The Maintenance Solution

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Three types of pump exist which employ centrifugal force to move liquids:

  • The first type, ANSI pumps, are named after the American National Standards Institute, which in 1977 established standards for the pumps. These are designed for use in almost any kind of fluid transfer.
  • The second type use standard end-suction, and are best for thin liquids. This type is preferred for water pumping.
  • The third type are self-priming pumps. With balanced pumping pressures to keep liquids from recirculating, these are ideal for high-capacity work, including loading and unloading of liquids.

One thing shared by all three types of pump is the need for routine maintenance to extend the product's lifespan. This reduces the frequency both of repairs and costly replacement of the pumps. Part of a maintenance routine should include record keeping to aid in the diagnosis of problems in the event of future repair needs.

Basic maintenance routines must include the following:

  • Bearing temperatures, lubricant level and vibration of the pump must be monitored to ensure that lubricant is clear and without frothing. Temperature changes can mean failure of the pump is likely in the immediate future.
  • Regular inspection of shaft seal for leaks is important; there should be no visible leaking. Packing may leak at 40-60 drops per minute.
  • Bearing failure can be predicted by changes in vibration of the pump overall, so this should be carefully watched. Additionally, vibration can happen because of changed pump alignment, cavitation and resonances between the foundation and the pump, or at the valving in the discharge and suction lines.
  • The developed head pressure of the pump, given by the difference between the suction and discharge gauge readings, must also be monitored. If the developed head pressure drops slowly over time, this may mean a widening of the impeller clearance, requiring changes to the impeller clearance to keep the pump working within ideal ranges.

Every three months the following maintenance should be performed, with the caveat that extreme conditions (highly corrosive liquid use, e.g.) require more frequent inspections:

  • Inspect pump's foundation and make sure hold-down bolts are still tight.
  • Oil-lubricated and grease-lubricated pumps require slightly different treatment. Oil-lubricated pumps should have an oil-change after the initial 200 hours of service when new, and every 2,000 operating hours (or three months, whichever comes first). Grease-lubricated pumps have bearings that should be re-greased every three months or after 2,000 hours.
  • Shaft alignment should be checked at least once every three months.
  • Following manufacturer instructions by re-greasing motor bearings every three months.

Every year the overall operation of the pump should be evaluated and documented annually. This should be done according to baseline data established at the beginning of the pump's service life. This data must include:

  • Developed head pressure, taken from suction and discharge gauges as outlined above.
  • Pump flow rate
  • Motor amperage draw
  • Vibration signature

Changes in the baseline data should be noted, and decisions made as to maintenance required to effect maximum efficient operation of the pump. It should be kept in mind that bearings will inevitably fail. But failure is more often the result of the lubricating medium than the equipment itself. Careful attention to lubricants can save considerable time and effort by prolonging the life of the equipment.

Only non-foaming and non-detergent oils should be employed as lubricants for pumps. Oil should be kept at the level of the midpoint on the bull's-eye sight glass on the side of the bearing frame. Over-lubrication, one must remember, is as destructive as under-lubrication, because it will draw more horsepower, resulting in excess heat and possible frothing of the oil.

If any cloudiness is seen in the oil there is possibly water contamination, likely from condensation, of over 2,000 parts per million, indicating a need for an immediate oil change.

Where grease bearings are concerned, it is critical never to mix different consistencies or types of grease. Shields must be located toward the interior of the bearing frame. During re-greasing, the bearing fittings must be kept clean or the bearing life will decrease.

Like excess oil, over-greasing can lead to higher temperatures (localized in this case). This runs the risk of creating caked solids. However, after greasing temperatures may increase slightly for an hour or two.

Additional inspections should be undertaken whenever the terminal operator needs to replace a part. Signs to be looked for include excessive wear and cracks, or any indicators of fatigue. All parts should be replaced when the no longer meet tolerance standards:

  • Bearing frame and foot should be inspected for cracking, rough spots, rust and scales. Machined parts should not have pitting or erosion.
  • The bearing frame has tapped connections that should be examined for dirt. Threads should be cleaned and chased as needed, and foreign or loose material removed. Lubrication passages should be checked to make sure they are open.
  • The shaft and sleeve should also be examined for grooves and pits. The bearing fits and shaft run out should be examined, and the shaft and sleeve replaced if worn or if run out is greater than 0.002 inches.
  • There should be no wear, corrosion or pitting in the casing on visual inspection. Replace casing if wear exceeds 1/8 inch in depth. Gasket surfaces should be checked for irregularities or wear.
  • If vanes on the impeller are worn more than 1/8 inch or bent at all, the impeller should be replaced.
  • Look for cracks, warping, or corrosion in the frame adapter and replace if any damage is found.
  • Look for visual signs of damage on the bearing housing, and replace if worn or out of tolerance.
  • Look for cracks, pits, and signs of erosion in the seal chamber/stuffing box cover. Pay attention to war, scoring and grooves on the chamber face. Replace if there is any damage greater than 1/8 inch in depth.
  • Inspect the shaft for signs of wear and damage, and also check the straightness. The maximum acceptable total indicator reading (TIR) at the sleeve journal and coupling joint should not be more than 0.002 inches.

Though requiring some work in terms of inspection, care and record keeping, this routine of maintenance and prevention can extend the equipment life of a pump and improve the safety of personnel and the environment in any fluid-handling operation.

Verderflex Peristaltic Pumps

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The sleek design of the peristaltic pump with it's flawless dependability in managing corrosive, abrasive, viscous, high density and highly solidified fluids, is an ideal pump for thriving when other pumps fail.  The versatile pump is able to stand up to the tough demands of the customer's expectations and is an extreme value to water and wastewater industries as well as mining and chemical processing plants.

Cutting edge design such as the smooth squeezing action that allows it to work with realistic results with the use of polymers, fragile cell cultures and flocculates, this pump handles sensitive products with absolute ease.  With a variety of choices of flow rates, pressures, and a multitude of hose and tube options, this pump provides compelling waste management to suit almost any need.

Peristaltic pumps are more visible on today's market and more industries are becoming aware of the pump's potential.  Applications of use are being made public, for instance it replaces air diaphragm pumps in the packaging and printing industries, as the peristaltic pump is able to process viscous metallic ink and is absolutely gentle on the product.  The demand for this pump is growing in the pharmaceutical, food and drink industries as well because of the ease of cleaning and sterilizing as well as the pump having no danger of contaminating the industry's product.

The skyrocketing success of this pump is due to it's fit-and forget genius.  With a lack of seals, glands and valves, this pump is economical and has low maintenance costs.  For example if anything needs to be replaced, it will be the tube or hose and is quickly and easily obtained for low fees.  As companies look for ways to minimize downtime and optimize there production, the popularity of the peristaltic pump continues to grow.

Design is the key to a peristaltic pump's success in the marketplace.  The product being pumped is contained within a reinforced hose while a rotating shoe, or roller, creates a seal between suction and discharge.  The rotor turns, sealing pressure moves through the hose, forcing the product to extract itself from the pump into the discharge line.  Pressure is released; the hose recovers and creates a vacuum, drawing in product to the suction pump, the priming mechanism.  Coupling suction and discharge creates a self-priming positive displacement pump.  The advantageous design of this pump is countless.  A perfect seal is created and there will be no slip-ups.  The pump's linear speed-flow characteristic makes it an unbeatable pump for dosing.  The liquids are securely contained within the hose or tube, benefiting in creating a hygienic environment for workers and industries.  No moving parts will clog or react with aggressive fluids, as this pump is designed without them.

Tubes and hose high-tech development has influenced the peristaltic pump's variety of applications.  Tube and hose assortments include ones resistant to corrosive chemicals, oils, fuels, high temperatures, solvents and mineral acids.  Special grade tubes and hoses are readily available for food, drink and pharmaceutical pumps.  Furthermore, exceptional advances have occurred in the manufacturing of hoses and tubes.  In the past there was a high rate of hose failure due to over-exertion and fatigue of the rubber layers and reinforcements.  Hose layers would become dis-bonded, a disintegration process.  New advancements in hose production have been developed, ensuring a uniform wall thickness, eliminating the need for secondary machinery while extending the life of the hose.

A classic and traditional application for peristaltic hose pumps has been in abrasive mining slurries having sub-micron solid contents in excess of 80 percent with specific gravity ratings of 2.0.  This pump is exclusive in its ability to handle these dense fluids.  Diaphragm pumps often clog due to the corrosive and variable nature of the reagents causing low plant efficiency and an increase in the amount of needed chemicals.  Burnt stators often mar progressive cavity pumps as they run dry.  The misfortune failures of different pump technologies have allowed the peristaltic pumps to gain popularity in these harsh environments. The peristaltic pump is high in merits and applications are varied.  There are some applications of this pump that are unique as well.

The peristaltic pump has the capability to run dry with no harmful effects, awarding its place of advantage in many different applications of use.  Paper manufactures process a huge amount of wastewater with fibrous substance, chemicals and fillers, and use of the peristaltic pump is paramount. With the low maintenance of a peristaltic pump, usage is efficient. 

The peristaltic pump handles ink with ease and bubble free in the packaging industries.  Air diaphragm pumps causes problems with handling ink in a gentle manner.  Peristaltic pumps handle fragile products such as yeast with ease and will not compromise the quail of the product.  The pump locks out harmful gases, as it is not prone to vapor lock.  These pumps are also quintessential for providing correct, accurate and reliable dosing.  The elimination of human error is fantastic to this industry as there is no risk of accidental overdose due to fatal incorrect doing errors.  This pump adheres to the Medicines Acts within the UK and delivers hygienic dispensing, guaranteed.  The very simplicity of its design makes a quick and easy to exchange tubes and no special training or tools is required, and the tubing can be safely disposed. 

The vending industry is an established customer of the peristaltic pump.  Sub-zero temperatures are not an issue for the pump.  In cold climates, chocolate syrup becomes highly viscous.  To relieved a high quality hot chocolate with a strict adherence to hygiene, in the correct measurements with a consistent flow rate, the vending industry turns to the use of a peristaltic pump.  With high suction and quality product, this pump is applicable for superior suction results.

The general attributes of the peristaltic pump are well rounded, making it a top choice for heavy-duty applications as well as lighter applications.  The seal-less design, gentle pumping action, high suction durability, low maintenance, reversible operation, hygienic qualities and it's amazing capacity to run dry without adverse side- effects makes this technology sharp and useful for many industry tasks.

Expanded Rotary Screw Line

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Ingersoll Rand has expanded its contact-cooled rotary screw air compressor line with the introduction of the R-Series 55-75 kW / 75-100 hp range.  This new range is available in fixed speed and Nirvana variable speed drive at capacities of up to 3.23-13.56 m3/min / 114-479 cfm.

Robert Horneman, global portfolio manager for Ingersoll Rand, stated: “With the 55-75 kW range of R-Series compressors, we are able to introduce new features and options that deliver reliability, efficiency and productivity for our customers, while providing the same industry-leading benefits offered by the larger 90-160 kW R-Series compressor range”.

The new range of compressors is equipped with the Xe-Series controller and a high resolution LCD screen. The display provides immediate and intuitive access to all vital compressor data and settings.  The controller allows access and remote control of the compressor from any PC, tablet or smartphone. The controller is even able to send automatic email notifications of trips and warnings.

The integrated Total Air System (TAS) dryer and filtration option provides clean, dry air in one package. This minimizes installation costs and footprint and allows single-point maintenance and monitoring for the complete system. The Total Air System option comes with refrigerated dryer technology and a high efficiency coalescing filter, which delivers ISO Class 1-4-2 quality air. The TAS option utilizes a patented 3-in-1 heat exchanger, which achieves improved energy efficiency and lower operating cost than traditional stand-alone dryers.

In addition to the new Xe-Series controller and TAS option, the advanced features introduced with the larger 90-160 kW / 125-200 hp range:  PACTM protection, V-ShieldTM technology, and sequential cooling, are present in the 55-75 kW R-Series range. Progressive Adaptive ControlTM (PAC) protection is an integrated, intelligent system. It monitors filtration, ambient temperature and other parameters, and adapts the operation of the compressor to reduce energy consumption, lower noise, and increase uptime. V-Shield technology is a superior configuration that eliminates possible leak paths by using stainless steel pipes, durable metal-flex hoses and a vibration isolation system. Sequential cooling utilizes a centrifugal blower that consumes less energy and operates much more quietly than traditional cooling fans do.

R-Series compressors are designed to require less maintenance and to be easy to service.  The amount of time required to service and maintain the compressors has been significantly reduced by the use of swing out separator covers, longer life consumables, easy-access hinged doors, single side maintenance access and slide out coolers.

Tips On Blast Hose

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When searching for a blast hose there are certainly a number of brands out there, however when it is quality and durability you are after, Clemco is the number one choice of all. Clemco uses only the best materials in their hoses, ensuring that you get all that you need in the product that you have purchased.

The rubber inside of your hose can quickly become worn, thanks to the friction against the flow, very similar to what car tires would produce. With Clemco you get high-quality rubber that resists abrasion but it doesn't stop there, as Clemco hoses use reinforced piles of braided strands and a tough outer casing to provide the reliability you are after.

Designed with reinforcing plies that withstand pressure and hold the shape of the hose, the outer casing protects the lies from abrasions and cuts allowing the hoses to stand up to the pressures that they undergo every day.

Along with ensuring that you are purchasing one of the best brands of hoses that are out there, you can also take steps to ensure that you make the life of your hose last much longer. This is easily done with regular inspections of the hose and its couplings. During these inspections you should check for things such as cracks, holes or disintegration of the hose. If damage is discovered it is time to replace the hoses.

Although it may be tempting, do not use tape or similar materials between the couplings. This can cause it to blow off when under pressure, causing serious injury to anyone who is in the way. Screws that do not fit are also a possible cause of injury, causing leaks and wear on the hose. This is possible for screws that are either too long or too short.  To ensure the screws get a good grip, insert a dowel for support to the hose as you tighten the screws.

If couplings look cracked or otherwise worn, they should be replaced as quickly as possible. The nozzle holder should also be replaced if the threads begin to show wear.  If it is discovered that the couplings and hoses are in good condition you can keep using them as you would.

Hoses should lie in a straight line, facing away from the vehicle traffic as well as chemicals and sharp edges. Ensure that the bends gradual as sharp turns will cause rapid wear; this is the number one cause of hose wear. An experienced contractor will use a short length of flexible whip hose for the last few feet before the nozzle and discard this whip hose when it wears.

In addition you should use a blast hose that is at least 3 to 4 times the ID of the nozzle.  This helps control the rate of flow through the hose and ensures that you aren't using a hose that is too close to the nozzle and reducing the amount of wear the hose will sustain.  If the hoses run up scaffolding or structures, secure them every 20 feet and install safety cables to keep the weight of the hose from pulling apart couplings.

Once blasting has occurred you should close the metering valve and blow air through the hose to remove any remaining abrasive.  Moisture and abrasive that is left inside of the hose through the night may collect in clumps, and those clumps can cause restrictions that increase wear the wear and tear of your hose. It is recommended that the coil be gently pulled to prevent kinks. It also enables a clean, dry area away free of oil, chemicals, and paint. A blast hoses should never be placed on racks for prolonged periods as this can cause kinks and worn spots on the outer casing.

While these steps will ensure that your hose needs replacing less often, it is inevitable that replacement will not be necessary at one point or another. Even taking the required precautions, your blast hose will wear out and eventually need replaced, and when it does, you should ensure that you are using only a high quality replacement hose.

New Energy Efficient HOC Dryers

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Ingersoll Rand has presented its new green lineup of heat of compression dryers (HOC), which use an energy efficient method to treat the compressed air.

The new HOC dryers not only offer energy efficiency, but also flexibility and reliability in a low-profile form. Wasted heat is converted into energy by the dryers, concluding in dry, oil free air that costs a fraction of mainstream desiccant dryers.

Clean, dry air is essential for an effective and productive compressed air system.  This high-tech, low energy solution is far less expensive to operate than alternative traditional desiccant dryers without losing out on productivity and efficiency, said Christopher Ursillo, marketing manager for air treatment products at Ingersoll Rand. HOC dryers are a great alternative to traditional desiccant dryers, delivering instrument quality air while making use of waste heat from the air compressor.

In order to quantify the HOC’s energy efficiency, you can compare the estimated cost of operating a traditional 1,000 scfm desiccant dryer operating at 8,700 hours a year at $.10/kWh to a comparable HOC dryer. Totaling up the operating costs of electricity and compressed air for purge requirements, the heatless desiccant dryer costs $24,000 yearly to run, and the blower purge desiccant dryer costs $18,000. In the same conditions, Ingersoll Rand’s HOC dryer costs $120 yearly to operate.

No-loss drains that prohibit the waste of compressed air are just one of the featured components of Ingersoll Rand’s HOC dryers. These drains feature a low-pressure drop design that allows the air compressors to run at a lower pressure, thereby conserving energy. Other unique components of the HOC dryer’s drain include stainless steel heat exchangers that provide optimum performance even in the worst conditions, and guaranteed removal of condensation via its automatic drain bypass feature.

The low profile form of the HOC dryers mean that they can be installed in many areas, including those with low overhead clearance. Ingersoll Rand HOC’s low profile design also allows for service personnel to easily service dryers when necessary. The HOC is unique in its class as it was designed to accommodate the use of multiple compressors, allowing its footprint to be reduced as well as installation costs.

Controlling Static Build Up

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Who really reads the owner's manual to their new product? Your Clemco owner's manual has information important to the efficient and safe use of our equipment. Doing you research and choosing the right media and equipment are the initial steps to achieve an efficient blast application operation.

The role of the blast equipment is to bring together elements that have materials flowing through hoses or pipes, while the resulting conditions of the activity result in static electricity. Dry air is necessary to an efficient blasting operation, it also adds to the buildup of static electricity. Blast media particles produce static electricity as they are propelled from the gun nozzle, when they move over the item being blasted, and when inside the recovery hose. Cyclone separators spinning media over large surfaces create static charges. If these charges accumulate and are not dissipated, they can cause a spark to occur. In a manual blast operation, if the charge is not eliminated, it will be released when the blast operator touches the blasting cabinet.

The cabinet must be wired to an earth ground in order to keep static electricity from building up. When all of the parts are connected, they all contain the same energy potential.

Properly grounding equipment is essential in light of the risks of static buildup. An electrical neutral or third wire can carry current in some areas, so connecting to a water pipe, electrical conduit or a metal frame building will not control static. Always remove any rust and paint from areas of contact to insure proper conductivity.

Low resistance static grounding cables must be used, at or less than 5 ohms of ground. Permanent ground installations should be checked yearly with an ohmmeter. Portable or temporary ground installations should be checked at startup and whenever the equipment is moved.

Avoiding a zap from your well-grounded cabinet is easy, just touch the blasted item to the metal grate or use a ground clamp to help dissipate any static being build up from the media ejection from the nozzle. Also, all rubber mats are nit the same. Rubber mats must be designed to withstand static charges and be connected to the earth ground. ZERO cabinets are all assembled with special hoses that rescue static thru its use of conducive material, and similar results can be achieved by using wire spiral exhaust hoses. The wire works to keep the hose from falling in on itself, and also dissipated electricity when grounded on either end. Shoes can also convey static electricity and should be inspected by the wearer to ascertain they will not supply a charge.

Grounding is the main way to reduce injury and loss of efficiency. Using these methods, the blast cabinet can be a safe operating space.

Griswold 811 Series ANSI Pumps

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Griswold's 811 Series ANSI Centrifugal Pumps are ideal for use in all types of coke-manufacturing processes, most crucially the removal of harmful by-products from the centrifuge. After being removed from the centrifuge, these by-products are pumped out of the facility where they go on to play important roles in a variety of other industries.

Foundry coke—which is available in a range of forms, such as industrial coke, egg coke, buckwheat coke, carbon coke and nut coke—is a critical component in the global manufacture of steel. Griswold’s 811 Series ANSI pumps are perfect for this type of application because the company is able to construct them with liquid paths that feature CD4MCu, which is a high-grade stainless steel that can withstand the corrosive fluids that are produced and handled during the manufacture of industrial coke.

Griswold 811 Series ANSI Centrifugal Pumps also offer a number of features and benefits that make them ideal for coke-producing applications. They are available with enhanced power frames that make them an estimated 33% stronger than competitive models, resulting in increased performance and longevity. They are also available in a full range of sizes, as well as options and upgrades that can be tailored to meet virtually any fluid-processing flow rate, up to and including 4,000 gpm (908 m3/hr). There is a wide array of mechanical-seal options, all of which gives 811 ANSI pumps the ability to operate in temperatures as high as 500ºF (260ºC).