Over 700 communities in the United States rely on their local combined sewer system to remove wastewater from homes and businesses. These systems are space-efficient and cost-effective, and they can often mitigate flooding into residential structures or even roads. Preventing downtime, especially in combined sewer systems, is essential for public health. It also ensures the efficient operation of wastewater treatment plants, particularly when managing double or triple the usual wastewater volume. This month’s blog will explore the various types of sewer systems. We will identify potential points of failure in treatment plants. Additionally, we will provide tips for minimizing downtime and reducing the amount of flush water used.
What is a Combined Sewer System?
Sewer systems are classified as ‘separate sanitary sewer systems’ or ‘combined sewer systems’. Separate sanitary systems use two sets of pipes: one for stormwater runoff leading to local bodies of water and another for wastewater directed to treatment plants. Combined sewer systems merge stormwater and wastewater into a single system, using flow regulators to direct water to treatment plants while excess stormwater flows to local bodies of water.
What Can Cause System Downtime in Wastewater Treatment Plants?
Pumps are simultaneously the key to treating wastewater and one of the most vulnerable points in a treatment plant. The submersible pumps that bring the wastewater into the plant are susceptible to clogging when encountering foreign objects that unintentionally enter sewer systems. End-suction pumps that deal with return-activated sludge (RAS) or waste-activated sludge (WAS) often break prematurely from mechanical seal failure. Many cartridge seal designs incorporate springs to support appropriate seal designs. Older designs submerge the springs in the process fluid to reduce heat. As a result, the springs often become clogged with suspended solids, leading to seal failure, premature shaft ware, and wastewater leakage. The latest best practice regarding spring placement is to have them outside of the process fluid for the best fit on the seal.
Broken seals and pumps can reduce output and increase safety hazards within the treatment plant. Slips and falls reduce the availability of on-site staff while also adding significant, preventable housekeeping costs to the facility’s budget.
How SpiralTrac Can Help:
SpiralTrac™ Environmental Controller by Enviroseal combined with AW Chesterton mechanical seal or packing on pumps protects against premature seal and pump failures. Adding SpiralTrac with a new seal or packing installation removes three potential problems associated with lengthy system downtime:
1. SpiralTrac prevents suspended solids from encountering the seal.
Suspended solids found in RAS and WAS greatly contribute to seal failure in wastewater treatment plants. Placing SpiralTrac between the impeller and the mechanical seal or packing prevents access for the suspended solids to clog the springs or packing. This, along with its unique, patented throat-brushing design, protects the seal and the pump shaft from abrasive solids.
2. SpiralTrac dissipates heat within the stuffing box.
Overheating seals or packing can warp the shape of the seal around the shaft. This warping can contribute to seal damage and eventually lead to pump failure. By adding a buffer to the mechanical seal or packing, SpiralTrac allows air to circulate within the mechanical seal, rather than using the fluid itself to allow for cooling.
3. SpiralTrac reduces or outright eliminates flush requirements for seals and packing.
Mechanical seals require maintenance staff to wash or ‘flush’ the seal face with water to remove debris at routine intervals. When it comes to packing, maintaining a delicate balance is essential: keeping as much fluid as possible inside the pump while ensuring the packing remains moist. Insufficient fluid can damage the packing, while excessive fluid may pose a safety risk and reduce the pump’s output. SpiralTrac helps reduce the flush rate for mechanical seals and minimizes leakage when used alongside packing.
Chesterton & Enviroseal engineer SpiralTrac & paired seal to the application at hand for maximum performance. They configure the designs based on operating parameters, stuffing box arrangement, and the materials of construction to ensure a long-lasting seal solution for your pumps. SpiralTrac can reduce the flush water use by 60% for packing and potentially eliminate it for mechanical seals. Utilizing SpiralTrac can save thousands of dollars annually in utility costs and increase the efficiency of maintenance staff.
Next Steps
Ready to drastically reduce your system downtime? Use the Contact Us button below to reach our team and discuss your new SpiralTrac Environmental Controller. If you need service for your current pumps or seals, use the Request Service button to schedule an appointment with our Chesterton-trained service technicians.
With 80% of the world’s goods traveling by ship, efficient loading processes are essential for keeping supply chains running smoothly. Marine environments pose unique challenges to loading systems. These systems must withstand corrosion and meet high safety standards to prevent equipment failure, loss of product, and workplace injury. Moreover, each shipyard, dock, or marina must have a system configured to the specific needs for the port’s layout. Here are a few options we sell.
DockReel from SafeRack
SafeRack stepped away from traditional dock loading systems for a new way to move materials on- and off-shore through DockReel. DockReel consolidates loading arm stations, gangways, connectors, and other components in your ship loading system into one complete, customized package. This package includes a wirelessly controlled fluid transfer system, auto-winding hose handling station, and tandem mooring system with flexible, reinforced hoses and breakaway couplings. The result is more floorspace in your port, reduced transfer time, lowered CO2 emissions, and decreased risk of workplace accidents and associated downtime.
Hose System Assemblies from Titeflex US Hose
Titeflex US Hose offers complete hose system assemblies for the harshest marine environments with industry-renowned safe and reliable performance. Their catalog includes options for braided metal, composite, and fluoropolymer hoses for medium to ultra-high-pressure applications. The American Bureau of Shipping (ABS), International Maritime Organization, and Lloyd’s Register of Shipping have certified specific Titeflex US Hose products for onboard vessels.
Marine Fuel & Exhaust Hoses from Continental
Continental manufactures rubber hoses for marine fuel loading and exhaust unloading applications. These rubber hoses are made of nitrile synthetic rubber, allowing them to float on the water if needed. All options are SAE J1527 compliant for safe fuel transfer onto ships, with Type A (fire-resistant) or Type B (non-fire-resistant) options available. Specific hoses comply with ISO 7840 standards and USCG Type A1, A2, or B2 standards. In addition to its hose products, Continental provides suspension coupling solutions to reduce unnecessary vibration and conveyor belt systems for seamless material transfer.
Marine Hoses from NovaFlex
Novaflex provides hoses for fuel, exhaust, bilge, sanitation, and other marine applications. Depending on the application, these hoses come in corrugated, smooth, hard wall, softwall, and PVC styles, with port sizes ranging from 3/16” to 18”. NovaFlex fuel and exhaust hoses comply with ISO 7840, SAE J1570, or SAE J2006, depending on the specific product.
Next Steps
Our industrial division has experts ready to help you find the ship-loading equipment for your port. Use the Contact Us button below to start the conversation. For service on your current loading system’s pumps or compressors, use the Request Service button.
Diesel engines have been the backbone of the marine industry since the early 1900s. Larger vessels utilize diesel-driven engines due to their simplicity, reliability, and energy efficiency. However, the challenge with this style of engine is often configuring the correct startup sequence to power the engine consistently and safely. This guide will delve into the difference between diesel air and electric start systems, the requirements for the system to operate, and other key applications for compressed air on marine vessels.
What is a start system?
Diesel engine start systems use air or electricity to kickstart the large turbines within the engine into gear. An air start system uses compressed air to directly or directly turn the diesel engine turbines through an air motor. Electric start systems utilize an additional motor that pulls energy from the boat’s batteries.
Electric vs. Air Start Systems
example of an air start system from machineryspaces.com
Air start systems for diesel-driven motors are generally recommended in marine applications, especially for larger vessels. Electric start systems require additional motors and batteries, which take up more floor space and add more weight onboard. The extra motor will siphon energy off from the ship’s main battery. The functionality of this added equipment will vary depending on the ambient temperatures. Having these complex electrical components out at sea puts them at risk of corrosion. Even if it doesn’t touch seawater, the air is humid and salty enough to cause corrosion.
A diesel air start system requires less equipment with less complex electrical components. This lowers the risk of corrosion and ignition sources in and around flammable materials. Air start systems also allow for more safety measures through interlocks. These interlocks are valves set up to block the initial burst of air from reaching the turbines prematurely. The result is additional protection against engine startup accidents and ensuring the correct air pressure is available to turn the turbines. While the properties of compressed air change with temperature, the fluctuations will not be significant enough to prevent the engine from turning on.
Diesel Air Start System Requirements
Building a diesel air start system starts with selecting the suitable compressor and tank combination. It is recommended to size the air tank- or “bottle”- to store enough compressed air for twelve startups when complete. An engine’s operating manual will specify the amount and pressure of air needed to start the specific engine model. This compressor system will also require air treatment to remove dust, water vapor, and flammable oil condensate from the air before it reaches the engine.
Regular air maintenance of this compressor system is as essential as selecting the initial unit and tank. Air tanks must be condensate-free to deliver as much air as possible to the engine. Valves and piping will also need regular inspection to prevent air leaks.
Other Common Compressed Air Uses on Ships
At least one air compressor system is usually already present on a vessel to assist with other necessary processes, including:
Control systems: Compressed air is used for throttle controls, control valves, and engine emission monitoring systems.
Water supply: Compressed air pressurizes hydrophores to distribute water for domestic and sanitary use.
Wastewater treatment: Compressed air powers onboard sewage systems to conduct aerobic sewage breakdown.
Safety features: Compressed air powers safety features like ship whistles, foghorns, and fire pumps.
Pneumatic pumps: Compressed air powers pneumatic pumps to transfer water, oil, and bilge.
Lifeboats: Air motors help heave up lifeboats for crewmen and staff.
Champion Air Compressors
The pressure-lubricated PL-series from Champion exceeds in demanding applications where typical compressors will falter. What sets this series apart is the heavy-duty, rugged design. Both the crankshaft and connecting rod are protected by pressure lubrication to ensure that the compressor oil is used when and where it is precisely needed. The PL-series also offers load-less starting, which provides easy, fast startup. Both of these features work together to extend the life of the compressor.
The PL-series comes in simplex and duplex styles and offers options between 3HP and 30HP. The difference between simplex and duplex builds is the number of pumps in the assembly. A simplex unit will have a pump, motor, and tank assembled in a single package. Duplex units have two pumps and two engines, all mounted together onto a tank. Having two pumps allows for a more consistent air supply. As one pump finishes its cycle, the second will start without reducing air output. Champion also sells the pumps individually for replacements or custom builds. PL-series compressors come with Champion’s standard 3-year warranty; alternatively, Champion also offers a 6-year warranty option with the parts and consumables needed to maintain the machine for an additional 3 years.
Next Steps
Northwest Pump offers air compressors and compressor parts from top vendors like Champion. Below, contact our team to find the right compressor for your diesel air start application. Use the request service button to schedule your compressor service appointment.
It can be challenging to balance the location of onsite compressor systems. They need to be in close proximity for optimal pressure output without occupying excessive space. Many facilities place their compressors outdoors to save floor space and increase airflow. However, this exposes the equipment to the risk of freezing temperatures. Storing equipment inside an air compressor cabinet safeguards your air supply and optimizes vital floor space.
What to Look for in an Air Compressor Cabinet
One important feature to look for in an air compressor cabinet is soundproofing. Air compressors typically produce noise levels of around 85 dBA, depending on factors such as the type of compressor, its horsepower, and how often it is maintained. Prolonged exposure to high noise levels without proper safety measures can lead to hearing loss. According to OSHA, exposure time should be limited to a maximum of eight hours at 90 dBA and two hours at 100 dBA. Installing an air compressor cabinet to reduce the ambient noise levels can help protect onsite employees from hearing loss.
When setting up an outdoor cabinet for your air compressor system, it’s important to ensure that it protects the compressor and piping from extreme weather. Low temperatures can cause any condensation inside the machine and its piping to freeze and expand, which may lead to pipe bursts. Running a compressor without a way to discharge the pressurized air can also cause severe damage, often resulting in the need for premature replacement of the machinery.
While cold weather poses a serious risk to compressors, excessive heat can also impact your compressor’s performance. An overheated compressor produces air that will have a harder time reaching lower dewpoints. This air will contain more condensate, leading to lower pressure output and posing a risk of clogging downstream air treatment.
All Weather Air
All Weather Air provides fully weatherized air compressor cabinet solutions built to protect compressors from weather hazards while providing increased filtration to ambient air. These compressor cabinets come in size options starting as small as four feet up to forty feet, with variable heights and widths depending on need. As a baseline, All Weather Air tests all cabinets to ensure compressors can work in outdoor temperatures of -40°F up to over 120°F.
Cabinets from All Weather Air come standard with one-inch-thick noise insulation on the interior of the enclosure to reduce noise, with a two-inch-thick insulation option available as well. They also have slip-resistant flooring and wide doors with safety latches to give you peace of mind regarding worker safety.
All Weather Air designs all its cabinets with portability in mind, with pockets below the flooring for forklifts or cranes to carry them as your facility grows. Cabinets come with centralized utility ports for water and electricity to further simplify moving them as needed.
Next Steps
Our team of experts can help you find the right compressor cabinets for your needs. Reach out via the Contact Us button below to start the conversation.
Looking for compressor service or installation? Whether your system is in an enclosure, inside your facility, or out in the elements, our compressor technicians can help. Use the Request Service button to reach our service team and schedule your compressor maintenance today.
In the mining industry, slurry pumps are crucial for daily operations, whether in the mine itself, refineries, or process plants. It is essential to find pumps that can effectively handle process water, suspended solids, and slurries without the risk of pump failure while maintaining their intended performance standards. Metso provides both horizontal and vertical slurry pump options to meet the diverse needs of its customers worldwide.
Why Choose Metso?
Metso specializes in manufacturing equipment for mining, specifically for aggregate production, mineral processing, and metal refining. All Metso pumps, pipes, and hoses use either a rubber-lined interior or high-chrome alloy material to give abrasive and slurry resistance by default. These designs have been thoroughly tested and refined in the field to ensure that customers have reliable pumps they can depend on. Metso backs all of its equipment by offering extensive technical support options and on-site training opportunities as needed.
Sala VS Series Vertical Sump Pumps
The Sala VS Series vertical slurry pump as we know them combines the original SALA series cantilever build with the wet end design from the Orion series horizontal slurry pumps. This change allows for easier maintenance and part availability and improves the total dynamic head of the pump for better performance.
A common issue vertical pumps face is the parts that may require the most maintenance being submerged in fluids or slurries, making them inaccessible when they require service. Metso side-steps this problem with the cantilever design. Bearings, shaft seals, and the stuffing box are all accessible at the top of the pump.
The impellers for the VS series come in open, semi-open, or closed styles and have two additional agitator options to extend the pump’s capabilities & performance.
Sala VT Series Vertical Tank Pumps
Sala VT series pumps have the same benefits offered by the cantilever design as the Sala VS series and come in a self-contained package with the pump, motor, and tank. This combination allows for greater layout flexibility in any facility and simplifies installation. The open sump and vertical intake combination prevent cavitation or other air blockage by allowing trapped air to run up within the shaft. This also allows the pump to run dry without causing significant damage.
These tank pumps work well in applications such as feeding dewatering cyclones, in mixing applications, and especially stand out where mobility is a concern.
Sala VF Series Vertical Froth Pumps
The Sala VF series vertical froth pump takes from the maintenance-friendly design of the Sala VS series and the simplified layout of the Sala VT series, with one more added benefit. By creating a vortex to separate the entrained air in the slurry, the Sala VF series allows for greater flow rates. Additionally, releasing entrained air removes the risk of cavitation and the damage it can cause in the downstream pump system.
Ironically, the Sala VF series pump can be used to separate lighter substances in flotation froth pumping and can also be used for mixing dry powers with water like in cement production. The VF series also lends itself well to washing stations for minerals like phosphate & apatite.
Next Steps
Our industrial equipment experts can help you determine the best vertical slurry pump for your needs. Start the conversation using the contact us button below.
Need service on your existing sump pumps or other industrial equipment? Our industrial service division can help. Request service with the button on the right.
Northwest Pump gained its 20th branch through the acquisition of Compressed Air Systems effective July 1st, 2024. This new Arlington, WA branch will provide further industrial equipment & equipment service support for the northwest and central Washington regions. This union will significantly enhance our product offerings and customer service, promising a more comprehensive and efficient experience for our valued customers.
About Compressed Air Systems
Ed & Kristin Graf founded Compressed Air Systems twenty-five years ago, offering sales, installation, and maintenance solutions for compressed air & vacuum pump equipment. The CAS team has provided their customers with industry-leading expertise and customer service. The most common feedback received is that their customers appreciate their prompt responses and professionalism. Over the past 25 years, CAS has met the air and gas needs of residential, industrial, and commercial customers. Their territory spans Snohomish, Skagit, and Whatcom counties into the Greater Seattle Metro Area, and the Greater Eastside Area.
Why Did We Acquire Compressed Air Systems?
Providing top-tier customer service is our highest priority for our Industrial and Industrial Service Divisions. Acquiring companies that share these values allows us to deepen our service capabilities in central Washington.
“Part of our strategy for bringing value to our customers is saturating the marketplace with a local Service presence to maximize responsiveness and reduce travel costs. CAS has provided elite service to compressed air and nitrogen customers in Western and Central WA for 25 years. By acquiring this great team, we can continue to deliver the best local service presence to the market both in the region and the other markets that we serve. This move also opens opportunities for their customers with our pump, sealing, and pump service products that we deliver throughout the Pacific NW.”
– Dave Mayfield, General Manager, Industrial Division
Is My Point of Contact Changing?
When looking for potential acquisitions, we prioritize looking for companies with a similar philosophy prioritizing customer service. Whether you have been a current customer of Northwest Pump or Compressed Air Systems, your point of contact will not change in the immediate future. Ed, Melody, Lee, Sam, and Derick have decided to continue working at Northwest Pump. We may eventually reassign customers to work with whichever branch is closest to ensure the fastest travel times. The only significant changes CAS customers should notice are the name on the sign and the breadth of products available to them.
Reach out to our Arlington staff for your compressor needs by emailing here or by calling the main office at 360-215-8228.
To schedule service out of the Arlington branch, or any other Northwest Pump Industrial branch, fill out our service request form using the button below.
The Sala VS Series vertical slurry pump as we know them combines the original SALA series cantilever build with the wet end design from the Orion series horizontal slurry pumps. This change allows for easier maintenance and part availability and improves the total dynamic head of the pump for better performance.
