Case Studies Archives - Denver Pumps

High Temperature Submersible Pumps Solve Food Service Challenges

Michael Morton — Sun, 15 Oct 2023 14:53:49 +0000

High Temperature Submersible Shredder Pumps – BJM’s Answer for Wastewater Management at Sheraton Hotel In Denver, Colorado

The Challenge
Food service environments are inevitably hard on equipment and potato chip production is no exception. The two production lines at Condor involve a maze of conveyors and chutes to move the potatoes along during the various stages of processing, which also involves a lot of water. On a normal day Condor processes approximately 120,000 pounds of potatoes, including sweet potatoes.

The raw tubers are delivered by the truckload to the factory where they are initially washed to remove dirt, rocks and other debris. The potatoes are then peeled and sliced and washed again to release and remove the potatoes’ starch. All along the production process, water is used to wash, move and rinse the potatoes.

Spent water flows off the equipment, and along with the debris from the initial wash, the starch and the potato peels flow into drains in the floor that then flow with their cargo into a sump. In addition, the potato chip fryers are washed down once a week with 180-degree water and caustic beads to clean the equipment and remove the various oils used in frying. Condor uses six different types of oils in its chip making, and each has different properties, explained Kevin Kobza, long-time maintenance manager at the Condor plant. This hot caustic liquid and the oils it cleans also flow into the sump and are added to the mix that then needs to be pumped out.

The quality of the debris in the sump has been problematic for Condor. Not only do the potato peels and other debris tend to clog pumps, but the weekly caustic hot-water cleaning creates an added difficulty for most pumps. Condor previously was using a non-clog pump to pull product from the sump, but had been dealing with daily clogging issues that required the front cover of the pump to be removed and cleaned multiple times a day during production.

Maintaining a “Green” Commitment
Consistent with parent company Utz’s earth friendly philosophy, process waste and things such as paper and packaging are recycled or repurposed as much as possible. For example, potato peels and spent oils go to a local cattle feed lot. Solenoid valves have been installed on the potato peelers and other wash systems so that they turn off when they’re not needed, saving precious water. Cardboard boxes are broken down, baled and recycled. And Kobza is in the process of changing out lighting in the factory to be more energy efficient.

“We’re trying to conserve, and I try to do whatever I can to save a little here and there,” Kobza said. In light of these efforts to operate efficiently, it was especially frustrating to have to clear the pump two to four times during a 16-hour shift.

The Solution
Condor has a long-standing relationship with Denver Industrial Pumps, a local distributor of BJM Pumps. Phoenix Sullivan is the representative on the Condor account. To address the specific challenges of the Condor sump, Sullivan recommended one of BJM’s newer SKGF Series submersible shredder pumps that use its new patent-pending RAD-AX® dual shredding technology. An SKG37CF 5-HP high temperature/high endurance high performance shredder pump was installed in the Condor plant in the first quarter of 2016. The BJM cast iron F-Series submersible pumps are specifically designed to be installed in sumps where liquids are too hot for other submersible pumps.

The SKGF solved Condor’s issues with clogging and build up around the pump. The original pumps were self-priming, an older style technology with a more challenging configuration for this type of application. Condor’s self-priming pumps sat outside the sump. A pipe from the sump sucked liquids up to the pump, but it was highly prone to clogging from the potato solids, explained Ben Wells, BJM Regional Manager.

“The BJM submersible pump puts the pump and shredder down at the bottom of the sump. It reduces the solid size before it enters the piping system. This has all but eliminated the clogging,” Wells said. “The self-primer was used because other submersibles could not handle the hot water from the fryer cleaning. The BJM high temperature submersible pump solved both the high temperature and clogging issues.”

The high-temperature motor, suitable to handle 200oF liquids, also allows the pump to handle the hot caustic washdown cycle without damaging the motor. After one year, the pump has been shut down for one planned maintenance event, but there have been no clogs or other downtime.

Sullivan said BJM had beefed up the series design by trimming the impeller, which allowed a larger motor and higher torque in a compact housing that still had room for the dual radial and axial shredding elements. Condor was one of the first installations of the SKGF with RAD-AX® technology.

The SKGF is designed to obliterate flushable wipes and other difficult solids in high temperature situations. Items previously considered difficult or near impossible to pump are effectively handled through the innovative design. The robust construction prevents downtime and reduces maintenance for longer life.

Additional Features of the SKG F Series:

High temperature/high endurance construction for challenging environments.
All shredding elements constructed of hardened 440C Stainless Steel with a Rockwell hardness of 55C plus.
Shredding System efficiency to alleviate potentially high surge load to the motor.
Efficient, high solids passage impeller and volute design, coupled to a high torque 4-pole motor that comes in 2, 3 and 5 horse power.
Oil-lubricated double mechanical seals and separate lip seal to protect the motor.
High temperature rated Santoprene power cable and Seal Minder cable – seal oil leak detector.
Choice of two impeller trims for each SKGF model to expand hydraulic coverage. The hardened impeller and plate materials provide maximum wear resistance for long service life and hardened cast iron construction stands up to rough handling, pumping gritty water and the effect of abrasives.

Winding protection and NEMA Class R motor insulation allow motor temperatures to rise to 428°F, superior to pumps with Class A and B insulation, allows the pump to handle liquids to 200°F. Thermal switches embedded in the motor will cut power to the pump should the temperature of the windings rise too high. When the motor cools the switch will automatically reset and the pump will turn back on.

The Outcome
The customer is thrilled with the performance and reliability.

Written by: Mike Bjorkman in conjunction with Phoenix Sullivan, Outside Sales, Denver Industrial Pump; and Ben Wells, Regional Manager, BJM Pumps

The post High Temperature Submersible Pumps Solve Food Service Challenges appeared first on Denver Pumps.

Wastewater Pump Upgrades Improves Uptime & Easier Maintenance for Denver Sheraton Hotel

Michael Morton — Fri, 15 Sep 2023 14:28:17 +0000

Submersible Shredder Pumps – BJM’s Answer for Wastewater Management at Sheraton Hotel In Denver, Colorado

Maintenance teams focus so much of their time and energy making sure equipment is running smoothly on a daily basis that they often do not have time to stop and consider opportunities that may exist to improve the efficiency of their day-today operations. About five years ago, one very proactive supervisor took the time, on top of his busy workload, to conduct extensive research that eventually enabled his company, the Sheraton Hotel, to upgrade their pumps. Dawit Anteneh, the Central Plant Stationary Engineers Supervisor, discovered BJM Pumps and then contacted Denver Industrial Pumps for support. Denver Industrial Pumps is an industrial equipment distributor and aftermarket service provider that has been supporting several industries in Colorado and Wyoming for the past 27 years.

Anteneh’s goal in searching for pumping solutions was to find new pumps that could operate reliably in the hotel’s wastewater collection system. The wastewater collection system at the downtown Denver Sheraton utilizes three waste water collection pits. Each pit had two vertical column pumps operating in a duplex arrangement; so when the primary pump would fail, the secondary back-up pump would start up.

“The vertical column pumps had been removed many times over the years. They were rusting out badly, and they were so old that they weren’t worth maintaining anymore,” explains Anteneh. “We really needed new pumps that would handle our waste water collection needs with lower maintenance than the old ones,” continues Anteneh.

Conducting an internet search, Anteneh first came across the BJM Pump line of submersible shredder pumps. After watching the videos and reading about the modern technology that these submersible shredder pumps offer, Anteneh contacted Phoenix Sullivan, an Outside Sales rep for Denver Industrial Pumps. Sullivan, who has provided many BJM Pumps to other end users over the years, considered Anteneh’s most important needs:

Easier Maintenance – vertical column pumps, which can be up to 15 feet long, can be very difficult to remove and install; especially in a hotel where access to this type of pumping equipment is typically located in very tiny spaces. The maintenance team needed a pump that would be easier to install and remove when maintenance was required.

Shredding capabilities – with the increased use of “flushable” wipes and other hygienic materials, the sewage entering the hotel’s wastewater collection pits is full of fibrous material. The old vertical column pumps were frequently being clogged with these solids, so the new pumps would have to be designed to handle solids in the wastewater.

Reduced downtime and improved pump reliability – nobody wants downtime. Downtime puts stress on the system, creates headaches for maintenance teams who often work overtime to solve the problem, and results in unplanned and unwanted expenses. It was critical to select pumping equipment that would operate reliably in the hotel’s wastewater collection system.

Sullivan worked with Ben Wells, Regional Manager at BJM Pumps, to find the best pump for the Sheraton’s wastewater collection system. Together, they selected the BJM SK110C-460T Submersible Shredder Pump, which can handle up to 3.5-inch solids at 845 gallons per minute with a maximum of 94 feet of head. When reviewing the SK110C-460T with Anteneh, Sullivan shared the following key qualities in his recommendation:

• It’s Compact. The SK110C is about 2 feet tall, and because it is a submersible pump, the motor and wet end are one unit. Using this submersible pump would make it so much easier to install, remove, and maintain – saving the maintenance team a great deal of time and effort.

• It’s Engineered to Shred Solids. The SK110C utilizes a cutting impeller with a Tungsten Carbide Tip to continuously rip apart solids against a tooth-edged spiral-shaped diffuser plate. With 360-degree shredding action and non-clog, single vane impellers, the SK110C would have the capacity to shred the wipes and fibrous materials that were being flushed through the hotel’s sewage system.

• Motor Protection. Manufactured with an abrasion-resistant stainless steel motor housing, the SK110C is built with “Three Seal Motor Protection”. The motor is protected with double mechanical seals wherein the lower seal is made of silicon carbide / silicon carbide and the upper seal faces are made of carbon / ceramic. An additional lip seal is installed above the impeller to help prevent unwanted materials from entering the seal chamber. The SK110C also utilizes winding protection and (NEMA) Class F motor insulation, making it superior to pumps with Class A and B insulation because the (NEMA) Class F motor insulation allows the motor temperature to reach up to 230°F. If the temperature and/or amp draw becomes too high, an automatic switch turns the pump motor off. The switch automatically resets when

the motor cools, and the pump resumes operation.

After reviewing the pump specs and other details, Anteneh decided to purchase one of the BJM SK110C-460T Submersible Shredder Pumps. The first pump was installed in 2011, and the maintenance team immediately acknowledged how much easier it was to install the pump into the 12-foot deep wastewater

collection pit. After working reliably for a year, Anteneh decided to systematically replace the other 5 vertical column pumps in all the wastewater collection pits throughout the hotel complex.

“These are a totally different style pump than we had before, and they have solved many problems we had experienced with the old ones – clogging, constant maintenance, etc. We have less maintenance and have saved so much in preventive maintenance costs. Our down time has been drastically reduced and we know we can trust the BJM Pumps,” declares Anteneh. “We are very pleased with the BJM Pumps’ performance and the service provided by Denver Industrial Pump.”

There are many advantages of using submersible pumps over vertical column pumps:

Less preventive maintenance and inspection are required for submersible pumps because their bearings are permanently lubricated.
Submersible pumps have lower true “cost of ownership” and less mean-time-between-failure because of the submerged motor. The submerged motor allows heat generated during operation to dissipate, which lowers the running temperature. A lower running temperature increases the life span of the motor’s insulation, mechanical seals, and bearings.
Submersible pumps located in the liquid sump are not subjected to the temperature, elevation, or height limitations of self-primers.
The compact rotating element of submersible pumps make them more reliable. Long-shafted vertical pumps that utilize close clearance line shaft bushings often become worn and fail.
The compact and portable features of most submersible pumps makes bench-servicing easier.
Liquid around the submersible pump isolates noise; therefore the submerged motor/pump operates more quietly than vertical column pumps.

In today’s world, many maintenance teams face challenges when trying to upgrade their pumping equipment. So it is important to consider the cost of NOT upgrading…how much is your company really spending if maintenance is frequent and down time is excessive? Embracing the technology shift and employing modern, highly engineered submersible pumping equipment can have a big impact on both the efficiency of day-to-day operations and long-term pump life cycle costs.

This case study originally appeared in the May/June 2016 issue of Industrial Water and Wastewater Digest

Written by: Mike Bjorkman, BJM Pumps; Dawit Anteneh, Central Plant Stationary Engineers Supervisor, Sheraton Hotel; Phoenix Sullivan, Outside Sales, Denver Industrial Pump; and Ben Wells, Regional Manager, BJM Pumps

The post Wastewater Pump Upgrades Improves Uptime & Easier Maintenance for Denver Sheraton Hotel appeared first on Denver Pumps.

BJM Hits A Home Run With Its Custom Shredder Pumps Solution For Coors Field

Michael Morton — Tue, 15 Aug 2023 12:20:05 +0000

BJM Shredder Pumps To The Rescue

The Challenge
During baseball season, the water and any trash and debris collected with it is pumped up and out of the vault and into the storm sewer system. In the off season, a much smaller amount of collected water is pumped out and diverted to any of several small detention ponds to evaporate.

The pumps that do the heavy lifting of moving all the collected water out of the vault were replaced in May 2015. The original pumps were chopper pumps installed in 1998. Although they were showing signs of wear — moisture was getting in the motors — they weren’t replaced.

When it became evident that the old pumps needed to be replaced, Young and James Leflar, an engineer and member of the HVAC team at Coors Field, reached out to Phoenix Sullivan, their contact at Denver Industrial Pumps.

The Solution
Sullivan recommended the old chopper pumps be replaced with two BJM SK55C Shredder Pumps and the associated electric submersible sump pump package. An integral part of the new solution was a variable frequency drive (VFD) control panel that was customized by BJM to be compatible with Coors Field’s existing alarm panels in the security room.

“The customer needed a pump that could handle debris getting into the vault/sump and not clogging the pump,” Sullivan said. “The BJM shedder pump has a cutting tool that cuts and shreds the debris . . . allowing it to pass without clogging the pump.” In addition to their ability to handle debris, other technological improvements also made the BJM shredder pumps a good solution. For one thing, the original pumps operated on a highly specialized and outdated air bubbler system, whereas the SK55C pumps use a simple float system to turn them on and off.

The BJM pumps operate on a lead–lag setup, Sullivan explained. The floats prompt the first pump to turn on, and if needed, also prompt the second pump to turn on. Likewise, the floats shut the pumps off when the water level is sufficiently lowered. For this installation, the target flow for each pump is approximately 350 gpm at 32 feet of total dynamic head. Generally, the BJM SK55C can handle a maximum flow of 570 gpm, with a maximum head of 59 feet.

The two pumps sit in a sump that’s approximately 16 feet deep. In addition to the two 7.5 HP pumps, this BJM sump package included two cast-iron slide rail assemblies, four stainless steel intermediate guide rail brackets, and 100 feet of 1.5 inch stainless steel pipe rails.

The newer pumps’ also take full advantage of advances in metallurgy and materials that allow all of the pump’s parts and components to be self-contained, Sullivan said. The only parts that may experience wear are the cutting bars, bearings, and seals. Those components aside, it would be realistic to expect these pumps to last 20 years.

BJM’s shredder pumps leave solids slightly larger than if passed through a grinder pump. The shredding action is caused by using a cutting impeller with a Tungsten Carbide Tip, against a “spiral” shaped diffuser plate.

Additional technical features of the BJMs Shredder pumps include:

Longer Power Cord — A 33-foot power cord is standard
304SS Motor Housing — The stainless steel motor housing provides superior abrasion resistance and will not wear out like aluminum motor housings when pumping sandy water.
Three Seal Motor Protection — The motor is protected by double mechanical seals. The lower seal is made of silicon carbide/silicon carbide, and the upper seal is made of carbon/ceramic. An additional lip seal has been installed above the impeller to help prevent abrasives such as dirt, silt or sand from entering into the seal chamber.
More Motor Protection — Winding protection and (NEMA) Class F motor insulation allows the motor temperature to rise to 230°F, superior to pumps with Class A and B insulation. An automatic switch turns the pump motor off if the temperature and/or amp draw gets too high. When the motor cools the switch will automatically reset and the pump will turn back on.
Tough Pump Construction — Hardened cast iron stands up to rough handling and pumping sandy water unlike pumps with soft resin impellers or plastic exterior components.

The pumps are also available in 316 cast stainless steel, and a new explosion proof shredder pump is also now available.

Another Advantage
BJM was also willing to go the extra mile to create a custom control panel so the ballpark could tie into its existing alarms in the security room. The Custom Duplex Control Panel BJM fabricated has auxiliary contacts allowing communication with the existing system that includes seal minders, elapsed time meters, and dedicated auxiliary contacts for seal fail 1, seal fail 2, overload 1, overload 2, and high level.

The Outcome
As a new baseball season draws near, the HVAC team at Coors Field feels confident that with the newly installed pumps they’ll be ready to handle any curveballs that may come at them. “It does exactly what it’s supposed to do. It was a good install and we haven’t had any issues with them,” said Leflar. “They’ve done what we asked them to do and they met our criteria.”

Written by: Mike Bjorkman in conjunction with Phoenix Sullivan, Outside Sales, Denver Industrial Pump; and Ben Wells, Regional Manager, BJM Pumps

The post BJM Hits A Home Run With Its Custom Shredder Pumps Solution For Coors Field appeared first on Denver Pumps.