Please ensure Javascript is enabled for purposes of website accessibility

A Vital Lesson In Double Checking Your Pump Specifications

(you’ll be glad this didn’t happen to you).

A while ago now, we were approached by an engineering firm (who will remain nameless for obvious reasons) to quote on a pumping system for their customer on peanut butter.

The engineering firm had been engaged to design the system and manage the construction project.

Like any good pump supplier we double checked their plans and made sure the specifications were going to deliver the desired outcome. We won the contract to supply the pumps they’d specified for the system.

So far, so good.

This was a fairly complex system. What you might not know about peanut butter and may not want to know, is that it has different viscosity's at different stages in the production life-cycle. There were multiple models of pumps, multiple configurations of some of the same models of pump depending on where it was going to be used in the system.

The pumps were purchased, the packages assembled and delivered. Everything was then installed.

The day the system goes live we get a phone call.

“These pumps you sold us aren’t up to the task.”

There is some back and forth… something about, they meet all the specs we were sent. We double checked everything… They should have worked.

“Let’s get our maintenance team out there and take a look – let’s get this fixed.”

We get there and we know something has gone horribly wrong…

I don’t know how it happened but many of the pumps ended up in the wrong spots in the system… a quick consult of the plans verses serial numbers confirms it.

We get the pumps cleaned up and repaired for the client and then spend the next few days working to get all the pumps correctly installed as per the original plans for the system.

We got the problem solved for the client with a minimum of fuss and downtime. The system works great now.

But I will say there are a couple of important lessons in this for you, the plant manager. First – double check that the right equipment is installed in the right place. Don't leave this all in the hands of on outside engineering firm. And second, respect the recommendations of the pump manufacturer’s representative. They know their product and regardless of the specifications you give them, they will give you the advice on the best way to achieve your goals.

Final Thought: If you are looking to build a new pumping/process system or want to increase the efficiency of an existing one, bring your specs to us. At no cost or obligation, we can make recommendations for you on how to reduce operating cost, increase run time and decrease ‘total cost of ownership’. Call 404-363-6000 or drop us a line at sales@pyebarker.com

Getting the Longest Possible Life Out of Your Air Compressor

 

A service managers guide to the most commonly asked questions about oilsA good air compressor should only be noticed when it isn’t working. The rest of the time it hums away doing its job so that all of your factory’s vital functions can continue on, as expected.

Downtime is frustrating not only because something you expect to work isn’t but also for many businesses we service, an air compressor being down means no product is going out the door.

The downtime is costing you in maintenance and profit as well as upsetting the guys on the floor.

Here are the questions we get asked over and over again about air compressor oil maintenance. Following this advice will save you a fortune in both downtime and repair bills.

Can I top off the existing compressor oil with another oil?

When you mix two different oils is you create a third oil. The resulting third oil’s chemical properties may vary significantly depending on the mixing ratio, 50/50, 90/10, 10/90, etc. The suitability of this new oil for your compressor is anyone’s guess.

Additionally, these different mixtures have never been tested in operating conditions for extended periods of time so the expected oil life is not predictable – so this just results in a need for more monitoring that could be avoided by using the right oil in the first place.

You place your compressor at even more risk if you mix your oils. Don’t do it.

What do you mean mixing your oils?

Mixing oils with different chemistries or mixing a PAO base oil with a Petroleum base oil can cause varnishing.

Varnishing can cause your compressor to run hot often leading to costly repairs and expensive downtime.

Mixing oils can cause solubility problems between base fluids. They could emulsify and/or lose viscosity. If soluble, the oil will behave as well as the worst lubricant, mineral lubricants shorten the life of synthetics. Which creates another unnecessary expense – faster oil change.

Will I invalidate the compressor warranty by using aftermarket oils?

It is recommended that you use the compressor manufacturer’s oil thru the warranty period. If there is a problem and you make a claim against the warranty, the oil will be tested. Contaminating one oil with another is typically grounds to invalidate a warranty.

How long will the compressor oil last?

This depends on several factors, including application, cleanliness of air and type of oil used. Use the following table to estimate how often you need to change your compressor oil

Discharge Aeon 4000 Aeon 6000FG  Aeon 9000SP Aeon 9000TH
Up to 180F   4000 Hours 4000 Hours 8000 Hours 8000 Hours
180F to 190F 3000 Hours 3000 Hours 6000 Hours 8000 Hours
190F to 200F 2000 Hours 2000 Hours 4000 Hours 8000 Hours
200F to 210F 1000 Hours 1000 Hours 2000 Hours 6000 Hours

 

Why do I have to change the oil anyway?

The short answer is oil oxidizes. Oxidization is the chemical reaction between oxygen in the air and the oil being forced together by mixing at high temperatures. Oxidation is the number one reason why the fluid must be changed out.

Oxidation of any PAO based fluid (Many compressor lubricants are PAO based) can lead generation to varnish formation in the fluid is allowed to run through the compressor without the presence of antioxidants. Oxidation by-products can accumulate in the fluid, become insoluble and collect on the surfaces of the compressor as varnish.

If the varnishing is bad enough if you turn the compressor off long enough for the oil to cool down – say for the weekend, the varnished oil will become a thick dense mass causing the compressor to lock up and not restart once the oil cools down to room temperature. Once the varnished oil has cooled down it turns into a thick mass and it cannot be cleaned out. Any piping containing varnish as well as the air end will need to be replaced.

As long as the varnished oil stays hot and in a liquid from the unit can be cleaned out using the Comp Clean product.

Obviously this can all be avoided with regular oil changes – so don’t let them slip through the cracks.

Oil Testing and Oil Analysis Reports

Pye-Barker Supply has free oil testing with a detailed analysis reports thru Gardner Denver Oil Services Laboratories, to get an analysis for your compressor just call 404-363-6000 or ask your technician the next time he is on site for a service.

Viking XPD 676 API Compliant Pump

Viking has just stepped up promotion of their new XPD 676 range, so we thought it would be a good time to review their offerings for chemical, petro-chemical oil and gas process applications – the XPD 676 pump series – the first internal gear positive displacement pump to be fully API 676 compliant.

Talking to the team over at Viking they said that designing the XPD 676 pump actually made them re-evaluate their design process and the R&D needed to design a pump to meet the API 676 standard. This has actually had a trickle down effect for how they design the rest of their pump range going forward.

The name of the game in here is risk mitigation. While you can use pumps based on exceptions to the API 676 standard it does mean that you are open to risks and that you must have risk mitigation strategies in place – many of which can be more expensive to enforce than just using a compliant pump in the first place (think air quality litigation, increased cost of insurance, clean up of chemicals or hydro-carbon spills or environmental reporting costs).

Here’s how using Viking Pump XPD 676 pumps will help you minimize risk:

Reduced Risk of Over Unplanned Downtime: API 682 seals will operate for 25,000 hours. The XPD 676’s thrust bearing are designed to three times the L10 lifespan. These pumps are meant to be operated at relatively low speeds to extend the seal/bearing life while providing higher energy efficiency.

These pumps also have options for hard parts for abrasive liquids or contaminates. So these pumps can be customized for most chemical, petro-chemical oil and gas process applications.

Reduced Risk of Leakage: The costs for even a ‘small’ petro-chemical spill can be outrageous; so Viking has used static O-ring seals to provide improved sealing compared to flat gaskets. As part of their quality control process each pump undergoes Non-Destructive Evaluation of welds and castings to ensure compliance. Pumps also feature cast-in drains so that the pumps can be drained prior to service.

Reduced Risk of VOC Emissions: You can use your plant’s standard API 682 seals in order to remain compliant with your environmental permit. Double seals can be used if you have more restrictive permits than the standard 1,000ppm. The pump’s class 300 flanges exceed the specified forces and moments for vapor-tight sealing at the inlet discharge and drain.

Reduced Risk of Corrosion Failure: The XPD 676 pumps have an additional 3mm corrosion allowance over the MACP on pressure containing components – they just have more steel in them than other pumps so that they last longer. Viking can cast custom alloys in-house to meet your needs – so everything remains above API 676 standard.

Viking can also comply with any customer paint specifications that you need.

Reduced Risk of Over Pressure Failure: XPD 676 use 80% more steel than the equivalent pumps in Viking’s standard range. The Viking XPD uses Grade WCC steel with a 40,000 psi minimum yield.

If you are looking to drive down the total cost of ownership of your pumps in an API 676 compliant environment, then get in touch with us here at Pye-Barker, we’ll review your existing operation or plans for your new process and recommend a pumping solution for you. Call our team on 404-363-6000 or drop us a line at sales@pyebarker.com

On The Front Page of ‘Processing’ Magazine!

One of Pye-Barker’s pump suppliers – ARO was featured on the front cover of ‘Processing’ Magazine.

United DMS (the largest silver-bearing film recycler in the United States) worked through several other unsuccessful alternatives, before using ARO’s pumps and monitoring systems to drive their fluid recovery systems.

They have been so successful in their fluid recovery process that they have been used for their bulk caustic tank and caustic day tank transfer processing areas.

You can check out the full story at http://www.processingmagazine.com/magazine/features/closed-loop-control-in-silver-recycling-2/

Product Review: Gardner Denver IQ Blower Packages

We’ve got clients in multiple industries using Gardner Denver IQ Blowers for applications including pneumatic conveying, vacuum and aeration in wastewater treatment. However, I know there are clients and customers who should be using them but aren’t.

I thought it was time to do a review of the IQ Blower range and talk about why they are, in my humble opinion, the best blower units on the market.

The design team at Gardner Denver has worked very hard with the IQ Blower range to achieve 3 primary goals:

Minimized Downtime: For many of our clients their blowers are mission critical – and downtime costs more than the costs of the parts and labor to repair their blower. It can result in missed production quotas, missed shipping deadlines, damage to reputation, and possibly even long standing client relationships.

The Gardner Denver IQ Blowers have several ‘low cost’ but high value features built in to them to minimize downtime and to give the buyer the lowest possible total cost of ownership. Features like the cooling fan – that runs for 10 minutes after shutdown – cooling down the unit sufficiently, or the automatic tensioner on the belt drive, to get maximum life out of each belt.

Ease of Maintenance and Repairs: The physical unit itself has been designed to make routine maintenance, repairs and even overhauls as easy as possible. The pop-up top on the unit gives direct access to filters, oil refill caps and conduit boxes.

The side panels can opened with a quarter turn latch key, where the oil drain taps, filters and sensors are immediately available.

If you need to remove the blower package for any reason it can be removed in one piece by forklift so that major works can be done in the open – as quickly as possible.

Control System Integration: The Air Smart Controller will sync up maintenance history, advisory history, temperature shutdowns and it can interface with a SCADA system – allowing you to monitor your IQ blowers from your control room.

Coupled with the fact that the unit is actually ‘plug and play’ – no special foundations – just put the unit on a level surface and connect power and plumb in the pipes, program the Air Smart Controller and you are pretty much away to the races.

If you need a new blower or are looking to replace an existing blower, Gardner Denver has a great blower sizing tool – if you need a rough estimate of what you need. Otherwise the team here at Pye-Barker can help you with an in-depth analysis of your existing system or new system and we can help you select the right blower for you. Just get in touch by phone at 404-363-6000 or drop us a line at sales@pyebarker.com

AUTHORIZED DISTRIBUTORS FOR

pye authorized logos
banner image
banner image
Forest Park (Atlanta) Address:
121 Royal Dr.
Forest Park, GA 30297
FAX: (404) 361-8579
Sylvania Address:
452 Industrial Park Rd.
Sylvania, GA 30467
FAX: (912) 564-2636
Orlando, FL Address:
524 Mid-Florida Dr., Suite 204
Orlando, FL 32824
FAX: (321) 282-6424
Copyright © 2019. Pye-Barker Supply Company. All Rights Reserved.
Marketing by:
 S3 Media
Translate »
linkedin facebook pinterest youtube rss twitter instagram facebook-blank rss-blank linkedin-blank pinterest youtube twitter instagram