Tag Archives: Integrated Pump Rental

DEMAND FOR FAGGIOLATI STAINLESS STEEL PUMPS

With the increased levels of acidity in mine water and associated slurry handling applications, Integrated Pump Technology has reported an increased demand for the Faggiolati stainless steel slurry pump.

Constructed from 316 stainless steel, the Faggiolati pump is engineered to operate in the toughest applications dealing with the handling of corrosive water and sludges.

“In all dewatering applications, whether in underground mine shafts, mine waste dumps, ore stockpiles, tailings facilities or power stations, reliability remains a key requirement, and there is no doubt that a stainless steel pump is by far the best choice for use in acidic environment,” Colin Adams, managing director of Integrated Pump Technology, says.

The excellent corrosion resistant properties of stainless steel ensure reliable operation even under the harshest conditions. By eliminating the risk of corrosion in pumps unscheduled downtime is dramatically reduced and the risk of pump failure is averted.

Faggiolati stainless steel pumps are able to withstand highly acidic water, even when it contains high concentrations of metals and sulphates. The pumps are also capable of handling abrasive particles and a high content of solids up to the size of the pump inlet diameter opening.

Adams says the cast stainless steel impeller ensures pumping capacities in the corrosive fluids and can handle pH values from two to 10.

The most recent order received by Integrated Pump Technology was for six Faggiolati stainless steel channel pumps, and Adams says the pumps will be operating in an extremely acidic environment at a power utility.

Integrated Pump Technology is the official distributor for the full range of Faggiolati submersible drainage and wastewater pumps, mixers and aerators, and the product is supported through the company’s network of 16 strategically located, specialised pump distributors. All these products are available in a flameproof option. The company is also the sole importer and principal distributor for the Grindex range of dewatering, slurry and sludge pumps for southern Africa.

SYKES PUMPS ARE THE SOLUTION FOR MINE DEWATERING IN AFRICA

Two Sykes XH150 trailer mounted pumps will soon be doing dewatering duty at a mine in Africa, supplied by southern African distributors Integrated Pump Rental based in Jet Park, Gauteng.

This range of diesel powered units is ideal for dewatering an open pit, offering characteristics that include high head and head flow, according to Lee Vine, managing director of Integrated Pump Rental.

Vine emphasises that even the best run mine sites can be plagued by expensive challenges if they do not effectively control groundwater ingress into the open pit.

“This can cause not only programme delays but could also adversely affect health and safety on site,” he says. “So, when addressing the need for dewatering, it is vital that contractors deal with a supplier that understands dewatering applications and is able to provide the correct level of technical assistance; this will ensure that the most efficient methods are selected for the demands of a specific site.”

The Sykes Xtra High Head pump set boasts automatic priming and solids handling, so it dewaters more efficiently and effectively; it also has one of the best shaft stiffness ratios of any automatic priming pump on the market.

“These are fully automatic priming pumps and can run dry for extended periods due to the oil bath mechanical seal assembly,” he adds. “The low fuel consumption makes them cost effective to use for extended periods for time when dewatering.”

The pumps – designed for robust and reliable performance with high volumes of water – have an established reputation for the fast and effective control and removal of sub-surface water, he says. They can be primed with long suction hoses and can manage suction lifts of up to nine metres.

The pumps can even operate in ‘snore’ condition, which accommodates fluctuating suction levels; the pump will snore until the liquid is available for the pump to fully reprime itself automatically.

MINES URGED TO DREDGE PONDS BEFORE RAINS ARRIVE IN EARNEST

With the rainy season approaching in most of South Africa’s mining regions, monitoring the capacity of process water return ponds becomes increasingly critical – to monitor whether silt build-up is jeopardising the dams’ functioning.

“Managing the water balance on mines is becoming more demanding as mines work to become more self-sufficient, and to draw less water from municipal sources,” says Lee Vine, managing director at dredging and dewatering specialist, Integrated Pump Rental. “Process water ponds therefore need to be carefully monitored and regularly dredged to prevent too much sediment from accumulating.”

More sediment means less water storage capacity, which can affect the efficient running of the process plant as well as create a potential environmental hazard if heavy rainfall leads to tailings over-topping the pond. Exacerbating the risk of insufficient water storage capacity is the widely held opinion that rainfall is becoming increasingly variable as a result of climate change factors.

“In many areas, this means that summer rains will include a higher number of heavy downpours within relatively short periods of time. And this will place an increased load on these ponds to contain more water than usual,” says Vine. “It is therefore vital that they are operating optimally, and do not have their capacity constrained by excess silt.”

He highlighted the environmental risk of tailings spilling out of ponds, and perhaps even out the boundaries of the mining lease area – an eventuality that mines work hard to avoid due to the stringent legal requirements.

“The regular desilting of return water ponds and dams is becoming more and more important, as we begin to appreciation the proper value of water on our planet, and especially in relatively dry countries like South Africa,” he says. “Not only must mines ensure there is enough capacity to receive and retain excess water during the rainy season, but there is also the need to store as much as possible for the dry season.”

He argues that purchasing treated municipal water to ‘top up’ their requirements is becoming less of an option for mines due to the rising cost of water and the growing competition for water among stakeholders like communities, industry and agriculture.

Applying a regular dredging programme need not be onerous, he adds, and can readily avoid a situation where silt or slimes threatens the water retention and water holding capacity of ponds and dams. Integrated Pump Rental has locally designed, engineered and manufactured the SlurrySucker dredge unit for precisely this purpose, and offers the technology on a rental or turnkey contract basis for mine pond maintenance.

“There are even conditions under which a mine may find it worthwhile to procure their own SlurrySucker, for permanent and ongoing use on desilting operations,” says Vine. “The equipment can be moved easily by road trailer and commissioned within a day. The operation of the equipment can be conducted by just one person, and we provide all the necessary training, support and maintenance required.”

Using the high quality Grindex brand of slurry pumps and a purpose-engineered dredge head, the units are capable of extracting high tonnages; 240 m3 per hour of slurry/water mixture in the case of the smaller SlurrySucker Mini (30 to 40 dry tons per hour) and double this using the SlurrySucker Maxi, which will remove 70 to 80 dry tons per hour.

Vine suggests that in many operations the retreatment of sediment may even pose an economic opportunity that would more than cover the costs of the dredging.

“We are able to assist the mine in designing arrangements that would allow the pond sediment, which is usually enriched to some extent with the ore being mined, to be pumped back to the process plant for retreatment,” he says.

The SlurrySucker’s design ensures that there is no danger to the high density polyethylene (HDPE) lining of the ponds, as the agitation of the sediment is conducted using only water jets. Recent modifications to the original model even allow for the system to suck up large solid objects, such as gloves, boots, plastic packets and hessian bags, without blocking up and slowing down operations.

“The benefits of being proactive about maintaining return water ponds cannot be overstated, but we realise that mines have many competing priorities to manage and this aspect of their operations is sometimes overlooked,” concludes Vine. “For this reason, we even offer a service where our technical team will schedule regular visits to the relevant water storage or treatment facilities to check what needs to be done, and when. We will then conduct the dredging as and when necessary, significantly reducing the operational and environmental risk to the customer.”

SYKES PUMPS ARE THE SOLUTION FOR MINE DEWATERING IN AFRICA

Two Sykes XH150 trailer mounted pumps will soon be doing dewatering duty at a mine in Africa, supplied by southern African distributors Integrated Pump Rental based in Jet Park, Gauteng.

This range of diesel powered units is ideal for dewatering an open pit, offering characteristics that include high head and head flow, according to Lee Vine, managing director of Integrated Pump Rental.

Vine emphasises that even the best run mine sites can be plagued by expensive challenges if they do not effectively control groundwater ingress into the open pit.

“This can cause not only programme delays but could also adversely affect health and safety on site,” he says. “So, when addressing the need for dewatering, it is vital that contractors deal with a supplier that understands dewatering applications and is able to provide the correct level of technical assistance; this will ensure that the most efficient methods are selected for the demands of a specific site.”

The Sykes Xtra High Head pump set boasts automatic priming and solids handling, so it dewaters more efficiently and effectively; it also has one of the best shaft stiffness ratios of any automatic priming pump on the market.

“These are fully automatic priming pumps and can run dry for extended periods due to the oil bath mechanical seal assembly,” he adds. “The low fuel consumption makes them cost effective to use for extended periods for time when dewatering.”

The pumps – designed for robust and reliable performance with high volumes of water – have an established reputation for the fast and effective control and removal of sub-surface water, he says. They can be primed with long suction hoses and can manage suction lifts of up to nine metres.

The pumps can even operate in ‘snore’ condition, which accommodates fluctuating suction levels; the pump will snore until the liquid is available for the pump to fully reprime itself automatically.

INTEGRATED PUMP RENTAL EXPANDS INTO INDUSTRIAL SECTOR

Signalling its expansion into the economy’s industrial segment, pump and dredging specialist, Integrated Pump Rental recently made short work of cleaning the sediment from the reservoirs of a customer in tile manufacturing.

According to Integrated Pump Rental managing director Lee Vine, the tile making process involves wastewater being fed into storage tanks and then through a filter press.

“During this process, an aeration system keeps the slurry in suspension and ensures the correct consistency for pumping,” says Vine. “With the aeration system under-performing, the slurry tended to settle in the reservoirs, reducing the water storage capacity and undermining the efficient running of the plant.”

The sediment also creates a potential environmental hazard should the tanks overflow, but its density makes it difficult to pump out.

This challenge in the water storage tanks – which measure about eight metres square and hold some 200 m3 of waste water each – then has a knock-on effect down the line, causing inefficiencies in the downstream process. In this particular operation, it also became necessary to incur the additional cost of introducing municipal water to the system.

“Our team was quickly able to assess the situation, and proposed the use of our innovative hydro solution, which has proven so successful and cost effective in desilting water reservoirs at mines or wastewater treatment plants,” he says. “The solution proved to be very successful and cleared the tanks of the sediment that had built up, allowing the customer to get their process back on track.”

With its high quality Grindex slurry pumps and purpose engineered hydro mining monitor guns, Integrated Pump Rental’s hydro cleaning units are capable of extracting high tonnages of sediment from reservoirs.
Vine emphasises that applying a regular cleaning programme need not be onerous for end-users, and will ensure that their tanks are sediment-free in a range of applications.

NEW SLURRYSUCKER MODEL PASSES TRIAL WITH FLYING COLOURS

The new, high solids capacity SlurrySucker dredging unit from Integrated Pump Rental recently proved its mettle at a Limpopo municipality’s wastewater treatment plant.

“We were requested to clean two wastewater settlement ponds which had silted up and were no longer performing their function of settling the sewage before it left the property,” says Lee Vine, managing director at Integrated Pump Rental. “Each dam measured about 100 metres by 100 metres and was about three metres deep; we estimated that they were about 70% filled with sediment.”

The company’s new SlurrySucker Mark II, with a vortex-type impeller in the slurry pump and a redesigned dredge head achieves up to about 50% solids concentration by volume. Vine says this significant especially when compared to the 30-40% concentration with the standard dredge head. The larger holes and the vortex-type impeller allow for larger solid objects like boots, gloves and hessian bags to pass through without blocking the system.

“After being awarded the contract, we quickly moved our equipment onto site; the total weight of the SlurrySucker is only about two tonnes – perhaps four tonnes with accessories – so it is relatively lightweight and easy to move around by road trailer,” says Vine. “We spent a day setting up the unit, then spent 25 days cleaning each dam, working an eight hour shift each day.”

Operated by just one person, the six metre long and three metre high unit agitates the sediment in single metre wide paths as it moves up and down the pond.

“After about two months on the job, we were pleased to have completed our mandate successfully without a single blockage,” he adds. “It took just one day at the end of the process to decommission the equipment and move off site.”

Vine emphasises that the design of the SlurrySucker allows it to be used on plastic-lined dams without risking any damage to liners, as it uses water to agitate the solids, and does not have cutters that could damage the pond liner.

“This is particularly important from an environmental perspective, as wastewater could leak out if the liner was cut or damaged, and could contaminate groundwater,” Vine says.

In addition to the turnkey service provided here, Integrated Pump Rental also offers contracts where the team will come to site every year to inspect and dredge the dams to ensure they are kept operational and efficient.

Also, if the end-user has a more regular and ongoing need, the company can also sell the equipment to the customer and provide training so that the application of the equipment can be effective.

Service levels are high on the SlurrySucker dredge units, as they are manufactured using locally produced components, and incorporate quality Grindex slurry and dewatering pumps. This means that spare parts are readily available and the expertise is on hand to maintain the equipment.

INTEGRATED PUMP RENTAL DEWATERS TUNNEL UNDER VAAL RIVER

Integrated Pump Rental recently made short work of dewatering a large pipe deep under the Vaal River, expelling over 1800 cubic metres in one day in a rapid turnkey solution.

The job was to clear a 2,5 metre diameter pipeline of water, so that engineers could safely enter the tunnel to conduct their inspections. Running underneath the Vaal River from Gauteng towards Sasolburg, the pipeline drops 50 metres down from surface, then runs a horizontal distance of 270 metres under the river before rising the 50 metres back up again.

“We were requested by the contractors to dewater the tunnel expeditiously, and to remain on site to ensure that any water ingress during the inspection period could be removed,” says Integrated Pump Rental managing director, Lee Vine.

To conduct the job, four Grindex Master SH drainage pumps were installed with level regulators; the pumps are 11,7 kW units with 3-inch discharge connections. In this application, the pumps needed to overcome a 70 metre head due to the static lift and the friction losses through the lay-flat hose.

“Our service team reported to site, supplying all the necessary accessories such as electrical panels, lay-flat hoses and other fittings,” says Vine. “We were then able to commission the equipment and dewater the tunnel in a 24 hour operation, although we stayed on site for about two weeks in case our services were required while the inspections were underway.”

The contract demonstrated the wide range of capabilities offered by Integrated Pump Rental, which can offer around-the-clock projects in dewatering and can provide skilled and experienced service teams on site – timeously and with reliable, fit-for-purpose equipment.

“Such is the depth of skills and capacity of our operation that we have evolved far beyond just the hiring out of pumps and related equipment,” he adds. “We now contract to a range of customers on a turnkey basis, in industries ranging from mining and wastewater to golf courses and industry. Wherever there is a need for dewatering and slurry dredging, we have shown that we have a solution to fit the challenge.”

In addition to the expertise of the service teams, the use by Integrated Pump Rental of the respected Grindex range of submersible dewatering and slurry pumps also helps ensure that every intervention is effective and reliably implemented.

“Our technical team conducts a full needs assessment of each application, and supports customers in the selection of the appropriate solution, which are all ISO 9001 certified,” he adds. “We can also offer a full engineering capability, from design through to finite element analysis (FEA), experimental fluid dynamics (EFD) and computational fluid dynamics (CFD) simulations – as well as supply and installation.”

Integrated Pump Rental supplied all the necessary accessories such as electrical panels, lay-flat hoses and other fittings.

EIGHT SYKES DEWATERING PUMPS TO COAL MINING OPERATION

Integrated Pump Rental reports that one of its surface coal mining customers recently purchased eight Sykes CP 150 self-priming diesel driven pumps from the company.

Lee Vine, managing directors of Integrated Pump Rental, says that most significantly the order was placed following a short term rental solution provided to the mine during the rainy season.

“Dewatering remains a critical activity in opencast mining operations and we were able to assist this customer at short notice over a weekend,” Vine says. Within hours of having received the request for assistance Integrated Pump Rental had supplied and installed eight diesel driven pumps with 2000 metres of lay-flat hose.

Integrated Pump Rental focuses on providing fit-for-purpose dewatering solutions to industry and Vine stresses that it is not just about moving pumps into the market.

“The Sykes pumps, which were hired out to the mine, were selected because we knew these units would be able to deal with the volume of water that needed to be transferred, and we were confident that the pumps would offer the reliability required,” Vine says.

The Sykes CP 150 self-priming diesel driven pump offers a maximum head of 60 metres with a flow rate of 172 litres per second. It is also capable of handling solids with a particle size of up to 77 mm.

“To put this dewatering capacity into perspective, one pump would be capable of draining the London 2012 Olympic Swimming Pool in just four hours,” Vine says.

The eight pumps are trailer mounted for ease of movement, and offer the mine the versatility of being able to move the units to where they are needed on the mine site.

The Sykes pumps feature cleverly designed automatic priming capabilities based on a Venturi system that can deliver suction lifts of up to 9 metres. The robust construction of the pumps ensure optimum reliability as well as long life, and importantly the pumps are fully automatic priming allowing the units to run dry for extended periods of time without damage.

Integrated Pump Rental was appointed as the official Sykes distributor for Southern Africa just over 15 months ago and the company has already established a strong product reference in Africa.