Pumps & Valves

Powerline help further prolong lifetime of proven Landia pumps

Banbury-based Powerline Electric Motors has completed the refurbishment of its latest batch of Landia slurry pumps, including one unit that has been in operation for almost 25 years.

With its ongoing investment in new equipment and growing number of apprentices, Powerline has seen a significant increase in demand for its repair services, which not only help prolong the lifetime of pumps, but also improve efficiencies.

Landia’s Paul Davies, commented:” Although we have our own nationwide service team, Powerline’s skill in overhauling pumps is first-class. We are pleased to see our equipment continue to provide excellent, long-term service.”

Richard Thompson of Powerline added: “We’re not in the habit of disappointing our customers. Landia make very robust pumps and they always have a good stock of spares on hand for us, so that we can offer the best possible turnaround.”

Landia and Powerline also both work closely with Shipston-on-Stour-based Midland Slurry Systems, who specialise in the supply and maintenance of industrial and agricultural wastewater treatment installations and animal slurry management.

Giles Russell for Midland Slurry Systems, said: “We have total confidence in the Landia pumps and mixers that we’ve used for many years. In slurry pits, equipment has to be tough, but it must be maintained properly too. After our pumps have been in for service with Powerline, they’re like new!”

In addition to the farming sector, Powerline also provides high-quality repairs, rewinding and refurbishment of electric motors, pumps, fans, and gearboxes to a wide variety of industries, such as manufacturers of foods, plastics, and automotive, as well as servicing customers working in chemicals, utilities, healthcare, construction, and Oxfordshire-based F1.

www.landiaworld.com

www.PowerlineElectricMotors.co.uk

www.midlandslurrysystems.co.uk

this article can also be found in the latest issue of  EMS

 

Identifying poor assets and inefficient pumps.

Despite the soaring prices brought on by an energy crisis that shows no signs of diminishing, ask pump and blower operators about the efficiency of their equipment, and the truth is that most don’t know – according to a leading monitoring technology provider.

The pumps, for example, might often be described as ‘working fine’ and ‘doing their job’, but is that, now more than ever, a strategy? How about saving money now, and in the future?

“The opportunity to truly maintain, protect and optimise assets is here and now, with a Return on Investment (ROI) that is shorter than ever”, says Julian Lowe from Riventa. “The cost of solving asset management challenges is on a much smaller scale than most companies imagine”.

So, just how can you make hidden costs more visible?

At minimum, put some testing in place. By obtaining accurate, quality data, this first proactive step will give you a snapshot of performance, as well as health and efficiency. Even this entry-level testing will help identify poor assets and inefficient pumps.

Riventa’s Julian Lowe added: “All we hear about at the moment, understandably, is the giant hike in energy prices, so best test your pumps (and/or blowers and turbines) to reduce energy consumption and maximise savings. This will almost immediately help identify actions to improve performance. In addition to pump efficiency, measuring key parameters such as flow rate, head and electrical power - current pump performance characteristics can be compared to ‘as new’ and ‘post-refurbishment’ conditions. This provides the same accuracy as a pump manufacturer’s test facility – but with the distinct advantage of real operating conditions”.

Across numerous industries, where for some, running pumps ‘til destruction is the modus operandi, Lowe has a point. He claims that for larger pumps, blowers and turbines, the ROI can be as little as 18 months.

A level up from pump testing is to look at an Optimisation Service, utilising secure on-site pump monitoring equipment to provide real-time data. This enables you to start seeing what’s happening across your system by capturing data over 14-days or longer. This doesn’t have to involve tons of ‘spaghetti’. Systems can now be cable-free; up and running in around 1 hour per pump, at low risk and with minimal disruption to existing operations.

‘Realistic payback calculations’

Dr Tom Clifford from Riventa, continued: “Once in place, real-time data for each asset can be evaluated, with information-driven insights highlighting performance issues and supporting decisions. This can establish best practice recommendations, realistic payback calculations and a business case for moving forward – all backed by precision measurement and innovative analytics”.

Clifford explained how Riventa had recently worked with a food manufacturer; testing the company’s cooling system, which is split into two pumping sub-systems: factory pumps 1-5 for sending chilled water from heat-exchangers to the factory; and evaporator pumps that send chilled water from the factory to refrigeration heat exchangers.

“To test the pumps, we used the thermodynamic measurement technique (with our specialist software) to measure suction and discharge pressures either side of the pump, differential temperature, and motor input power. These measurements enabled us to calculate differential head across the pump, hydraulic efficiency and volumetric flow. Pumps were altered gradually. After each change, a test point was taken, while allowing enough time to obtain the best statistical average. Tests also involved a routine of testing performance at an incumbent set point, followed by throttling the pump to reduce its flow rate. The latter action allowed other pumps running in parallel to increase in speed to compensate, with a final test point taken at this moment”.

He continued: “Throttling meant we could observe the maximum possible flow through each pump under test, without altering the overall flow to the plant. At times this was challenging, because conditions downstream in production would change, altering the cooling load and in-turn the flow set point. Nevertheless, good quality performance information was obtained.

‘Strong case for robust savings’

“We found that all pumps were showing signs of wear. Moreover, manufacturer performance levels were not being achieved. None of the pumps we tested reached the manufacturer’s BEP (81%). In fact, the maximum pump efficiency possible was found to be 75% (achieved by pumps 1 & 2 only). Our findings enabled us to put pumps into a descending order of repair: 1, 2, 3, 4 & 5. While pumps 1-3 achieved a good relationship between power and flow, pumps 4 & 5 were not performing when at lower flows. This indicated a high likelihood of internal recirculation – from high to low pressure parts of the impeller – being caused by high wear. We were able build a strong case for robust savings through the pump refurbishment. Broadly, two options were made available:

  • Basic Refurbishment: Internal coating plus replacement of wear-rings, bearings and seals.
  • Comprehensive Refurbishment: As per the Basic Refurbishment, plus a new tailored impeller.

“We calculated that pump refurbishment would bring potential

savings of £19,200 per year, with possibilities to refurbish 2, 3

or 5 pumps”.

This is just one example of what Riventa say they are helping companies achieve across industries that also include water, power, mining, petrochemical, to name but a few.

Advanced pump monitoring and optimisation are available too, continuously focusing efforts by evaluating and understanding performance gains across priority pumps and sites. And for some organisations, full optimisation of networks is available.

‘Change in Mindset’

“Nobody wanted an energy crisis”, concluded Clifford, “but as prices soar, we are beginning to see a change in mindset about just how important it is to know how your assets such as pumps, blowers and turbines are really performing.  Initially, some basic testing might reveal some not altogether pleasing facts (!), but you can soon put yourself on a very positive course to make some seriously good, ongoing savings”.

www.riventa.com

Grease sludge can’t halt powerful Borger pump

A submerged Börger rotary lobe pump has put a Midlands wastewater treatment plant back on course with what was a troublesome grease-sludge-basin application.

Previously, the WWTP was incurring unsatisfactory amounts of additional, complex maintenance and downtime, because its centrifugal pump couldn’t cope with the total solids content.  When attempting to pump sludge from a grease-sludge-basin into a storage shaft (from which a second pump fed a digestion tower), the centrifugal pump was all too regularly becoming blocked.

In addition to making significant savings on maintenance, the WWTP also no longer requires a storage shaft and a second pump. The Börger rotary lobe pump has more than sufficient power and stability to consistently convey the viscous grease sludge from the grease-sludge-basin, directly into the digestion tower.

Since its installation, the Börger rotary lobe pump has not suffered any blockages or failures, despite the challenging high total solids contents of the pumped medium.

 

Borger UK

01902 798 977

www.boerger.com

This email address is being protected from spambots. You need JavaScript enabled to view it.

New pump brings classic aeration solution to Timothy Taylor’s

Following an intensive 5-day survey of its wastewater treatment process, the highly renowned brewery, *Timothy Taylor’s (family-owned since its founding in 1858) has upgraded its aeration process by introducing the AirJet system from Landia.

The survey, which was conducted by leading wastewater treatment provider, Ogden Water, found that the pumps used for the brewery’s 45m3 balance tank were not providing enough agitation to adequately keep solids in suspension.

“Solids had begun to accumulate,” said Dr David Shepherd, Managing Director of Ogden Water. “The existing pumps were insufficient to fully mix and aerate the balance tank, so we set about finding Timothy Taylor’s with a much better, long-lasting solution.”

Nick Berkovits, Second Brewer at Timothy Taylor’s added: “Ogden Water’s rigorous survey showed that an upgrade to superior aeration equipment would eliminate odours caused by solids not being sufficiently suspended, and also provide a much more consistent homogenous feed to our DAF (Dissolved Air Flotation) unit”.

Designed with a venturi nozzle from the Chopper Pump that Landia invented in 1950, the AirJet aeration system was recommended by Ogden Water as the best and long-lasting solution.

“We’d previously used Landia’s pumps and mixers,” continued Ogden Water’s David Shepherd. “They are extremely effective, as well as being easy to maintain – and with a typical lifetime of at least 15-20 years, are a very sound, peace of mind investment for our customers”.

Simultaneously mixing and aerating, the Landia AirJet is an uncomplicated system that introduces air automatically to keep wastewater fresh; economically delivering dissolved oxygen at depths of up to 7.5m, to provide complete aeration

Nick Berkovits from Timothy Taylor’s, commented: “It’s fair to say that before the installation of the Landia AirJet, the performance of our DAF was being compromised. We also had the time and cost of having to use chemicals to address odours. But now, through the expert advice we’ve received from Ogden Water, and the success of what is a first-class aeration system from Landia, our wastewater treatment system is operating very well indeed”.

*In 1858, Timothy Taylor opened his brewery in Cook Lane, Keighley, Yorkshire, England.  A year later, he bought his first pub, The Volunteers Arms.

Today, Timothy Taylor’s brewery sits upon a particularly pure and consistent source of water (the Knowle Spring), that is the unique source for its beers – and key, for example as to why its much-loved ‘Boltmaker’ has been crowned Supreme Champion Beer of Great Britain at the CAMRA (Campaign for Real Ale) Great British Beer Festival.

Water from the Knowle Spring has filtered over time through layers of sandstone and black rock, to create the special mineral qualities that marry perfectly with Timothy Taylor’s Golden Promise barley malt. This unique combination is the foundation of the complex flavour and subtlety of the brewery’s most popular beer, Landlord.

www.landiaworld.com

www.ogdenwater.co.uk

This article can also be found in the issue below.

 

Snack attack continues for hungry Chopper Pumps

At a London-based snack-food manufacturer, Landia has just supplied its 25th pump in a partnership that is now celebrating its 20th anniversary.

Supplying branded and private-label snack and crisp products for both independent and major retailers within the UK and across Europe, the food manufacturer began using Landia long-shaft chopper pumps two decades ago to transfer effluent from below-ground pits to its wastewater treatment plant.

First supplied as 5.5kW units, but in more recent years as 7.5kWsome of the original smaller chopper pumps are still working, with only a bare minimum of basic wear and tear parts ever required.

Landia’s MPG-I long-shaft vertical chopper pumps are designed with a fan-cooled motor that sits above the liquid surface and is therefore well protected. The pump contains no seals, which makes it extremely robust and tough.

This latest long-term landmark for Landia follows its recent milestone with North Wales-based KK Fine Foods (manufacturers of high-quality meat, fish and vegetarian meals), where its wastewater mixing and aeration system has completed five years of uninterrupted service. Landia has also provided numerous wastewater pumping, mixing and aeration solutions to the food and drink industry, including at Hook Norton Brewery, 2 Sisters Food Group and Aspall Cyder.

AFB6E1B8 3226 4D0E 8E10 6127FFA776C3

 

 

CUSTOM ACTUATED BUTTERFLY VALVES FOR IRAQI OIL REFINERY

 

D1F00883-1BE0-47D3-83FD-2922DBA8F4C6.jpeg

When a major Iraqi-based oil refinery required custom actuated butterfly valves for a large-scale plant refurbishment, T-T Flow’s expert product knowledge, access to quality manufacturing partners and extensive export experience made us the ideal choice to deliver a robust, reliable and fully compliant customised solution both on-time and within budget.

THE PROBLEM

During a major refurbishment project at a plant operated by South Refineries Company in Iraq, there was a requirement for custom actuated butterfly valves constructed of materials that needed to be fully traceable and certifiably of UK, EU or USA origin.

As the client specified non-standard materials, a completely customised valve build was required. To ensure full compliance, the valves underwent several independent third-party functional inspections and even the chemical analysis of components, along with the supply of extensive expert documentation including attested embassy origin certificates.

In addition to the non-standard materials, the client specified actuator connectivity to integrate with existing control panels and operating philosophy.

THE SOLUTION

T-T's expert product knowledge, access to quality manufacturing partners and extensive export experience made us the ideal choice to supply this actuated valve package within budget and on time. 

Supplied indirectly through an Iraqi-based specialist engineering company, we assembled and supplied 30 lugged centric butterfly valves to EN598, rated to 175psi with limit-set directly mounted non-modulating 230V/60Hz actuators.

To meet client specifications, the valves have a chemical resistant epoxy coated carbon steel body, acid resistant stainless steel (grade 1.4404 / SS316L) discs, EPDM liner, and are suitable for installation between ASME B16.5 Class 150 flanges.  

Versatile actuators were selected, offering quarter-turn reliability, weatherproof IP68 enclosure, feedback functionality and manual override. T-T identified proven partners that would ensure end-user acceptance and functional longevity.

6DCA95B5-59FF-467A-9C8B-F943320661F0.jpeg

 

T-T Flow were able to select, source, assemble, coordinate third party inspections, undertake comprehensive in-house hydrostatic and functional testing, and arrange global logistics, offering the end user full assurance. We also produced an instructional video detailing step-by-step actuator settings for trouble-free site commissioning.

T-T are experts in the design and manufacture of custom valves and associated ancillary equipment, utilising our expert product knowledge, manufacturing partners and extensive export experience to deliver solutions to even the most challenging projects. Our flexible approach allows the supply of just a single valve, a combination of stock products, or the ability to work with our clients to provide a complete engineered valve package, as was the case with this project.

Explore our range of valves or find out more about our custom valve solutions. For expert advice, chat to our friendly and knowledgeable team on +44 (0)1630 647200.


 This article also featured in the December/Jan issue below

 

 

 

How Sealless Pump Technology can Reduce Maintenance & Pump Wear

A customer contacted us who was experiencing issues with their vane pump handling a new blend of adhesive consisting of 3 parts -Solvent, Resin and Ceramic. They were experiencing high levels of wear with their vane pump with the mechanical seal repeatedly failing, allowing air ingress into the pump, hazardous flammable liquid would leak from the casing, and end product would fail to meet quality standards. 

At each breakdown not only did wearing parts have to be replaced, but the casing and any small parts would require a full clean using hazardous chemicals to remove any product set. When the seal leaked, product would ingress into the bearings, quickly rendering them useless. Maintenance required at least two people, and the downtime that the factory was experiencing was annualised at over £200,000 of lost product output per year.

The Vane pump was feeding a batching line which would batch fill containers on an assembly line before bottles were packaged, and dispatched for delivery. Having to repeatedly disassemble the vane pump, change the seal, bearings and vanes meant repeated stoppages which the plant could no longer accept.

The capacity of the existing unit was between 5-15L/min with a discharge pressure of 4 bar. The glue had a viscosity similar to Ketchup (1000cps) but Various pump technologies were studied before finalising our specification for an ATEX(UKCA EX) roller Peristaltic pump controllable via Variable Frequency Drive. This design of pump which contains a single wearing part – a hose eliminating any chance of mechanical seal failure, and more importantly air ingress contaminating product. 

Our Low Maintenance Solution

Hose pumps are of non clog design meaning there was no chance of blockages forming within the pump. They are of positive displacement design meaning the pressure will be constant, and flow rate proportionate to speed. This meant that the speed of dispensing and bottling could be altered according to line speed.

As solvent can attack cast iron the unit was coated in Halar. Halar is a type of plastic coating highly resistant to temperature fluctuations, chemicals and corrosion, protectingthe pump in case of spillage or liquid escapement should the hose fail.

The ATEX (UKCA EX) Peristaltic pump was supplied with a motor suitable for operation via external variable frequency drive. The customer had existing 1¼ inch NPT fittings which we had fitted to the pump to enable plug and play operation. 

The main difference in output flow from the Peristaltic to the vane pump is that vane pumps do not have a pulsating flow. To ensure accuracy within their liquid filling packaging machinery we supplied the pump complete with an inlinepulsation dampener which eliminates up to 98% of pulsations during operation, meaning the customer receives a smooth linear flow important for flowmeter accuracy during dispensing, and that containers are not over or underfilled as an unintended consequence.

Process Improvements, Payback Period, & Outcome

The customer received the pump within 3 weeks of order and is set to save over £200,000 in lost output with a payback period of less than 1 month. 

Maintenance is far simpler requiring only one person with the pump kept in situ. As there is only one wearing part – the hose, when this approaches the end of its useful life, it is removed from service, sent for disposal and replaced without any cleaning of parts using hazardous chemicals and added risk to personnel. 

Furthermore as the plant had experienced some restructuring with team members who had expertise in pump overhaul and maintenance leaving the business, having such a simple to maintain solution accelerated training and meant outside expertise was not required. 

If you are experiencing frequent pump downtime, repeated maintenance or seal replacement speak to us on 01773 302 660 or visit www.northridgepumps.com to see how we can help.

MSE Systems bring in Landia pumps and mixers to help treat potato effluent

Following the successful installation two years ago of Landia Chopper Pumps and a Landia Aeration System, MSE Systems is set to install a further three units from Landia for one of the UK’s leading supplier of potatoes.

During an upgrade to the customer’s potato processing factory, Chesterfield-based MSE Systems found that the addition of a high-efficiency Dissolved Air Flotation (DAF) plant would improve the activated sludge process by reducing oxygen demand. To ensure that the plant could meet future needs, a new chemical addition system was introduced to remove suspended solids, free emulsified oils, grease and elevated residual phosphorus.

For odour control, an 11kW Landia AirJet system was installed to mix, aerate and control odours of screened potato effluent in a balance tank. In addition, two submersible Landia Chopper Pumps were brought in to pump screened potato effluent from a 4.5m deep pit (500m away), which included an additional 4m lift.

Andy Neal, Design Manager at MSE Systems, said: “Our challenge, which meant utilising a very small footprint between the existing plants, was to help our customer meet and maintain a stringent Environment Agency discharge consent, so that they remain fully compliant. The Landia AirJet and Chopper Pumps have proved very reliable and cost-effective, so it gave us the confidence to invest further in this equipment as the best, long-term solution.

He added: “For a new packing line, two submersible Landia Chopper Pumps will pump potato effluent, whilst a Landia Jet Mix system will mix organic sludge (dissolved solids 3-5%) in a 60m3 tank”.

MSE Systems ensured that the initial installation proceeded with the minimal amount of disruption, in order for their customer to reopen on schedule. Despite the tight time frame, the new wastewater treatment plant was delivered by MSE Systems ahead of deadline and within budget.

www.msesystems.co.uk

www.landia.co.uk

MSE Systems bring in Landia pumps and mixers to help treat potato effluent

Following the successful installation two years ago of Landia Chopper Pumps and a Landia Aeration System, MSE Systems is set to install a further three units from Landia for one of the UK’s leading supplier of potatoes.

During an upgrade to the customer’s potato processing factory, Chesterfield-based MSE Systems found that the addition of a high-efficiency Dissolved Air Flotation (DAF) plant would improve the activated sludge process by reducing oxygen demand. To ensure that the plant could meet future needs, a new chemical addition system was introduced to remove suspended solids, free emulsified oils, grease and elevated residual phosphorus.

For odour control, an 11kW Landia AirJet system was installed to mix, aerate and control odours of screened potato effluent in a balance tank. In addition, two submersible Landia Chopper Pumps were brought in to pump screened potato effluent from a 4.5m deep pit (500m away), which included an additional 4m lift.

Andy Neal, Design Manager at MSE Systems, said: “Our challenge, which meant utilising a very small footprint between the existing plants, was to help our customer meet and maintain a stringent Environment Agency discharge consent, so that they remain fully compliant. The Landia AirJet and Chopper Pumps have proved very reliable and cost-effective, so it gave us the confidence to invest further in this equipment as the best, long-term solution.

He added: “For a new packing line, two submersible Landia Chopper Pumps will pump potato effluent, whilst a Landia Jet Mix system will mix organic sludge (dissolved solids 3-5%) in a 60m3 tank”.

MSE Systems ensured that the initial installation proceeded with the minimal amount of disruption, in order for their customer to reopen on schedule. Despite the tight time frame, the new wastewater treatment plant was delivered by MSE Systems ahead of deadline and within budget.

www.msesystems.co.uk

www.landia.co.uk

ABB to share its flow measurement expertise at forthcoming factory open day

abb march 15ABB Measurement & Analytics to hold open day at its Stonehouse factory to demonstrate its flow testing facility and expertise for industrial flow measurement applications

ABB Measurement & Analytics will be holding an open day at its Stonehouse factory on the 25th March to share its expertise on flow measurement and calibration. Free to attend, the event is open to anyone involved in the specification, operation and maintenance of flowmetering equipment and will cover a variety of areas relating to flow measurement and calibration.

New Sauer standard for safety valves

sauer-april-5They make a considerable contribution to safe operation: Safety valves have to defy high temperatures, pressure fluctuations and vibrations while reacting precisely – requirements that mass-produced valves often do not satisfy sufficiently.

This website is owned and operated by: MSL Media Limited

msl logo
www.mslmedialtd.com

Co. Number: 05359182

© 2022 MSL Media Ltd. All rights reserved. E&OE

ems logo mobile