection

The main objective of a vibration monitoring program is the detection of incipient machine failures. The methodologies associated with fault prediction usually involve comparing current vibration information with a vibration description of that machine or a similar machine in satisfactory operating condition. This comparison is made by two methods:

• Comparison to industrial standards – ISO 10816-3-7
• Comparison to a previously measured reading.

ISO 10816-3-7

The ISO 10816-3-7 is the current standard for the evaluation of “standard” rotating machine operating condition. Issued in 2009 it covers “large and medium size industrial machines with nominal power rating above 15 kW and nominal speeds between 120 rpm and 15000 rpm”. In addition pumps are added as a specific category for consideration. This range covers most rotating machines and can therefore be used as a good guide for in-situ operating condition. Variations will inevitably occur when comparing these standards to actual machine operating condition. Machines should not however be condemned because of variations in readings without first considering other potential reasons for the difference in readings.

The use of these zones shown in Figure 2 and the numerical values ascribed to them are not intended as an acceptance standard for machine manufacturers and customers but the values do help to establish alarm and warning criteria for a routine condition monitoring program. If machines are found to be operating at vibration levels consistently above the nominal values shown in the standard, investigation as to the cause should always be carried out.

 Comparison to previous readings

This method is the most widely used method of identifying changes in machine operating condition. Most commonly referred to as trending, comparison quickly shows the machine operator or manager if the machine condition has changed, and by how much, and in what period of time. Trended graphical measurement values combined with ISO alarm limits give clear visual warnings of machine condition change and with some software packages, can be used to predict likely run to failure intervals in order to schedule remedial repair. (Graphic predictions of machine trends should always be considered as a guide to likely failure and not as a definitive measurement of machine failure intervals.)

Fault mode analysis

There is a great deal of literature on diagnostic techniques employed for various types of equipment. Although we will not discuss specific diagnostic methods in this article, you will find that a great deal of information must be readily available to execute an effective vibration monitoring program. Once the vibration monitoring program flags a machine as potentially having a mechanical problem, the following questions must be answered.

• How severe is the problem?
• What is the problem?
• When must the machine be taken out of service for repair?

Machinery diagnostics using vibration analysis provides information that addresses these questions. The machinery diagnostics technique viewed here is based on a technique known as “fault mode” analysis. This technique utilizes the fact that specific mechanical events, such as unbalance, misalignment, looseness, bearing defects, aerodynamic and hydraulic problems, and gearbox problems usually generate vibration frequencies in specific patterns. The frequency, amplitude and pattern of the peaks in a vibration spectrum can be a telling indication of the type of problem being experienced by the machine. The principles of “fault mode” analysis include:

• Measurement of mechanical faults such as unbalance and misalignment generate mechanical vibration in a well defined frequency pattern.
• Comparing the vibration levels and vibration spectra on similar types of machines will help establish the severity and cause of a vibration problem.

Fig. 3 Due to Vibscanner 2 vibration measurements can be taken within seconds – literally.

Unbalance

Vibration caused by unbalance occurs at a frequency equal to 1 rpm of the unbalanced part, and the amplitude of vibration is proportional to the amount of unbalance present. Normally, the largest amplitude will be measured in the radial (vertical or horizontal) directions.

Misalignment

Generally, misalignment can exist between shafts that are connected with a coupling, gearbox or other intermediate drives. Three types of misalignment are:

• Angular – where the center line of the two shafts meet at an angle
• Offset – where the shaft center lines are displaced from one another
• A combination of angular and offset misalignment

A bent shaft looks very much like angular displacement, so its vibration characteristics are included with misalignment. Misalignment, even with flexible couplings, have two forces, axial and radial, which result in axial and radial vibration. The significant characteristics of vibration due to misalignment or a bent shaft is that it will be in both the radial and axial directions. For this reason when axial vibration is greater than one half of the highest radial measurement (horizontal or vertical), then misalignment or a bent shaft should be suspected. All misalignment conditions will produce vibration at the fundamental (1 x rpm) frequency components since they create an unbalanced condition in the machine. Misalignment will sometimes produce vibration at the second harmonic (2 x rpm).

Looseness

Mechanical looseness can be caused by loose rotating components or loose machine foundations. Mechanical looseness causes vibration at a frequency of twice the rotating speed (2 x rpm) and higher orders of the loose machine part. In most cases, vibration at the fundamental (1 x rpm) frequency will also be produced.

Bearing problems

One of the results of damage to rolling element bearings is that the natural frequencies of the bearing components are excited by the bearing defect. The resonant vibration or “ringing” occurs at frequencies between 2 kHz and 60 kHz. This vibration is most effectively measured at a level of acceleration in units of g’s Peak. Vibration is measured by the machinery monitoring system as a HFE (High Frequency Energy) measurement and gives an effective indication of the condition of rolling element bearings. Based on field experience, the shock pulse technique works well on motors and other quiet equipment. Care must be taken when using the technique on pumps and gearboxes, where flow, cavitation, and tooth meshing can produce impulses which interfere with and mask the impacts produced by bearing defects. Rotational frequencies related to the motion of the rolling elements, cage and races are also produced by mechanical degradation of the bearing. These frequencies are dependent on bearing geometry and shaft speed and can be found typically, in the 3 – 10 x rpm range and because of these reasons the “enveloping” method is the most widely adopted method of viewing specific bearing defects.

Aerodynamic and hydraulic problems

Normally associated with blade or vane machinery such as pumps or compressors, aerodynamic and hydraulic vibration is created by an unstable or unbalanced condition within the machine. In most cases this will produce a vibration at the fundamental frequency (1 x rpm) of the machine and blade pass/vane frequency components.

Gearbox problems

Gear defects or faulty gears produce low amplitude, high frequency vibration. The vibration is predominantly at gear mesh frequency. Gear mesh frequency is calculated as follows: Gear mesh frequency (GMF) = Speed of output gear x Number of teeth in output gear Example: 52 tooth gear running at 90 rpm (90/60 = 1.5 Hz). GMF = 52 x 1.5 = 78 Hz. Most gear problems exhibit vibration at the gear mesh frequency, and may be summarized as follows:

• Unbalance – predominant at the 1 x rpm of the gear.
• Misalignment – predominant at the 1 x rpm and 2 X rpm; may excite GMF.
• Pitch line run out – predominant at GMF with 1 x rpm sidebands.
• Faulty gear teeth – predominant at GMF with sidebands at 1 x rpm of faulty gear.

To assure proper machine health care throughout the whole lifetime of the machine, vibration measuring and analysis are necessary tools to reduce energy waste and maintenance costs on the long run and improve quality even on the short run. Pruftechnik technologies and services help to set your machines’ status to “running healthily”.

Owing to their operating principle and their roots in waste water treatment, Progressive Cavity Pumps (PCP) come with typical deviations against petrochemical standard API 676. Some of these deviations are inevitable, others can be healed. It is a preservative headache and topic of discussion for project engineers to understand and identify which of these deviations are relevant, critical or acceptable for their project.

Progressive cavity pumps are positive displacement pumps that handle fluids gently and with minimal shear or agitation / turbulence / emulsifying. They manage fluids of highest viscosity and highest solids content, even abrasive or large particles. They can generate high pressure, 48 bar and more. They are suitable for high vapor pressure (low NPSH) as well as multiphase fluids. Due to linear performance curve and low pulsation they are suitable for dosing applications. Flow direction can be reversed simply by reversing the motor rotation.

In the oil & gas industry PCP are often applied to convey sludge or oily water, or in situations where light hydrocarbons raise the vapor pressure to a level where other pump types would cavitate. A forte of PC pumps is vertical semi-submersed installation on a drum; open/closed drain drums or flare knock-out drums are a frequent application.

The following table compares some basic requirements of API 676 and petrochemical applications on the one hand, and typical waste water applications on the other hand.

Let us look at the two critical issues that give rise to most discussion and customization.

Casing design

Welded constructions with their associated high effort of engineering, procedure approval, fabrication, non-destructive examination, inspection and documentation are needed to meet such requirements.

Fig. 1 Progressive Cavity Pump based on API 676 requirements

Shaft Seal
PCP typically have rotor joints with cardanic articulation to allow for the eccentric rotor movement. A rotor with such joints comes with assembly restrictions that are not compatible with installation of an API 682 mechanical seal which is bolted to the pump casing. PCP design typically clamps the seal housing between the pump casing and a lantern. As a result, the mechanical seal cannot be fully API 682 compliant; it can be a heavily engineered seal in spirit of API 682 at best.
Most PCP vendors use bespoke universal cartridge seals tailored to the needs and dimensional restrictions of the pump type.
Other deviations and exceptions are rooted in the PCP principle itself and cannot – or need not – be avoided. Again we look at reasons and consequences:

1. First and foremost, the progressive cavity principle is based on permanent tight contact (clamping) of a steel rotor and elastomer stator. There is no gap.

• Elastomer can never be fabricated with the same precision as steel; this results in performance tolerance exceeding the limits of API 676 (para 8.6.3) which is +3/-0% of characteristic capacity; a PCP can typically manage +10/-5%; tolerance is even higher for small pumps or high pressure. The only standard that correctly takes into account the characteristics of a PCP is the ancient German VDMA 24284 which is why PCP vendors still refer to it for test tolerance.
• A consequence of the clamping contact is that the stator is a wear part, to be exchanged at regular intervals that depend entirely on the application and are hard to predict. Non-stop operation over three years as required by API 676 (para 6.1) is not something a PCP can guarantee.

2. There is the eccentric kinematic of the rotor and its impact on vibration:

• For a given capacity, vibration levels of a PCP are necessarily higher than other API 676 pump types based on concentric motion. A standard PCP may exceed the limit of 3.8 mm/s (para 6.11).
• This low frequency vibration is inherent in the design and not a sign of trouble, thus vibration monitoring makes little sense.
• Vibration is a critical issue and limiting factor only for vertical semi-submersed PC pumps, where the shaft can become several meters long. [ILLU long BE pump]

3. PCPs typically operate at slow speed 100 – 300 rpm, about 10-20% of a centrifugal pump. Thus:

• There is no motive for precise alignment or balancing. PCP baseplates are typically not designed with precision machined pads and jacking screws that facilitate alignment.
• Shaft bearings are grease lubricated and typically sealed / lubricated for life. Elaborate oil lubrication systems with associated monitoring and cooling function are not needed but nevertheless specified by API 676 / API 614 and present in the mind of project engineers familiar with other pump types.
• It is common practice for PC pump design to omit dedicated shaft bearings altogether and use the gearbox bearings to support the shaft – this is called “block pump” and it can omit also the coupling.
• Shaft seals do not generate much heat by friction, therefore, seal cooling is rarely needed and standard seal plans offered by PCP vendors may minimize or omit the cooler, as a deviation from API 682.

Finally, there are those exceptions that are related to sourcing and US standards. API standards usually cross-reference other API standards or US manufacturing standards.

4. Gearbox and bearings

• API 676 references AGMA and ABMA standards and requires gearboxes > 18 kW (25 HP) to conform with AGMA 6010, or even API 677.
• API 677 gears are generally not available for the typical power ratings and drive configuration of PCP. Please refrain from specifying API 677; pump vendors could not comply even if they wanted to.
• Outside the Americas the AGMA and ABMA standards are not used. European gear manufacturers will design and calculate according to DIN 3990 or ISO 6336. American and European gear standards are not compatible because they are based on different physical models and basic assumptions. It is also not possible for the vendor to demonstrate that a gearbox designed to DIN/ISO is ‘equal or better’ to an AGMA design, which is a frequent requirement of project engineers trying to circumvent the issue. Sometimes this leads to a hot debate of almost religious dimensions without practical result. Comparative papers by gear specialists can be found on the web. However, it is absolutely safe to assume that a gearbox following European standards will perform just as well.

5. IEC/IEEE

• API 676 requires motors to follow IEEE 841.
• However, most international projects outside the Americas prefer IEC motor standard. IEEE 841 motors are only produced in the Americas; import by European pump vendors raises the price and lead time.

6. Welding

• API 676 references ASME BPVC IX for welding of pressurized parts and AWS D1.1 for structural welding.
• While ASME IX is customary in Oil&Gas applications, most European workshops are basing their fabrication on ISO standards which result in a quality level at least equal to ASME IX. Welders may be additionally qualified to ASME IX but if you make that a firm requirement you may raise the price tag without benefit. The economical decision is to leave this choice to the Vendor.
• Welding to AWS D1.1 is unusual in Europe and hardly available. Welding of non-pressure or structural parts according to ISO welding standards should be allowed or tolerated.

Project engineers preparing or evaluating a bid typically spend many hours in discussion with pump vendors to identify which of these points are relevant for the actual project, which can be accepted to cut cost, and which are viewed critically by the client so that a concession request becomes necessary, adding to the time.

Range of API 676 compliant pumps

To provide project engineers with smooth sailing and purchasers with favorable price and lead time,  Seepex introduced a new range of horizontal PC pumps that are designed based on API 676 requirements – the BNA pump range (Fig. 1). Main features are:

• heavy-duty cast casing with design pressure 50 bar
• flanges class 300
• standard flanged casing drain
• high nozzle loads
• full uncompromised compliance to API 682 Cat. 2 / API 610 for shaft seals
• materials suitable for corrosive or harsh environment and for fluids including Chloride and H2S

Fish is not just one of the staple foods in all the world’s coastal regions, its high-quality constituents – from omega 3 fatty acids to iodine – mean it is also becoming a significant component of a healthy diet worldwide. On the other hand, most of the residues are disposed of or processed into cheap animal feed, although the skins do for instance contain valuable proteins. In addition to fillet production, Vinh Hoan Corp., one of the largest pangasius exporters in Vietnam, has therefore built up its own production line for collagen powder. The powder is now used in food supplements, cosmetics and pharmaceuticals. For this, Netzsch supplied a combination of a high-performance twin shaft macerator and a hygienic full-metal rotary lobe pump.

Collagen powder is produced by enzymatic hydrolysis from the pangasius skins derived from the production of fillets for the global market. The fish skins are around 18 cm long, depending on the age of the fish, and also elastic and extremely slippery due to the humid environment, so the company needed suitable pump technology in order to be able to transport them for processing.

Netzsch set up a hygienic solution for this using closed pipes and a pump, which prevents contamination of the raw material and at the same time ensures cleanliness in the production environment. Robust macerator also handles hard impurities.

An issue of the application was that the fish skins are mixed with hot water in an 80:20 ratio and come into the macerator at a pressure of around 2 bar, which means they are moving very fast and there is a risk that unprocessed parts might slip through. A twin shaft macerator was therefore used, as its speed can be adjusted to the flow of the difficult medium mixture to achieve an ideal result in terms of cutting.

High pumping capacity, simple maintenance

The macerated pieces of skin flow out of the macerator directly into a rotary lobe pump which handles further conveyance. The pump, which is part of the Tornado T2 series, is particularly recommended for very lumpy media due to its large free ball passage. Even with coarse pieces of skin, which might have slipped through the macerator due to their slippery consistency, the pump can easily cope without any risk of clogging: instead of complex helical and multiple lobes which are more prone to defects and harder to clean or maintain, there are two smooth bi-lobe rotors installed which rotate in opposite directions and continuously convey the medium from the inlet to the discharge side. This design leaves a lot of space for the solid loaded fluid and at the same time enables the rotary lobes to be removed individually, and easily in case of maintenance.

The front of the pump can easily be removed for any maintenance work, enabling access to the whole interior. It is also just as easy to remove the rear covering to access the drive. The pump is using a belt drive with teeth on both sides, which firstly transmits the torque from the motor to the shafts and secondly synchronises the rotation of the shafts, along with the rotary lobes. For easy cleaning and sterilisation, as well as to improve food safety, an all-metal version of the rotary lobe pump was installed at Vinh Hoan.

Intended for use in metalworking applications, transfer lines, and grinding and deep drilling machines, Emtec-C pump delivers coolant at a high flowrate, allowing machines to run at peak levels without compromising tool life.

“We’ve improved Emtec-C to achieve maximum three-screw pump efficiency with a lighter weight and fewer components,” said Kapil Rai, Circor Vice President, Industrial Pumps, EMEA, India & Asia. “It also features several difference-making innovations.”

Those include:

• A new screw system with a patented reversed hanging idler and integrated thrust compensation system for durability, reliability and precision
• Improvements to seal life expectancy and need for maintenance
• A transparent backflow pipe that alerts the user to possible medium return into the system
• An extra-long piston to minimize flow loss
• The option of connecting a pressure sensor to the frequency controller for easy control and measurement

In addition, the surface of Emetc-C has a hardness similar to ceramic in the housing bores, yet is elastic enough to eliminate the danger of bore surface fracture.

Rai added that users interested in a new solution will find that Emtec-C is interchangeable with previous models and available in different sizes and spindle pitch angles to accommodate tank-top, submerged and horizontal installation configurations.