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The proof is in the pump

JUL/AUG 2021

Pumping for perfection

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CONTENT COVER STORY Casting into the future

PUMPS

JUL/AUG 2021

ENDORSED BY SAPMA, SAPSDA, SAVAMA AND VAMCOSA

Producing fruit juice that’s pumped with flavour!

Break-down order? No problem

The proof is in the pump

Vacuum systems for heat treatment furnaces

Monitor distributors/Hawk Pumps celebrates 55 years of success

Integrated Pump Rental rebuild gives unreliable water pump new life

Maintain consistent pressure to pumps regardless of upstream flow changes

Well dewatering is done well: what to consider when planning the job

Xylem’s Flygt electric pump for sewer bypass solution saves costs and increases efficiency

Weir Minerals launches Multiflo® Mudflo™ submersible pump for large particle handling

Pumping for perfection

VALVES Additive manufacturing advantages

Bosch Rexroth is electrifying subsea process automation with electric subsea valve actuator

Does Legionella affect us in our daily lives?

Allmech extends Runxin range of locally available valves

PRODUCTS & SERVICES How do I increase air flow performance in my air system?

The new pinch valves from GEMÜ make your tubes smile

AESSEAL receives US patent for seal support system

BUYERS GUIDE

The proof is in the pump

Pumping for perfection

On the cover Steloy Foundries Pty Ltd, +27 (0) 13 110 2681, support@steloyfoundries.com, www.steloyfoundries.com

Pipes, Pumps & Valves Africa Managing Editor: Surita Marx Tel: +27 (0) 87 153-1217 Cell: +27 (0) 83 281-5761 Email: info@pumpsandvalves.co.za Web: www.pumpsandvalves.co.za Sales: Mark Bennett Email: sales@pumpsandvalves.co.za Production Manager: Xane Roestroff Email: adverts@pumpsandvalves.co.za Sub-Editor: Debbie van Rensburg

Advertisers Actom 9,37 Bilfinger 25 Golf Day IFC Industrial Valve Summit IBC Integrated Pump Technology OBC Invincible Valves 17 KSB 21,39 LVSA 19 Macsteel 35 Pamodzi Unique 33 Steloy Foundries OFC,5 Stewarts & Lloyds 29 Verder Pumps 7 Xylem 13

Disclaimer:

Opinions in this Publication are those of the authors and do not necessarily reflect those of this publication, its editorial board, its editor or its Publishers SAPMA or VAMCOSA The mention of specific products in articles and advertisements does not imply that they are endorsed or recommended by this Publication or its publishers in preference to others of a similar nature, which are not mentioned or advertised. Reliance on any information contained in this journal is at your own risk. While every effort is made to ensure the accuracy of editorial board makes no representations or warranties, express or implied, as to the correctness or suitability contained and/or the products advertised in this publication. The Publisher shall not be liable for any damages or loss, howsoever arising, incurred by readers of this publication or any other person/s. The Publisher disclaims all responsibility and liability for any damages, includes pure economic loss and any consequential damages, resulting from the use of services or products advertised in this publication. Readers of this publication indemnify and hold harmless the publisher, its officers, employees, and servants for any demand action, application or other proceedings made by any third party and arising out or in connection with the use of any services and/or products or the reliance on any information contained in this publication.

Pipes, Pumps and Valves Africa - Jul/Aug 2021

COVER STORY

Casting into the future Mere months after opening its doors Steloy Foundries are already on the up and up. Pipes, Pumps and Valves Africa spoke with the general manager, Ferdi Engelbrecht, to find out more about the new business and its strategy going forward. It is a hive of activity at Steloy Foundries in Bronkhorstpruit in Mpumalanga. Understandably so, as this business is on a mission to deliver only the best quality products to its customers mere months after opening its doors. It has been a complete overhaul for the business – formerly known as Steloy Castings and liquidated just over four years ago with millions of rands of debt. Says Engelbrecht, “There is no link whatsoever between the new owners and the liquidated company. The decision to keep the name Steloy speaks directly to the quality of the products that came out of this foundry over the years. Steloy products have a reputation and that reputation is worth remembering and re-instating.” Two foundry sites named Cobalt Street and Tungsten Road in the Ekandustria area of Bronkhorstpruit were part of the purchase and work started immediately to get the business back up and running. “When we arrived on site in those first weeks it was hard to imagine we would be casting as quickly as we are. Most of the assets of the business had been sold to pay off debt and much of the plant itself was in complete disrepair. It resembled more of a war zone than a foundry. It was just a shell of a building.”

All of the electric cablings had been vandalized and the property did not have a single working light or running tap. Work immediately kicked off to build the business back up. Not only in rehabilitating the foundry, but also procuring the latest equipment and technology. “Our goal from the get-go has been very clear. We want to establish a world-class foundry. The owners of the business have invested heavily and continue to do so as we set ourselves up to be one of the best foundries not only in the country but in the world.” According to Engelbrecht, the facility will be producing static castings in stainless steel and high allow metals for the petrochemical, pump, valve and actuator, pulp and paper, steel and cement industries. “Technical capabilities will enable the production of sand castings ranging from 0,5 to 2000 kilograms, once we are up and running fully. We have installed a 1,1-ton furnace another 500kg and two 250kg furnaces. This gives us the necessary capacity, not only to service our clients now but to meet future growth. The plant was made bigger creating the capacity that will be needed when we grow our footprint.” He said already targets of 75 to 100 tons per month had been revised and were now set at 272 tons per month. Steloy Castings in its heyday owned 40% of the South African market share and getting that market back is undoubtedly a goal for the new owners, explains Engelbrecht. “And it is an achievable target at that. Already we have customers that have returned and our outlook going forward is extremely positive.” Quality drives growth Over and above its brand-new equipment the management team have also ensured they grab back the skills lost with the liquidation of STelow Castings. “We have some of the most skilled people in the country working for us and we are extremely proud of the capability within this foundry. Skills are something of critical importance in our industry and it is about being able to give attention to detail. With the production personnel now in place, we can deliver quality products in a variety of fields.” He said to achieve the growth targeted Steloy Foundries needed to armour itself with the right people. “We have also set up to cater for all the ranges of stainless steel, all the steels, and the cast irons. We cater for the special alloys, the duplex cast alloys, the low allow steels, austenitic en martensitic cast irons, carbon and manganese

Pipes, Pumps and Valves Africa - Jul/Aug 2021

The team was also in the process of obtaining all the necessary accreditations including ISO and PED. “There are many benefits to having a foundry of this standard on local shores,” says Engelbrecht. “Not only can we deliver a quality product, but lead times are much faster and the cost is far more competitive.” But it is not just the local market being targeted. Engelbrecht and his team are confident that they can compete internationally. “The name Steloy in the past was known for being one of the leading stainless steel foundries capable of making a product such as micro-alloy that our overseas competitors battled with. There is no reason we cannot do that again. That is exactly what we plan to do.” Steloy Foundries (Pty) Ltd, +27 (0) 13 110 2681, support@steloyfoundries.com, www.steloyfoundries.com

COVER STORY

steels.” Engelbrecht said automation of processes was also on the cards. “Process such as moulding carousel, a flood coating station, a closing station including a pneumatic riser removal are all part of the plan.”

Producing fruit juice that’s pumped with flavour!

PUMPS

Fruit juices are one of the fastest-growing agro-processing sub-sectors. According to the Insight Survey 2020, the South African juice market is forecasted to grow at a compound annual growth rate (CAGR) of 0.9% between 2019 to 2023. While this is a more subdued growth rate than the market achieved in preceding years (CAGR of 2.8% over 2013 to 2018), this projection also takes into account the inescapable impacts of the COVID-19 pandemic over the same forecast period. And this projected growth despite the pandemic demonstrates the value proposition of the local fruit juice market – not only for local consumption but as a keen exporter to numerous markets, including Netherlands, USA, Canada, Singapore and Japan. Substantiating this forecasted growth is the change that can be seen in consumer behaviour and consumption, as more consumers become health conscious and look to switch to food and beverages that offer higher nutritional value for their money’s worth. Ready to serve the more mindful consumer, South Africa’s premier 100% pure and natural fruit juices offer good quality products and numerous flavours, with staples like apple, grape, pineapple and exotic blends forming the basis of the South African range. That said, remaining competitive in an increasingly saturated market is no small feat. From crop to grading, to the perfect blend and everything delectably juicy in between; for every processor in this market, ensuring high product quality – both in terms of flavour and safeguarding the health and wellbeing of the public/end consumer – is critical to their business sustainability. Maintaining the highest standards in hygiene in the production of

Pipes, Pumps and Valves Africa - Jul/Aug 2021

their products is non-negotiable, as even the slightest contamination could mean a batch of product is unusable, or unsafe for consumption, which could lead to product recalls, financial losses and potential reputational risks. Producing high-quality fruit juice products every time, therefore, requires machines that are 100% reliable,

PUMPS

safe equipment and every part of the production line should be accessible for regular cleaning, sanitisation and sterilisation. And the pump and piping solutions installed throughout the plant are the backbone of the production line and what keeps the product flowing through the entire processing operation to the final stage of bottling. Understanding the intricate and technical details and implications of selecting the right pumping solutions for specific use applications can be challenging, however, it is an important purchase decision - and continued and sustainable optimum production performance of the plant is dependent on the longevity of the equipment. For example, consider replacing progressive cavity pumps with Packo hygienic pump solutions (such as our twinscrew, rotary lobe and CIP pumps), which will negate issues with current progressive cavity pumps, such as tiny rubber filaments getting into the juice batch, and thereby

aid in ensuring a pure product is produced every time. Additionally, standardising equipment throughout the plant can reduce downtime and total cost of ownership, due to fewer breakdowns and the need for repairs on equipment/ machinery, which also results in fewer stock holding requirements in terms of spares. To be assured of the quality of equipment, fruit juice processors should look to a trusted and reputable brand that can offer a wide range of long-lasting, cost-effective and integrative pumping solutions that are certified and fit-for-purpose for numerous applications throughout the production line, which means more plant uptime, efficiency and high-quality outputs, and better service delivery. Verder Pumps, +27 (0) 11 704 7500, info@verder.co.za, www.verderliquids.com

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07-07-2021 10:17

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Break-down order? No problem

PUMPS

When Vesconite Bearings’ team visited knife-gate valve manufacturer A.C.Valves to fully understand how its client was using low-friction wear-resistant Vesconite polymer guide strips in knife gates, the company was manufacturing two valves for a South African gold mine that had experienced a break-down. The 20” valves had been requested the day before and the mine’s supplier was due to pick them up on the day of Vesconite’s visit to the company, which can manufacture 200 - 300 knife gate valves a month depending on the size of the valve. A.C.Valves director Colin Scott notes that the gold mine required two narrow-design Wafer Ring Flange (RF) bidirectional valves, which are A.C.Valves’ most popular

design and the design that uses Vesconite as a guide strip. The valves, which handle light and medium slurries, are relatively thin and are designed in keeping with mining company plant designs that require small compact plants. The Wafer RF valves consist of two cast iron pieces with a stainless steel gate that lies sandwiched between the two. A PTFE rod with O-ring acts as a scraper at the bottom of

The production of knife gate valves for a gold company

Pipes, Pumps and Valves Africa - Jul/Aug 2021

cast-iron valve halves and a rubber seal fits onto the blade. Three Vesconite strips, meanwhile, are fitted on to the valve casing and act as guide strips, describes Scott. “The Vesconite gives a longer life to the blade. It prevents metal-on-metal wear, which would otherwise result in scratches on the blade which, when it was retracted into the stuffing box, would cause leakages,” he elaborates. Scott notes that he manufactures quality products that will not break down and cause downtime and unscheduled shutdowns for unexpected replacements and maintenance.

“We have had no complaints about the Vesconite guide strips and there has not been a case where the valve has failed due to the guide strips,” Scott continues. “I have been using it for 10 years and it has worked perfectly,” he says. Many of A.C.Valves’ customers are in the mining industry, and these companies would require robust knife-gate valves of different sizes depending on the size of their plants. They would need reliable valves that do not result in the loss of any commodity-containing slurry. Other customers include those in the water industry. These also have demanding requirements since valves

Three Vesconite strips are fitted on to the valve casing and act as guide strips on the knife gate valves

PUMPS

His clients are aware that he has developed a product that is known for its quality, for its improved sealing, repairability and parts availability.

are specified to remain in situ and have no maintenance requirements for twenty years. A.C.Valves was established in 1996 and specialises in knifegate valves that are supplied to many countries in Africa, as well as Canada, Argentina and other countries. Vesconite Bearings, +27 11 616 1111, vesconite@vesconite.com, www.vesconite.com

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Pipes, Pumps and Valves Africa - Jul/Aug 2021

The proof is in the pump

PUMPS

Air-operated double-diaphragm (AODD) pumps have played a profound role in the modern global manufacturing and fluid-handling operations of many companies for more than 50 years. The original pump concept has changed little over the decades and works through its sheer simplicity of operation and construction. With operating efficiency and cost reductions being a major focus of businesses today, AODD pump manufacturers have introduced new technologies in air distribution systems (ADS) to increase pump efficiency and meet these demands. The new ADS technologies utilized range from electronic controls to mechanical innovations. However, the resulting savings in compressed air usage and increase in pump efficiency varies considerably by the system. This white paper will present the results of head-to-head comparisons between the top AODD pumps and the final data acquired during those tests. The results will help illustrate the impact differing ADS technologies have on air consumption, energy use and overall flow rate. The Challenge In AODD pump operations, energy use is directly related to the rate of consumption of air used to drive each stroke of the pump during the pumping cycle. With increasingly high energy costs, facility operators understand that the initial purchase and installation of a new pumping system is but a small part of the total cost of ownership and operation during the pump’s life cycle. Routine costs of energy and maintenance remain the primary cost drivers in the total cost of ownership.

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Much like cars, pumps can be rated according to efficiency. The goal is to utilize the least amount of air to pump the greatest amount of product. The ultimate objective is to reduce the rate of air consumption about the product flow rate while also minimizing the overall amount of air that is not producing product yield (wasted energy) during the pumping cycle. If attained, this combination will directly impact an operation's bottom line — the profitability being determined by something as simple as the volume of air being consumed and the energy required to compress it. In addition to wasted energy, air overfilling stretches the diaphragm unnecessarily. This stretching produces excessive diaphragm wear and tear resulting in more frequent replacement and downtime, while also increasing operating costs. Second, this electronic ADS technology requires a "learning period" of 30 to 40 seconds where it monitors the operation of the pump before it can estimate when to cut off the air supply before the end of the stroke. This can result in erratic and sometimes wasteful flow rates during this learning period. During the period from the end of each stroke to the completed shift of the valve, the air is allowed to "overfill" the air chamber without any corresponding displacement of fluid. This volume of compressed air is entirely wasted.

The mechanically actuated method is a simple yet extremely effective way to control the air with each stroke and prevent wasteful overfilling. The air is mechanically controlled constantly to maximize efficiency, minimize complexity and maintenance considerations, and allow for operation in explosive and submerged pumping environments.

Although the technology is more than 50 years old, AODD pumps can be made more efficient by recent ADS developments that better control the airflow and prevent wasteful air overfilling, which will reduce air consumption, and operating and maintenance costs. Two primary methods have been introduced to control airflow and prevent overfilling by cutting off the air supply to the air chamber before the end of the pump cycle: electronically controlled and mechanically actuated ADSs. Electronic control has two shortcomings. First, the electronics raise an entirely different set of maintenance and operational concerns, including the prohibition of use in explosive environments like mines and an inability to be submerged. Second, this electronic ADS technology requires a "learning period" of 30 to 40 seconds where it monitors the operation of the pump before it can estimate when to cut off the air supply before the end of the stroke. This can result in erratic and sometimes wasteful flow rates during this learning period. During the period from the end of each stroke to the completed shift of the valve, the air is allowed to "overfill" the air chamber without any corresponding displacement of fluid. This volume of compressed air is entirely wasted. The mechanically actuated method is a simple yet extremely effective way to control the air with each stroke and prevent wasteful overfilling. The air is mechanically controlled constantly to maximize efficiency, minimize complexity and maintenance considerations, and allow for operation in explosive and submerged pumping environments. The Controlled Comparisons To create real-world conditions to measure the effectiveness of various ADS technologies industry-wide, a controlled, objective head-to-head test was arranged comparing the industry’s top AODD pumps that have been fitted with traditional, electronically controlled and

PUMPS

The Controlled Comparisons To create real-world conditions to measure the effectiveness of various ADS technologies industry-wide, a controlled, objective head-to-head test was arranged comparing the industry’s top AODD pumps that have been fitted with traditional, electronically controlled and mechanically actuated ADSs. Common conditions of service that are seen in the field were replicated in the laboratory. This simulated application required each pump to produce a flow of 320 litres per minute (L/min) (85 GPM) against a head pressure of 2.1 bar (30 psi). To achieve a fair comparison between these competing pumps, each pump was run at the inlet air pressure needed to meet the common condition of service. Air consumption data was then recorded.

mechanically actuated ADSs. Common conditions of service that are seen in the field were replicated in the laboratory. This simulated application required each pump to produce a flow of 320 litres per minute (L/min) (85 GPM) against a head pressure of 2.1 bar (30 psi). To achieve a fair comparison between these competing pumps, each pump was run at the inlet air pressure needed to meet the common condition of service. Air consumption data was then recorded. Although the technology is more than 50 years old, AODD pumps can be made more efficient by recent ADS developments that better control the airflow and prevent wasteful air overfilling, which will reduce air consumption, and operating and maintenance costs. Two primary methods have been introduced to control airflow and prevent overfilling by cutting off the air supply to the air chamber before the end of the pump cycle: electronically controlled and mechanically actuated ADSs. Electronic control has two shortcomings. First, the electronics raise an entirely different set of maintenance and operational concerns, including the prohibition of use in explosive environments like mines and an inability to be submerged. Second, this electronic ADS technology requires a "learning period" of 30 to 40 seconds where it monitors the operation of the pump before it can estimate when to cut off the air supply before the end of the stroke. This can result in erratic and sometimes wasteful flow rates during this learning period. During the period from the end of each stroke to the completed shift of the valve, the air is allowed to "overfill" the air chamber without any corresponding displacement of fluid. This volume of compressed air is entirely wasted. Pipes, Pumps and Valves Africa - Jul/Aug 2021

PUMPS

The mechanically actuated method is a simple yet extremely effective way to control the air with each stroke and prevent wasteful overfilling.

with the lowest air consumption in SCFM, the lowest strokes per minute and the highest volume of fluid pumped per SCFM.

The air is mechanically controlled constantly to maximize efficiency, minimize complexity and maintenance considerations, and allow for operation in explosive and submerged pumping environments

Pump D averages an overall 30% reduction in air consumption compared to Pumps A, B and C. It also manages the largest reduction in air consumption among the four pumps while still managing the best overall volume of fluid moved per stroke, requiring the lowest strokes-per-minute.

The Wilden® Pro-Flo® SHIFT Air Distribution System in Pump D is not just an incremental improvement in ADS technology, but an entirely new way of looking at how pneumatic pumps operate. To combat the phenomenon of overfilling, the Pro-Flo SHIFT restricts the airflow into the filling air chamber at the end of the pump's stroke to minimize the compressed air that is wasted. The revolutionary air control spool of the Pro-Flo SHIFT meters the air to prevent overfilling with no reduction in product yield. The result is reduced air consumption while still maintaining maximum operational efficiency and flow rates. Compared to the electronic ADS solution, which requires an electrical power source and the delayed “learning” period after each startup, the Pro-Flo SHIFT, with no electrical power requirement or delay needed to achieve peak operation, clearly makes choosing the best AODD pump an easy decision. Conclusion Although reliably utilized in a host of applications for more than 50 years, AODD pumps can be enhanced to deliver greater efficiency and cost savings through improved ADS technology that prevents air overfilling. While manufacturers understand that AODD pumps featuring new ADS technologies can deliver the results that support their ever-shrinking budgets and operating margins, Wilden’s Pro-Flo SHIFT exhibits the innovation and results that set it apart from the competition. The Pro-Flo SHIFT ADS addresses the overfilling waste of traditional AODD pumps, providing considerable savings by decreasing air consumption while still maintaining the same fluid volume output to provides savings and output efficiencies when compared to other systems. The Wilden Pro-Flo SHIFT does not require electrical power, allowing it to be submersible and ATEX-compliant. While competing pumps may offer ATEX compliance and increased efficiency ADS options, these come with additional costs that contribute to the front-end expense. In addition to its dramatic reduction in strokes per minute compared to the competition, the Pro-Flo SHIFT also delivers extraordinary maintenance advantages with its minimization of wear and tear during every minute of operation through the optimization of every pump stroke. The Proof Is In The Pump (psgdover.com) Wilden Pumps, wilden@psgdover.com, www.psgdover.com

Pipes, Pumps and Valves Africa - Jul/Aug 2021

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Pipes, Pumps and Valves Africa - Jul/Aug 2021

Vacuum systems for heat treatment furnaces

PUMPS

Vacuum furnaces can be divided into two distinct categories: medium and high vacuum furnaces. Depending on the desired operating pressure, this will determine both the vacuum pumps as well as the measurement equipment. The precise measurement of pressures or pressure curves in vacuum-assisted processes in process engineering is an important parameter for ensuring optimum efficiency and the best product quality. Busch Vacuum Solutions has a series of VACTEST vacuum measurement equipment options designed to combine the latest advances in vacuum metrology with exceptional manufacturing quality. Robust construction, reliability and measurement accuracy are key features of these devices, making them the ideal choice to monitor and control vacuum processes. Stateof-the-art technologies allow for a wide measuring range from 1,200 to 4 x 10-10 torr covering all vacuum levels with accuracy. All sensors comply with international standards and regulations such as European Conformity (CE) and Restriction of the Use of certain Hazardous Substances in Electrical and Electronic Equipment (RoHS). With VACTEST vacuum metrology, Busch provides numerous sensor technologies to cover all ranges of vacuum (Figure 3). These technologies are divided into two main categories: direct and indirect pressure measurement. The direct measuring principle is independent of the process gas and is based on the pressure that the molecular flow exerts on a membrane.

Pipes, Pumps and Valves Africa - Jul/Aug 2021

This method is principally used for rough and medium vacuum processes. Medium vacuum furnaces operate at pressure in the millitorr (sometimes referred to as micron) range or above one millitorr. A Pirani gauge is used to monitor the vacuum level during the whole process. Pirani & cold cathode Pirani The robust and reliable Pirani technology measures the thermal conductivity of gases. The heat transfer between a heated filament and its environment changes proportionally to the pressure. Pirani sensors are the best solution for medium vacuum applications.Pirani sensors can be used reliably in a wide measurement range from 760 to 1 • 10-4 Torr. As vacuum levels increase, indirect measuring principles based on special properties of the process gas, such as thermal conductivity or ionization probability, are used. Unlike the direct measurement method, these principles depend on the type of process gas. For this reason, a specific correction factor must be applied for each process gas except air or nitrogen. In high vacuum furnaces, the operation takes place belowone millitorr which renders the Pirani gauge

inadequate. In this case, a cold cathode gauge is used along with one or two Pirani gauges. The cold cathode gauge measures the pressure in the furnace while the Pirani gauges monitor pressure on the vacuum foreline near the exhaust of the diffusion pump as well as the pressure during roughing of the vessel.

Role of vacuum gauges Gauge and Roughing Gauge High vacuum furnaces also employ an oil diffusion pump (Figure 4) which must be evacuated to turn on the oil heaters. A small rotary vane such as a Busch R5 or ZEBRA vacuum pump is used as a holding pump to keep the diffusion pump under vacuum, and the foreline gauge is used to control the start of the diffusion pump. Since the required vacuum to start the diffusion pump is the millitorr range, a Pirani gauge is ideal. A second Pirani gauge is often installed on the chamber to track the vacuum level to the crossover pressure at which point the diffusion pump opens to the process. The additional gauge can help generate data about how quickly the system pumps down for the analysis of roughing pump performance. High vacuum gauge Once the diffusion pump is ready for operation and the roughing pumps evacuate the vessel to the millitorr range, the valve between the furnace and diffusion pump can open allowing the beginning of high vacuum operation. During high vacuum operation, the roughing pumps back the diffusion pump and the holding pump is isolated. A third gauge mounted on the furnace chamber is typically a cold cathode gauge that measures the high vacuum levels required for the process. Location of the gauge is important as placing it near the diffusion pump carries the risk of oil contamination. The sensor head should be positioned as close to the load as possible, ideally near the centre of the chamber. Maintenance gauge Another helpful installation of a gauge is at the inlet of the mechanical vacuum pump or booster system to be used for maintenance or troubleshooting purposes. A simple Pirani gauge or a piezoresistive/Pirani gauge can be installed in line with a shut-off valve. The piezoresistive gauge will more accurately sense higher pressure readings so that the performance of the vacuum pumps can be easily checked. Proper gauge selection Several factors must be considered when selecting the correct sensor. Knowledge of the pressure range, the required accuracy, the gas composition as well as the process and ambient conditions are of great importance for optimum measurement results. As indicated earlier,

different vacuum gauges have different capabilities, and each pressure range has an ideal measurement for a given gauge type. In either medium or high vacuum furnaces, the challenge is to match the operating pressure to the correct gauge.

PUMPS

Cold cathode The cost-effective and robust cold cathodes (inverted magnetron) measure the electrical conductivity of a plasma. Neutral gas molecules are ionized by collision with electrons and captured by the cathode. The current generated is an indication of the pressure in high and ultrahigh vacuum processes. Cold cathodes can be used in the range from 1 • 10-3 to 4 • 10-9 Torr. In combination with Pirani sensors, they cover measuring ranges from 760 to 1 • 10-9 Torr.

Gauge considerations Resistance Against Shock Venting Shocking a gauge, meaning the sudden exposure to the atmosphere when under vacuum, is never an ideal situation but can happen. Sensors with a filament such as the Pirani gauge are typically the most sensitive to such a scenario and the sudden increase in pressure can damage or even destroy the gauge. While it is not indestructible, a filament with a spiral coil design is more resilient than a straight filament or a microelectromechanical system (MEMS) sensor. Given the potential of shock venting in heat treatment processes, a spiral filament will be the more robust selection for a Pirani gauge. Protection Class Furnaces that are used in casting applications or the automotive industry sometimes require protection from splashing or dust which is common in these industrial environments. If the gauge is in potentially wet or dusty environments, it is important to consider the ingress protection of the gauge. If the potential of exposure to water or dust is even remotely possible, choosing an Ingress Protection Code (IP54)-rated gauge is recommended. This will improve the long-term reliability of the gauge as well as seamlessly adapt to unforeseen changes in environment or application. Combined Pirani and Cold Cathode Sensors When there is a limited number of ports available for pressure sensing equipment, it sometimes becomes necessary to measure vacuum through multiple pressure regions. Gauges are available that combine two sensors─both filament and cold cathode technologies. When selecting this type of gauge, certain considerations must be made to ensure the different technologies are not damaged by being exposed to unsuitable pressures. For example, operating a cold cathode gauge at pressures in the millitorr range or higher can lead to self-contamination by the magnetic field within the gauge. To prevent contamination and extend the lifetime of the gauge when using a combination gauge, control of the starting pressure of the cold cathode should be done automatically by the Pirani sensor. Pipes, Pumps and Valves Africa - Jul/Aug 2021

PUMPS Ease of Maintenance On digital gauges, it is possible to exchange the sensor head without recalibrating the gauge or the need to change any settings. Selecting a gauge that allows for the automatic integration of a factory-calibrated replacement ensures fast and efficient maintenance so that furnace downtime is minimized and productivity is maximized. Resistance to Contamination In addition to resisting shock venting, choosing a Pirani gauge with a spiral coil design also provides a larger exchange surface, which makes the filament much less sensitive to contamination. The inclusion of a metal screen or other media to protect the filament from contamination is beneficial as well. This can be internal to the gauge but can also be added as an accessory to further protect the gauge. Items such as spiral tubes, baffles or right-angle adapters offer further protection between the gauge and the process. Gauge calibration – aerospace Vacuum gauges that measure critical processes require periodic calibration to maintain accuracy. Heat treaters often must comply with Aerospace Materials Specifications (AMS) 2750F and National Aerospace and Defense Contractors Accreditation Program (Nadcap) standards. To meet these standards, calibration certificates are necessary as well as periodic calibration of the gauge every three to six months. Gauges that comply with these standards often help avoid future complications as customers and processes change. Furthermore, some vendors offer exchange programs to ensure calibrated gauges are readily available. With the various VACTEST products, (Figure 6) Busch meets all requirements for the measurement of pressures of a vacuum system or process in terms of accuracy, measurement range and functionality. VACTEST VACTEST analogue transmitters have a compact, robust and functional design. Thanks to their excellent measurement accuracy and stability, these transmitters are the ideal solution for centralized monitoring and control systems.

Pipes, Pumps and Valves Africa - Jul/Aug 2021

VACTEST digital transmitters are high-end gauges with a full range of options as standard. Their intelligent microcontroller architecture provides optimum sensor control and various adjustment options, making them the ideal solution for a variety of applications. VACTEST digital transmitters work with Pirani sensor technology, cold cathode sensor technology or with Pirani/cold cathode or Pirani/hot cathode combinations. VACTEST mobile gauges are the perfect hand-held solution for quality assurance of vacuum process maintenance. These battery-powered gauges offer many functions, such as a USB interface for exporting and displaying data as well as a data logger and can even be used under vacuum. Busch Vacuum Solutions offers the VACTEST explorer as a software tool to provide fast and efficient visualization, analysis and comparison of process data on a computer or tablet. VACTEST explorer is available in a Lite and a Pro version and includes numerous functions, for example, calculation of leakage rates, Active Sensor Controller remote control, pump-down curve comparison, the configuration of all digital transmitter parameters and many more. The VACTEST viewer is an included Bluetooth monitoring application for mobile devices with an Android operating system and can display the pressure values of up to 16 connected sensors. The tool was designed for Bluetooth data exchange between software and sensors and is ideally suited for maintenance or calibration purposes. Visual and audible alarms can be preset for maximum and minimum pressure values. Conclusion Vacuum pumps are a critical component of many heat treatment processes but without reliable measurement of that equipment, one may be left to guess. There are many potential solutions for vacuum measurement requirements depending on each facility’s situation. Contact Busch Vacuum Solutions with any requirements and our experienced staff of vacuum professionals can customize the right solution for your company. Busch Vacuum Solutions, info@buschusa.com, www.buschusa.com

If its not INVAL, it’s not Invincible

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Monitor distributors/Hawk Pumps celebrates 55 years of success

PUMPS

Hawk Pumps, manufacturers and distributors of a range of quality high-pressure pumping equipment, is leading the way in a tough environment. With the company’s long-standing history of providing individualised attention to every client, Hawk Pumps has crafted a reputation as the go-to company for inventive high-pressure pumping solutions. Company history The Monitor Engineering Company (Natal) Pty Ltd was established in 1966. But when Gavin Pote joined in 1977 as Manager, he observed that it had no clear focus or direction and was overburdened with product lines that lacked relevance. The company was also under financial pressure due to previous ill-advised management decisions. In 1982, when the previous owner retired, Gavin purchased the company and began to implement a fresh approach. Under his leadership, several strategic improvements were put into place, including staff cutbacks – a necessary but difficult step that would streamline the operation. The company also reviewed its brand offerings, and a renewed focus was identified in industrial and agricultural spray nozzles, speciality pumps and pumping machines. Gavin renamed the company Monitor Distributors CC. And while it still formally operates under that name, it is now a Pty Ltd organisation. The Johannesburg branch operates under the name Hawk High-Pressure Pumps. Gavin launched an international search for premium brands with which to form partnerships. He forged a strong alliance with Hawk Pumps in Italy – a partnership that still endures today. With the permission of Hawk Pumps Italy, Gavin chose to adopt Hawk as the brand name for locally manufactured equipment. Gavin could not have built the company, Monitor

Distributors, or the brand, Hawk, without two key people; Paul Garnham – a master at sales who was largely responsible for growing the client base; and “Doc” Dockrat, who was initially responsible for running manufacturing operations and internal sales. Paul and Doc became partners in 1984 and were an integral part of the business. From humble beginnings, the company has grown to 60 staff with a head office, a sale and repairs centre in Johannesburg and a distributor network nationally and neighbouring countries. Melanie Mokawem joined the team in 2006, initially intending to stay for three months, to assist with marketing. But she quickly became passionate about the brand and dedicated herself to the company full-time, following which she was made partner in 2008. Since then, Melanie has worked in various roles within the company, including marketing, custom design, costings, operations, human resources, and now, overall management of the company in partnership with her husband. Troy Mokawem heads up the Technical and Sales Management departments and has been with the company since 2008. Troy has continued to leverage new product innovations to grow Hawk Pumps’ footprint, both in South Africa and internationally, driving custom product solutions for various unique customer applications. Co-founder Paul Garnham left South Africa in the mid-2000s, and Doc and Gavin retired in 2020. Gavin, however, remains as a consulting director to offer advice and assistance when needed. Hawk High-Pressure Pumps The range of Hawk pumps is extensive. There are pumps capable of putting out up to 1000 bar and volumes up to 420 l/min. They all use three pistons. The plungers are ceramic, and the seals are self-lubricating. There are models made from brass, stainless steel and a new product called Eco-Brass. Eco-Brass is an alloy that has the mechanical strength of 316 stainless steel and is suitable for use with seawater. Vision and Philosophy Hawk is driven by strong business ethics. Honesty and transparency have enabled long-standing relationships with the vast cross-section of customers it serves. The Hawk difference is the company’s innovative and individualised approach to solving unique customer problems. Once-off custom product solutions often become standard products in the Hawk range. Hawk’s

Pipes, Pumps and Valves Africa - Jul/Aug 2021

factory, with its customisation and manufacturing capability, is a key benefit for clients. It enables fully customised solutions on request, which many other suppliers are unable to offer. Well-trained and motivated staff are propelled by a strong internal culture that is reflected in the company’s approach to customers. As such, Hawk remains at the forefront of innovation, making it a company that is a cut above the competition, moving ahead during the pandemic and beyond.

The larger units are available with hydraulically powered hose reels. The nozzles at the end of the hoses have a variety of configurations. Most have a forward-facing jet to break up blockages and several rear-facing ones, which pull the hose into the drain and clean the pipe walls at the same time. Models range from small, portable trolleymounted units for domestic drains, to large truck or trailer mounted ones for commercial, industrial and municipal applications. Hot Water Washers Hot water cleaning is ideal for removing stubborn grease and grime or cleaning where high temperatures destroy germs. This type of cleaning has become particularly popular during COVID where operators prefer not to use chemicals. Hawk’s range of hot water washing equipment delivers hot water at temperatures of 65ºC or 90ºC and are available as a separate attachment, the HotBox, or as a cabinet or mobile units. The “All Diesel” Hot Water unit is ideal for sites where electricity is not available and is

PUMPS

Hawk Drain & Sewer Cleaners A range of trailer and skid-mounted machines have been designed for drain and sewer cleaning.

powered by a diesel generator. Conveniently, the singlephase alternator also provides 2 x 220volt outlet plugs. These can be used to power other electrically operated equipment like floodlights for night work and small electric tools. Distribution is managed by loyal partners that provide localised supply and support services, making Hawk products broadly accessible, both within South African borders and in other African territories, for a variety of professional applications. Hawk Pumps, +27 (0) 11 822 4039, sales@hawkpumps.co.za, www.hawkpumps.co.za

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Integrated Pump Rental rebuild gives unreliable water pump new life

PUMPS

When a leading company in the petrochemical sector lost patience with the lack of reliability of a trailer-mounted water pump, Integrated Pump Rental delivered a costeffective solution: refurbishment. The water pump’s constant breakdowns meant that an intervention was required, but budgets were constrained. When consulted, Integrated Pump Rental was able to offer the option of either a completely new trailer-mounted Sykes diesel driven pump or a refurbishment that would include fitting a new Sykes pump-end. To make the decision, the pump was stripped and assessed in Integrated Pump Rental’s modern workshop in Jet Park. After discussion with the customer, it was agreed to conduct a complete refurbishment, as the diesel engine driving the pump was also underperforming – further disrupting the pump’s operations at critical times. Andre Strydom, rental development manager at Integrated Pump Rental, explains that in any refurbishment, it is vital to match the customer’s on-site duty requirement with the pump’s technical capacity. “In this case, 220 litres per second needs to be pumped at a head of 35 metres, and the decision was made to replace the pump-end with a Sykes CP250i with a 355 impeller which would the reliable delivery of a maximum flow rate of 280 litres per second,” Strydom says. “At a total head of 55 metres, the Sykes CP250i diesel driven pump can still manage a flow of around 100 litres per second.”

Pipes, Pumps and Valves Africa - Jul/Aug 2021

The engine was replaced with a Kirloskar 4K1080TA diesel unit which was close-coupled to the Sykes CP250 pumpend, together with the dropped discharge pipework. An acid wash was used to clean off old paint and rust, while all non-working parts were stripped down to the fuel tank and chassis. Mechanical improvements were also made to the trailer and included a new hand-winch installed to lower the A-frame for easier coupling and uncoupling from the tow vehicle. Strydom says the fitting of this winch system will also reduce the risk of injuries, such as lower back strains or feet being caught when the trailer is unhooked. The turnkey operation was completed by Integrated Pump Rental in a quick turnaround time and within the customer’s limited budget, without compromising on quality. The complete rebuild – including delivery to site – took less than a month to complete. Strydom says Integrated Pump Rental also conducted the commissioning of the refurbished unit on the customer’s site. Integrated Pump Rental, +27 (0) 11 894 2906, admin@pumprental.co.za, www.pumprental.co.za

We offer valves for precision processes - and demandingapplications Our valves fulfill the highest of standards and are designed for many years of safe and reliable operation. Our service specialists regularly check, monitor and maintain all relevant system components - depending on what has been agreed. Our modular framework agreements offer you individual service and spare parts concepts. And we even go one step further. We additionally check systems for efficiency in order to reduce operating costs and increase productivity. For example, with the SES System Efficiency Service.

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Contact our dedicated Valves Sales Engineers for all your Valve requirements Tel: 011-876-5600 • Email: info-za@ksb.com KSB Pumps and Valves (Pty) Ltd www.ksb.com/ksb-za Your B-BBEE Partner

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Maintain consistent pressure to pumps regardless of upstream flow changes

PUMPS

When selecting fluid system valves, the type of hydraulic valve chosen can make a critical difference in the consistent operation and service life of that equipment. Changes in flow and pressure in one part of the system can have grave consequences for downstream equipment. Ongoing pressure fluctuation can increase component wear and drastically shorten pump life. Guided piston valves have unique flow and stability characteristics that provide reliable performance without chatter. Understanding the relative advantages of guided piston valves will ensure the long pump and system equipment life. Understanding Valve Types The terms pressure “safety” valve and pressure “relief” valve are often used interchangeably. On the face, they both perform the same function–let off pressure when a system becomes over-pressurized–but when and how they function is very different. A standard pressure safety valve is most often used on systems to meet ASME SEC VIII requirements for safety. It is actuated by inlet static pressure and characterized by rapid opening or popping action. A safety valve opens only in the event of a system failure. Pressure in the line is allowed to build until the valve reaches the set point. Then the valve opens fully to reduce

Pipes, Pumps and Valves Africa - Jul/Aug 2021

the pressure as quickly as possible. This tight shut-off safety valve meets ASME’s basic requirements and protects people, equipment, and facilities from catastrophic overpressures but does little to protect downstream equipment from ongoing transient pressures. In contrast, a pressure relief valve is intended to control pressure in a system, ideally preventing systems from reaching the extreme pressures that would activate a pressure safety valve. While a pressure safety valve has two operating settings, totally closed or fully open, a pressure relief valve modulates, opening in proportion to the increase in system pressure. The relief valve doesn’t open fully in response to increased pressure; it opens gradually until the system returns to a preset pressure level. When the set pressure is reached without blowdown, the valve closes again. A pressure relief valve maintains consistent system pressure, reducing strain on downstream equipment. As pressure and friction build inside a pump, the temperature rises, creating vapour that can lead to cavitation which eats away at the impeller and casing.

Increased temperatures also compromise the integrity of mechanical seals and bushings. This leads to cracking and scoring and causes the seal’s elastomers to burn up. Over time, this component damage puts the pump at risk for failure. In short, a pressure safety valve is a last resort failsafe, a pressure relief valve is a best practice safeguard– a “workhorse” valve to control constant line pressure. Relief Valve Operation There are many pressure relief valve types available –some of the most common are spring-activated ball, poppet, and guided piston valves. They all operate in the same basic way, fluctuating on a spring to maintain the set pressure:

Because of the relative drawbacks of the ball and poppet valves–most notably their noisier operation, flow limitations and unsuitability for continuous duty operation– guided piston valves are generally considered the superior relief valve option. The remainder of this paper will focus on the benefits of guided piston valves. In guided piston valves, the opening and closing action described above is operated by a spring-loaded piston, which is self-modulating. It functions consistently, and modulates, at any degree of opening and closing. This self-modulation is pressure actuated and self-powered; it does not require any external sensing or control systems for operation. Designed to operate reliably at pressures as low as 3 psi and as high as 1000 psi, guided piston valves reduce velocities through all but the controlling interface of the valve, thereby minimizing system power loss, preventing equipment damage and costly system shut down. The valves provide a constant pressure unaffected by transient pressure surges, providing smooth and reliable line pressure. Other Guided Piston Valve Advantages Guided piston valves operate effectively with all types of liquids in the full range of viscosities, including hydraulic oils, water, solvents and chemicals. For equipment destined for outdoor use, the temperature can play a significant role, as engine oil and hydraulic fluids thicken appreciably on cold days and become less viscous on warm days. Oxidation, moisture and ordinary wear can also contribute to significant changes in viscosity over time. The guided piston valve’s immunity to viscosity makes it an ideal choice

Furthermore, as guided piston valves can be mounted in any position, without affecting performance, they can easily be worked into systems where space permits, enabling more compact equipment footprints. The availability of NPT, flange, socket weld and SAE threaded connection types further increases the range of installation possibilities. As mentioned above, unlike other direct-acting relief valves, guided piston valves are less responsive to transient pressure surges, thereby eliminating the tendency to pound, squeal or chatter. Quiet, stable, efficient performance is assured in both load regulation and system protection applications. Guided piston valves can significantly reduce equipment noise pollution. Use Case: Protecting Pump from Deadheading In the diagram shown below, a typical process using either a centrifugal or positive displacement pump has a manual shutoff installed after the pump in the line leading to the loading zone.

PUMPS

• The system pressure reaches a predetermined set limit (cracking pressure), the relief valve will open to divert some of the liquid flow away from the process. • As pressure on the system increases, the valve will continue to open further, allowing more flow to be diverted. • As the fluid is diverted, the pressure on the system will stop rising, maintaining a set pressure to the downstream flow. • As upstream pressure decreases, the valve will gradually close, shutting fully when the pressure reaches a few pounds per square inch (psi) below the set pressure.

for many applications. When designing fluid systems, there is always a tradeoff between function and size to make the most of available space. A hallmark of the guided piston valve is providing large flows without excessive bulk.

When the loading operation closes this valve without warning, considerable pressure builds in the line leading back to the pump, creating strain on the pump and risk for deadheading. The solution is to add a pressure relief valve to protect the pump. A new recycling line with a pressure relief valve is installed between the pump and the manual shutoff valve. When the manual shutoff valve is closed and pressure begins to build, the guided piston valve activates automatically, diverting flow back to the tank and relieving pressure on the line to the pump. When the shutoff valve is reopened, and the pressure on the line returns to normal, the pressure relief valve returns to the closed position automatically. As this is a guided piston relief valve, the orientation of the valve does not impact the valve operation or set pressure. It can be mounted upright, sideways or even upside down– however space permits. This is a unique characteristic of the guided piston valve and provides a lot of design flexibility in retrofitting problem processes. Conclusion While pressure safety valves provide basic protection from catastrophic pressure spikes, pressure relief valves help control the pressure variations that are often a normal part of most process operations that result in undue stress on pumps. Properly regulating pressure with guided piston pressure relief valves protects downstream pumps and systems from ongoing damage, preventing failure, process downtime and the associated repair and operational costs. Fulflo, info@fulflo.com, www.fulflo.com Pipes, Pumps and Valves Africa - Jul/Aug 2021

Well dewatering is done well: what to consider when planning the job

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Planning and choosing the right pumps are crucial for a well-executed dewatering operation. Tsurumi Pump’s Western Regional Sales Manager Jeff Davis discusses how to maximize efficiency and avoid unexpected costs. What is temporary good dewatering and what are some examples? Jeff Davis: Temporary good dewatering is a technique used for temporarily lowering the groundwater table level in a designated area to allow work to be done at depths or site elevations that would ordinarily be submerged. Examples of types of work that may require temporary wells are underground mining, sewer and water pipeline installation, tie-ins to existing sewer and water pipelines, new building footings or repairs to existing foundations, and new bridge support piling installations or maintenance. What are some of the aspects to consider when planning a good dewatering operation? JD: The procedure of temporary good dewatering can be divided into three stages: the information collection stage, the planning stage, and the execution stage. During the information collection stage, we need first to measure the current level of the groundwater table and the type of soil (sand, gravel, rock, or clay layers) in the area of the job site. These can be accomplished by test drilling for core samples in the work site area and gathering historical information on soil characteristics or even previous dewatering operations. Once the information is gathered, we step into the planning stage, where we need to determine the desired water level for the work to be done and the actions we need to take for achieving the goal. How many wells do we need? What spacing of the wells do we require? What size slots are required in the good casings?

Pipes, Pumps and Valves Africa - Jul/Aug 2021

How much water is going to be moved, and where will the water be discharged? These are the questions that we need to answer before we dive into the execution stage when we drill or jet the wells, and install the good casing or pipe into the ground to the depth required and below. Power availability is another crucial aspect to consider and may involve requesting a line drop from the local power company or arranging for generators. After the good casings are fully installed and fixed in place, we will lower the pumps into the wells to or near the bottom of the well. Electric submersible pumps are the type of pump most commonly used for good dewatering. With the pumps properly installed in the wells, we can maintain the desired water level throughout the job. When the job has completed the wells and pumps are removed, the groundwater level will return to normal. How do you go about choosing the correct pumps for each operation? JD: When choosing the pump, it is critical to select a pump that is best suited to the task at hand. The pump’s horsepower and impeller type are determined by the required flow rate of the water and the total dynamic head on the discharge. It is also important to select the pump with the right materials of construction to cater to different situations. For instance, when dewatering mining and construction sites, it is necessary to use a pump made of durable materials such as high chrome cast, cast iron or heavy-duty cast aluminium. When operating in water with corrosive chemical content, a corrosion-resistant pump

Good casing size is another important factor when selecting the right pump. Typically, the inside diameter of dewatering well casing is 20 cm, 30 cm or 40 cm (8", 12", or 16") in construction. These are common sizes of PVC and steel pipes available from typical manufacturers. It is crucial to select the right pump size to fit inside the good casings with enough clearance to manoeuvre during installation and removal. Slimline designed pumps are commonly used for these operations. However, depending on the inside diameter of the good casings, different designs can be utilized. Individual pump control panels are also standard equipment for the operations. The pump controls have automatic features that can sense the water level and turn the pump on and off as necessary to maintain water levels while conserving energy and allowing the pump to operate only when needed. Depending on the operations, it is essential to decide if an auto-control panel is required. What are some of the main pitfalls of a good dewatering operation? JD: Electric submersible pumps need constant steady power with the proper voltage and amperage capability. It is important to make sure there is a reliable power source, whether a line drop from the power company or gas/ diesel-powered generator(s). An improper power supply can damage the pump motors and cause failure.

Bilfinger Intervalve Africa (Pty) Ltd. is one of the enterprises in Bilfinger Power Africa (Pty) Ltd., the South African subsidiary of German based Bilfinger SE. For years, we have been adding value to the power, mining, paper pulping and broader industry through comprehensive valve supply, valve maintenance and heat treatment solutions. www.intervalve.bilfinger.com

Abrasive particles passing through the good slots in large quantities may cause pumps to wear out prematurely. The impellers and other wear parts, as well as the outer casings and motor housings, can wear thin and cause complete and catastrophic failure. This is one reason that proper well slot sizing is critical. It’s also important to perform routine maintenance to help mitigate issues that can arise in these harsh applications. Allowing the pumps to run dry for extended periods can damage the pump physically. The electric motors use the water passing over the outside of the motor housing to dissipate heat and may also overheat if no water is present. This is one of the reasons proper level control panels are critical in temporary good dewatering. If power cables become damaged, water may get into the pump and ultimately into the motor compartment, which will cause the electric motor to short out and possibly burn up. This is a common issue when lowering and handling the submersible pumps on a construction or mine site.

PUMPS

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is required. Sometimes the pump can overheat due to running dry for extended periods or experiencing a power supply voltage drop. In this case, thermal motor protection is a must for the pump.

Adequate strain relief on the power cable and a separate lifting rope or cable installed on the pump will reduce the chances of damage. Our network of expert dealers can guide customers through all these considerations to ensure they precisely receive the right pumps. The Tsurumi team is also always ready to help. Tsurumi Pumps, +27 (0) 82 404 4743, yentl@tsurumipumpsafrica.com, www.tsurumipumpsafrica.com

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2021/02/17 4:10 PM

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Xylem’s Flygt electric pump for sewer bypass solution saves costs and increases efficiency

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The city rents Flygt electric pump as a more sustainable alternative to a diesel pump. When the city of Columbia, Tennessee, was upgrading a pump station, it needed a reliable pump for a long-term, temporary sewer bypass project. The city decided to use an electric-drive pump, instead of a diesel pump, to improve pumping efficiency and reduce operating costs. By using the Flygt N 3312 electric pump provided by Xylem Rental Solutions, the temporary bypass system ran for eight months without clogging and saved nearly R1.7 million ($124,000). Located 45 miles south of Nashville, the city of Columbia, Tennessee, has a population of approximately 36,000 people. As part of its wastewater system, the city maintains 510 km (317 miles) of gravity-enforced main sewer lines, 25 pump stations and 52 million litres (14 million gallons) per day (MGD) wastewater treatment plant. In recent years, Columbia has engaged in sewer rehabilitation projects to help reduce or eliminate system overflows, including renovating and replacing several existing pump stations. Among the pump stations slated to undergo scheduled upgrades sometime in 2020 was the Santa Fe Pike pump station.

Pipes, Pumps and Valves Africa - Jul/Aug 2021

But before those repairs could begin, the station experienced a major pump failure during the spring of 2020 that led to sewage overflows, spurring the city of Columbia to engage Xylem Rental Solutions for emergency pump rental. Xylem’s local Nashville branch quickly dispatched a Godwin HL250 diesel pump for an emergency sewer bypass system. Selecting an electric-drive pump for a temporary bypass Once the initial crisis was under control, the city of Columbia decided to move ahead with the R17 million ($1.2 million) planned upgrades for the Santa Fe Pike facility. City officials hired W&O Construction as the contractor on the project. To maintain treatment operations while the upgrades were completed, W&O Construction needed to set up a temporary sewer bypass system, and because rehabbing the pump station would take several months to complete,

the Columbia Wastewater Department decided to switch to electric-drive pumps to improve pumping efficiency and reduce operating costs. "For temporary bypass projects that last longer than three months, electric bypass pumps are a cost-effective option as they do not rely on expensive diesel fuel,” says Bill Beasley, Regional Sales Manager, Xylem. However, Xylem Rental Solutions hit a snag in the process – the only Godwin electric option in the local fleet (Godwin HL250 pump with a 450 horsepower motor) was too powerful for the site's 400-amp service.

"The pump our competitor recommended to W&O Construction as an alternative isn't made to pump solids. We knew clogging would be an issue." Seeking to ensure the Columbia Wastewater Department had the right electric pump and equipment for its temporary bypass system, Xylem's Nashville branch tapped the experience and expertise of its national Xylem Rental Solutions base to identify the best solution within its expansive rental fleet. A cost-effective and environmentally friendly rental alternative Working with Ken Albaugh, Director of Sales, Rental and Equipment Sales, Xylem, the Nashville team looked to Xylem’s Flygt pump line. "It took Ken about 90 seconds to go through the Flygt options and identify a 3000 series Flygt pump with

Xylem offers a wide horsepower range of its versatile Flygt 3000 electric submersible pumps – from 2 to 470 horsepower – that can handle flow rates up to 16,000 GPM with heads up to 400 feet. The broad parameters of the Flygt 3000 series enabled Xylem to select the proper pump for this application. In particular, the Flygt 3000 Series pumps feature patented N-technology with innovative self-cleaning impellers, which are designed to prevent clogs and build-ups. Made with robust, hard iron impellers that are corrosion and abrasion-resistant, they also offer a long life span. Delivering a custom-engineered pump and priming system The Xylem team quickly identified the Flygt N 3312 submersible pump as the best model for the Santa Fe Pike pump station bypass.

PUMPS

"The local station didn't have the correct electrical setup for the 450 horsepower pump," says Beasley.

priming,” says Beasley. “When utilities need to repair pump stations or upgrade plants, Flygt 3000 Series submersible pumps are a cost-effective and environmentally friendly rental alternative. They provide a quiet, efficient and easyto-install bypass solution for many applications.”

But while the Flygt N 3312 met the flow and head characteristics, it was too large to fit down the sewer manhole. To address this new challenge, the Xylem team used a horizontal, dry pump installation. The Flygt N 3312 pump was delivered to Xylem’s dewatering fabrication centre in Carterville, Illinois, where a crew built stands for both the pump and priming system within one working day. By the end of the weekend, the custom-engineered pump and priming system was delivered to the temporary bypass site in Columbia, Tennessee, where the rental solution operated continuously for the duration of the bypass. "We took the technology of the Godwin priming system and married it to the Flygt pump performance,” Beasley explained. Running continuously for eight months without clogging With the Flygt N 3312 electric pump serving as the primary pump and the Godwin HL250 diesel pump still onsite as the backup pump, the temporary bypass system has been running continuously for eight months with no issues and no clogging. Additionally, the use of an electric bypass pump over a conventional diesel-powered pump has improved pump efficiency and reduced costs, resulting in savings of nearly R1,7 million ($124,000) to date. "It's great to see how our electric pumps are helping utilities increase efficiency and operate more sustainably," says Beasley. "We're proud to support the city of Columbia in providing more cost-effective, environmentally friendly services to its customers." Xylem, makingwaves@xyleminc.com, www.xylem.com Pipes, Pumps and Valves Africa - Jul/Aug 2021

Weir Minerals launches Multiflo® Mudflo™ submersible pump for large particle handling

PUMPS

Weir Minerals, a global leader in the provision of mill circuit technology, dewatering solutions and services, has launched the new Multiflo® Mudflo™ hydraulic submersible slurry pump. Engineered for abrasive applications and large particle handling, the Multiflo® Mudflo™ pump features a hydraulically driven wet-end specifically designed to efficiently and safely reprocess and relocate tailings ponds, maintain water retention dams and manage slimes and sludge ponds. The innovative solution combines the Warman® MGS pump-end, Multiflo® CB32 hydraulic cutters and ESCO® excavation teeth to provide efficient pumping of highly charged and abrasive slurries. Weir Minerals' unique Ultrachrome® A05 chrome alloy impeller ensures high wear resistance and the specially engineered suction strainer minimises the risk of clogging by preventing large solids & debris from entering the pump. Drawing on decades of Warman® pump design experience, the Multiflo® Mudflo™ pump is capable of

pumping between 150 and 1,200m3/h, up to 82 metres head. The Multiflo® CB32 hydraulic cutters feature a marketleading ESCO® Ultralok® tooth system to prevent premature breakage, avoid tooth loss and protect the integral locking system to ensure the continuous operation of the pump. Engineered by the Weir Minerals dewatering pump experts in Australia, it is available for global customers from July 2021. “The Multiflo brand is synonymous with high quality and long-lasting equipment. In designing the Mudflo pump, our dewatering experts drew from the very best Multiflo, Warman and ESCO technology and used advanced hydraulics to create an innovative and cost-effective new solution for mine dredging applications,” Cameron Murphy, Director of Dewatering Weir Minerals APAC said. Weir Minerals understands that success is built from enduring partnerships based on close collaboration and a mutual commitment to safety and technical excellence. “It is not uncommon for sites to use a combination of pumps, shovels, excavators and trucks for dredging applications. When one of our long-time partners in Indonesia contacted us about developing a custom solution for the slurry build-up in their sumps, we knew we could provide a better solution,” Geoff Way, Weir Minerals Dewatering Specialist said. “We’re problem solvers. We considered our customer’s pain points and engineered a new solution to efficiently and safely manage their site processes,” he said. The Multiflo® Mudflo™ pump can also be retrofitted to competitor OEM equipment; the quick-hitch plate attachment ensures convenient installation and removal from hydraulic excavators. The Multiflo® Mudflo™ pump can be assembled on land, eliminating the safety risks associated with assembling pumps over water. Furthermore, the new hydraulic hose management system reduces the risk of hose entanglement and trip hazards, all the while providing a reliable hose bend radius to ensure smooth oil flow. Weir Minerals Africa, +27 (0) 11 929 2600, Africa.minerals@mail.weir, www.minerals.weir

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Pumping for perfection As the global need for water continues, urban water loss is an increasing challenge for water distribution networks around the world. At Grundfos, efforts to deliver smart and cost-effective solutions to ensure stable and efficient water supplies never stops. Pipes, Pumps and Valves Africa finds out more.

PUMPS

Clean water scarcity is a major issue in today’s world. Considering that the world’s population is expected to increase by 2 billion persons in the next 30 years, from 7.7 billion currently to 9.7 billion in 2050, a 22 to 24% increase, the strain on water systems is inevitable. Krzysztof Myslinski, IMEA development manager at Grundfos, a global leader in the supply of pumps and controls, when it comes to water distribution systems it is essential to never compromise on the quality of pumps, always using the most optimal equipment available. Speaking during a recent online conference, Myslinski said as the global need for water continued to increase, improving pumping system performance to prevent water leaks and reduce utility operating costs would increase. Using a general example of a water supply system he said optimal equipment was needed at the water intake site as well as for the transmission and distribution. “Some of the main considerations for a water supply system include that it should be capable of supply water at all the intended places with sufficient pressure heat and it should be capable of supplying the requisite amount of water at all times – even during events such as firefighting.” He said the layout of water supply systems was of critical importance as no consumer should ever be left without

Pipes, Pumps and Valves Africa - Jul/Aug 2021

water, for example, when any section of the system needed maintenance or repairs. “All the distribution pipes should be preferably laid away or above the sewer lines. Water quality should not get deteriorated in these pipes.” And it should all happen while keeping the energy cost to a minimum and avoiding any or all water loss. Every year, 45 million cubic meters of drinking water are lost daily through water leakage in the distribution networks. This is enough to serve nearly 200 million people. “We have to reduce the yearly non-revenue water (NRW),” says Myslinski. NRW is water that has been produced but is lost before it reaches the customer. Beat the leaks Leaking pipes and equipment are a global problem experienced in the most developed and least developed regions of the world. It remains true that one of the surest ways to reduce water loss and address cost is to use optimal quality pumps and equipment, says Myslinkski. He also advises the water network to be divided into sections as this makes it far easier to cope with problems as they arise than trying to address an entire distribution network in one go. “At the start of the network one has the main pumping station and the treatment works. There are some typical arrangements.

PUMPS

These pumps that supply water to the distribution system are located near the water treatment facility or potable water storage facility and will pump directly into the distribution system or transmission lines. Normally they are rated for high flows and high heads and are operational 24 hours a day,” says Myslinkski emphasizing the need for quality.

Manage the pressure Another important element to remember is that of pressure management – especially in water supply networks, says Rajesh Sunkarineni, a product manager at Grundfos.

By using pumps and systems specifically designed for durable use and variable flows one ensures the right balance between self-contained systems and pressure zones in the water distribution system.

“A lot of the infrastructure being used is old and that results in increased leaks and bursts. It is also part of the reason why it is so difficult to make systems more efficient. There is also the fact that many systems are still maintained and operated in old-fashioned ways sometimes.”

“Overall efficiency of your pumps and systems is highly dependent on the controls. This means controlling the entire system is of critical importance. Proven reliability lies in best quality and process control.”

He says there is a need to optimize the pressure management systems to provide more intelligence to the system itself and to control the pumps in an improved fashion.

Compromising on quality comes at a price and one must look at delivering high standard performance.

“The primary focus has to be operational efficiency. The overall efficiency curve for a pump system is important and pumps must be operated at the most efficient level.”

According to Myslinkski, the importance of pumps cannot be overemphasized in delivering optimal solutions. Whilst a wide range of pump types and sizes are available, using the correct pump delivers benefits such as lower costs, ease of use, safer operations and less maintenance. Using the pump correctly delivers a longer operating life. “A horizontal split case pump, for example, is very reliable but also a very simple pump design that is easy to operate and use. It offers high energy efficiency and low life-cycle costs from the easy to service split case design. The double suction minimizes axial load, extending the life of the wear rings, shaft seals and bearings. The double volute reduces radial forces and minimizes noise and vibration. Another option at pumping stations that is often used is single-stage, end-suction, close- and long-coupled pumps. These pumps offer benefits such as optimized hydraulics in housing and impeller for unimpeded liquid flow. “Housing, impeller and wear ring in different materials for improved corrosion resistance and sticking elements also add benefit, while the back pull-out design for easy dismantling for service is also worth mentioning.”

He says many pumping stations are equipped with a system that starts and stop pumps and regulate the speed of the pumps, but often the operational efficiency of the pump is ignored. Improving this efficiency can allow for serious gains and benefits across the system. Sunkarineni and Myslinski maintain that improving system performance and reducing water loss requires a two-fold approach – good quality pumps selected correctly and operational efficiency. From having the correct size pump in place to the right number to operating them correctly it is all part of an ongoing process where the overall monitoring and maintenance of the system is just as important to stop loss and achieve savings. Grundfos South Africa (PTY) Ltd, +27 (0) 10 248 6000, info_za@grundfos.com, www.grundfos.com/za Pipes, Pumps and Valves Africa - Jul/Aug 2021

Additive manufacturing advantages

VALVES

The Covid-19 pandemic has highlighted the need for on-premise or on-demand manufacturing. It has also presented manufacturers with the opportunity to reconsider the supply chain and how parts are manufactured. Few companies are fully aware of the benefits additive manufacturing offer, says Valeria Tierelli, CEO of Aidro Hydraulics. For her, this new technology is an enabling tool to improve business by delivering products faster by avoiding bottlenecks and other time-consuming processes. It also has the potential to drive down cost as fewer raw materials are used and end-products are often easier to transport and handle. “The products can also be manufactured closer to the site – even on-premises if required,” she said. Admittedly, additive manufacturing is still a relatively new concept and much testing of the final products is required. “I don’t see it ever replacing standard manufacturing. It will never become the way that we produce valves and other critical components. It is, however, a fantastic technology that brings added value to the manufacturing processes and that allows us to deliver certain components faster and more cost-effectively than before.” One of the major benefits of added manufacturing, she says, lies in the digital inventory that it creates. “For 3D printing, a 3D design is drawn up and once completed this is simply stored in a digital management file. Such a system can take thousands and thousands of designs. No matter the size of the component required once designed it is merely a matter of going to the digital file, getting the component or product information and feeding it into the 3D printer and printing it.” Faster, more efficient and far more productive it no longer requires a massive warehouse for valves and other parts. “Parts can be printed from the digital file as and when required after which it can be tested and machined if necessary and then installed in the field.”

From a prototype perspective, there is also a benefit as this can be accelerated greatly as is the ability to customize. “There is no doubt, however, that additive manufacturing has a massive inventory stock reduction, while also reducing material waste.” She said there were two areas that she saw additive manufacturing successfully adopted by end-users. “The first is the design freedom it offers us to produce parts that would otherwise be impossible to deliver with standard manufacturing and the other is in printing it with little or no waiting time. Especially the replacement of standard parts will be faster and quicker.” She said another reason why it could be beneficial was that it offered improved performance through optimized design. It also offers production flexibility that is not necessarily possible with traditional manufacturing in large-scale factories. It allows the benefit of producers being able to quickly switch between different products delivering an inherent made-to-order scenario. Furthermore, said Tierelli, additive manufacturing would have a positive impact on the supply chain. Thanks to it reducing material waste, simplifying production and manufacturing products on demand, supply chain risk and cost was significantly reduced. Aidro Hydraulics, aidro@aidro.it, www.aidro.it

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Bosch Rexroth is electrifying subsea process automation with electric subsea valve actuator VALVES

Called the SVA R2 Subsea Valve Actuator, it is the world’s first electric actuator that can replace conventional hydraulic cylinders with field-proven safety technology – and without taking up additional space. It has an integrated electric controller that offers precise motion control and, due to condition monitoring and a safety spring, it satisfies Safety Integrity Level (SIL) 3 by IEC 61508 and IEC 61511. The actuator minimises energy consumption and is geared toward delicate ecosystems, and installation and operating costs are reduced. When the SVA R2 is used in subsea factories at a depth of up to 4 000 meters, hydraulic pipes or power units are no longer required. The electric supply pipes which are already installed for sensors are adequate to ensure the reliable operation of the actuators. These functions, the operating life and actuator safety have been successfully tested by international standards. Previously, process systems’ operators have mainly relied on hydraulic cylinders to open and close subsea valves with a quarter turn and a defined force. With offshore installations like oil & gas production, these cylinders are supplied by a central hydraulic power unit with hydraulic pipes several kilometres long. This uses a great deal of energy to compensate for the cumulated losses and cannot control the movement with precision. Plant engineers and operators relied on hydraulic cylinders because they are the only components to offer field-proven safety systems with a mechanical spring in a compact design. Conventional electric actuators do not have a safety function like this due to the size and weight requirements. Other designs to ensure safety using subsea batteries cannot guarantee the reliable closing of valves over the required operating life of up to 25 years. For the agile development of the SVA R2, the Bosch Rexroth team worked closely with suppliers and operators of offshore installations and international universities. The new module comprises a pressure-compensated container incorporating an electric drive, a motion control system and a safety device – and can replace the hydraulic cylinders previously used on a 1:1 basis. It requires only one cable for the power supply and communication. The SVA R2 is designed to actuate valves reliably with the power supply that is commonly used for subsea sensors. Switching to compact and safe electric actuators means that the hydraulic pipes several kilometres long and the associated power units and controllers are no longer required. 34

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Designed for high volume production, the electronics for the motion control system offer proven robustness and reliability. The SVA R2 is protected by several patents and is designed to operate for 25 years. Bosch Rexroth relies on globally accepted interfaces throughout and supports plant engineers, operators and offshore service providers when standardising equipment. The actuators for rotary adjustment complement the SVA L2 Subsea Valve Actuator for linear movements, which received the “Spotlight On Technology™ Award” from the renowned Offshore Technology Conference (OTC) in 2020. The SVA R2 Subsea Valve Actuator was nominated for and won the HERMES AWARD 2021, the most important international industry award. The Award Jury Chair (and President of the Fraunhofer-Gesellschaft), Professor Reimund Neugebauer said: “With the SVA R2, the developers at Bosch Rexroth combine economic and ecological aspects into a sustainably innovative product for the maritime process industry.” Bosch Rexroth tests full-scale prototypes on a specially built test stand by the most stringent international standards for subsea applications. Compared to other applications, they set the highest requirements in regards to the functions and safety of the components and modules used. As a result, the SVA R2 is suitable for other applications both below and above water such as hydrogen production, CO2 storage and general applications in the process industry. The first pilot tests began in the third quarter of this year. This valve actuator is available in Southern Africa through Bosch Rexroth SA Group of Companies. Bosch Rexroth South Africa, +27 (0) 11 979 4630, gillian.allin@boschrexroth.co.za, www.boschrexroth.africa

Whatever the flow it’s under control with Schubert & Salzer At Macsteel, we know that high-end technology delivers the best results. Our partnership with Schubert & Salzer ensures that we deliver the most precise control systems for the process industry and help to keep your business flowing.

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Does Legionella affect us in our daily lives?

VALVES

Legionnaires’ disease is recognised worldwide as an important cause of both community- and hospital-acquired pneumonia. It is caused by Gram-negative bacilli of the Legionella genus. The mortality rate in infected individuals ranges between 10 – 20%. It was named after a large outbreak in 1976 that occurred at a meeting of the American Legion, which affected 221 people, causing 34 deaths. Legionella bacteria are common and can be found naturally in environmental water sources, including rivers, lakes, natural pools, and moist soil. Water temperatures in the range of 20°C to 50°C favour the growth of the organism. Legionella pneumonia serogroup 1 is the most important species of Legionella that causes disease in humans, although other species can occasionally cause disease. Legionella spp. may also cause Pontiac fever, a mild, self-limiting flu-like illness. Who can get Legionnaires’ disease? All persons can develop Legionnaire’s disease. However, the risk is higher in persons over the age of 50 years. Male gender, persons with immunodeficiency syndromes or chronic underlying medical conditions of the lung, heart or liver and smokers are also at increased risk. Where does Legionnaires’ disease occur in South Africa? Legionnaires’ disease Legionnaire’s disease may manifest as sporadic cases, small clusters, or outbreaks of disease that can involve hundreds of cases. It is also an important cause of travel-related illness, and may be acquired on cruise ships, in hotels and resorts. In South Africa, both sporadic cases and outbreaks of Legionnaires’ disease have been described. Serological testing identified that approximately 8% of community-acquired pneumonia

are caused by Legionella species. Prospective surveillance identified 21/1805 (1.2%) cases of legionellosis amongst persons with severe respiratory illness However, due to difficulties in diagnosis and lack of awareness of the disease, very few cases are diagnosed in SA at present. It is very likely that sporadic cases, clusters and even outbreaks occur and are missed. How is Legionnaire’s disease transmitted? Persons become infected by breathing in water droplets containing the Legionella bacteria. Water droplets are generated by spraying or bubbling air through water in which the bacteria are present. Human-to-human transmission of Legionella has never been documented. The incubation period for Legionnaires’ disease is 2 – 10 days. Wherever water droplets can be created there is a risk of infection, including: • Hot and cold-water systems (e.g., showers and taps) • Cooling towers and evaporative condensers of air conditioners • Spa baths (Jacuzzis) and whirlpool baths and natural pools or thermal springs • Turkish baths and saunas • Ornamental fountains (particularly indoors) and sprinklers • Humidified food display cabinets • Respiratory therapy equipment How can Legionnaires’ disease be prevented? The proper design, maintenance and temperature of potable water systems are the most important method for preventing the amplification of Legionella. Hot water should be maintained above 60˚C and delivered to taps at temperatures above 50˚C. Coldwater should be maintained below 20˚C. Plumbing systems should be flushed regularly, and low flow areas eliminated. There are currently no vaccines to prevent Legionnaire’s disease. As can be seen from the above information we are all at risk. Especially when summer is coming, and restaurants are once again starting to use those misting systems that have been lying dormant and sitting in the sun giving it plenty of time to breed those lovely and willing Legionella bacteria. Most sports/gym facilities also use circulating blended hot water kept at a constant 38-42℃. This temperature range is a good safe temperature to prevent scolding of any user but, it is also the ideal breeding temperature for any Legionella spores present in the circulatory system. Any instance that uses a circulatory blended water supply should do regular maintenance. This would include decommissioning the system and raising the temperature

Pipes, Pumps and Valves Africa - Jul/Aug 2021

which responded promptly to any variation in temperature, pressure, and inlet flow rate to quickly restore the mixed water temperature value at the outlet. This standard mixing valve is effectively handled by a motorised actuator that, upon the signal coming from the temperature probes and under the control of a specific regulator, changes the mixed water temperature set position. The electronic regulator, directly on the actuator, allows the mixed water temperature control according to different functional programs, both for normal control and for the thermal disinfection for the prevention of Legionella.

We need to design these systems in such a way that the cleaning cycle is done automatically without human intervention. One such method is to use an automated cleansing system like the LEGIOMIX that is supplied by Calafrica. The electronic hybrid mixing valve combines the typical function of the mechanical thermostatic mixing valve and the management efficiency of an electronic mixing valve in a single device. The thermostatic mixing valve uses the mechanical action performed by the internal control thermostatic element,

The regulator is fitted for remote control with specific transmission protocols such as MODBUS, through the optional board, for use in Building Management Systems (BMS).

VALVES

to above 60℃ for half an hour. But as South Africans we do not schedule maintenance as a rule so how can we make sure that we do not get infected?

An optional memory system allows recording of every minute of flow temperature, return temperature, alarm, and functional statuses, useful for monitoring the operating status of the entire system. Appropriate relays are used to manage the alarms and external appliances, for example for loading accumulation hot water and the switching on/off recirculation pumps.

So, in a nutshell, we need to join the 4th Industrial Revolution and start using current-day technology available to us so that we can ensure our own and others safety. Calafrica, +27 (0) 11 795 1519, technical@calafrica.co.za, www.calafrica.co.za

EFFICIENCY meets PERFORMANCE • • • •

Low Voltage TEFC frame Electric Motors to IEC60034 Ratings from 0,37kW up to 680kW at 400V, 525V and 1000V Premium Efficiency to IEC 60034-30 (IE3) IP66 & Class H Insulation

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Allmech extends Runxin range of locally available valves

VALVES

Allmech, a leading South African manufacturer of boilers and supplier of water treatment components, is the sole official agent in South Africa for Runxin water treatment systems. The company has decided to extend the range of Runxin softener and filter valves it stocks to accommodate projects with budget constraints as well as smaller plants that need to minimise installation costs. “These valves are ideal for residential softeners, smaller boiler softeners, ion exchange systems and for RO pretreatment softeners,” explains Lynette Morrey, Business Development Administrator at Allmech. “Stocking these items will help us to serve a greater segment of the market. We’re now able to offer products for smaller applications, a cost-effective option for cash-constrained customers, as well as continuing to offer top-spec Runxin products to larger operators.” The new additions to Allmech’s Runxin line include: • F65P1 Auto Softener Valve: These can handle a flow rate of up to 2000 litres per hour. Ideal for domestic use. Time setting controls when the softener regenerates. • 63P3 Auto Softener Valve: An automatic softener valve ideal for industrial use for plants with a flow rate requirement of 4000 litres/hour. Can be set to regenerate based on water volume. • F71P1 Automatic Filter Valves: With a maximum flow rate of 2000litres/hour. Ideal for domestic applications and smaller sites. Handles a maximum flow rate of 4000 litres/ hour. Morrey says all of these valves are easy to programme and use, with simple, user-friendly displays. “As with all the Runxin valves we stock, Allmech offers reasonably priced repairs and replacement spares,” she adds. “We also choose Runxin because of the valves’ longer service life – some of our valves have run for more than 10 years with no maintenance required.” All Runxin valves are made from durable and flameretardant materials, ensuring they are impact and heat resistant. Their ceramic core components are wear and

corrosion resistant, increasing their longevity. “The ceramic ball valve range is also chemical resistant, which saves on replacement of expensive brass fittings,” says Morrey. “All Runxin valves carry a one-year manufacturer’s warranty, giving you peace of mind. We provide additional technical backup assistance, a repair centre and test facilities from the Allmech premises in Benoni, ensuring you have our full support when installing a Runxin valve.” Other useful features include: • No power outage worries: The last setting is saved automatically in the valve so that when the power is restored it continues the normal cycle from where it left off. All the user needs to do is reset the time. • Automatic display lock: If there is no further programming within one minute, the display automatically locks to prevent unintended operation. • Patented interlocking function: If there are multiple valves in the system, only one valve will stay in rinse or regeneration status while the other is operational. • Adjustable parameters: All parameters can be adjusted based on your needs during operation according to water quality and usage. All the Runxin valve manuals are also easily downloaded from the Allmech website for customer convenience. Allmech is also the only authorised South African agent for Runxin valves, produced by the global Wenzhou Runxin Manufacturing Machine Co., headquartered in China. Allmech, +27 (0) 11 849 2731, lionelm@allmech.co.za, www.allmech.co.za

Pipes, Pumps and Valves Africa - Jul/Aug 2021

Standardised

Customised

Systems-based

You choose. We supply. Our wide range of standard pumps and valves provides plenty of scope for individual demands. You can select the materials, hydraulic systems and drives. When you’re facing complex tasks, we’re with you from Day One – whether you want planning guidance, specially designed components or help with commissioning. But see for yourself. Test our products for quality and versatility, and discover why KSB is so often first choice. KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za tel: +27-11-876-5600

Our technology. Your success. Pumps

Valves

Service

One provider

PRODUCTS & SERVICES

How do I increase air flow performance in my air system? Air Flow System Problem Solver: Your Facility’s Air System Components. Tiny air particles are a major threat to your facility. Many plants lack proper point-of-use airline filtration – and you may not even know it. Many of these contaminants can’t be compressed. So they become even more concentrated as they move at high speed through airlines, causing accelerated wear, eroding lubrication and potentially forcing equipment offline. That’s what makes clean air such an essential ingredient in the effective operation of equipment and machinery. The most productive facilities trust ARO-Flo FRLs. Air flows better through ARO-Flo Series Filters, Regulators and Lubricators (FRL) than almost any other air filtration device. • Modularity: All ARO-Flo accessories integrate within each size range. Your complete FRL assembly and its components can be easily, safely, and quickly assembled or disassembled with minimum tools. • Performance: Air flows better through ARO-Flo filters, regulators, and lubricators than almost any other air filtration device. This means fewer pressure drops during the air preparation process, so your equipment can operate at its peak performance. • Safety: Providing safe tools and equipment is our top priority. ARO-Flo FRLs feature integrated safety features such as locking bowls. Clear multilingual markings and optional accessories further allow the air supply to be safely managed and controlled.

Pipes, Pumps and Valves Africa - Jul/Aug 2021

ARO-Flo Series sets the standard for airflow performance. These FRL solutions can keep your facility online and your equipment in shape. We combined best-in-class airflow performance with the flexibility to work in any environment.

PRODUCTS & SERVICES

Products Primed for Performance Like every ARO product, the ARO-Flo Series are premium products built to deliver top-quality and peak performance for your operation. These solutions give you excellent means of keeping your air supply in top condition, enabling your tools and equipment to work every time you need them. Filters ARO-Flo compressed air filters remove airborne solid and liquid contaminants. Filters can be ordered with different elements, including coalescing models which are capable of removing oil aerosols and particles down to 0.3 microns. Standard filters come with 5-micron elements; 40-micron elements can be purchased and installed separately. Regulators Airline regulators provide the controlled consistent air pressure required for specific pneumatic equipment connected to the air system. All ARO-Flo regulators come with a standard adjustment range of 0-140 PSIG (0-9.6 bar). They offer large integral flush mount gauges. Alternative spring ranges are offered for easy conversion to suit different requirements. Non-relieving regulators are offered for applications where the venting of downstream pressure is undesirable. Lubricators ARO-Flo mist-type lubricators help ensure that pneumatic devices receive the required lubrication to maintain peak performance, reduce wear and prolong service life. They provide the correct amount of oil required for most general applications in a pneumatic system, delivering a constant ratio of oil to airflow. Precise oil feed adjustment sets the proper oil drip-rate. Install your lubricators close to the downstream application to ensure the effective distribution of oil.

Filter-Regulator “Piggybacks” Filter-regulator, or “piggybacks,” combine the functions of both a filter and regulator. Piggybacks are compact and most effective when space is a constraint. Piggybacks can be ordered with different filter elements and can be modified with different springs, depending on the filtration and air regulating requirements. 2- & 3-Piece Combination Units Filters, regulators, lubricators and piggybacks can be combined to form combination units. They are typically strung together in the F+R+L arrangement (three-piece combo) and F/R+L (two-piece combo) arrangement. Other configurations also may be used depending on application needs. ARO-Flo combination FRLs are easily assembled using modular spacer kits. ARO-Flo Series of Filters, Regulators, Lubricators and select accessories can be used in hazardous locations requiring ATEX compliance, keeping your employees safe and your operation running. Ingersoll Rand attests that ARO-Flo Series of filters, regulators, lubricators (1000, 1500, 2000, 3000 Series) and select accessories are out of scope for ATEX Directive 94/9/ EEC or 2014/34/EU. The products listed in the form IRITS-1215-197 certificate can be used in group II, category 2 environment; Gas and Dust with the temperature a T6 (Ex II 2GD T6) if all conditions set up in the Instruction Manual are met. Air & Vacuum Technologies, +27 (0) 11 318 3241/2/3/4, Instrupump1@vactech.co.za, www.vactech.co.za Pipes, Pumps and Valves Africa - Jul/Aug 2021

PRODUCTS & SERVICES

The new pinch valves from GEMÜ make your tubes smile With the new Q series, GEMÜ is expanding its wide range of valves to include pinch valves. This series includes the GEMÜ Q50 eSyStep, a motorized version of the new pinch valves, alongside the GEMÜ Q30 and GEMÜ Q40 piston actuators, in plastic and stainless steel respectively, which are both pneumatically operated. The valves are specially designed for single-use applications and facilitate fast and simple replacement of mediaconveying tubes. A compressor is used to control or regulate the flow of media in the tube. The specially developed contour of the compressor ensures the pressure applied to the tubes is very gentle. This minimizes the stress and extends the service life. The new pinch valves are designed to allow fast, simple replacement of tubes without tools. At the same time, a circlip prevents accidental opening of the tube bracket. The tube holder also serves as a safety guard during operation. One valve size can be used for several nominal tube sizes. Should you need to change the size of the tube within a valve size, the tube holder and the compressor can be replaced afterwards. The actuators remain in the system and must not be removed. For panel mounting of the valves, in a cleanroom for example, an optional flange plate in stainless steel is available. The GEMÜ Q series is suitable for a wide variety

of applications such as media mixing, fermentation or cell harvesting. Further applications may include purification, filtration or chromatography. GEMU, +27 (0) 11 462 7795, info@gemue.co.za, www.gemu-group.com

AESSEAL receives US patent for seal support system AESSEAL has been granted a US patent (US 10844961) for its CIP cleanable barrier fluid system, EasyClean, which improves hygiene standards in the food, beverage, and pharmaceutical industries. EasyClean ensures that the product being pumped is not contaminated in any way, for example in the manufacture of paints and automotive coating lines. Although these industries must maintain a high level of hygiene in production lines and throughout their factories, seal support systems often harbour dirt and bacteria on the interior of the main vessel, due to their inherently enclosed design, making them difficult to inspect, clean and maintain high levels of hygiene. The EasyClean vessel is designed to allow more control over the level of hygiene in plants. It has a detachable lower section, which enables the vessel to be taken apart for inspection and cleaning, offering manufacturers the opportunity to quickly inspect and clean their systems and so eliminating the harmful build-up of dirt and bacteria. The EasyClean seal support system also has patent protection in the UK and China, with decisions pending in Germany and India. 42

Pipes, Pumps and Valves Africa - Jul/Aug 2021

AESSEAL, +27 (0) 11 466 6500, admin@aesseal.co.za, www.aesseal.co.za

PUMPS PUMPS FOUNDRY

FIRE PUMPS

Sulzer Pumps (South Africa) (Pty) Ltd Steloy Foundries

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KSB (Pty) Ltd C.R.I Pumps S.A. (Pty) Ltd

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info@vactech.co.za

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PRICE PUMPS, for Air Operated Double Diaphragm Pumps for harsh mining applications. A&VT are the SOLE Agents for Southern Africa.

Air & Vacuum Technologies

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

AESPUMP SA

T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za

APE Pumps

T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@apepumps.co.za W: www.apepumps.co.za

SAM Engineering

T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za MULTISTAGE PUMPS

APE Pumps

T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@apepumps.co.za W: www.apepumps.co.za

AESPUMP SA

T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za

C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

AESPUMP SA

C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

APE Pumps

T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@apepumps.co.za W: www.apepumps.co.za Pipes, Pumps and Valves Africa - Jul/Aug 2021

PUMPS SELF PRIMING PUMPS

Sulzer Pumps (South Africa) (Pty) Ltd T: +27 (0) 11 820 6000 F: +27 (0) 11 820 6206 E: CSSEnquiries@sulzer.com W: www.sulzer.com PINCH PUMPS

VERTICAL SPINDLE PUMPS

KSB (Pty) Ltd C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com VACUUM PUMPS

Walter Meano Engineering VersaFlo VSE Pumps T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za

VERTICAL TURBINE PUMPS

LVSA Group (PTY) LTD

T: +27 (0) 11 680 2005 E: sales@lvsa.co.za W: www.lvsagroup.co.za PISTON PUMPS

Integrated Pump Rental

T: +27 (0) 11 894-2906 E: admin@pumprental.co.za W: www.pumprental.co.za SLURRY PUMPS

PRICE PUMPS, for Air Operated Double Diaphragm Pumps for harsh mining applications. A&VT are the SOLE Agents for Southern Africa.

Air & Vacuum Technologies SALES, SPARES AND REPAIRS

T: +27 (0) 861 822-832 +27 (0)11 318 3241/2/3/4 C: +27 (0)82 576 9373 E: burnm@vactech.co.za W: www.vactech.co.za info@vactech.co.za

0861 VACTEC (822 832)

www.vactech.co.za

PRICE PUMPS, for Air Operated Double Diaphragm Pumps for harsh mining applications. A&VT are the SOLE Agents for Southern Africa.

Air & Vacuum Technologies SALES, SPARES AND REPAIRS

Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za

PLUNGER PUMPS

T: +27 (0) 861 822-832 +27 (0)11 318 3241/2/3/4 C: +27 (0)82 576 9373 E: burnm@vactech.co.za W: www.vactech.co.za info@vactech.co.za

0861 VACTEC (822 832)

AESPUMP SA

T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za

www.vactech.co.za

HORMA PUMPS (PTY) LTD T: +27 (0) 11 452 4300 F: +27 (0) 11 452 4400 C: +27 (0) 82 779 2464 E: sales@horma.co.za w: www.horma.co.za

C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

Integrated Pump Rental

T: +27 (0) 11 894-2906 E: admin@pumprental.co.za W: www.pumprental.co.za

Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za

POSITIVE DISPLACEMENT PUMPS

SUBMERSIBLE PUMPS

T: +27 (0) 11 824-4810 E: info@pumptechnology.co.za W: www.pumptechnology.co.za

C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

AESPUMP SA

T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za

Integrated Pump Technology

Integrated Pump Rental

uality

Sulzer Pumps (South Africa) (Pty) Ltd T: +27 (0) 11 820 6000 F: +27 (0) 11 820 6206 E: CSSEnquiries@sulzer.com W: www.sulzer.com

WASTEWATER PUMPS

VAC-CENT SERVICES (PTY) LTD.

VAC-CENT SERVICES (PTY) LTD T: +27 (0) 11 827 1536 F: +27 (0) 11 824 3590 E: karishma@vaccent.co.za W: www.vaccent.co.za

VERTICAL SUMP PUMPS

T: +27 (0) 11 894-2906 E: admin@pumprental.co.za W: www.pumprental.co.za

KSB (Pty) Ltd

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com WELL PUMPS

KSB (Pty) Ltd Unique Engineering

T: +27 (0) 11 826-6111 F: +27 (0) 11 826-6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za 44

Integrated Pump Technology T: +27 (0) 11 824-4810 E: info@pumptechnology.co.za W: www.pumptechnology.co.za

Pipes, Pumps and Valves Africa - Jul/Aug 2021

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

KSB (Pty) Ltd

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

VALVES BALL VALVES

CONTROL VALVES

KV Controls (Pty) Ltd LVSA Group (PTY) LTD

T: +27 (0) 16 100-4592 E: fred@kvcontrols.co.za W: www.kvcontrols.co.za

T: +27 (0) 11 680 2005 E: sales@lvsa.co.za W: www.lvsagroup.co.za

Bray Controls Africa

T: +27 (0) 10 007-3222 E: sales@bray.com W: www.bray.com

T: +27 (0) 11 736-4994 C: +27 (0) 83 461 0801 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

Valcon Valve & Controls

T: +27 (0) 11 453-7537 E: valconsa@iafrica.com Web: www.valcon.co.za

T: +27 (0) 11 736-4994 C: +27 (0) 83 461 0801 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za CHECK VALVES

T: +27 (0) 10 007-3222 E: sales@bray.com W: www.bray.com

CMY

Enserve Engineering Services (Pty) Ltd

T: +27 (0) 11 795 1519 C: +27 (0) 83 303 1437 E: technical@calafrica.co.za W: www.calafrica.co.za

C.R.I Pumps S.A. (Pty) Ltd

Macsteel Fluid Control

T: +27 (0) 82 495 2772 C: +27 (0) 11 383 4000 E: Rowan.Blomquist@macfluid.co.za W: www.macsteel.co.za DIAPHRAGM VALVES

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

C.R.I Pumps S.A. (Pty) Ltd

Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

Kaytar Valves (Pty) Ltd Kaytar Valves (Pty) Ltd

T: +27 (0) 21 987-8292 C: +27 (0) 81 555-5288 E: clinton@kaytarvalves.co.za W: www.kaytarvalves.co.za

Macsteel Fluid Control

T: +27 (0) 82 495 2772 C: +27 (0) 11 383 4000 E: Rowan.Blomquist@macfluid.co.za W: www.macsteel.co.za

Pleix-Quip KSB (Pty) Ltd

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

T: +27(0) 16 971 3385 F: +27(0) 16 971 3935 E: mail@enserve.co.za W: www.enserveonline.com

Invincible Valves (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

CALAFRICA Hydronic Solutions

BUTTERFLY VALVES

Bray Controls Africa

Pleix-Quip Pleix-Quip

T: +27 (0) 11 736-4994 C: +27 (0) 83 461 0801 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

T: +27 (0) 21 987-8292 C: +27 (0) 81 555-5288 E: clinton@kaytarvalves.co.za W: www.kaytarvalves.co.za

LVSA Group (PTY) LTD

T: +27 (0) 11 680 2005 E: sales@lvsa.co.za W: www.lvsagroup.co.za

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

FLOW CONTROL VALVES

VACSERVE (PTY) LTD

T: +27 (0) 11 827 1536 F: +27 (0) 11 827 3590 E: karishma@vaccent.co.za W: www.vacserve.co.za GATE VALVES

KSB (Pty) Ltd

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

Pipes, Pumps and Valves Africa - Jul/Aug 2021

VALVES THERMOSTATIC CONTROL VALVES

KV Controls (Pty) Ltd

T: +27 (0) 16 100-4592 E: fred@kvcontrols.co.za W: www.kvcontrols.co.za

ADVERTISE WITH US TODAY !!

VACSERVE (PTY) LTD

T: +27 (0) 11 827 1536 F: +27 (0) 11 827 3590 E: karishma@vaccent.co.za W: www.vacserve.co.za

Macsteel Fluid Control

T: +27 (0) 82 495 2772 C: +27 (0) 11 383 4000 E: Rowan.Blomquist@macfluid.co.za W: www.macsteel.co.za KNIFE GATE VALVES

VALVE RECONDITIONING

Enserve Engineering Services (Pty) Ltd T: +27(0) 16 971 3385 F: +27(0) 16 971 3935 E: mail@enserve.co.za W: www.enserveonline.com

C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

Mine Track & Tools (Pty) Ltd

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

VALVES FOUNDRY

T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

PRESSURE REDUCING VALVES

Steloy Foundries

T: +27 (0) 13 110 2681 E: support@steloyfoundries.com W: www.steloyfoundries.com

CALAFRICA Hydronic Solutions T: +27 (0) 11 795 1519 C: +27 (0) 83 303 1437 E: technical@calafrica.co.za W: www.calafrica.co.za

SAFETY & RELIEF VALVES

KEW Foundries

T: +27 (0) 53 841 0474 F: +27 (0) 53 841 0473 E: info@kewfoundries.co.za W: www.kewfoundries.co.za

CALAFRICA Hydronic Solutions T: +27 (0) 11 795 1519 C: +27 (0) 83 303 1437 E: technical@calafrica.co.za W: www.calafrica.co.za

Ukuthela Foundry Projects T: +27 (0) 12 719 8860 E: ukuthela@live.co.za

Pipes, Pumps and Valves Africa - Jul/Aug 2021

+ 27 (0) 83 281 5761 info@pumpsandvalves.co.za www.pipespumpsandvalves.co.za

MAY 25

26 2022