Case Study: Process Technology Training

Case Studies

Whatever it takes.

How the R. A. Ross team knowledge and experience can help you.

Process technology training provides valuable information for industrial engineering firm

“I knew some of these types, but it was new exposure for me on the other half of the list”

– Todd Hess, Vice President and
Senior Designer
with Hess Engineering

Sometimes, the very solution you need for a complex process may involve a technology that you may never have heard of. Engineers are often called upon to design complicated systems in industrial and municipal processes that require a specific type of pump or piece of equipment.

That’s where R.A. Ross & Associates can help!

We’ve put together a training module covering the various types of pump technologies available today and the typical applications they are best suited for. We provided our Process Technology class during a “lunch and learn” at the well respected firm of Hess Engineering (formerly A.J. Hess & Associates) in Calvert City, KY. Hess Engineering has been around since 1984 and provides civil, mechanical, electrical, chemical engineering and project management services in Western Kentucky and surrounding areas.

Contact us today to set up your class and see what you might be missing!

Some of the types of pumps covered in our training class:

Personal Development Hours Certificate Training

We also provide a PDH (personal development hours) Certificate upon completion of the training.

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Case Study: Tough pumps for tough applications

Case Studies

Doing whatever it takes.

The Ross team provides tough pumps for tough applications!

If you need it, Team Ross has it!

PROBLEM/SOLUTION:
A global automotive plating company with operations in Eastern Kentucky needed some rugged pumps for a rinse water application that would be required to handle a mixture of aggressive chemicals.

The existing pumps in service couldn’t hold up to the various chemicals present in the rinse water. After review of the application, the R.A. Ross team had the perfect solution in mind; the Vanton® Chem-Gard® ANSI centrifugal pump with PVDF (Kynar) wetted materials with clean water flush to protect the seal.

Wet end components of Vanton CHEM-GARD® centrifugal pumps are injection molded of corrosion resistant polypropylene (PP), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyvinylidene fluoride (PVDF), ethylene chlorotrifluoroethylene (ECTFE) or other non-metallic materials that are 100% inert to the fluids being handled across the entire pH range. This eliminates the corrosion and failure associated with pumps constructed of stainless steel and other alloys, the wicking associated with fiberglass pump components and the delaminating inherent with plastic-lined metal pumps.

Application info:
Transfer of corrosive rinse water at the following rates: 100 GPM @ 40’ TDH

Vanton Chem-Gard® ANSI-Centrifugal pump model CGA-KY-3x2x8

• Horizontal centrifugal with all fluid contact parts of homogeneous non-metallic materials, dynamically balanced keyed semi-open impeller, stainless steel shaft with wet end sleeved with PVDF (Kynar).
• Materials of Construction PVDF / Kynar
• Impeller Dia. 8”
• Suction and Discharge 3” x 2” 150# flanged
• Mechanical Seal
• Water Jacket Standard (Seal water supply & drain required).
• Pedestal Guard Polyethylene
• 5 HP, 230-460 volt / 3-phase / 60-Hz, 1800 RPM, TEFC, severe duty motor mounted on an epoxy coated, steel base plate including spacer coupling and coupling guard 400 GPM @ 70’ THD

Vanton Chem-Gard® ANSI-Centrifugal pump model CGA-KY-4x3x10

• Horizontal centrifugal with all fluid contact parts of homogeneous non-metallic materials, dynamically balanced keyed semi-open impeller, stainless steel shaft with wet end sleeved with PVDF (Kynar).
• Materials of Construction PVDF / Kynar
• Impeller Dia. 10”
• Suction and Discharge 4” x 3” 150# flanged
• Mechanical Seal
• Water Jacket Standard (Seal water supply & drain required)
• Pedestal Guard Polyethylene
• 20 HP, 230-460 volt / 3-phase / 60-Hz, 1800 RPM, TEFC, severe duty motor mounted on an epoxy coated, steel base plate including spacer coupling and coupling guard

The Vanton Chem-Gard ®pump used in this case study:

• Flows to 1150 GPM (261 m3/h)
• Heads to 185 ft (56 m)
• Temps to 275°F (135°C)
• Construction: PP, PVDF

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Over $80,000 per year compressed air savings.

Case Studies

Our solution will save a customer over $80,000 a year for just ONE drying operation.

Big savings by less compressed air usage for drying parts

SITUATION
Compressed air is often referred to as the “third utility” in industrial plants as the cost to produce it can be extremely high. Many companies use compressed air to blow off or dry parts during certain stages of the manufacturing process. Large air compressors are expensive to purchase and maintain not to mention the cost of compressed air delivery equipment (ie, high pressure hoses, air knives, blades and nozzles, etc.) used to get the air to the process. R.A. Ross and Associates was able to bring an air savings solution to a major brake pad manufacturer in Kentucky by recommending the use of regenerative air blowers instead of compressed air to dry parts. Regenerative air blowers produce a higher volume of air at a lower pressure at the same time using less energy. The cost savings to the customer by switching to the regenerative blower and air knife system for one drying operation came to approximately $80,000 per year*. Equipment payback was about 9 weeks. That’s a serious solution! And at R.A. Ross & Associates, that’s what we do everyday!

HOW IT WORKS
Since each product and application is unique, Republic Blowers will ask that you fill out an Evaluation Guide (example below) detailing size of product, description of product, (holes, shape, etc.), speed of conveyor belt and so on. Once your specific need is determined, a custom designed air knife system will be recommended. Once approved, we will then test and be able to determine the amount of savings over traditional compressed air operations.

REPUBLIC MANUFACTURING AIR KNIFE SYSTEMS
• Custom designed and manufactured
• Perfect for: Drying parts, bottles, cans, food products, packaging,fruits, vegetables, meat, fish, poultry, textiles, carpet,film, wire, cable, metal, tile, wood, flooring
•Belt cleaning: Debris removal, sawdust removal, confectioner and food topping removal, liquid blow-off
•Static control
•Air curtain: Prevent hot air loss from oven, prevent cold air loss from freezer

Over $80,000 per year compressed air savings!

Case Study: Another Above and Beyond

Case Studies

The R. A. Ross team goes above and beyond to keep you up and running.

Whatever it takes.

Heat exchanger plates and gaskets needed NOW!

Problem/Solution:

Our customer was in need of 14 plate and Nitrile gasket sets for its heat exchanger.

The customer, whose primary function is the application of corrosion-resistance coatings for all types of metals for the automotive industry, was unable to operate without its heat exchanger and would be down until the exchanger was brought back into service.

The customer requested that we supply these parts TODAY, and indicated they would be willing to drive to pick up the parts if we could locate the correct parts for their heat exchanger. While we don’t stock parts for heat exchangers, we made numerous phone calls until we were able to work with one of our supplier’s in Tennessee that not only had the parts in stock, but was able to have the order available for pick up within a few hours. What normally would take at least a day to get delivered with expedited delivery was available to the customer and they were able to get their operations back on track within the same day. This “Whatever it takes” attitude by our team is how we operate every day, no matter how large or how small the order.

In addition to plates and gaskets for heat exchangers, we stock or can order parts, part kits and drop in replacements for the following brands of pumps, blowers and vacuum.