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Lead Lag or Get Out of H100 s Way DON T GET MUCKED UP WITH OUR PUMP CLEAN FUNCTIONALITY Intuitive and easy to use 1 HP to 800 HP available for delivery Single phase ratings up to 400 HP Simple pressure control setup and operation Lead lag software ideal for lift stations and PLAY coordinated multi pump controls www lselectricamerica com D EO VI
NOVEMBER 2020 20 28 MPT Modern Pumping Today www mptmag com P O Box 660197 Birmingham Alabama 35266 modpumpmag I N D U STRY N E W S What s Happening in the Industry 4 CA SE STU DIE S GPRS Uses Ground Penetrating Radar to Expand Business 8 Versatile technology helps company diversify services WAT ER WAS T E WAT E R S O L U T I O NS Manage Dredge Operations from Your Smartphone 12 DSC Dredge launches first of its kind dredge production smartphone app M A INTENA N C E RE L IABIL IT Y Keeping Spills in Check 14 Four strategies for spill prevention and containment in the workplace Estimating True Life cycle Cost 16 P UMP SOL U T IO N S Seal less Magnetic Drive Pumps for Chemical Processing Applications Part 2of 2 20 J CAMPBELL Editor jay mptmag com TONYA BROWNING Vice President tonya mptmag com JEFF FLETCHER National Sales Manager jeff mptmag com LISA AVERY Art Director CRISTELA TSCHUMY Graphic Designer SETH SAUNDERS Digital Media Specialist INGRID BERKY Office Manager SUBSCRIPTION inquiries or changes 205 380 2048 Bridging the IoT Gap 24 Collaboration creates new line of Ethernet IP controlled peristaltic pumps SE AL ING SOL UT IO N S The Royal Discipline of TIG Welding 28 Optimization welding results through the correct sekection of high quality tungsten electrodes Part 2 of 2 B U YERS GUID E Company Profiles 33 EDITORIAL ADVISORY BOARD www highlandspublications com 312 Lorna Square Birmingham Alabama 35216 866 251 1777 TIM GARMON CEO RUSSELL HADDOCK President CHRIS GARMON CFO DONNA CAMPBELL Vice President Editorial TONYA BROWNING Vice President Terry Bell Product Manager ABB Heinz P Bloch P E Consulting Engineer Process Machinery Consulting Robert G Havrin Director of Technology Centrisys Corporation Michael Mancini Consultant and Trainer Mancini Consulting Services John M Roach Engineering Manager for New Product Development Trebor International Inc A Unit of IDEX Lisa Riles Business Development Manager Wastewater Pumps Xylem Inc Flygt Frank Knowles Smith III Executive Vice President Blacoh Surge Control Greg Towsley Director of Regulatory and Technical Affairs Grundfos Trey Walters P E President Applied Flow Technology No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopy recording or any information storage and retrieval system without permission in writing from the publisher The views expressed by those not on the staff of Modern Pumping Today or who are not specifically employed by Highlands Publications Inc are purely their own All Industry News material has either been submitted by the subject company or pulled directly from their corporate website which is assumed to be cleared for release Comments and submissions are welcome and can be submitted to jay mptmag com
Lead, Lag or Get Out of H100’s Way!■ Intuitive and easy to use ■ 1 HP to 800 HP available for delivery ■ Single phase ratings up to 400 HP■ Simple pressure control setup and operation■ Lead-lag software ideal for lift stations and coordinated multi-pump controlswww.lselectricamerica.comDON’T GET MUCKED UP WITH OUR PUMP CLEAN FUNCTIONALITYwww.lselectricamerica.comPLAY VIDEO
4 | November 2020 | Modern Pumping Today www.mptmag.comINDUSTRY NEWSDRÄGER AND VECTOR CAG TEAM UP TO PROMOTE PRODUCT PORTFOLIO Dräger, an international leader in the field of safety technology, announces the appointment of Vector Controls and Automation Group (Vector CAG) a leading manufacturers’ representative of control and automation solutions. The organization will represent and promote Dräger’s fixed flame and gas detection systems portfolio sales in the states of Texas, Oklahoma, Kansas, Missouri, Southern Illinois, Iowa, Nebraska, and Southeastern New Mexico.“We are very pleased and excited to partner with Vector CAG as an official manufacturer representative for our innovative line of fixed gas and flame detection solutions,” said John Wilson, Dräger’s senior vice president of sales and marketing for safety solutions in North America. “Working alongside our own Dräger personnel and through Vector‘s strong customer relationships, we will continue to grow our installed base of fire and gas detection system solutions in this key geographic territory.”“Vector CAG has always committed to partnering with best-in-class manufacturing companies to represent the top products in the industry,” says Jared Boudreaux, president, Vector CAG. “We are proud to enhance our extensive safety product portfolio with Dräger’s world-class fixed gas and flame detection solutions.”ABB NAMES NEW DODGE PRESIDENTABB recently named company veteran Roger Costa as president of its global Mechanical Power Transmission Division, also known as the Dodge business. Established in the United States in 1878, the Dodge business today is considered the leading manufacturer of mounted bearing, enclosed gearing, and power transmission components in the nation."ABB's recognition as a global leader in the mechanical business stems from a strong culture that focuses on customer experience," Costa says. "I look forward to joining a team that values that culture. Together, we will work to continue to develop and grow markets for our superior products." With more than seventeen years of experience at ABB, Costa has held executive roles in both the United States and Canada. During his tenure at ABB, Costa has gained considerable knowledge of the company's extensive operations ranging from mechanical to motors and robotics. Costa's unique perspective brings valuable insight to ABB's leadership team.Costa has a bachelor's degree in electro-mechanical engineering from Humber College and completed an advanced university program in business management at the University of Toronto-Roman School of Management.
Covid-19 Responses: Our facility is open and working • 24/7 Emergency Service On-SiteBabbi Bearing Repair, Refurbishment & ManufacturingBABBITT BEARING REPAIRISO9001:2015
6 | November 2020 | Modern Pumping Today www.mptmag.comINDUSTRY NEWSBLACOH INDUSTRIES ANNOUNCES NEW HIRES Blacoh Industries announces the addition of two new specialists to support the company’s goal of growth by providing innovative solutions for improved performance in fluid pumping systems. Scott Bradley and Luis Ornelas were appointed for their diverse talents and experience, and will increase Blacoh’s capacity for innovation in engineering, product design, manufacturing and services.Professional mechanical engineer Scott Bradley joins the Blacoh Surge division bringing extensive experience in designing, sizing, and specifying pressure vessels, piping, pumps, compressors, and various other equipment. Bradley began his career managing multiple projects from award stage to ready-to-ship for CSI Compressco, a natural gas compressor packaging company, and later went on to manage a team of engineers at HPF Consultants, Inc.With a bachelor’s in mechanical engineering and a master’s in engineering management, Blacoh’s new quality assurance engineer, Luis Ornelas, combines valuable skills with experience in efficiency and quality improvement, process auditing, ISO compliance, certifications, training, and team development. Before joining Blacoh, Ornelas led a team of quality inspectors for EGR Incorporated, a leading designer and manufacturer of automotive accessories for OEM and aftermarket applications.SUNDYNE APPOINTS NEW CHIEF COMMERCIAL OFFICER Sundyne announces that Colin Guppy has been promoted to chief commercial officer. In this newly created role, Guppy will lead the original equipment and aftermarket strategies for Sundyne’s vertical markets in the Americas, Europe, the Middle East, Africa, and India. With more than twenty-five years of industry expertise, and a successful career with Sundyne that dates back to 2000, Guppy is uniquely qualified to bring the breadth and depth of Sundyne’s engineering and operational resources to meet today’s challenges. His proven track record of co-creating innovative solutions and leading global sales teams will ensure the success of Sundyne’s customers and channel partners.In the newly created role of chief commercial officer, Guppy will work with Sundyne customers and channel partners to continue developing the right mix of products and aftermarket services that customers in the oil and gas, chemical, and industrial markets need to meet their evolving business needs.“Sundyne has always been a customer-focused company … we’re realigning some of our internal resources and our business processes to match the evolving needs of our customers,” says Sundyne’s CEO Mark Sefcik.FEDERAL PROCESS CORPORATION IS NOW FPC INTERNATIONAL, INC.Federal Process Corporation, a diversified manufacturer of specialty chemicals and premium-quality building products and supplier of innovative plumbing products, is rebranding as FPC International, Inc. As the company has grown, building its product offerings through its own research and scientific innovations, along with recent acquisitions, the action is a more fitting reflection of the company’s expansion into a much broader range of niche industries.“We have evolved significantly over the course of our rich history, and our name change is an appropriate action to more clearly demonstrate our growing presence in the markets we serve,” says Jon Outcalt, Jr., president, FPC International, Inc. “With that said, as we grow, we continue to take pride in our commitment to maintaining close connections with our customers and providing expertise and counsel on a very personal level.”Today, FPC International, Inc. remains loyal and dedicated to its local roots, retaining its global headquarters in Cleveland, and manages five distinct businesses within the building product and specialty chemical industries.QUALITY COMPANIES APPOINTS NEW BUSINESS DEVELOPMENT MANAGERQuality Companies has appointed Iain Gault as business development manager for Houston and International. Based in Houston, Gault will serve to grow the Quality Companies client base in the deepwater and international arenas and introduce an expanded range of Quality Companies services to the energy sector.Previously, Gault served as business development and technical services manager at Stork Technical Services USA, where he was the technical authority for rope access and specialist services in the Americas and the Caribbean. He has also provided assessment and evaluation of rope access classes throughout the Americas and Europe for Industrial Rope Access Trade Association (IRATA) and Society of Professional Rope Access Technicians (SPRAT). Richard Tang, director of business development, Quality Companies, says, “Iain has a deep and wide-ranging technical proficiency, specializing in rope access with hands-on experience acquired in locations around the world. This, coupled with his extensive managerial expertise, ensures he is the ideal individual to manage deepwater and international business development initiatives for Quality Companies.” ◆Colin Guppy
8 | November 2020 | Modern Pumping Today www.mptmag.comCASE STUDIESGPRS Uses Ground Penetrating Radar to Expand BusinessVersatile technology helps company diversify services By Jason Schaff, GPRS LLCMany early adopters of ground penetrating radar (GPR) technology found concrete scanning to be the effective application. Those anchoring, saw cutting, or core drilling concrete would hire a contractor to scan the area before cutting to avoid accidentally hitting an object. For this reason, construction firms have come around to the notion that concrete scanning is vital to job site safety and efficiency. In recent years, service companies have also found synergy between concrete scanning and the need to provide utility locating services. Many contractors find GPR to be an important tool that allows them to scale and expand their business while maintaining a high level of service. NON-DESTRUCTIVE SUBSURFACE SURVEY TECHNOLOGY IN DEMANDToledo, Ohio, based Ground Penetrating Radar Systems (GPRS) LLC was one of the first companies in the country to focus on concrete scanning, using GPR technology. They determined that GPR was preferable to other non-destructive subsurface survey technologies, including x-raying. While concrete x-raying remains a valid technique to locate reinforcing steel in certain applications, GPRS found it lacked the flexibility to meet the demands of many projects. The method must be done in conditions in which radioactivity can be safely introduced; it also requires access to the underside of the concrete to be scanned and the job site to be closed. GPR is used without any radioactive element, instead emitting a pulse of energy into the concrete that bounces off any objects in the slab. When some of that energy returns to the antenna, it creates a signature which clearly shows where and at what depth items within the slab are located. GPRS opted for this more versatile technology, which can be used for both elevated concrete slabs and slab-on-grade applications.GPRS found that GPR equipment helps contractors safely avoid obstacles in concrete, reducing costly delays and potential injuries. For example, during a recent project to revitalize the upper deck at New York’s Yankee Stadium, the general contractor had to penetrate the concrete floor to work on the ballpark’s protective railings and expected the presence of post-tension cables. If accidentally severed, these high-tension steel strands can snap with enough force to break through the concrete and possibly injure the contractor. Due to the severity of the potential risk and the popularity of Yankee Stadium, x-ray was impossible for this job.The contractor turned to GPRS, who scanned the area with the GSSI StructureScan™ Mini XT. This compact tool combined with a GSSI Palm XT antenna, gives operators the ability to cross-polarize for an enhanced level of horizontal and vertical positioning accuracy. Since GPR is entirely safe to use around people, no section of the stadium had to be closed off for other workers, avoiding any major work disruption. A concrete job like this would not be possible without GPR. You never really know what’s beneath the surface. GPR lets us provide quantitative data and relevant GPRS operators using the GSSI StructureScan Mini at Yankee Stadium
Modern Pumping Today | November 2020 9www.mptmag.comCASE STUDIESinformation to our customers so that they’re able to do their jobs more safely.The GPRS team was also hired by a structural engineering firm to determine the structural reinforcement of a Boston, Massachusetts, building originally used to manufacture cannons and as an armory. The building featured an 8-inch slab with a 1.5-inch topping slab. Scanning the slab and topping with the SIR 4000 and Palm Antenna, the technicians uncovered a complex circumferential reinforcement design. GPRS provided a mark-out of the location and depth of targets as well as a 3D camera report with a virtual tour to the structural engineering client. Along with GPR equipment, GPRS also uses other tools that complement each other, including a reference point locater that gives operators an added certainty that the area they scan on one side of a thick slab corresponds exactly to the same scan on the other side, and an electromagnetic tool that hooks onto a conduit to passively look for something drawing power. To meet the need to locate live power in conduits, GPRS also began providing utility detection services.BRANCHING INTO DIFFERENT MARKETSIn recent years, GPRS has moved into using GPR for utility location, diversifying its business from 95 percent concrete scanning in the early 2000s to now performing 40 percent concrete scanning and The Palm XT gives GSSI StructureScan Mini users a handheld miniaturized GPR antenna for enhanced access to tightly spaced areas.GSSI’s easy-to-read visualization allowed GPRS to create drawings with locations and depths of obstacles.
10 | November 2020 | Modern Pumping Today www.mptmag.comCASE STUDIES60 percent utility scanning. Utility projects range from mapping out an entire facility’s utility plan and providing a detailed AutoCAD file to examining a small area before installing even a single light pole. Just like combining GPR with other techniques for concrete scanning, GPR is an integral part of the utility locator’s toolbox. Rodders are used to send traceable lines through pipes to then put a tone on the tracer to assist location. A radio detection tool actively locates pipes under the surface, putting a tone on a tracer and tracing metallic pipes. Magnetometers measure magnetic fields and provide a useful back-up to confirm the location of a cleanout. Other electromagnetic induction equipment serves a similar purpose. GPRS also uses closed-circuit video (CCTV) robots that navigate pipes internally to produce an inside-out visual pipe inspection. GPR can determine the location of a PVC pipe that does not have a tracer wire, which would have evaded radio detection or discovery by an electromagnetic tool. GPR technology really allows us to hone in, be more precise, and sets us apart from other service companies that don’t have it.GPRS demonstrates the efficacy of their technique when executing a recent contract to locate utilities under parking lots at Target and Walmart locations nationwide. These retailers demanded uniform parking spots to allow customers to quickly pick up online orders. The project had a unique set of challenges because they were not conducting a complete utility location survey of the property to enable them to fully identify all gas, water, sewer, and electrical hazards that lay under the surface. When we’re in those parking lots, we don’t have visible meters, tracer wires or cleanouts that we can just find and trace out utilities with. GPR units are fully capable to locate unknown objects. If we did not have GPR we would not be able to properly locate each one of those sections before they run the electrical conduit and put the bollards in. GSSI’s easy-to-read visualization allowed GPRS to create drawings with locations and depths of obstacles. Overlaid on Google Earth maps, these detailed references enabled contractors across the country to quickly and safely expedite excavation and construction of these novel parking features.Utility locating also came into play at the Yankee Stadium project, where GPRS had to locate utilities under the sidewalk in front of the stadium before the contractor dug a 125 square foot trench. For the utility locating portion of the job, GPRS used GSSI’s SIR® 4000, with a 400 MHz Antenna. The SIR 4000’s modular design enabled the team to easily configure the system for utility location. Mark-out of the location and depth of complex circumferential reinforcement design.
Modern Pumping Today | November 2020 11www.mptmag.comCASE STUDIESGround penetrating radar allows GPRS to scale both halves of business nationwide. Because our business has two different verticals with concrete scanning and utility location, we want to use an equipment company that has the ability to cross over and do both. In 2019 alone, GPRS completed 70,000 individual projects in nearly sixty markets with an overall accuracy rate of 99.5 percent. We use GSSI GPR for every one of those markets and every one of those jobs. CROSS-TRAINING IS KEY TO QUALITYGPRS has adopted a strategy of developing new markets with limited personnel by cross-training its personnel. All GPRS project managers undergo a three-month training process to ensure a repeatable methodology so each customer gets the same level of service.The strategy is furthered by the availability of systems small enough to transport in the trunk of a sedan, and capable of quickly determining the reinforcement of concrete (hollow core, rebar, post-tension cables, metal decking) or adjusting to soil makeup at a utility location site with ease.To ensure quality across the company, GPRS instituted an intensive training program and developed a specification, Subsurface Investigation Methodology (SIM), that lays out requirements for training, equipment, and process. In addition, GPRS has partnered with GSSI for their GPR equipment to ensure they’re using professional-quality equipment. GSSI has been at the forefront, developing new technologies. They know what they’re doing, and we know what we’re doing. It makes total sense to pair with the manufacturer that fits us so well. THE FUTURE OF GPR SERVICESHistorically, nearly 80 percent of GPRS clients are either repeat or referral. The company focuses on long term performance, recognizing that repeatable accuracy is at the core of their services. By effectively leveraging the flexibility and precision of GPR technology, GPRS has diversified and expanded its business from regional to nationwide—all without diminishing service quality. To continue to build on its success, the company has acquired four GPR service provider companies to better meet customer needs and prepare for market growth.◆Jason Schaff is vice president of sales and marketing at GPRS LLC. Ground Penetrating Radar Systems LLC is the nation’s largest company specializing in the detection of underground utilities, video pipe inspection, and the scanning of concrete structures. GPRS has an extensive nationwide network of highly trained and experienced project managers in every major U.S. market. For more information, visit www.gp-radar.com.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.comCUSTOMIZED SUBMERSIBLE MOTORSPLAY VIDEO
12 | November 2020 | Modern Pumping Today www.mptmag.comWATER & WASTEWATER FOCUSManage Dredge Operations from Your SmartphoneDSC Dredge launches first-of-its-kind dredge production smartphone appBy Mercedes Gabriel, DSC DredgeFor over fifty years, DSC Dredge has met the needs of the dredging industry in terms of designing and manufacturing quality dredges and dredge equipment. A three-generation family business, each generation has introducted new and innovative opportunities to better serve this unique community, it’s no surprise that DSC has continued to grow more innovative in addressing the technology gaps experienced by the dredging industry.The most recent addition to DSC Dredge’s custom services is the launch of its new app for iOS mobile devices—the DredgeMaster Suite. This addition to DSC’s technology suite illustrates the company’s initiative in building the most comprehensive experience for dredge owners and operators.CLOSING THE GAP THROUGH TECHNOLOGY“We get dozens of requests to do dredge evaluations on a weekly basis,” says William “Bill” J. Wetta, senior vice president and chief technology officer. “For years we have tried to figure out a way to allow customers to have access to this information themselves without giving away all of our trade secrets. From this desire to better serve our customers, the concept of the DSC DredgeMaster Suite app was born.”The first comprehensive solution of its kind, the DSC DredgeMaster Suite app has been developed entirely in-house as a collaborative father-son effort. Bill’s youngest son, Nick Wetta, has spent the past two years working tirelessly to bring this concept to life.This app is the first of its kind that will allow dredge owners and operators to take better control of their operations. “As time evolves, it is important to remember that it is not that we live in technology but that we use technology daily and the dredging industry should be no different,” states Nick Wetta, official creator of the DSC DredgeMaster Suite app. DSC’s newest dredge class, the Sharkuda, now in operation and utilizing the new DSC Vision software.
Modern Pumping Today | November 2020 13www.mptmag.comWATER & WASTEWATER FOCUSFROM “WHAT IF” TO “CAN DO”This digital tool is a comprehensive production toolbox that provides users with benchmarking data, operational information, and “what-if” options at their fingertips. When paired with DSC’s Dredge Rx system, it becomes part of a complete maintenance solution that allows users to view and track dredge performance and required servicing while on the dredge or while working remotely.According to Bill Wetta, “We are living in an age where technology can offer enormous upsides, and Nick has brought to life an idea that my brother, Bob, and I have been talking about over the past decade. This app, in a nutshell, shows whether a particular dredge meets the conditions requested. We are excited to introduce this technology to the dredging community as it will allow for easy access to information in real-time.”THE FUTURE OF DREDGING SOLUTIONSOver the years, DSC has focused its expertise on the design and manufacturing of customized dredges of all sizes and purposes for the dredging market. As a result, we have dredge units in use throughout the world and across an expanse of industries; aggregates, mining, construction, environmental, navigational, recreational, restoration, and specialty projects. This is all about customer service and helping make our product more user-friendly by putting the control in the palm of your hand. It can save time, increase operational efficiency and instill confidence in the day-to-date operation.◆DSC is also a global leader in the dredge manufacturing industry, engineering superior customized dredging solutions to meet specific application needs. DSC Dredge designs and manufactures high quality, durable cutter suction, and underwater pump mining dredges. DSC Dredge operates from three manufacturing facilities located in Reserve, Louisiana; Poplarville, Mississippi; and Greenbush, Michigan. For more information, visit www.dscdredge.com.DSC DredgeMaster Suite is now available in the Apple AppStore and currently available for the iPhone or iPad. Additional versions to be released soon.
14 | November 2020 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITYKeeping Spills in CheckFour strategies for spill prevention and containment in the workplace By Prajakta PingulkarVarious companies need to use, store, transport, or handle liquids and chemicals that are hazardous in nature. Hence, it’s imperative to take some precautionary and counteractive measures for containing an accidental spill. It may be easier to, at times, neglect the rudiments of sustaining a safe workplace, especially when you are responsible for smoothly running a business. Nevertheless, failure to take precautionary measures for spill containment can put your company at risk for hefty fines by OSHA or EPA. It also can impact the health of the workers, leading to massive downtime at work. Thus, spill containment products at workplaces are indispensable for avoiding leaks, spills, or unanticipated mishaps. This article broadly speaks about four must-do strategies to implement for spill containment in workplaces. Let’s dive in!1. REGULAR MAINTENANCE AND INSPECTION OF THE INDUSTRIAL MACHINERYThe maintenance group should be appointed to examine all equipment routinely to ensure they are in the midst of safe and stable working conditions. It’s also a good practice to report their checking and audits in an inspection log for easy tracking. Additionally, in case of any observed issues, the safety manager should be promptly notified. You can even develop your own preventative maintenance program for spill containment. An effective preventative maintenance program for spill containment will help distinguish all segments required to be examined, then set a timeline for inspecting and repairing the components, and finally include a record for easy tracking. Below are a few things your maintenance personnel should check while inspecting the industrial machinery:1. Spraying or splashing2. Tight connections3. Drip marks or slow drips4. Corrosion5. Pooling or puddling6. Various tools and machinery are in the desirable working state7. Any leaks or spills in the pipes, seams, or containment pansIt’s a smart practice to ensure that these containers are guarded with quality secondary spill containment, to avoid any unforeseen disaster.
Modern Pumping Today | November 2020 15www.mptmag.comMAINTENANCE & RELIABILITYNevertheless, some techniques can be implemented for ascertaining the records of spills in your company. For instance, you can analyze how many spill kits have been employed in your workplace for spill containment. Below are a few guidelines:1. Whenever a spill kit or an absorbent is used, the safety supervisor should be informed about it.2. When you employ various spill containment services, maintain records regarding their utilization.3. Regularly speak with the different machine workers in your workplace to gather information regarding the non-reportable spills or leaks.4. ANALYZE AND ASSESS THE SPILL CONTAINMENT PLAN In case your primary spill containment solution, such as a storage container defaults, a qualitative secondary spill containment solution is your holy grail of a shield for containing accidental spills and leaks. In an unprecedented development of a leak or spill, a secondary spill containment solution will help counter the liquid from spreading. Hence, ensure that you have an active as well as a passive spill containment solution in place. An active spill containment solution implicates a containment solution that needs an individual to take a relevant action when a spill transpires. This may entail using a spill kit or the mops to clean the spill, putting down the drain covers, or up a temporary containment wall, among others. Meanwhile, passive spill containment involves a solution that is already in place if and when a spill happens. This may include secondary spill containment berms, absorbent mats or pads, drip pads, and safety floor mats.◆2. ENSURE THAT THE VESSELS AND SPILL CONTAINMENT BERMS USED ARE IN GOOD SHAPEEnsure that you examine storage tanks and bulk storage vessels frequently through visual inspections and integrity testing. Drip marks, gaps, corrosion, cracks, or discoloration are some of the things that you need to look out for, among others. On noticing any of these aforementioned symptoms, make sure that you replace the containers as soon as possible. Also, in case you are qualified for SPCC, you must definitely conduct integrity testing while also judiciously examining bulk storage containers with an enormous capacity, as listed below:1. Double-walled containers2. Large bulk storage containers that are field-constructed or field-erected 3. Small bulk storage containers for shops4. Vessels that are partially located/ buried/ bunkered/vaulted in or off the ground wherever positionedIt’s a smart practice to ensure that these containers are guarded with quality secondary spill containment, to avoid any unforeseen disaster.Ensure to run a meticulous 360-degree inspection of all the storage vessels, and tanks, that may be prone to oil leaks or spillage of any other fluids. If there’s a storage failure, ensure the secondary spill containment solution employed intercepts the liquid from reaching the drains or pathways.Going forward, it’s the best practice to keep a record of all kinds of spills, big or small, to avoid manual hassles later on.Basic Concepts, Inc. is the world leader in the portable spill containment market because they offer high quality products that have features that customers prefer year after year. Customers can discuss their secondary containment requirements with one of BCI’s experienced, on-staff technical sales representatives. BCI gladly supplies references, comparative test data, and sample spill containment materials to help you make an informed decision. Basic Concepts is part of the Justrite Safety Group. For more information, visit www.basicconcepts.com.3. CHECK AND EVALUATE YOUR COMPANY’S SPILL RECORDSEnsure that you analyze your company’s track record history concerning leaks, spills, and even slips and drops for each tool and device used in the work area and also, the surroundings of your department. Do study the data for identifying the major pain points, and then accordingly design a suitable plan of action based on your verdicts. Not every spill gets documented at all times. At times, only the EPA or the OSHA reportable spills get documented.
16 | November 2020 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITYEstimating True Life-cycle CostBy Ben Keiser, Applied Flow TechnologyWe all want reliable pumps and piping systems that meet requirements with a cost-effective design. The resulting design may come in under budget. But does that mean it is cost-effective? The reality is if you are neglecting the system’s full life-cycle cost and only pushing design to meet or come in under the initial cost budget, you most likely do not have a cost-effective design. The reason why is because designs using smaller diameter piping to help reduce initial costs will require higher horsepower pumps, which lead to significant energy costs in the long run. The energy costs can easily be many times more expensive than the initial cost of the system itself.A BETTER UNDERSTANDING OF ENERGY COSTSWhen designing a system, it is best to base the design off the system’s full life-cycle cost, which considers energy costs as well as initial costs. However, we often find this is not regular practice. Engineering companies typically design a system to stay within some budgetary limit and do not consider energy costs.Why are energy costs often ignored? Engineering companies are not responsible for the energy bill and may not pay attention to the energy costs. Their primary goal is to stay within budget. This usually means smaller piping, fittings, and equipment. The plant owner/operators are the ones that should pay attention to what they spend on energy costs, but they often do not pay much attention either.Although better efficiency and lower energy costs are important to some, plant owners/operators care more about better reliability, minimizing repair and maintenance costs, minimizing downtime and product losses, and increasing overall profitability. In previous articles (see “Going Beyond Efficiency Standards,” MPT: June and July 2020), I described how flow analysis software can easily help improve all of these aspects from better reliability and efficiency to reduced energy costs and increased profits.CONSIDERING DESIGN INFLUENCESWhen a piping system is designed, pipe sizes and pumps are often selected based on the system requirements and various rules of thumb. This is a very iterative and difficult process when done by hand or with spreadsheets. Engineers do not have time to try different combinations of pumps and pipe sizes that can result in a lower cost. Flow analysis software with cost calculation and automated pipe sizing capabilities can aid the design process greatly. In addition to simply determining the pressure, flow, and temperature distribution among many other advantages, it can help the engineer evaluate many more pump and pipe size combinations that can result in a much lower cost than anticipated.Consider a new design for a simple cooling water system example as shown in the piping system flow model in figure 1. Two pumps operate in parallel pump through flow control valves, followed by a flow split that delivers cooling water through three heat exchangers. The cooling water recirculates through this closed system.To determine the required pipe size and pumps needed to meet system requirements, one would start with a guess on pipe size. The system in figure 1 starts with a pipe
Modern Pumping Today | November 2020 17www.mptmag.comMAINTENANCE & RELIABILITYsize guess of 8 inches for all piping. Manually, the user would change the pipe sizes individually, run the model, compare results with design requirements, and continue iterating. This process will be repeated until all design requirements have been met. The initial cost of the system would be whatever results from the material and installation costs of the size and length of the piping, fittings, pumps, heat exchangers, control valves, etc. For the sake of simplicity, this example only considers the material and installation cost for the piping, fittings, and pumps (costs for the pressurizer, control valves, and heat exchangers are neglected).UNDERSTANDING PIPE SIZINGTo do this manually would be difficult and could take a lot of time. If the resulting costs are within the initial cost budget and design requirements are met, the sizing process for the design usually stops there. If there is any time left over, the user might be able to make some small changes to see if a lower cost is available. But this would usually only consider the initial costs. The powerful advantage to using a flow analysis software tool that has automated sizing capabilities is that the simulation process will dramatically speed things up by sizing the piping system for the user. This allows the software engine to consider even millions of possible combinations of pipe size to help find a design that truly results in the lowest cost. The other advantage is that the pump energy costs over a system’s lifetime can be easily considered concurrently with the initial costs. This provides the user a powerful ability to truly obtain the lowest cost design with a full life-cycle cost analysis.But this is where the challenge lies. If the user only considers the initial cost of the system, the simulation will determine smaller pipe sizes that will result in lower up-front costs. If this is done by hand, the user will often be blind to what the associated energy costs would be. As mentioned before, smaller pipe sizes require larger pumps that result in higher energy costs in the long run.For the system in figure 1, I have assumed a system life of twenty years and an energy cost of $0.11 per kW-hr. Material and installation costs for piping change with diameter and are considered on a $/length basis, costs for fittings vary based on diameter, and pump costs are functions of horsepower.MODIFYING DESIGN TO REDUCE COSTSThere are three ways the flow analysis software solver can modify design to reduce cost. The goal of the first case is to determine pipe sizes that will minimize initial cost. The goal for the second case is to minimize the entire life-cycle cost, which considers energy costs to drive design. The third case will be
18 | November 2020 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITYa hybrid that minimizes life-cycle costs while keeping the initial cost within a budgetary limit. Table 1 contains the resulting costs for all three scenarios.The first scenario modified pipe size to minimize initial cost. This is more typical because as described previously, neither the engineering contractors nor the plant owners/operators pay as much attention to energy costs. The total material and installation costs for the piping, fittings, bends, and pumps is $750,802. With a flow analysis software tool’s cost calculation and automated pipe sizing capabilities, it is no extra work for the software to perform an additional calculation to determine energy cost based on selected sizes. Assuming a system life of twenty years and $0.11 per kW-hr, the energy costs here is $3,293,986. Almost 4.5 times more than the initial cost of the system itself. The total cost of the system is $4,044,788.In the second scenario to minimize life-cycle cost, larger diameter pipes might be selected and although this will increase the initial cost of the system, the larger diameter pipes result in less pressure losses. Smaller pumps can be used due to lower horsepower requirements. This will have a dramatic effect on the overall energy costs. There is an increase in total initial costs by $315,626. But the savings on energy costs is $1,017,693. The total cost of the system at $3,342,720 represents a total system savings of $702,068. That is 21 percent total savings!WORTH THE INVESTMENTWith significant savings like this, who would not choose to base their design off life-cycle cost instead of reducing only initial costs? Spend more initially and save a lot in the long run. The major constraint is obviously the budget. It may not be possible to spend more than the budget allows, even if it can save much more in the long run. This is where you can implement a hybrid approach where the design is modulated to minimize life-cycle cost first, until the budget is met.A quality software tool will do this for you by allowing the specification of an initial cost budget, and then will size the pipes accordingly. In case three, an initial cost budget of $900,000 was specified. The solver iterates through the millions of combinations of pipe sizes and finalizes on sizes that meet budget while minimizing life-cycle cost. It provides the best of both worlds.Comparing the third case with the initial case, we reduced energy cost and total life-cycle cost by $727,361 and $577,123, respectively while meeting the initial cost budget. Although this is about $1,000 over budget, that can perhaps be adjusted with the software tolerances. In the end, this still saves 17 percent in the long run in comparison to cases where full life-cycle costs are ignored by minimizing only initial cost.Overall, it is important to consider total life-cycle cost by accounting for energy costs in the design process. This allows dramatic savings in the long run. With flow analysis software that has cost calculation and automated pipe sizing capabilities, the massive savings is truly realized with the click of a button. ◆table units: us dollarsmaterial installationnon-recurring sub totaloperation/energytotalPipe Subtotal$388,405 $229,113 $617,518 $0 $617,518Additional Fittings Subtotal$37,055 $52,946 $90,001 $0 $90,001Bend Subtotal$900 $1,778 $2,678 $0 $2,678Pump Subtotal$31,038 $9,566 $40,604 $3,293,986 $3,334,590Total of All Costs$457,398 $293,404 $750,802 $3,293,986 $4,044,788table units: us dollarsmaterial installationnon-recurring sub totaloperation/energytotalPipe Subtotal$613,327 $291,912 $905,239 $0 $905,239Additional Fittings Subtotal$58,313 $72,300 $130,613 $0 $130,613Bend Subtotal$1,648 $2,772 $4,420 $0 $4,420Pump Subtotal$20,309 $5,847 $26,155 $2,276,293 $2,302,448Total of All Costs$693,597 $372,831 $1,066,428 $2,276,293 $3,342,720table units: us dollarsmaterial installationnon-recurring sub totaloperation/energytotalPipe Subtotal$493,379 $260,987 $754,365 $0 $754,365Additional Fittings Subtotal$50,908 $63,638 $114,547 $0 $114,547Bend Subtotal$1,418 $2,197 $3,615 $0 $3,615Pump Subtotal$22,106 $6,408 $28,513 $2,566,625 $2,595,138Total of All Costs$567,810 $333,230 $901,041 $2,566,625 $3,467,665 DESIGN TO MINIMIZE LIFE CYCLE COST DESIGN TO MINIMIZE INITIAL COST DESIGN TO MINIMIZE LIFE CYCLE COST WITH $900,00 INITIAL COST BUDGET Table 1: Cost comparison of three automated pipe sizing design scenarios. First case sizes pipes based on initial costs only, resulting in smaller pipe sizes while allowing energy costs to be calculated. Second case minimizes total life-cycle cost by allowing larger pipe sizes to reduce energy cost. Third case minimizes life-cycle cost while keeping initial costs within an initial cost budget.Ben Keiser is technical sales consultant at Applied Flow Technology. With a primary focus on developing high quality fluid flow analysis software, AFT has a comprehensive line of products for the analysis and design of piping and ducting systems. For more information, visit www.aft.com.
20 | November 2020 | Modern Pumping Today www.mptmag.comPUMP SOLUTIONSAs we mentioned in last month’s installment of this series, standards play a key role in the chemical industry. The characteristics they define assure customers that performance and safety requirements are met, while also guaranteeing interoperability for equipment throughout a plant. STRICT ADHERENCE TO INDUSTRY STANDARDSThe ANSI/ASME B73.3 standard specifically addresses centrifugal pumps for the chemical industry. The standard covers 27 pump sizes and specifies dimensions for height, length, nozzle, and shaft diameters, plus the location and spacing of mounting bolts. The ISO 5199/2858 standards cover the same type of industrial pumps as ANSI B73.3. The pumps deployed for chemical processing applications should meet all relevant ISO, ASME/ANSI standards. They should be available in metallic options to withstand extremely high temperatures (such as stainless steel with silicon carbide internal bearings, or Alloy 20/Alloy C with PTFE gaskets). Pumps should also be available in non-metallic configurations, for highly corrosive applications. ADDITIONAL PROTECTION AND PEACE-OF-MIND FOR HANDLING HARSH AND HAZARDOUS CHEMICALSSeal-less pumps offer the best solution to fugitive emission regulation. But every pump can use help defending against unstable process conditions. Sensors and monitors alert operators to potential problems and secondary containment systems ensure that problems do not escalate. “Gas-in-liquid” Detectors To avoid the risk of damage and dry running, ultrasonic signal technology is available to instantaneously detect the presence of gas in a liquid stream from outside the confines of the pump pressure boundary. Traditional temperature and power control monitoring solutions sense the secondary effects of a gas build-up in the pump—but in most cases, pump damage occurs before any change is registered. By using ultrasonic technology, the build-up of bubbles in liquid can be identified early, and operators can be warned if a pump suffers from incorrect priming or venting, entrained process gas, or incipient vaporization. This ultrasonic technology—called VapourView—is adaptable to any application and can be retrofitted onto any seal-less magnetic drive pump. The system eliminates the potential for dry running and brings peace-of-mind against catastrophic failures and unexpected repair costs.Eliminating Induction Heating and Eddy Current Losses Applications that span the full hydrocarbon chain can pose Seal-less Magnetic Drive Pumps for Chemical Processing ApplicationsBy Colin Guppy, Sundyne LLCPart 2 of 2www.mptmag.comSee Part 1VapourView
Modern Pumping Today | November 2020 21www.mptmag.comPUMP SOLUTIONSchallenges to pump seals by creating magnetic losses and by heating the process fluid. Pumps used in chemical processing applications can overcome these challenges with containment shells that eliminate induction heating and eddy current losses.Most magnetic drive pump containment shells are made of metal. A preferred option for chemical processing applications are shells called ZeroLoss—which are engineered from a combination of poly-ether-ether-ketone (PEEK) and carbon fiber that was initially developed for military and aerospace equipment. Five times lighter than steel but just as strong, ZeroLoss Shells increase the pump’s reliability, widen temperature ranges from -40 to 305 degrees Fahrenheit (-40 to 150 degrees Celsius), bolster the pump’s resistance to thermal shock, eliminate potential vaporization of process chemicals near the pump’s bearing, and provide greater efficiency—by enabling a smaller motor to be specified (which also saves on power costs).CHEMICAL PROCESSING PLANTS NEED ACCESS TO LOCAL AFTERMARKET SERVICEChemical plants run operations around the clock. If any part of the operation fails, it must be brought back on line immediately. A pump manufacturer’s Authorized Service Centers (ASCs) must be able to support every pump, and bring engineering expertise and technical support to the customers’ job site at a moment’s notice. From routine maintenance programs and onsite troubleshooting to replacement parts and components, the service network must be able to provide everything it takes to keep chemical plants up-and-running—anywhere around the globe. The containment shell (in green) protects the pump in several ways.
22 | November 2020 | Modern Pumping Today www.mptmag.comPUMP SOLUTIONSMAKING THE CASE FOR SEAL-LESS PUMPS IN CHEMICAL PROCESSING APPLICATIONS When it comes to handling harsh and hazardous chemicals, safety for plant personnel and the environment are critical factors—but bottom-line ROI is just as important. In summary, here are ten reasons for operators to choose seal-less magnetic drive pumps for chemical processing applications:1. Design Simplicity: seal-less pumps = no leaks and no emissions2. Lower Installation Costs: no need for seal support systems 3. Extensive Flow and Pressure Envelope: supported via a wide range of pumps4. Support for all Industry Standards: in any geography5. Construction Materials to handle any job:• Metallic liquid ends for high temperature applications• Plastic liquid ends for highly corrosive substances6. Monitoring Solutions: to identify potential problems before they escalate7. Secondary Containment Options: to deliver peace-of-mind 8. Flexibility: to handle solids and withstand dry running9. Extended MTBF: to decrease maintenance costs10. Global Service and Support: to deliver same day local support, anywhere in the world. ◆Colin Guppy is Sundyne’s chief commercial officer. He is responsible for developing strategies and tactics for Sundyne’s chemical industry sector. He can be reached at colin.guppy@sundyne.com. Sundyne has assembled industry-leading brands that provide customers with a wide range of fluid and gas handling services and solutions. Brands like Ansimag, HMD Kontro, and Marelli have broadened the original Sundyne portfolio for a wider range of markets. Sundyne equipment can be built to most standards, including ANSI, ISO, and API. For more information, visit. www.sundyne.com or www.hmdkontro.com.• Metallic Options: HMD pioneered the seal-less magnetic drive pump for the chemical industry in 1947—and since that time, HMD’s engineers have leveraged more than seventy years of experience to ensure that HMD Kontro seal-less pumps adhere to, and exceed the latest ASME and ISO standards.• Non-Metallic Options: For highly corrosive chemical applications, ANSIMAG pumps are ASME / ANSI B73.3 compliant and are available in materials that can stand up to most abrasive or highly-corrosive applications.MEETING OR EXCEEDING CHEMICAL INDUSTRY STANDARDS
24 | November 2020 | Modern Pumping Today www.mptmag.comPUMP SOLUTIONSBridging the IoT GapCollaboration creates new line of Ethernet/IP controlled peristaltic pumpsBy Rob Martindale, Watson-Marlow Fluid Technology GroupCytiva, a global provider of technologies and services that advance and accelerate the development and manufacture of therapeutics, collaborates with Watson Marlow Fluid Technology Group (WMFTG) to develop a new line of Ethernet/IP peristaltic pumps. The new pumps enable biopharmaceutical drug manufacturers to improve process control and access data using Ethernet networks. The pumps are well-suited for manufacturing biological drugs, including those used for cell therapy and gene therapy.
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NOVEMBER 2020 20 28 MPT Modern Pumping Today www mptmag com P O Box 660197 Birmingham Alabama 35266 modpumpmag I N D U STRY N E W S What s Happening in the Industry 4 CA SE STU DIE S GPRS Uses Ground Penetrating Radar to Expand Business 8 Versatile technology helps company diversify services WAT ER WAS T E WAT E R S O L U T I O NS Manage Dredge Operations from Your Smartphone 12 DSC Dredge launches first of its kind dredge production smartphone app M A INTENA N C E RE L IABIL IT Y Keeping Spills in Check 14 Four strategies for spill prevention and containment in the workplace Estimating True Life cycle Cost 16 P UMP SOL U T IO N S Seal less Magnetic Drive Pumps for Chemical Processing Applications Part 2of 2 20 J CAMPBELL Editor jay mptmag com TONYA BROWNING Vice President tonya mptmag com JEFF FLETCHER National Sales Manager jeff mptmag com LISA AVERY Art Director CRISTELA TSCHUMY Graphic Designer SETH SAUNDERS Digital Media Specialist INGRID BERKY Office Manager SUBSCRIPTION inquiries or changes 205 380 2048 Bridging the IoT Gap 24 Collaboration creates new line of Ethernet IP controlled peristaltic pumps SE AL ING SOL UT IO N S The Royal Discipline of TIG Welding 28 Optimization welding results through the correct sekection of high quality tungsten electrodes Part 2 of 2 B U YERS GUID E Company Profiles 33 EDITORIAL ADVISORY BOARD www highlandspublications com 312 Lorna Square Birmingham Alabama 35216 866 251 1777 TIM GARMON CEO RUSSELL HADDOCK President CHRIS GARMON CFO DONNA CAMPBELL Vice President Editorial TONYA BROWNING Vice President Terry Bell Product Manager ABB Heinz P Bloch P E Consulting Engineer Process Machinery Consulting Robert G Havrin Director of Technology Centrisys Corporation Michael Mancini Consultant and Trainer Mancini Consulting Services John M Roach Engineering Manager for New Product Development Trebor International Inc A Unit of IDEX Lisa Riles Business Development Manager Wastewater Pumps Xylem Inc Flygt Frank Knowles Smith III Executive Vice President Blacoh Surge Control Greg Towsley Director of Regulatory and Technical Affairs Grundfos Trey Walters P E President Applied Flow Technology No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopy recording or any information storage and retrieval system without permission in writing from the publisher The views expressed by those not on the staff of Modern Pumping Today or who are not specifically employed by Highlands Publications Inc are purely their own All Industry News material has either been submitted by the subject company or pulled directly from their corporate website which is assumed to be cleared for release Comments and submissions are welcome and can be submitted to jay mptmag com
INDUSTRY NEWS DR GER AND VECTOR CAG TEAM UP TO PROMOTE PRODUCT PORTFOLIO Dr ger an international leader in the field of safety technology announces the appointment of Vector Controls and Automation Group Vector CAG a leading manufacturers representative of control and automation solutions The organization will represent and promote Dr ger s fixed flame and gas detection systems portfolio sales in the states of Texas Oklahoma Kansas Missouri Southern Illinois Iowa Nebraska and Southeastern New Mexico We are very pleased and excited to partner with Vector CAG as an official manufacturer representative for our innovative line of fixed gas and flame detection solutions said John Wilson Dr ger s senior vice president of sales and marketing for safety solutions in North America Working alongside our own Dr ger personnel and through Vector s strong customer relationships we will continue to grow our installed base of fire and gas detection system solutions in this key geographic territory Vector CAG has always committed to partnering with best in class manufacturing companies to represent the top products in the industry says Jared Boudreaux president Vector CAG We are proud to enhance our extensive safety product portfolio with Dr ger s worldclass fixed gas and flame detection solutions 4 November 2020 Modern Pumping Today ABB NAMES NEW DODGE PRESIDENT ABB recently named company veteran Roger Costa as president of its global Mechanical Power Transmission Division also known as the Dodge business Established in the United States in 1878 the Dodge business today is considered the leading manufacturer of mounted bearing enclosed gearing and power transmission components in the nation ABB s recognition as a global leader in the mechanical business stems from a strong culture that focuses on customer experience Costa says I look forward to joining a team that values that culture Together we will work to continue to develop and grow markets for our superior products With more than seventeen years of experience at ABB Costa has held executive roles in both the United States and Canada During his tenure at ABB Costa has gained considerable knowledge of the company s extensive operations ranging from mechanical to motors and robotics Costa s unique perspective brings valuable insight to ABB s leadership team Costa has a bachelor s degree in electro mechanical engineering from Humber College and completed an advanced university program in business management at the University of Toronto Roman School of Management www mptmag com
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INDUSTRY NEWS BLACOH INDUSTRIES ANNOUNCES NEW HIRES Blacoh Industries announces the addition of two new specialists to support the company s goal of growth by providing innovative solutions for improved performance in fluid pumping systems Scott Bradley and Luis Ornelas were appointed for their diverse talents and experience and will increase Blacoh s capacity for innovation in engineering product design manufacturing and services Professional mechanical engineer Scott Bradley joins the Blacoh Surge division bringing extensive experience in designing sizing and specifying pressure vessels piping pumps compressors and various other equipment Bradley began his career managing multiple projects from award stage to ready to ship for CSI Compressco a natural gas compressor packaging company and later went on to manage a team of engineers at HPF Consultants Inc With a bachelor s in mechanical engineering and a master s in engineering management Blacoh s new quality assurance engineer Luis Ornelas combines valuable skills with experience in efficiency and quality improvement process auditing ISO compliance certifications training and team development Before joining Blacoh Ornelas led a team of quality inspectors for EGR Incorporated a leading designer and manufacturer of automotive accessories for OEM and aftermarket applications SUNDYNE APPOINTS NEW CHIEF COMMERCIAL OFFICER Sundyne announces that Colin Guppy has been promoted to chief commercial officer In this newly created role Guppy will lead the original equipment and aftermarket strategies for Sundyne s vertical markets in the Americas Europe the Middle East Colin Guppy Africa and India With more than twenty five years of industry expertise and a successful career with Sundyne that dates back to 2000 Guppy is uniquely qualified to bring the breadth and depth of Sundyne s engineering and operational resources to meet today s challenges His proven track record of co creating innovative solutions and leading global sales teams will ensure the success of Sundyne s customers and channel partners In the newly created role of chief commercial officer Guppy will work with Sundyne customers and channel partners to continue developing the right mix of products and aftermarket services that customers in the oil and gas chemical and industrial markets need to meet their evolving business needs 6 November 2020 Modern Pumping Today Sundyne has always been a customer focused company we re realigning some of our internal resources and our business processes to match the evolving needs of our customers says Sundyne s CEO Mark Sefcik FEDERAL PROCESS CORPORATION IS NOW FPC INTERNATIONAL INC Federal Process Corporation a diversified manufacturer of specialty chemicals and premium quality building products and supplier of innovative plumbing products is rebranding as FPC International Inc As the company has grown building its product offerings through its own research and scientific innovations along with recent acquisitions the action is a more fitting reflection of the company s expansion into a much broader range of niche industries We have evolved significantly over the course of our rich history and our name change is an appropriate action to more clearly demonstrate our growing presence in the markets we serve says Jon Outcalt Jr president FPC International Inc With that said as we grow we continue to take pride in our commitment to maintaining close connections with our customers and providing expertise and counsel on a very personal level Today FPC International Inc remains loyal and dedicated to its local roots retaining its global headquarters in Cleveland and manages five distinct businesses within the building product and specialty chemical industries QUALITY COMPANIES APPOINTS NEW BUSINESS DEVELOPMENT MANAGER Quality Companies has appointed Iain Gault as business development manager for Houston and International Based in Houston Gault will serve to grow the Quality Companies client base in the deepwater and international arenas and introduce an expanded range of Quality Companies services to the energy sector Previously Gault served as business development and technical services manager at Stork Technical Services USA where he was the technical authority for rope access and specialist services in the Americas and the Caribbean He has also provided assessment and evaluation of rope access classes throughout the Americas and Europe for Industrial Rope Access Trade Association IRATA and Society of Professional Rope Access Technicians SPRAT Richard Tang director of business development Quality Companies says Iain has a deep and wideranging technical proficiency specializing in rope access with hands on experience acquired in locations around the world This coupled with his extensive managerial expertise ensures he is the ideal individual to manage deepwater and international business development initiatives for Quality Companies www mptmag com
CASE STUDIES GPRS Uses Ground Penetrating Radar to Expand Business Versatile technology helps company diversify services By Jason Schaff GPRS LLC M any early adopters of ground penetrating radar GPR technology found concrete scanning to be the effective application Those anchoring saw cutting or core drilling concrete would hire a contractor to scan the area before cutting to avoid accidentally hitting an object For this reason construction firms have come around to the notion that concrete scanning is vital to job site safety and efficiency In recent years service companies have also found synergy between concrete scanning and the need to provide utility locating services Many contractors find GPR to be an important tool that allows them to scale and expand their business while maintaining a high level of service NON DESTRUCTIVE SUBSURFACE SURVEY TECHNOLOGY IN DEMAND Toledo Ohio based Ground Penetrating Radar Systems GPRS LLC was one of the first companies in the country to focus on concrete scanning using GPR technology They determined that GPR was preferable to other non destructive subsurface survey technologies including x raying While concrete x raying remains a valid technique to locate reinforcing steel in certain applications GPRS found it lacked the flexibility to meet the demands of many projects The method must be done in conditions in which radioactivity can be safely introduced it also requires access to the underside of the concrete to be scanned and the job site to be closed GPR is used without any radioactive element instead emitting a pulse of energy into the concrete that bounces off any objects in the slab When some of that energy returns to the antenna it creates a signature which clearly shows where and at what depth items within the slab are located GPRS opted for this more versatile technology which can be used for both elevated concrete slabs and slab on grade applications 8 November 2020 Modern Pumping Today GPRS operators using the GSSI StructureScan Mini at Yankee Stadium GPRS found that GPR equipment helps contractors safely avoid obstacles in concrete reducing costly delays and potential injuries For example during a recent project to revitalize the upper deck at New York s Yankee Stadium the general contractor had to penetrate the concrete floor to work on the ballpark s protective railings and expected the presence of post tension cables If accidentally severed these high tension steel strands can snap with enough force to break through the concrete and possibly injure the contractor Due to the severity of the potential risk and the popularity of Yankee Stadium x ray was impossible for this job The contractor turned to GPRS who scanned the area with the GSSI StructureScan Mini XT This compact tool combined with a GSSI Palm XT antenna gives operators the ability to cross polarize for an enhanced level of horizontal and vertical positioning accuracy Since GPR is entirely safe to use around people no section of the stadium had to be closed off for other workers avoiding any major work disruption A concrete job like this would not be possible without GPR You never really know what s beneath the surface GPR lets us provide quantitative data and relevant www mptmag com
CASE STUDIES to the same scan on the other side and an electromagnetic tool that hooks onto a conduit to passively look for something drawing power To meet the need to locate live power in conduits GPRS also began providing utility detection services BRANCHING INTO DIFFERENT MARKETS In recent years GPRS has moved into using GPR for utility location diversifying its business from 95 percent concrete scanning in the early 2000s to now performing 40 percent concrete scanning and The Palm XT gives GSSI StructureScan Mini users a handheld miniaturized GPR antenna for enhanced access to tightly spaced areas information to our customers so that they re able to do their jobs more safely The GPRS team was also hired by a structural engineering firm to determine the structural reinforcement of a Boston Massachusetts building originally used to manufacture cannons and as an armory The building featured GSSI s easy to read visualization allowed GPRS to create drawings with locations and depths of obstacles an 8 inch slab with a 1 5 inch topping slab Scanning the slab and topping with the SIR 4000 and Palm Antenna the technicians uncovered a complex circumferential reinforcement design GPRS provided a mark out of the location and depth of targets as well as a 3D camera report with a virtual tour to the structural engineering client Along with GPR equipment GPRS also uses other tools that complement each other including a reference point locater that gives operators an added certainty that the area they scan on one side of a thick slab corresponds exactly www mptmag com Modern Pumping Today November 2020 9
CASE STUDIES Mark out of the location and depth of complex circumferential reinforcement design 60 percent utility scanning Utility projects range from mapping out an entire facility s utility plan and providing a detailed AutoCAD file to examining a small area before installing even a single light pole Just like combining GPR with other techniques for concrete scanning GPR is an integral part of the utility locator s toolbox Rodders are used to send traceable lines through pipes to then put a tone on the tracer to assist location A radio detection tool actively locates pipes under the surface putting a tone on a tracer and tracing metallic pipes Magnetometers measure magnetic fields and provide a useful back up to confirm the location of a cleanout Other electromagnetic induction equipment serves a similar purpose GPRS also uses closedcircuit video CCTV robots that navigate pipes internally to produce an inside out visual pipe inspection GPR can determine the location of a PVC pipe that does not have a 10 November 2020 tracer wire which would have evaded radio detection or discovery by an electromagnetic tool GPR technology really allows us to hone in be more precise and sets us apart from other service companies that don t have it GPRS demonstrates the efficacy of their technique when executing a recent contract to locate utilities under parking lots at Target and Walmart locations nationwide These retailers demanded uniform parking spots to allow customers to quickly pick up online orders The project had a unique set of challenges because they were not conducting a complete utility location survey of the property to enable them to fully identify all gas water sewer and electrical hazards that lay under the surface When we re in those parking lots we don t have visible meters tracer wires or cleanouts that we can just find and trace out utilities with GPR units are fully capable Modern Pumping Today to locate unknown objects If we did not have GPR we would not be able to properly locate each one of those sections before they run the electrical conduit and put the bollards in GSSI s easy to read visualization allowed GPRS to create drawings with locations and depths of obstacles Overlaid on Google Earth maps these detailed references enabled contractors across the country to quickly and safely expedite excavation and construction of these novel parking features Utility locating also came into play at the Yankee Stadium project where GPRS had to locate utilities under the sidewalk in front of the stadium before the contractor dug a 125 square foot trench For the utility locating portion of the job GPRS used GSSI s SIR 4000 with a 400 MHz Antenna The SIR 4000 s modular design enabled the team to easily configure the system for utility location www mptmag com
CASE STUDIES Ground penetrating radar allows GPRS to scale both halves of business nationwide Because our business has two different verticals with concrete scanning and utility location we want to use an equipment company that has the ability to cross over and do both In 2019 alone GPRS completed 70 000 individual projects in nearly sixty markets with an overall accuracy rate of 99 5 percent We use GSSI GPR for every one of those markets and every one of those jobs CROSS TRAINING IS KEY TO QUALITY GPRS has adopted a strategy of developing new markets with limited personnel by cross training its personnel All GPRS project managers undergo a three month training process to ensure a repeatable methodology so each customer gets the same level of service The strategy is furthered by the availability of systems small enough to transport in the trunk of a sedan and capable of quickly determining the reinforcement of concrete hollow core rebar post tension cables metal decking or adjusting to soil makeup at a utility location site with ease To ensure quality across the company GPRS instituted an intensive training program and developed a specification Subsurface Investigation Methodology SIM that lays out requirements for training equipment and process In addition GPRS has partnered with GSSI for their GPR equipment to ensure they re using professional quality equipment GSSI has been at the forefront developing new technologies They know what they re doing and we know what we re doing It makes total sense to pair with the manufacturer that fits us so well Historically nearly 80 percent of GPRS clients are either repeat or referral The company focuses on long term performance recognizing that repeatable accuracy is at the core of their services By effectively leveraging the flexibility and precision of GPR technology GPRS has diversified and expanded its business from regional to nationwide all without diminishing service quality To continue to build on its success the company has acquired four GPR service provider companies to better meet customer needs and prepare for market growth u PLAY THE FUTURE OF GPR SERVICES D EO VI CUSTOMIZED SUBMERSIBLE MOTORS Sun Star Electric Inc Jason Schaff is vice president of sales and marketing at GPRS LLC Ground Penetrating Radar Systems LLC is the nation s largest company specializing in the detection of underground utilities video pipe inspection and the scanning of concrete structures GPRS has an extensive nationwide network of highly trained and experienced project managers in every major U S market For more information visit www gp radar com www mptmag com 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 Modern Pumping Today November 2020 11
WATER WASTEWATER FOCUS Manage Dredge Operations from Your Smartphone DSC Dredge launches first of its kind dredge production smartphone app By Mercedes Gabriel DSC Dredge F or over fifty years DSC Dredge has met the needs of the dredging industry in terms of designing and manufacturing quality dredges and dredge equipment A three generation family business each generation has introducted new and innovative opportunities to better serve this unique community it s no surprise that DSC has continued to grow more innovative in addressing the technology gaps experienced by the dredging industry The most recent addition to DSC Dredge s custom services is the launch of its new app for iOS mobile devices the DredgeMaster Suite This addition to DSC s technology suite illustrates the company s initiative in building the most comprehensive experience for dredge owners and operators DSC s newest dredge class the Sharkuda now in operation and utilizing the new DSC Vision software CLOSING THE GAP THROUGH TECHNOLOGY We get dozens of requests to do dredge evaluations on a weekly basis says William Bill J Wetta senior vice president and chief technology officer For years we have tried to figure out a way to allow customers to have access to this information themselves without giving away all of our trade secrets From this desire to better serve our customers the concept of the DSC DredgeMaster Suite app was born The first comprehensive solution of its kind the DSC DredgeMaster Suite app has been developed entirely in house 12 November 2020 Modern Pumping Today as a collaborative father son effort Bill s youngest son Nick Wetta has spent the past two years working tirelessly to bring this concept to life This app is the first of its kind that will allow dredge owners and operators to take better control of their operations As time evolves it is important to remember that it is not that we live in technology but that we use technology daily and the dredging industry should be no different states Nick Wetta official creator of the DSC DredgeMaster Suite app www mptmag com
WATER WASTEWATER FOCUS DSC DredgeMaster Suite is now available in the Apple AppStore and currently available for the iPhone or iPad Additional versions to be released soon FROM WHAT IF TO CAN DO This digital tool is a comprehensive production toolbox that provides users with benchmarking data operational information and what if options at their fingertips When paired with DSC s Dredge Rx system it becomes part of a complete maintenance solution that allows users to view and track dredge performance and required servicing while on the dredge or while working remotely According to Bill Wetta We are living in an age where technology can offer enormous upsides and Nick has brought to life an idea that my brother Bob and I have been talking about over the past decade This app in a nutshell shows whether a particular dredge meets the conditions requested We are excited to introduce this technology to the dredging community as it will allow for easy access to information in real time dredges of all sizes and purposes for the dredging market As a result we have dredge units in use throughout the world and across an expanse of industries aggregates mining construction environmental navigational recreational restoration and specialty projects This is all about customer service and helping make our product more userfriendly by putting the control in the palm of your hand It can save time increase operational efficiency and instill confidence in the day todate operation u DSC is also a global leader in the dredge manufacturing industry engineering superior customized dredging solutions to meet specific application needs DSC Dredge designs and manufactures high quality durable cutter suction and underwater pump mining dredges DSC Dredge operates from three manufacturing facilities located in Reserve Louisiana Poplarville Mississippi and Greenbush Michigan For more information visit www dscdredge com THE FUTURE OF DREDGING SOLUTIONS Over the years DSC has focused its expertise on the design and manufacturing of customized www mptmag com Modern Pumping Today November 2020 13
MAINTENANCE RELIABILITY Keeping Spills in Check Four strategies for spill prevention and containment in the workplace By Prajakta Pingulkar V arious companies need to use store transport or handle liquids and chemicals that are hazardous in nature Hence it s imperative to take some precautionary and counteractive measures for containing an accidental spill It may be easier to at times neglect the rudiments of sustaining a safe workplace especially when you are responsible for smoothly running a business Nevertheless failure to take precautionary measures for spill containment can put your company at risk for hefty fines by OSHA or EPA It also can impact the health of the workers leading to massive downtime at work Thus spill containment products at workplaces are indispensable for avoiding leaks spills or unanticipated mishaps This article broadly speaks about four mustdo strategies to implement for spill containment in workplaces Let s dive in 1 REGULAR MAINTENANCE AND INSPECTION OF THE INDUSTRIAL MACHINERY The maintenance group should be appointed to examine all equipment routinely to ensure they are in the midst of safe and stable working conditions It s also a good practice to report their checking and audits in an inspection log for easy tracking Additionally in case of any observed 14 November 2020 issues the safety manager should be promptly notified You can even develop your own preventative maintenance program for spill containment An effective preventative maintenance program for spill containment will help distinguish all segments required to be examined then set a timeline for inspecting and repairing the components and finally include a record for easy tracking Below are a few things your maintenance personnel should check while inspecting the industrial machinery 1 2 3 4 5 6 Spraying or splashing Tight connections Drip marks or slow drips Corrosion Pooling or puddling Various tools and machinery are in the desirable working state 7 Any leaks or spills in the pipes seams or containment pans Modern Pumping Today It s a smart practice to ensure that these containers are guarded with quality secondary spill containment to avoid any unforeseen disaster www mptmag com
MAINTENANCE RELIABILITY 2 ENSURE THAT THE VESSELS AND SPILL CONTAINMENT BERMS USED ARE IN GOOD SHAPE Ensure that you examine storage tanks and bulk storage vessels frequently through visual inspections and integrity testing Drip marks gaps corrosion cracks or discoloration are some of the things that you need to look out for among others On noticing any of these aforementioned symptoms make sure that you replace the containers as soon as possible Also in case you are qualified for SPCC you must definitely conduct integrity testing while also judiciously examining bulk storage containers with an enormous capacity as listed below 1 Double walled containers 2 Large bulk storage containers that are field constructed or field erected 3 Small bulk storage containers for shops 4 Vessels that are partially located buried bunkered vaulted in or off the ground wherever positioned It s a smart practice to ensure that these containers are guarded with quality secondary spill containment to avoid any unforeseen disaster 3 CHECK AND EVALUATE YOUR COMPANY S SPILL RECORDS Ensure that you analyze your company s track record history concerning leaks spills and even slips and drops for each tool and device used in the work area and also the surroundings of your department Do study the data for identifying the major pain points and then accordingly design a suitable plan of action based on your verdicts Not every spill gets documented at all times At times only the EPA or the OSHA reportable spills get documented www mptmag com Nevertheless some techniques can be implemented for ascertaining the records of spills in your company For instance you can analyze how many spill kits have been employed in your workplace for spill containment Below are a few guidelines 1 Whenever a spill kit or an absorbent is used the safety supervisor should be informed about it 2 When you employ various spill containment services maintain records regarding their utilization 3 Regularly speak with the different machine workers in your workplace to gather information regarding the non reportable spills or leaks Going forward it s the best practice to keep a record of all kinds of spills big or small to avoid manual hassles later on 4 ANALYZE AND ASSESS THE SPILL CONTAINMENT PLAN In case your primary spill containment solution such as a storage container defaults a qualitative secondary spill containment solution is your holy grail of a shield for containing accidental spills and leaks In an unprecedented development of a leak or spill a secondary spill containment solution will help counter the liquid from spreading Hence ensure that you have an active as well as a passive spill containment solution in place An active spill containment solution implicates a containment solution that needs an individual to take a relevant action when a spill transpires This may entail using a spill kit or the mops to clean the spill putting down the drain covers or up a temporary containment wall among others Meanwhile passive spill containment involves a solution that is already in place if and when a spill happens This may include secondary spill containment berms absorbent mats or pads drip pads and safety floor mats u Ensure to run a meticulous 360 degree inspection of all the storage vessels and tanks that may be prone to oil leaks or spillage of any other fluids If there s a storage failure ensure the secondary spill containment solution employed intercepts the liquid from reaching the drains or pathways Basic Concepts Inc is the world leader in the portable spill containment market because they offer high quality products that have features that customers prefer year after year Customers can discuss their secondary containment requirements with one of BCI s experienced on staff technical sales representatives BCI gladly supplies references comparative test data and sample spill containment materials to help you make an informed decision Basic Concepts is part of the Justrite Safety Group For more information visit www basicconcepts com Modern Pumping Today November 2020 15
MAINTENANCE RELIABILITY Estimating True Life cycle Cost By Ben Keiser Applied Flow Technology W e all want reliable pumps and piping systems that meet requirements with a cost effective design The resulting design may come in under budget But does that mean it is cost effective The reality is if you are neglecting the system s full life cycle cost and only pushing design to meet or come in under the initial cost budget you most likely do not have a cost effective design The reason why is because designs using smaller diameter piping to help reduce initial costs will require higher horsepower pumps which lead to significant energy costs in the long run The energy costs can easily be many times more expensive than the initial cost of the system itself A BETTER UNDERSTANDING OF ENERGY COSTS When designing a system it is best to base the design off the system s full life cycle cost which considers energy costs as well as initial costs However we often find this is not regular practice Engineering companies typically design a system to stay within some budgetary limit and do not consider energy costs Why are energy costs often ignored Engineering companies are not responsible for the energy bill and may not pay attention to the energy costs Their primary goal is to stay within budget This usually means smaller piping fittings and equipment The plant owner operators are the ones that should pay attention to what they spend on energy costs but they often do not pay much attention either Although better efficiency and lower energy costs are important to some plant owners operators care more about better reliability minimizing repair and maintenance costs minimizing downtime and product losses and increasing overall profitability In previous articles see Going Beyond Efficiency Standards MPT June and July 2020 I described how flow analysis software can easily help 16 November 2020 Modern Pumping Today improve all of these aspects from better reliability and efficiency to reduced energy costs and increased profits CONSIDERING DESIGN INFLUENCES When a piping system is designed pipe sizes and pumps are often selected based on the system requirements and various rules of thumb This is a very iterative and difficult process when done by hand or with spreadsheets Engineers do not have time to try different combinations of pumps and pipe sizes that can result in a lower cost Flow analysis software with cost calculation and automated pipe sizing capabilities can aid the design process greatly In addition to simply determining the pressure flow and temperature distribution among many other advantages it can help the engineer evaluate many more pump and pipe size combinations that can result in a much lower cost than anticipated Consider a new design for a simple cooling water system example as shown in the piping system flow model in figure 1 Two pumps operate in parallel pump through flow control valves followed by a flow split that delivers cooling water through three heat exchangers The cooling water recirculates through this closed system To determine the required pipe size and pumps needed to meet system requirements one would start with a guess on pipe size The system in figure 1 starts with a pipe www mptmag com
MAINTENANCE RELIABILITY size guess of 8 inches for all piping Manually the user would change the pipe sizes individually run the model compare results with design requirements and continue iterating This process will be repeated until all design requirements have been met The initial cost of the system would be whatever results from the material and installation costs of the size and length of the piping fittings pumps heat exchangers control valves etc For the sake of simplicity this example only considers the material and installation cost for the piping fittings and pumps costs for the pressurizer control valves and heat exchangers are neglected UNDERSTANDING PIPE SIZING To do this manually would be difficult and could take a lot of time If the resulting costs are within the initial cost budget and design requirements are met the sizing process for the design usually stops there If there is any time left over the user might be www mptmag com able to make some small changes to see if a lower cost is available But this would usually only consider the initial costs The powerful advantage to using a flow analysis software tool that has automated sizing capabilities is that the simulation process will dramatically speed things up by sizing the piping system for the user This allows the software engine to consider even millions of possible combinations of pipe size to help find a design that truly results in the lowest cost The other advantage is that the pump energy costs over a system s lifetime can be easily considered concurrently with the initial costs This provides the user a powerful ability to truly obtain the lowest cost design with a full lifecycle cost analysis But this is where the challenge lies If the user only considers the initial cost of the system the simulation will determine smaller pipe sizes that will result in lower up front costs If this is done by hand the user will often be blind to what the associated energy costs would be As mentioned before smaller pipe sizes require larger pumps that result in higher energy costs in the long run For the system in figure 1 I have assumed a system life of twenty years and an energy cost of 0 11 per kW hr Material and installation costs for piping change with diameter and are considered on a length basis costs for fittings vary based on diameter and pump costs are functions of horsepower MODIFYING DESIGN TO REDUCE COSTS There are three ways the flow analysis software solver can modify design to reduce cost The goal of the first case is to determine pipe sizes that will minimize initial cost The goal for the second case is to minimize the entire life cycle cost which considers energy costs to drive design The third case will be Modern Pumping Today November 2020 17
MAINTENANCE RELIABILITY a hybrid that minimizes life cycle costs while keeping the initial cost within a budgetary limit Table 1 contains the resulting costs for all three scenarios The first scenario modified pipe size to minimize initial cost This is more typical because as described previously neither the engineering contractors nor the plant owners operators pay as much attention to energy costs The total material and installation costs for the piping fittings bends and pumps is 750 802 With a flow analysis software tool s cost calculation and automated pipe sizing capabilities it is no extra work for the software to perform an additional calculation to determine energy cost based on selected sizes Assuming a system life of twenty years and 0 11 per kW hr the energy costs here is 3 293 986 Almost 4 5 times more than the initial cost of the system itself The total cost of the system is 4 044 788 In the second scenario to minimize life cycle cost larger diameter pipes might be selected and although this will increase the initial cost of the system the larger diameter pipes result in less pressure losses Smaller pumps can be used due to lower horsepower requirements This will have a dramatic effect on the overall energy costs There is an increase in total initial costs by 315 626 But the savings on energy costs is 1 017 693 The total cost of the system at 3 342 720 represents a total system savings of 702 068 That is 21 percent total savings WORTH THE INVESTMENT With significant savings like this who would not choose to base their design off life cycle cost instead of DESIGN TO MINIMIZE INITIAL COST table units us dollars material installation non recurring sub total operation energy total Pipe Subtotal 388 405 229 113 617 518 0 617 518 Additional Fittings Subtotal 37 055 52 946 90 001 0 90 001 Bend Subtotal 900 1 778 2 678 0 2 678 Pump Subtotal 31 038 9 566 40 604 3 293 986 3 334 590 Total of All Costs 457 398 293 404 750 802 3 293 986 4 044 788 DESIGN TO MINIMIZE LIFE CYCLE COST table units us dollars material installation non recurring sub total operation energy total Pipe Subtotal 613 327 291 912 905 239 0 905 239 Additional Fittings Subtotal 58 313 72 300 130 613 0 130 613 Bend Subtotal 1 648 2 772 4 420 0 4 420 Pump Subtotal 20 309 5 847 26 155 2 276 293 2 302 448 Total of All Costs 693 597 372 831 1 066 428 2 276 293 3 342 720 reducing only initial costs Spend more initially and save a lot in the long run The major constraint is obviously the budget It may not be possible to spend more than the budget allows even if it can save much more in the long run This is where you can implement a hybrid approach where the design is modulated to minimize life cycle cost first until the budget is met A quality software tool will do this for you by allowing the specification of an initial cost budget and then will size the pipes accordingly In case three an initial cost budget of 900 000 was specified The solver iterates through the millions of combinations of pipe sizes and finalizes on sizes that meet budget while minimizing life cycle cost It provides the best of both worlds Comparing the third case with the initial case we reduced energy cost and total life cycle cost by 727 361 and 577 123 respectively while meeting the initial cost budget Although this is about 1 000 over budget that can perhaps be adjusted with the software tolerances In the end this still saves 17 percent in the long run in comparison to cases where full life cycle costs are ignored by minimizing only initial cost Overall it is important to consider total life cycle cost by accounting for energy costs in the design process This allows dramatic savings in the long run With flow analysis software that has cost calculation and automated pipe sizing capabilities the massive savings is truly realized with the click of a button u DESIGN TO MINIMIZE LIFE CYCLE COST WITH 900 00 INITIAL COST BUDGET table units us dollars material installation non recurring sub total operation energy total Pipe Subtotal 493 379 260 987 754 365 0 754 365 Additional Fittings Subtotal 50 908 63 638 114 547 0 114 547 Bend Subtotal 1 418 2 197 3 615 0 3 615 Pump Subtotal 22 106 6 408 28 513 2 566 625 2 595 138 Total of All Costs 567 810 333 230 901 041 2 566 625 3 467 665 Table 1 Cost comparison of three automated pipe sizing design scenarios First case sizes pipes based on initial costs only resulting in smaller pipe sizes while allowing energy costs to be calculated Second case minimizes total life cycle cost by allowing larger pipe sizes to reduce energy cost Third case minimizes life cycle cost while keeping initial costs within an initial cost budget 18 November 2020 Modern Pumping Today Ben Keiser is technical sales consultant at Applied Flow Technology With a primary focus on developing high quality fluid flow analysis software AFT has a comprehensive line of products for the analysis and design of piping and ducting systems For more information visit www aft com www mptmag com
PUMP SOLUTIONS Seal less Magnetic Drive Pumps for Chemical Processing Applications See Part 1 www mptmag com Part 2 of 2 By Colin Guppy Sundyne LLC A ADDITIONAL PROTECTION AND PEACE OF MIND FOR HANDLING HARSH AND HAZARDOUS CHEMICALS STRICT ADHERENCE TO INDUSTRY STANDARDS Seal less pumps offer the best solution to fugitive emission regulation But every pump can use help defending against unstable process conditions Sensors and monitors alert operators to potential problems and secondary containment systems ensure that problems do not escalate s we mentioned in last month s installment of this series standards play a key role in the chemical industry The characteristics they define assure customers that performance and safety requirements are met while also guaranteeing interoperability for equipment throughout a plant The ANSI ASME B73 3 standard specifically addresses centrifugal pumps for the chemical industry The standard covers 27 pump sizes and specifies dimensions for height length nozzle and shaft diameters plus the location and spacing of mounting bolts The ISO 5199 2858 standards cover the same type of industrial pumps as ANSI B73 3 The pumps deployed for chemical processing applications should meet all relevant ISO ASME ANSI standards They should be available in metallic options to withstand extremely high temperatures such as stainless steel with silicon carbide internal bearings or Alloy 20 Alloy C with PTFE gaskets Pumps should also be available in non metallic configurations for highly corrosive applications 20 November 2020 This ultrasonic technology called VapourView is adaptable to any application and can be retrofitted onto any seal less magnetic drive pump The system eliminates the potential for dry running and brings peace of mind against catastrophic failures and unexpected repair costs Eliminating Induction Heating and Eddy Current Losses Applications that span the full hydrocarbon chain can pose Gas in liquid Detectors To avoid the risk of damage and dry running ultrasonic signal technology is available to instantaneously detect the presence of gas in a liquid stream from outside the confines of the pump pressure boundary Traditional temperature and power control monitoring solutions sense the secondary effects of a gas build up in the pump but in most cases pump damage occurs before any change is registered By using ultrasonic technology the build up of bubbles in liquid can be identified early and operators can be warned if a pump suffers from incorrect priming or venting entrained process gas or incipient vaporization Modern Pumping Today VapourView www mptmag com
PUMP SOLUTIONS The containment shell in green protects the pump in several ways challenges to pump seals by creating magnetic losses and by heating the process fluid Pumps used in chemical processing applications can overcome these challenges with containment shells that eliminate induction heating and eddy current losses Most magnetic drive pump containment shells are made of metal A preferred option for chemical processing applications are shells called ZeroLoss which are engineered from a combination of poly ether etherketone PEEK and carbon fiber that was initially developed for military and aerospace equipment Five times lighter than steel but just as strong ZeroLoss Shells increase the pump s reliability widen temperature ranges from 40 to 305 degrees Fahrenheit 40 to 150 degrees Celsius bolster the pump s resistance to thermal shock eliminate potential vaporization of process chemicals near the pump s bearing and provide greater www mptmag com efficiency by enabling a smaller motor to be specified which also saves on power costs CHEMICAL PROCESSING PLANTS NEED ACCESS TO LOCAL AFTERMARKET SERVICE Chemical plants run operations around the clock If any part of the operation fails it must be brought back on line immediately A pump manufacturer s Authorized Service Centers ASCs must be able to support every pump and bring engineering expertise and technical support to the customers job site at a moment s notice From routine maintenance programs and onsite troubleshooting to replacement parts and components the service network must be able to provide everything it takes to keep chemical plants upand running anywhere around the globe Modern Pumping Today November 2020 21
PUMP SOLUTIONS MAKING THE CASE FOR SEAL LESS PUMPS IN CHEMICAL PROCESSING APPLICATIONS When it comes to handling harsh and hazardous chemicals safety for plant personnel and the environment are critical factors but bottomline ROI is just as important In summary here are ten reasons for operators to choose seal less magnetic drive pumps for chemical processing applications 1 Design Simplicity sealless pumps no leaks and no emissions 2 Lower Installation Costs no need for seal support systems 3 Extensive Flow and Pressure Envelope supported via a wide range of pumps 4 Support for all Industry Standards in any geography 5 Construction Materials to handle any job Metallic liquid ends for high temperature applications Plastic liquid ends for highly corrosive substances 6 Monitoring Solutions to identify potential problems before they escalate MEETING OR EXCEEDING CHEMICAL INDUSTRY STANDARDS Metallic Options HMD exceed the latest ASME and pioneered the seal less ISO standards magnetic drive pump for the Non Metallic Options For chemical industry in 1947 and highly corrosive chemical since that time HMD s engineers applications ANSIMAG pumps have leveraged more than are ASME ANSI B73 3 compliant seventy years of experience to and are available in materials that ensure that HMD Kontro sealcan stand up to most abrasive or less pumps adhere to and highly corrosive applications 22 November 2020 Modern Pumping Today 7 Secondary Containment Options to deliver peace of mind 8 Flexibility to handle solids and withstand dry running 9 Extended MTBF to decrease maintenance costs 10 Global Service and Support to deliver same day local support anywhere in the world u Colin Guppy is Sundyne s chief commercial officer He is responsible for developing strategies and tactics for Sundyne s chemical industry sector He can be reached at colin guppy sundyne com Sundyne has assembled industry leading brands that provide customers with a wide range of fluid and gas handling services and solutions Brands like Ansimag HMD Kontro and Marelli have broadened the original Sundyne portfolio for a wider range of markets Sundyne equipment can be built to most standards including ANSI ISO and API For more information visit www sundyne com or www hmdkontro com www mptmag com
PUMP SOLUTIONS Bridging the IoT Gap Collaboration creates new line of Ethernet IP controlled peristaltic pumps By Rob Martindale Watson Marlow Fluid Technology Group C ytiva a global provider of technologies and services that advance and accelerate the development and manufacture of therapeutics collaborates with Watson Marlow Fluid Technology Group WMFTG to develop a new line of Ethernet IP peristaltic 24 November 2020 Modern Pumping Today pumps The new pumps enable biopharmaceutical drug manufacturers to improve process control and access data using Ethernet networks The pumps are well suited for manufacturing biological drugs including those used for cell therapy and gene therapy www mptmag com
PUMP SOLUTIONS The new line of Ethernet IP cased pumps offers easy network integration which makes it easy to package data for making real time decisions during manufacturing This ability to access more information helps customers improve the efficiency quality and safety of automated production processes and improves speed to market ultimately helping reduce the cost of the drug manufacturing process At Cytiva we choose to work with companies that have proven technology high quality standards superior product support and a focus on innovation says Michelle Stafford Cytiva s global marketing leader for bioprocess solutions Biomanufacturers value speed to market and they need flexible manufacturing platforms that comply with global requirements We select to work with companies that support and deliver products on a global basis and that is exactly what we get from WatsonMarlow Fluid Technology Group WMFTG s Ethernet IP 630 and 730 pumps are currently undergoing trials on a variety of liquid management applications including managing the transfer of an entire batch of materials from an Xcellerex bioreactor to a mixer WMFTG s smaller Ethernet IP 530 pumps are being used to control pH levels in mixers and bioreactors along with managing antifoam and glucose in bioreactors Cytiva also uses the pumps for continuous processing for harvest and perfusion steps in some applications PRODUCT DEVELOPMENT Cytiva requested WMFTG assistance in developing a pump as part of a product refresh initiative to address the movement towards automation and the internet of things IoT in the biopharmaceutical industry A huge amount of data is coming out of the drug making process including process parameters set points and output Biomanufacturers face challenges managing the vast amount and different types of data collected and we wanted a way to package the www mptmag com data such that it is easier to make decisions with confidence in real time during manufacturing explains Stafford This information could ultimately affect the cost and delivery of the drug to the patient Many legacy products had been developed using the well established but aging fieldbus PROFIBUS networking protocol The automation team was seeking to develop products that could access the move towards online cloud based big data analytics They also had an eye on future proofing products to the extent possible by selecting the right PUMP MO T OR BEARING PROTECTION You can extend the life of your motors and prevent costly damage to bearings Reduce downtime Save money Easy Installation Superior performance 1 800 962 4851 helwigcarbon com Modern Pumping Today November 2020 25