Tag Archives: Integrated Pump Rental

PUMP STATION FAILURE CALLS FOR RAPID DEWATERING RESPONSE

There was no time to lose when dewatering specialist Integrated Pump Rental took a call from a long-standing customer recently; a vital pump station had gone down and they needed help urgently.

“The customer’s pump station was being refurbished, and its two pumps unexpectedly went down,” recalls Andre Strydom, rental development manager at Integrated Pump Rental. “These pumps performed a critical function for the customer, maintaining a constant flow of 200 m3/h per pump – over a one kilometre distance.”

What was required was an urgent water bypass solution to take over this duty while the in-situ pumps were attended to, and the pump station refurbishment went ahead. Within a day of the customer’s call, the nature of the application had been assessed and the quotation sent out. This was quickly followed up with the despatch of Integrated Pump Rental’s dewatering solution to site, where its pumps were rapidly commissioned.

“Having taken the call on day one, we had the pumps selected, delivered, commissioned and operational by day two,” says Strydom. The solution included the deployment of two diesel driven Allight Sykes high head dewatering pump sets, providing bypass water lines. These rental pump sets operated 24 hours per day to maintain the required flow rate through these pipelines.

“One of our primary advantages is that we can react with speed to our customers’ emergency dewatering situations,” he says. “This is because we operate a large and varied fleet of diesel driven dewatering pump sets, which are capable of dealing with different sizes of applications – each with their own operational requirements and site conditions.”

He also highlighted the team’s depth of knowledge in dealing with dewatering applications and their technical expertise. This allows them to apply expert judgement in identifying the most appropriate dewatering solution.

In this recent application, the two high head dewatering rental pumps remained on site until the pump station was completed and commissioned. Allight Sykes dewatering pumps, such as those selected for this application, are well known for their performance, efficiency and reliability.

Over the years, Integrated Pump Rental has built a strong reputation for its 24/7 service to industry, delivered for 365 days of the year. Irrespective of the dewatering application, the company can offer an appropriate solution, he says.

“The team prides itself on being able to respond to requests from customers at short notice,” says Strydom. “We understand that most requests for dewatering pump rentals are urgent, so they demand a rapid response with a solution that matches the needs of the job.”

PUMP LEADER TRIPLES DEWATERING FLEET AS RAINS PLAGUE MINES

Flooding of open pit mines and quarries has become widespread following intense and unseasonal rainfall in many parts of South Africa recently, demanding added dewatering capacity.

Lee Vine, managing director of dewatering pump specialist Integrated Pump Rental, says the rains have had a dire effect on many mining operations – leading to increased demand for the company’s rental and contract services. Vine highlights that unexpectedly high rainfall events generate large volumes of water that need to be pumped out rapidly.

“Even though many of our customers are on top of their operational requirements, some were unprepared for the huge volumes of groundwater that flowed onto and out of their operations,” he says. “This called for an urgent response, especially in those cases where flooding threatened to disrupt or even halt mine production – as this would severely affect bottom line performance.”

He also emphasises the safety issues related to excess water in mining operations, adding to the importance of quick and effective solutions. These require not only the input of experts with plenty of experience in assessing dewatering applications, but a service provider with enough units of sufficient capacity to do the job.

“Our large and varied rental fleet has allowed us to assist numerous mining operations with emergency dewatering,” he says. “We have even augmented our fleet further with new units to ensure we meet the growing need.”

In fact, Integrated Pump Rental has almost tripled the size of its rental fleet since late 2021, adding a range of new diesel-driven pump sets to its population.

“We are well known for responding effectively and without much warning, and much of our success as a dewatering pump specialist is based on having a large enough fleet to always have capacity for the unexpected,” he says. “The depth of our rental fleet also means that we can cater for varying dewatering application needs.”

The company relies mainly on the well-proven Sykes brand of pumps, which boast a reputation for fast and effective removal of clean water, slimes, sewage, sludge and liquids laden with solids. These diesel driven fully automatic priming pumps can manage lifts of up to 9 metres, and feature an oil bath mechanical seal assembly which allows units to run dry for long periods.

FULL STAINLESS STEEL PUMP SET FROM LOCAL SPECIALIST

Pump specialist and local Sykes distributor Integrated Pump Rental is breaking new ground for customers in corrosive environments, offering a pump solution that is built entirely from stainless steel.

According to Steve du Toit, rental development manager at Integrated Pump Rental. while the pumps themselves or pump components are commonly available in stainless steel, the market has not yet made something like this readily available.

“Our focus on specific customer requirements, built to order in our modern workshop, has led us to develop a fully stainless steel solution – from the tank and skid to the lifting frame and other components,” says du Toit. “We have seen a definite interest in the market for this build design, as customers see the value in having this corrosion resistant material in all aspects of the pump set.”

He notes that the initial interest has come from the mining sector, where mine water being pumped is often acidic. However, he expects further interest from the chemical and process industries where corrosive liquids are pumped and stored. 

“The design is based on our ‘total solution’ approach, where we consider the complete application and its challenges,” he says. “While the upfront cost of stainless steel is obviously higher, the value gained by the customer in terms of longevity and reliability far outweigh this.”

Among the applications is open pit dewatering where there are low pH levels in the water, as well as coastal applications where salt water and air cause rapid rusting of mild steel. Integrated Pump Rental has already successfully placed a stainless steel unit in a coastal application, where it is performing well.

“Different grades of stainless steel are used in the design, depending on which components have the most contact with the acidic medium,” he says. “A range of materials is therefore employed to suit each application, and to achieve optimal performance at the most competitive cost.”

This custom engineering is made possible by the company’s range of technical skills and specialist experience that resides in its people. This in-house expertise includes draughting, fabrication and pump assembly, making use of coded welders and qualified boilermakers. Depending on the application, the stainless steel build can be supplied on a road trailer or with a site trolley.

LOCALLY BUILT DIESEL PUMPS FOR EVERY APPLICATION

With its expertise and experience in custom-building diesel driven pumps locally, Integrated Pump Rental ensures their customers get exactly what they need with a short lead time.

“Our in-house capability allows us to design and build pumps to any required specification,” says Steve du Toit, rental development manager at Integrated Pump Rental. “Part of our process is to assess the application and discuss options with the customer, advising on a solution that suits both the operational requirement as well as their budget.”

As the local distributor of the high quality Sykes diesel driven  pump range, Integrated Pump Rental generally uses the appropriate Sykes wet end for each pump design, usually coupled to a Kirloskar diesel engine – a well-respected and popular brand. However, the brands of key components can be chosen by the customer according to their preference, says Du Toit.

“We then design and construct the fuel tank and base or trailer unit, the scale of which depends on the pump’s intended working conditions, mobility and fuel consumption,” he says. “The material of construction must also be carefully selected, based on factors like water acidity and abrasiveness.”

In the case of high acidity, for instance, stainless steel is the preferred material, while more abrasive applications can be served with a coated S.G. iron material. The solution is put together by a team that includes qualified draughtsmen and experienced boilermakers, electricians and diesel mechanics. 

“Our performance driven approach ensures that all the necessary specialists collaborate closely in turning the customer’s requirement into reality,” he says. “This includes hands-on involvement by top management, making for quick decisions, innovative solutions and a fast process all round.”

The result is a top quality locally assembled pump which draws on readily available components and can be delivered within tight timeframes. Customers can also rely on Integrated Pump Rental’s well-known service levels to ensure ongoing maintenance and optimal uptime. 

“Our versatile team, combined with the wide range of Sykes pump capacities, allows us to locally build pumps for every application – from small-scale contract dewatering to large open pits on mines,” he says. 

Du Toit notes that many of their custom-built pumps are for customers who have previously rented pumps from the company, and are impressed by the performance and reliability of those Sykes units. While diesel driven pumps are most in demand, Integrated Pump Rentals can also design pumps with electric motors, for those applications where electrical power is available on site. 

BIGGEST SYKES PUMP YET FROM INTEGRATED PUMP RENTAL

In another milestone for southern African Sykes distributor Integrated Pump Rental, the company recently delivered its largest unit to date – a Sykes MH300 pump with stainless steel pump end was built at the company’s Jet Park facility

Driven by a Kirloskar DV8 engine, this auto-prime Sykes pump unit was fitted with a custom engineered fuel tank and skid, according to Steve du Toit, rental development manager at Integrated Pump Rental.

“The sheer scale of the project is demonstrated by the unit’s final dry weight of about 8 tonnes,” says du Toit. “Measuring nearly 7 metres long, this pump set is 2,5 metre wide and 2 metre high.”

With a pumping capacity of 500 litres per second at a head of 40 metres, the Sykes MH300 has been delivered to a customer in the mining sector where it will dewater an open pit to ensure that no flooding occurs during the rainy season. The presence of abrasive particles in the water required that the inside of the pump be coated with tungsten, while the stainless steel wet end would resist acidity.

“Effective dewatering demands that you don’t just keep up with the required volumes, but that you keep ahead of them,” he says. “For this application, there was no better pump than this one.”

The Sykes MH300 is the top of Sykes’ medium-head range, with a 300 mm – or 12-inch – suction or discharge. This compares with the 6-inch suction of the well-known Sykes CP150 model popular among contractors. A generous 3,000 litre fuel tank was included in the design to allow for long running time, and this reduces the monitoring and refilling necessary by mine personnel. 

Built in less than two months at Integrated Pump Rental’s modern facility, the pump’s vacuum capabilities were extensively tested in-house before delivery. 

“The pump was built for plug-and-play on site, with an auto-prime function for added ease of use,” du Toit says. “Supplied with the necessary pipework, it can be easily connected and immediately operated.”

Du Toit highlights that Integrated Pump Rental also conducts project work in addition to renting and selling its locally built pump units – providing a one-stop shop for customised pumping solutions.

WARNING TO OPERATORS OF PROCESS DAMS TO DESILT AS SOON AS POSSIBLE

As the rainy season approaches, Integrated Pump Rental has issued a dire warning to operators of water storage and process dams to make sure that these are desilted as soon as possible and ready to accept additional rainwater. 

Managing director, Lee Vine says that the progressive build-up of silt over time would have caused many of these facilities to reach close to critical volume and excessive rainwater could have major implications. 

“While it is critical to ensure that water storage dams, settlement ponds and similar reservoirs are kept at their required storage volumes at all times, it is just as important to regularly clean and desilt these to avoid any environmental occurrences should these facilities become overfull due to heavy rainfall,” Vine says. 

Vine says that increased demand has already been seen for the company’s innovative and effective SlurrySucker desilting solution with many operators becoming more proactive than in previous years. He says this applies across a range of industry sectors where water is stored either for recycling or as part of the process such as settlement ponds. 

He is quick, however, to point out that while desilting or cleaning of settlement ponds may seem like a simple task, it is not always as straightforward as it would initially appear. Cleaning these facilities can become an onerous task, as it involves the pumping of high solids materials from the facility being desilted and should an incorrect system or equipment that is not fit for the task be specified this can cause issues including environmental harm.

“Historically many operations have used manual excavation methods for desilting and cleaning, but our established track record with proven references has proved that this is not only inefficient, but it often fails to remove the required volume of sediment,” he says. 

There are several ways to accomplish effective desilting, but it has to be done effectively and cost efficiently, and this is where Integrated Pump Rental’s skilled and experience team come into play. The best option, according to Vine, is a site visit to assess the application requirements and conditions.

“In some instances, it is possible to pump the high solids material to another nearby dam or reservoir. However, this is sometimes not possible and in this type of scenario we implement an alternate solution such as capturing and storing the content in specialised geotextile bags while the water is separated from the solid material,” he explains. 

Once the actual condition of the dam or pond has been assessed the decision can be made as how to proceed. The SlurrySucker itself needs sufficient volume of water on which it can be floated, and should there be areas where this is not possible, then a hydro-mining solution is applied to these drier areas. 

The SlurrySucker is equipped with a high performance pump capable of moving high solids volumes so it can dredge quickly and cost effectively over the full area. Where necessary monitoring guns are used to blast the drier slurry towards the discharge point. 

In addition, specialised pumps with chopper blades can also be deployed in instances where required. An example would be where dislodged reeds or other plant materials are present in the dam. 

Locally engineered and manufactured by Integrated Pump Rental, the SlurrySucker is designed to deal with a range of high solids material including coal slurry, general silt and sand. 

In conclusion, Vine says that the opting for the SlurrySucker option is also far safer as the barge itself can be operated remotely from a defined distance away from the dam or pond edge. This is much safer than having equipment and personnel on the dam. 

IPR REBUILD GIVES UNRELIABLE WATER PUMP NEW LIFE

When a leading company in the petrochemical sector lost patience with the lack of reliability of a trailer mounted water pump, Integrated Pump Rental delivered a cost effective solution: refurbishment.

The water pump’s constant breakdowns meant that an intervention was required, but budgets were constrained. When consulted, Integrated Pump Rental was able to offer the option of either a completely new trailer mounted Sykes diesel driven pump or a refurbishment that would include fitting a new Sykes pump-end. 

To make the decision, the pump was stripped and assessed in Integrated Pump Rental’s modern workshop in Jet Park. After discussion with the customer, it was agreed to conduct a complete refurbishment, as the diesel engine driving the pump was also underperforming – further disrupting the pump’s operations at critical times.

Andre Strydom, rental development manager at Integrated Pump Rental, explains that in any refurbishment, it is vital to match the customer’s on-site duty requirement with the pump’s technical capacity. 

“In this case, 220 litres per second needs to be pumped at a head of 35 metres, and the decision was made to replace the pump-end with a Sykes CP250i with a 355 impeller which would the reliable delivery of a maximum flow rate of 280 litres per second,” Strydom says. “At a total head of 55 metres, the Sykes CP250i diesel driven pump can still manage a flow of around 100 litres per second.”

The engine was replaced with a Kirloskar 4K1080TA diesel unit which was close coupled to the Sykes CP250 pump-end, together with the dropped discharge pipework. 

An acid wash was used to clean off old paint and rust, while all non-working parts were stripped down to the fuel tank and chassis. Mechanical improvements were also made to the trailer and included a new hand-winch installed to lower the A-frame for easier coupling and uncoupling from the tow vehicle. Strydom says the fitting of this winch system will also reduce the risk of injuries, such as lower back strains or feet being caught when the trailer is unhooked.   

The turnkey operation was completed by Integrated Pump Rental in a quick turnaround time and within the customer’s limited budget, without compromising on quality. The complete rebuild – including delivery to site – took less than a month to complete. 

Strydom says Integrated Pump Rental also conducted the commissioning of the refurbished unit on the customer’s site. 

RAPID DEWATERING BY SYKES HIGH HEAD PUMP AT BOTSWANA OPEN PIT

Providing solutions to challenging dewatering applications is what Integrated Pump Rental built its solid reputation on and mines from as far afield as Botswana have called on this dewatering specialist to resolve water issues. 

Recently a Sykes diesel driven pump set was used to rapidly dewater an open pit at an existing copper mine in northern Botswana. Using this high performance, high head pump set, 103 million litres of water was removed in just 30 days to enable exploratory drilling to take place. 

Steve du Toit, rental development manager at Integrated Pump Rental, explains that due to unseasonably high rainfall it was no longer possible to reach the benches and the face where the exploratory core drilling needed to be done. 

“This was when the mine reached out to us requesting rapid assistance to avoid any further delays,” du Toit says. “After assessing the application requirement and operating conditions, we selected and dispatched one of our Sykes XH 150 rental pump sets.” 

The Sykes XH 150 Rental pump sets are available either as trailer mounted units or on skids, allowing for easy installation on site, also facilitating the moving of the unit from section to section as required. In this instance, a skid mounted unit was used. 

An advantage with the Sykes XH150 is that it offers automatic priming which meant that on arrival at the mine the unit could quickly be put to work dewatering the open pit. This unit has a flow rate of 120 litres per second which meant that is could move some 3456 m3 of water in eight hours, and as bonus it is also capable of handling solids with ease. 

Engineered for reliable performance with low fuel consumption, the pump is able to work in dewatering applications for extended periods of time and its ability to operate in ‘snore’ conditions allows for conditions where suction levels may fluctuate. 

Du Toit explains that in this particular application, renting a Sykes pump set made more sense for the mine but where ongoing dewatering is required in surface and underground mines customer often prefer to purchase the pump set outright. “In a lot of these instances, we are still called upon to enter in service level agreements to ensure that the pump sets are correctly maintained ensuring the lowest total cost of ownership.” 

INNOVATIVE SEWAGE POND DREDGING FOR SUGAR PRODUCER

The recent upgrading of sewerage facilities at an Eswatini sugar producer required more than the dredging of a sewage pond – but Integrated Pump Rentals was up to the demanding task. 

Cleaning of a settlement pond usually involves the pumping of high solids material to another nearby dam. In this case, however, there were no containment areas for the sewage on the customer’s site. According to Ruaan Venter, rental development manager at Integrated Pump Rental, an innovative solution had to be found to capture and store the sewage. 

“The pond in question was close to the company’s sugar cane fields, so absolutely no spillage was permitted onto those lands during our cleaning process,” says Venter. 

At the heart of the cleaning operation was Integrated Pump Rentals’ well-proven SlurrySucker mobile dredging unit. On this project, the SlurrySucker Mini was employed, emptying the pond of 30 to 40% solids material at 150 m3 per hour.

“To contain the sewage, we procured specialised geotextile bags measuring 30 m long by 18 m in circumference,” he says. “These were laid out on a large area near the dam, which had been allocated for this purpose.”

Before the sewage could be pumped into the bags, however, it required the addition of flocculant to facilitate the separation of solids and liquid. This was achieved using an in-line dosing system, feeding the flocculant into the pipeline from a 1000 litre tank. Effective mixing in the pipeline could be reached over a 100 m distance of the pipeline. 

“After two weeks, we had filled three of these large bags with the material from the pond,” Venter says. 

As the water separated from the solid material, it was able to drain through the bags’ porous sides and flow back into the pond. The solids could then be left to dry out in the geotextile bags, after which it could be moved from the site and discarded safely. 

MINE ADDS ANOTHER SYKES TO SOLVE FLOODING

When heavy rains flooded a Northern Cape mine recently, it was the tried-and-tested Sykes XH150 dewatering pump from Integrated Pump Rental that once again came to the rescue. 

The mine, which already had one of these units in operation, signed a long-term contract for a second unit – replacing a competitor’s product on site. In response to the rains, the pump was required to dewater a flooded area at a 100 metre static head pumping a distance of 1,8 km though a 250 mm pipeline. 

“The ingress of water into the mine could cause major issues, so effective and efficient dewatering is critical to ensure productivity and safety,” says Andre Strydom, rental development manager at Integrated Pump Rental. “The Sykes XH150 has an established reputation as a hardworking, reliable dewatering pump, which is a key reason why many customers in the mining sector specify this pump for challenging dewatering applications.”

Known for its rapid response to urgent calls from customers, Integrated Pump Rental was able to deliver technical assistance and ensure an appropriate pump solution for the application. Both Sykes dewatering pumps provided to the mine are mounted on a double-axle, heavy-duty site trailers, allowing for rapid transportation to site and quick installation. 

“The Sykes XH150 pump offers automatic priming and solids handling capability,” says Strydom. “It also has one of the best shaft stiffness ratios of any automatic priming pump on the market.”

The pump can be primed with long suction hoses and can manage suction lifts of up to nine metres. Low fuel consumption is another important benefit, adding to the pump’s cost effectiveness when used for dewatering over extended periods of time. 

“The pump’s ability to operate in ‘snore’ conditions accommodates applications where suction levels fluctuate,” he says. “It can also run dry for extended periods, thanks to the oil bath mechanical seal assembly.”