1. For Environmental &
Support Service Professionals
LIKE DIRT
Tech Perspective:
Drillers turn to natural gas generators
PAGE 24
Bakken Extra:
Bakken’s impact is far-reaching
PAGE 30
www.GOMCmag.com | SEPTEMBER 2013
Don’t Treat Soil
TM
TWI AND NER PROVIDE THERMAL SOIL
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contents
features
14 CONTRACTOR PROFILE: DON’T TREAT SOIL LIKE DIRT
Nelson Environmental Remediation and TWI team up to provide cost-effective
thermal soil remediation.
- Doug Day
24 TECH PERSPECTIVE: GENERATING SAVINGS
With prices competitive with diesel, some drillers are turning to all-natural gas
designs for generators.
- Peter Kenter
34 PRODUCT FOCUS: PUMPS, VALVES & INSTRUMENTATION
-Craig Mandli
39 CASE STUDY: PUMPS, VALVES & INSTRUMENTATION
-Craig Mandli
COMING IN
OCTOBER 2013
ISSUE FOCUS:
SupportTrucks andTrailers
n Contractor Profile:
Bulldog Hot Shot Service, Casper, Wyo.
n Tech Perspective:
Cleaning programs that work for any tank
departments
8 EDITOR’S NOTEBOOK: THE TRIALS OF TRANSPORT
Oil companies and service providers need to work together to improve all
methods of carrying crude.
- Luke Laggis
10 EDITOR’S CHOICE
30 BAKKEN EXTRA: JUST THE FACTS
The Bakken Shale Formation is booming, and as these numbers show, the
impacts are far-reaching.
- Luke Laggis
42 MONEY MACHINES: PUMPING UP PROFITS
Hydra-Tech equipment helps Colorado contractor improve efficiency for drilling
companies.
- Ken Wysocky
44 EXPO SPOTLIGHT: PUMP OF THE FUTURE
New line of liquid-cooled, liquid-ring pumps prove popular at Expo.
-Ed Wodalski
46 BUILDING THE BUSINESS: EMPLOYEE MOTIVATION IS JOB ONE
Follow these four steps to raise the level of enthusiasm, job satisfaction and
performance among your workforce.
- George Hedley
50 ON THE MONEY: EASING THE PAIN
Fluctuating fuel prices can put a dent in your profitability, but there are ways to
control your costs.
- Erik Gunn
54 PRODUCT NEWS
Product Spotlight: Insulated stainless steel DEF truck loads from bulk tank or rail car
-Ed Wodalski
60 INDUSTRY NEWS
62 CALENDAR
66 SAFETY FIRST: DANGEROUS BUSINESS
Safe hydroexcavation requires an understanding and respect for all the potential risks.
- Doug Day
SEPTEMBER2013
on the cover
Todd and Kelly Chamber-
lain ofTWI Oilfield Fabrica-
tion stand beside a TWI
truck in the company’s
yard in Fruita, Co. TWI has
been providing manu-
facturing and fabrication
services for 17 years, and
recently partnered with
Canada-based Nelson Environmental Remediation to
offer thermal soil remediation. (Photo by Kelley Cox)
14
24
42
www.facebook.com/GOMCmag
www.twitter.com/GOMCmag
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www.youtube.com/GOMCmag
Get Social with GOMCFor Environmental &
Support Service Professionals
LIKE DIRT
Tech Perspective:
Drillers turn to natural gas generators
PAGE 24
Bakken Extra:
Bakken’s impact is far-reaching
PAGE 30
www.GOMCmag.com | SEPTEMBER 2013
Don’t Treat Soil
TM
TWI AND NER PROVIDE THERMAL SOIL
REMEDIATION AS A COST EFFECTIVE
ALTERNATIVE TO LANDFILLING PAGE 14
7. SEPTEMBER 2013 - www.gomcmag.com GOMC 7
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8. 8 GOMC www.gomcmag.com - SEPTEMBER 2013
il pipelines are the subject of
continued debate. Opponents say
it isn’t safe and environmental
catastrophes are imminent, but that
approach glosses over the potential risks
posed by other methods of transport.
And in reality, the statistics show a very
different story.
The Association of Oil Pipe Lines pre-
dictably says pipelines are the safest way to
deliver crude oil and petroleum products,
but they back it up with some convincing
numbers, noting that U.S. pipelines trans-
ported over 13.5 billion barrels of crude
oil, gasoline, diesel and jet fuel across the
nation in 2012, with 99.99 percent of those
reaching their destination safely.
Rail transport, the chief alternative
to pipelines, boasts virtually identical
numbers. An Association of American
Railroads fact sheet released this year
states that 99.9 percent of all rail-bound
hazardous materials shipments reach their
destination without incident. And Federal
Railroad Administration statistics show
that the number of rail cars containing
hazardous material that were damaged or
derailed declined by 38 percent over the
past 10 years.
Still, accidents can
happen regardless of how
the crude is transported.
The train derailment in
Quebec, Canada, which
happened in early July as
I was finishing up this
issue of GOMC, is a great
example.
The Montreal Maine &
Atlantic train was parked
for the night seven miles
from Lac-Megantic, near
the Maine border. All but
one of the train’s 73 tanker
cars were carrying oil when they broke
free from the locomotives early Saturday
morning and rolled downhill into town
and derailed. Several of the cars exploded.
Approximately 30 buildings were
destroyed and dozens of people died as
a result of the explosions and fire. Crews
also had to try to contain 27,000 gallons
of light crude that spilled from the tankers
and made its way into nearby waterways.
The oil was reportedly being trans-
ported from North Dakota to a refinery in
New Brunswick. Because of limited pipe-
line capacity in the Bakken region, over 70
percent of the oil pumped from that region
leaves by rail.
Comment boards were quickly filled
with people blaming environmentalists
for standing in the way of pipelines. Ar-
guments were as simple as people point-
ing out that pipelines don’t derail. True,
but tanker cars don’t typically rupture
like pipelines, so there are trade-offs with
any method of transport. This spring, the
U.S. State Department noted that methods
of transporting oil from the Alberta tar
sands other than pipelines – including rail,
trucks and barges – each pose risks to the
environment.
There is no 100 percent safe way to
transport oil and petroleum products, but
one thing is certain: Those products will
keep moving across the country in some
fashion, and there is no one-size-fits-all
solution. The best thing is for all involved
to work together to find ways to improve
safety measures, reduce environmental
concerns and develop better emergency
response strategies. Oil companies and
oilfield service providers, from pipeline
contractors to rail car manufacturers and
spill containment specialists, can all play
an important role in this task.
Protesting a given method of transport
doesn’t make any sense if a better solution
isn’t presented, because the oil is going
to move no matter what. The focus needs
to be on making all methods of transport
safer, or else one set of risks will simply be
supplanted by another. GOMC
Luke Laggis
Editor’s Notebook
THETRIALS OFTRANSPORT
Oil companies and service providers need to work together to improve
all methods of carrying crude
By Luke Laggis
O
There is no 100 percent safe way to transport oil and petroleum products, but one
thing is certain: Those products will keep moving across the country in some fashion,
and there is no one-size-fits-all solution. The best thing is for all involved to work
together to find ways to improve safety measures, reduce environmental
concerns and develop better emergency response strategies.
It’syourmagazine.
Tellyourstory.
At Gas Oil & Mining Contractor, we’re looking for service companies
with an interesting story to tell. If you’d like to share your story,
send us a note at editor@gomcmag.com.
10. 10 GOMC www.gomcmag.com - SEPTEMBER 2013
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s
e’ve been adding lots of fresh new content on our website. In addition
to everything you see on these pages, the site features a wealth of
product and industry information, as well as blogs and original
features you can’t get in print. The following are just a few of the stories you’re
missing if you’re not visiting GOMCmag.com.
Resolving Conflicts With Business Partners
Two years ago, I met Bob and Tim; two business partners who were so
different that they couldn’t see their way past their differences. They were ready
to dissolve the business relationship. Employees felt torn by loyalties to both; the
clients felt the tension and were leaving the business. The owners were not on
the same page and felt there was nothing that could be done, but there was: We
started with values. Values may seem like a fluff topic, but they’re not.
Innovative Treatment
Plants Recycle
Frac Water in
Marcellus Region
Five privately owned
water treatment facilities in
Pennsylvania, capable of recycling up to 700,000 gallons of flowback, produced,
tophole and drill water a day, are up and running in the booming gas and
oilfields of the Marcellus Shale region. Officials at Aquatech International Corp.,
a global company that specializes in water purification and wastewater treatment
technology, say the plants — operated by Fluid Recovery Services (FRS), a
company recently acquired by Aquatech — will make the fracking process more
environmentally friendly by reducing the use of freshwater.
Hydroexcavation and Conventional
Digging Work Together
Working in sales and marketing for the largest fleet
of hydroexcavators in Texas, Karl Lassberg doesn’t see
conventional excavators as competition. “We’re really
working in conjunction with mechanical equipment,”
says Lassberg, of T-Rex Services Hydro Excavation and
Industrial Vacuum Services. Founded with one truck in
2001 by former NASCAR driver Bobby Hillin Jr., T-Rex
now has a fleet of more than 38 hydroexcavation and
vacuum excavation trucks.
Officials Gear Up For Second
Annual Oil & Gas Awards
After a successful first year of the Oil & Gas Awards,
officials are gearing up for the second annual awards in
October. “These awards are a platform for the industry to
recognize the outstanding achievements taking place on
an annual basis (in the oil and gas industries),” says Daniel
Creasey, chairman and CEO of the Oil & Gas Awards.
“We have three core values that are interwoven into all the
categories and those are health and safety, environmental
stewardship and corporate social responsibility.”
Check out all these stories and more at
www.gomcmag.com/ec/2013/September.
Editor’s Choice
Learn more about your industry with the
exclusive online content at GOMCmag.com
By Luke Laggis
W
12. 12 GOMC www.gomcmag.com - SEPTEMBER 2013
Global Vacuum Systems, Inc.
15431 State Hwy 6 • Navasota, TX 77868
Toll Free: 800-843-0866 • Phone: 936-825-2000
Email: info@globalvacuumsystems.com
Web: www.globalvacuumsystems.com
Call for quotes
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Pressure Vessels
14. 14 GOMC www.gomcmag.com - SEPTEMBER 2013
Cover Story
Nelson Environmental
Remediation and TWI team
up to provide cost-effective
thermal soil remediation
By Doug DayLIKE DIRT
Don’t Treat Soil
AnNERequipmentoperatorusesafront-end
loader to move huge piles of contaminated
soil to the thermal desorber for remediation.
(Photo by Jordan Cartwright)
14 GOMC www.gomcmag.com - SEPTEMBER 2013
15. SEPTEMBER 2013 - www.gomcmag.com GOMC 15
“When we get there, it’s con-
taminated. When we leave, it’s cer-
tified clean,” says Kirk Shellum, the
U.S. president of the Canadian firm
Nelson Environmental Remediation
of Edmonton, Alberta. NER, which
has been in the soil remediation
business for 18 years, is now providing its thermal solution in the US by team-
ing up with TWI Oilfield Fabrication in Fruita, Co., (formerly Todd’s Welding).
TWI has been serving the oil and gas industry for 17 years offering
manufacturing and fabrication services and wanted to offer soil remediation
services. “It’s a very capital-intensive business,” says Shellum, noting it was more
efficient for the two firms to work together rather than offer identical services.
NER has three mobile thermal treatment systems that it can bring to a
contaminated site. Such work is usually a turnkey project, including excavation,
sampling, testing through an independent laboratory, treatment, post-treatment
sampling and testing, backfilling and compaction.
Shellum says thermal remediation is useful at gas, oil and mining sites to
remove total petroleum hydrocarbons (TPH) from drill cuttings and contami-
nated soils from spills of oil or gasoline at drilling sites, refineries, bulk storage
facilities and pipelines. Other candidate sites include industrial plants, military
bases, manufactured gas plants, flare pits and underground storage tanks. Cur-
rent NER projects include a pipeline spill and an old oil well site. TWI and NER
have teamed up on several projects in Colorado.
NER has sales offices in Edmonton, Calgary, Seattle, Minneapolis and
France and is negotiating on projects in Eastern Europe and the Middle East.
THE TECHNOLOGY
NER’s mobile thermal desorption systems use heat to evaporate the
hydrocarbons so they can be collected and combusted. NER’s three units
are sized at 20, 40 and 45 tons per hour with the 20-ton system available to
customers in the U.S. With its smaller size, it is easier to transport to remote
sites, such as the mountains in the western U.S.
Each unit consists of four compo-
nents: control house, primary treatment,
bag house and secondary treatment
(thermal oxidizer). “The control house
is staffed by an operator at all times to
make sure everything is in balance with
the temperatures in the primary and sec-
ondary treatment units,” says Shellum.
The process runs around the clock.
The contaminated soil is first excavated and stockpiled near the thermal
desorbtion equipment so a front-end loader can feed it into a hopper. The soil
is carried by a belt to a 60-inch-diameter, 28-foot-long drum that serves as the
primary treatment unit. As the drum rotates the soil, a burner adds air and
heats the material to anywhere from 450 to 1,000 degrees F. The company’s
largest system can be configured for higher temperatures to treat long-chain
hydrocarbons.
D
Disposing of contaminated
soils in a landfill may leave a
company with a clean site, but it
doesn’t get rid of a possible lifetime
of liability for any subsequent
environmental effects. Thermal
remediation can clean such soils
so they can be reused onsite or for
other purposes.
TWI OILFIELD FABRICATION,
FRUITA, COLO.
Founded: 1996
Specialties: Oilfield equipment fabrication, thermal
soil remediation, solids control, drilling
mud recovery systems
Service Area: United States
Website: www.twi-fab.com
An NER crew hauls contaminated soil to the hopper at the start of the remediation
process. (Photo courtesy TWI)
“When we get there, it’s
contaminated. When we
leave, it’s certified clean.”
Kirk Shellum
NERcrewsworkattheNelsonEnvironmental
Remediation site in Pincher Creek, Alberta.
(Photo courtesy TWI)
16. 16 GOMC www.gomcmag.com - SEPTEMBER 2013
E N E R G Y M I N
Q U A L I T Y P E O P L E P R O D U C T S
Fabrication Fusion Pumps PipeYour HDPE Specialists
An NER equipment operator moves soil away from
the thermal remediation equipment at the end of
the treatment process. (Photo by Jordan Cartwright)
17. SEPTEMBER 2013 - www.gomcmag.com GOMC 17
M I N I N G M U N I C I PA L I N D U S T R I A L E N V I R O N M E N TA L 1.800.353.3747
www.leesupply.comS E R V I C E S I N C E 1 9 5 4
(continued)
“The first thing to come off the impacted soil is the moisture,” explains
Shellum. “That becomes part of the process gas stream. As the contaminants hit
their boiling point, they also become part of the gas stream, which is pulled out
of the drum.”
The gasses and dust are removed to the baghouse where the dust
is collected. The gasses continue to the thermal oxidizer where they are
combusted at temperatures ranging from 1,400 to 1,800 degrees. Shellum says
the oxidizer removes from 99.5 to 99.99 percent of the contaminants before
exhausting to the atmosphere.
“There are no particulates coming from the stack, just heat and water
vapor,” he adds. “There’s no smoke, all you see is heat waves.” The exhaust
contains nitrogen, water, oxygen and carbon dioxide.
The dust is added back into the primary treatment drum before the soil is
expelled to a mixer/cooler where water is added to bring the moisture content
to about 8 percent. Depending on the level of contamination, the soil is in the
drum for just five to 10 minutes.
RESULTS
Post treatment analysis is done to make sure the soil has been decon-
taminated properly. The soil is now ready for reuse and compacts very well. “It
can go back into the excavation site and be compacted and we’ve completely
recycled the soil,” says Shellum. He adds that NER is the only soil remediation
company that guarantees its results. If the soil needs further treatment, it is
done at NER’s expense.
To illustrate the viability of the soil, Shellum points out that treated soil
left in a pile after treatment will have weeds growing on it within three to four
weeks. “If it’s topsoil that was treated, you put fertilizer on it and you can grow
anything you want. You have the same material that came out of the ground
going back into the ground,” without the petroleum contamination, of course.
While the soil is clean, Shellum says NER would not recommend it for
use in a residential setting simply because of the stigma of it being previously
contaminated and to ensure public health and safety. How it is used is up to
“There are no particulates coming from the stack, just heat
and water vapor.”
Kirk Shellum
NelsonEnvironmentalRemediationhasspecializedinmobilethermal
soil remediation for 18 years. It is now considering a fixed location for its
technology to serve customers for whom an onsite system is not required.
“We can’t mobilize economically to a site that has 500 to 1,000 tons of
contaminated soil,” says Kirk Shellum, president of Nelson Environmental
Remediation USA.
A fixed location for a thermal desorber would allow companies to
truck smaller amounts of petroleum contaminated soil for treatment.“We
could completely recycle the soil into reusable material,” says Shellum.
By having a stockpile of clean soil on hand, customers could pick up
replacement soil immediately instead of waiting for their soil to be treated.
That would save on trucking costs and speed the remediation time for
contaminated sites.
Fixed site a possibility
18. 18 GOMC www.gomcmag.com - SEPTEMBER 2013
the customer. “It works great for backfilling a large excavation at a spill site,
road base, construction fill and things like that.”
Shellum says generally the option of landfilling contaminated soil is
less expensive than thermal remediation, but landfilling results in a long-
term liability that most companies would probably prefer to avoid. “Landfills
typically use it as daily cover over the garbage,” he says. “As it rains on that
landfill, contaminants begin to seep down and become part of the leachate.”
The light end hydrocarbons are released
untreated into the atmosphere.
Landfills keep a manifest of all
materials so they have record of companies
that have provided such soil. “Anyone
who puts soil into a landfill has what’s called ‘cradle-to-grave liability,’” says
Shellum. “The minute there is a problem or the landfill has to close, they get a
tap on the shoulder to help fund a cleanup and they pay for it a second time.”
By removing the contamination, thermal remediation “severs that chain
of liability right at their site,” he adds. “They may pay us more up front, but
they’ll only pay us once.”
Shellum says a typical soil remediation project will cost from $50 to $80
a ton. He estimates the final cost of landfilling is between $40 and $60 a ton.
“Landfills can set whatever price they want,” he adds. That is because without
contaminated soil, they would have to pay to bring in cover soil. “It’s the
trucking that adds up. You also have to fill in the hole left behind by removing
contaminated soil.” That means buying dirt and the associated trucking costs.
NER and TWI can provide several options for a remediation project. A
turnkey project would include everything from excavating the soil, through
treatment and reuse. Or the equipment can be brought in to just treat soil that
has already been excavated and the customer can do their own reuse work if
they prefer.
It requires six to 10 semi loads to fully mobilize the equipment, so the
minimum size of a project is about 5,000 tons of soil to make it an economical
option. That would require about three weeks for mobilization, setup, thermal
treatment and demobilization. “It all depends on the quantity of soil,” says
Shellum. “But we can give a predictable and guaranteed timeframe.”
Shellum sees a good market into the future. “I’ve been in this business
since 1990 when landfills were taking all the material. Thermal remediation
took off and we had a growth spurt in the 90s with underground tank work.”
There are an untold number of contaminated sites around the country,
and world, still waiting for cleanup, such as many manufactured gas plants,
Superfund and brownfield sites. “They’re sitting next to rivers or beautiful
properties,” says Shellum. “In some cases, the regulators don’t force them to
do anything. Those that seem to get cleaned up are those where someone
suddenly says, ‘We need that land,’ and someone pulls the trigger to get
it done.” GOMC
TWI Oilfield Fabrication
970/440-3084
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more info
“Anyone who puts soil into a landfill has what’s called
‘cradle-to-grave liability.’ The minute there is a problem or
the landfill has to close, they get a tap on the shoulder to
help fund a cleanup and they pay for it a second time.”
Kirk Shellum
Contaminated soil moves up the conveyor belt from the hopper on its
way to the primary treatment unit. Right: Soil is heated to anywhere
between 450 and 1,000 degrees F in the 60-inch-diameter, 28-foot-
long primary treatment unit. (Photos by Jordan Cartwright)
Thermal soil remediation is designed to eliminate petroleum
hydrocarbons so that the soil can be put to a beneficial reuse rather
than disposed of in a landfill. Here are some examples of projects
completed by Nelson Environmental Remediation:
• Honolulu, Hawaii – Former oil refinery site remediated so the
property could be sold
• Coxsackie, New York – Superfund site contaminated with
chlorinated solvent
• Greenville, Texas – Gasoline contamination from pipeline break
• Port Stanley, Ontario – Styrene contamination at petrochemical
site
• Battrum, Saskatchewan – Hydrocarbon contamination at tank
farm and landfill facility
• Oviedo, Spain – Hydrocarbon contamination at mining site
• Edson, Alberta – 100,000 tons of hydrocarbon contamination at
former oil and gas production site
• Edmonton, Alberta – Crude oil contamination from pipeline
rupture
A wide range of projects
19. SEPTEMBER 2013 - www.gomcmag.com GOMC 19
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24. 24 GOMC www.gomcmag.com - SEPTEMBER 2013
Tech Perspective
WITH A RECENT DECLINE IN NATURAL GAS PRICES AND INCREASED
environmental oversight regarding diesel engine emissions, some drill rig op-
erators and contractors are looking at making the switch from diesel generators
to natural gas units powered either by field gas or liquid natural gas (LNG)
delivered to the site.
To serve that market, GE’s Waukesha gas engines and Waukesha-Pearce
Industries are now offering the Waukesha VHP L7044GSI-EPA for drill rig ap-
plications. The unit provides a rich-burn engine that’s 100 percent natural
gas fired, designed to reduce fuel costs while meeting state and federal mobile
emissions guidelines.
“The greatest expense in operating drill rigs is fuel costs,” says Fred Stow,
WPI sales director. “With all of the recent domestic natural gas exploration
and development and a spike in supply, natural gas is currently finding itself
in a position where it’s very competitive with diesel. The fuel cost for a diesel
engine versus a 100 percent natural gas engine is currently about one third. In
many cases, field gas gets flared on the drill site, so making the field gas avail-
able to operate the generator adds directly to the bottom line. Additionally, flar-
ing gas will soon be prohibited. Since the units would largely operate on field
gas that requires no transportation, to provide a more accurate comparison you
would also need to count the transportation and liability costs associated with
trucking diesel fuel to the site.”
FIRST DRILL RIG GENERATOR APPLICATION
While the engine model itself is not new, it’s the first time that it’s been
employed on a drill rig. Antero Resources and Patterson-UTI Drilling are ini-
tially putting the gas generators through their paces with the first installation
of three engines at a well in Harrison County, W. Va. The company has also
announced plans to use gas engines on drill rigs in several other locations.
The switch-out of diesel for natural gas generators was “plug-and-play,”
he says.
“What we did on the first rig at the Patterson site was to simply move
the diesel skids out and drop the natural gas skids in using the exact same
footprint,” says Stow.
WPI notes that it’s not the only company currently offering a natural gas
engine-powered generator that can operate on field gas.
(continued on page 26)
With prices competitive with diesel, some drillers
are turning to all-natural gas designs for generators
By Peter Kenter
SAVINGS
Generating
“Natural gas engines can be located as high up as 8,000 feet
without being derated. There are quite a number of oil and
shale plays located up to 8,000 feet above sea level.”
Fred Stow
Some drill rig operators and contractors are looking at switch-
ing from diesel generators to natural gas units powered either
by field gas or liquid natural gas (LNG) delivered to the site to
meet emissions standards and lower fuel costs. (Photos courtesy
of Waukesha-Pearce Industries)
26. 26 GOMC www.gomcmag.com - SEPTEMBER 2013
“However, our model runs on a full range of field gases all the way up to
propane,” says Stow. “Rich-burn engines operate with a wide margin for both
knock and misfire, so that allows a high tolerance for different fuel composi-
tions that might be available. If you had an interruption in natural gas flow
from field gas, you could use alternate fuels such as trucked-in propane or
LNG. If you were going to truck in LNG, the fuel delivery distance makes the
difference in terms of economic advantage. If you’re within 500 miles of an
LNG facility, then delivery makes economic sense when compared to diesel
delivery.”
The Waukesha engine model also requires no ancillary equipment, such as
a load bank. While the skid of the gas engine generator is identical in footprint
to that of the diesel platform, the elimination of the load bank allows additional
engine displacement. The natural gas engine’s 12 cylinders offer a total of 7040
cubic inches in displacement in a 21,000-pound unit.
The natural gas engine generator is oversized to minimize voltage dip dur-
ing heavy loading. Stow says that the resulting voltage response performance is
similar to that of a diesel.
Stow also notes that diesel engines must be derated as they’re deployed in
elevations in excess of 3,000 feet.
“Natural gas engines can be located as high up as 8,000 feet without being
derated,” he says. “There are quite a number of oil and shale plays located up
to 8,000 feet above sea level.”
MAINTENANCE COSTS ARE COMPETITIVE
Maintenance costs are about the same between natural gas and diesel en-
gines over the life of the engine, says Tom Countryman, senior sales engineer
with WPI. He notes, however, that natural gas engines require less routine
maintenance than both diesel and other spark-ignited engines, in part because
they operate at lower cylinder pressures.
He estimates that a similar diesel engine requires an oil change every 750
hours, while the natural gas engine requires one every 3,000 hours. He also
says that diesels require top end overhauls approximately every 10,000 hours,
while natural gas engines can run for 24,000 hours before requiring similar
service. While diesels require a major overhaul every 24,000 hours, a natural
gas engine can operate for twice that period.
Engines fueled by field gas will power a new generation of
submersible pumps to be used in the oil industry.
“We’re working with GE to develop a gas-driven generator
solution for the submersible pump application,” says Fred Stow, sales
director of Waukesha-Pearce Industries.“An oil reservoir under natural
pressure that has already played out and is no longer producing can
be brought back to service life by placing pumps in the oil reservoir
and inducing pressure in the well to resume pushing crude out of the
hole.”
The pumps may remain in service for a considerable period – as
long as the well remains productive.
“They’ll be down there a long time, so we’re designing them to
operate on field gas in the same way as our natural gas engine-driven
generators for drilling rigs,” says Stow. “Over their service life, using
field gas will result in significant fuel cost savings over diesel.”
SUBMERSIBLE PUMPS TO
BE FUELED BY FIELD GAS
Antero Resources and Patterson-UTI Drilling are initially putting the gas generators
through their paces with the first installation of three engines at a well in Harrison
County, W. Va.
27. SEPTEMBER 2013 - www.gomcmag.com GOMC 27
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An operator inspects a skid-mounted natural gas generator
at an oil well drilling site in West Virginia.
NATURAL GAS HELPS MEET
EMISSIONS REQUIREMENTS
The natural gas generators also meet stringent state and federal mobile
emissions guidelines.
“As new rounds of emissions regulations go into effect, the EPA has chal-
lenged the natural gas industry to reduce levels of emissions during operation,”
says Countryman. “The natural gas engines are very green and CO, NOx and
volatile organic compounds emissions are significantly lower than diesel genera-
tors. US federal regulations reduced allowable NOx and CO emissions by 50
percent in 2010. However, some states are considering enacting tougher limits,
particularly on NOx. The natural gas engines also don’t
produce the black carbon and particulate matter – soot
– that diesel engines are known to produce.”
At lower levels of NOx, lean-burn engines oper-
ate in a narrow window, limiting fuel flexibility and
making them more sensitive to site conditions. In
addition, fuel consumption increases and efficiency
decreases as combustion deteriorates due to the high
amount of excess air used to lower NOx. Rich-burn
engines aren’t subject to the same trade-off.
In general, formaldehyde formation also increases
as an engine is operated leaner and combustion tem-
perature and exhaust temperature drop. Rich-burn
engines produce up to 10 percent less formaldehyde
than lean-burn engines.
Countryman also notes that the natural gas generators use Non-Selective
Catalyst Reduction (NSCR) technology, commonly referred to as a Three Way
Catalyst (TWC), which can achieve lower methane emissions.
“Rich-burn engines emit much less methane than lean-burn engines,”
he says. “The EPA requires that both CO2 and methane be included in total
carbon calculations. When we factor methane into the equation, rich-burn
engines may be able to deliver a better greenhouse gas profile.”
The NSCR technology used in the gas engines is less expensive than the
Selective Catalysis Systems used to meet emissions requirements in diesels.
The TWC needs to be cleaned or have its elements switched out every two
28. 28 GOMC www.gomcmag.com - SEPTEMBER 2013
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to three years, says Countryman. The elements are user removable and can be
used two to three times if cleaned.
EPA MOBILE CERTIFIED
Two of GE’s Waukesha VHP Gas Engines recently received mobile certifi-
cation from the EPA.
“With non-road mobile certification, these units can be used anywhere
in the United States, other than California, and still retain their certification,”
says Countryman.
Patterson has already begun to install Waukesha natural gas generators at
a second location and has committed to using them at additional drill sites.
“When considering investment in new equipment or improvements to
existing equipment, reduced emissions and cost-saving solutions have been
identified by customers as a major area of opportunity,” says Stow. “GE and
WPI worked with the customers to identify a solution that meet a range of key
requirements, such as fuel gas tolerance and no load bank requirements and
delivered additional operational benefits such as reduced fuel truck traffic at
the drill site through consumption of a local Appalachian fuel source.”
Another drilling company has also ordered 12 GE Waukesha natural gas
engines to be packaged by WPI to be used on its land rig platforms.
“The generators have undergone significant testing here at WPI,” says
Stow. “This phase of the roll-out is designed to demonstrate that the natural
gas engine-driven generators will do what they’re supposed to do in the field.”
GOMC
Comments or Suggestions ...
Is there an emerging technology in the gas, oil or mining industries you’d like us to investigate in
Tech Perspectives? Send your questions and story suggestions to editor@gomcmag.com.
Swapping out the existing diesel generators for newer natural gas models went smoothly
at the first installation. It was basically a plug-and-play operation. The old skids were
moved out and the new skids were put in their place.
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For drill pipe cleaning,
water jet systems beat
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You can get drill pipe back into service sooner — and keep it working
longer — when you clean it with NLB high-pressure water jets.
Our water jets (up to 40,000 psi) remove scale and hardened mud
more thoroughly than rattle-and-brush systems, making it easier to
pass inspections. Water jets also flush out debris and drilling fluids
without a separate rinse operation. That means fewer plugged drill
heads, less corrosion, and more work done between cleanings.
For drill pipe that easily passes inspections and goes longer between
cleanings, you can’t beat water jets. To learn more about NLB
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30. 30 GOMC www.gomcmag.com - SEPTEMBER 2013
he Bakken Shale Formation is
booming for Montana, North
Dakota and South Dakota. The area
is outperforming most of the rest of the
country in everything from unemployment
rates to new housing development, all
because of oil and gas. This isn’t the first oil
boom in North Dakota, but this one seems
more sustainable over the long haul, and
rapid development is following the rush to
drill new wells. The numbers below shed
some light on the area’s explosive growth.
North Dakota’s first oil well was
established just south of Tioga in Williams
County on April 4, 1951. The well
produced more than 585,000 barrels of oil
in 28 years.
In January 2003, North Dakota
produced 51,373 barrels of oil. By
January 2013, oil production had risen to
20,883,546 barrels. Between February and
March of this year, production increased by
2,263,801 barrels, almost four times the
entire production volume from 2003.
Oil has created more than 65,000
jobs and added over $12 billion to North
Dakota’s economy.
In 1995, the U.S. Geological Survey
reported that the Bakken Formation held
151 million barrels of technically recoverable
oil. That estimate rose dramatically to 3.0
to 4.3 billion barrels in 2008. The latest
assessment, which was completed early this
year and includes the deeper Three Forks
Formation, put the number at 7.4 billion
barrels.
Bakken oil accounts for 11 percent of
total U.S. oil production.
Average weekly wages increased 19
percent in the Bakken area during the
four-quarter year ending in the first quarter
of 2012, compared to 4 percent growth
in the rest of North Dakota, 1.9 percent
growth in Montana and basically no growth
nationwide.
Per capita household income in the
Bakken area is above that in the rest of
Montana, North Dakota and the U.S. as a
whole based on data through 2011. Bakken
workers make about $200 more per week
than the average U.S. wage.
Construction and land development
loans in the Bakken area increased 64
percent from $107 million to $176 million
from March 31 to Sept. 30, 2012, compared
to a 12 percent increase for the rest of North
Dakota and a 2 percent decrease for the rest
of Montana.
As of April 2013, the Bakken Formation
had produced 673 million barrels of oil,
Three Forks had produced 46 million
barrels and the Williston Basin as a whole
had produced 3.3 billion barrels of oil.
Current oil company leases are paying
mineral owners 20 percent or more, up
almost 2 percent from 2010.
The 2010 ND Oil Roads Study put
the combined number of inbound and
outbound truckloads per Bakken well at
2,024. Water required the most loads, at
400, followed by wastewater at 200. Frac
tanks, sand, scoria/gravel, rig equipment
and drilling mud, in that order, accounted
for the next highest volumes of truck traffic.
Nearly three-quarters of crude oil
leaving the Williston Basin is transported
by rail.
BNSF Railway has 14 major rail yards in
place or under construction in the Bakken.
Williston N.D. is home to more than
400 oilfield businesses, and over 31 percent
of its employment base contributes to
mining.
Job Search North Dakota’s Williston
office posted an average of 56 job openings
per day in March, including 225 openings
with 54 oilfield employers and 336
positions with 106 non-oilfield employers.
North Dakota’s Williams and Ward
counties ranked first and second in the
nation for new housing growth. North
Dakota is developing new housing at a
faster rate than any other state in the nation,
with 7,388 new units added last year, and
has the nation’s strongest growth rate at 2.3
percent, according to U.S. Census
Bureau estimates. The national
average was 0.3 percent.
Oil and gas exploration has
taken place in every county in North
Dakota except Trail County. The
success rate of horizontal wells in
Mountrail County is over 99 percent.
The current fleet of rigs drilling Bakken
and Three Forks wells will take 15-20 years
to develop the entire thermally mature
resource area. With today’s best technology,
it is predicted that 1 to 2 percent of the oil
reserves can be recovered.
Drilling and completion of the average
Bakken well costs approximately $9 million.
The average drilling time for a Bakken
well is down to just over 20 days, and the
time from spud date to completion date is
down to 110 days. GOMC
Bakken Extra
JUSTTHE FACTS
The Bakken Shale Formation is booming, and as
these numbers show, the impacts are far-reaching
By Luke Laggis
T
Between February and March of this year, production increased by 2,263,801 barrels,
almost four times the entire production volume from 2003.
32. 32 GOMC www.gomcmag.com - SEPTEMBER 2013
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34. 34 GOMC www.gomcmag.com - SEPTEMBER 2013
Product Focus
SLURRY PUMPS
FAN-COOLED PUMP
The VK650 from Masport is a fan-cooled pump capable of 377 cfm, 20 psi continuous duty, and
23 inches Hg continuous duty vacuum. The pump also includes an integrated stainless steel air filter to
protect the pump, as well as an integrated 1-gallon oil tank. The four-way integral valve has bolt-on 3-inch
NPT flanges for ease of installation, as well as a posi-lock handle for secure positioning. Heavy-duty bear-
ings, automatic oil pump, cushioned spring washer end thrust protection and carbon fiber vanes ensure
superior pump life. 800/228-4510; www.masportpump.com.
PROPPANT SLURRY PUMP
The MPX 12X14X22 proppant slurry pump from Master Pumps & Power is ideal for fracking jobs
that require a proppant to be pumped through slurry pump systems. The pump features a mechanical
seal lubricating system to extend the life of the mechanical seals and the fluid ends. Pump mechanical
seals and wetted parts will continue to wear, but it will pump more proppant. This along with reduced
downtime can lead to a high capital equipment payback. 800/410-0045; www.masterpumps.com.
PLASTIC PNEUMATIC PUMP
The Pumps 2000 America 2-inch pneumatic pump from Megator Corp. was introduced to address
difficult underground mining applications, including slurry. The air motor is stall free, freeze proof, kept
smoothly running without any lubrication and operates with low air consumption. It is made of light-
weight fire-retardant anti-static (FRAS) conductive plastic carrying an Atex M1 rating, and resists dete-
rioration even in low pH locations. The high suction lift allows for efficient, maintenance-free usage. The
super suction ability is due to the unit’s double-hinged diaphragms, long stroke, and self-cleaning slurry
and ball valves. Other production models include 1/2-, 1-, 1 1/2-, 3- and 4-inch models. 412/963-9200;
www.pumps2000america.com.
DEWATERING PROGRESSIVE CAVITY PUMP
The Moyno 2000 progressive cavity pump from Moyno Inc. offers efficient, cost-effective handling
of slurries and solids-laden materials in mining industry applications. The pump contains Ultra-Shield
rotor coatings and Ultra-Flex stator elastomer materials to pump abrasive, corrosive and viscous fluids.
It features a crowned gear universal joint drive train configuration to provide torque and thrust control.
Joint seals protect the gear joints from pumpage contamination. It offers flow rates to 2,500 gpm and
pressure capabilities to 1,000 psi. Models with standard flange or open throat configurations are avail-
able in a variety of construction materials with many different options, allowing customization to specific
needs. 877/486-6966; www.moyno.com.
ROTARY LOBE PUMP
The TORNADO T2 rotary lobe pump from NETZSCH Pumps features lobes running inside a metal
housing with a replaceable elastomer liner. This design doesn’t require O-rings or gaskets, yet delivers ro-
bust construction along with simplicity and ease of maintenance. A single, synchronous-toothed timing
belt eliminates the maintenance-intensive and costly gearbox. A pulsation-reduction system of channels
molded into the rubber walls of the pumping element releases lobe energy and dampens pulsation. The
housing design permits full flange-to-flange access when servicing the pump, and offers more room to
get into pump internals without having to disassemble piping. 610/363-8010; www.netzschusa.com.
By Craig Mandli
Pumps, Valves and Instrumentation
MasportMasterPumps&PowerMegatorCorp.MoynoInc.NETZSCHPumps
Dependable non-clogging pumps are a staple on the work site, keeping materials moving and production ongoing.
Here are several pumps, along with valves and components, designed to meet all job site needs.
35. SEPTEMBER 2013 - www.gomcmag.com GOMC 35
HORIZONTAL SLURRY PUMP
The Southern Cross SXHS heavy-duty horizontal slurry pump from Pentair / Myers is designed
for handling abrasive high-density slurries in a wide range of applications. It is manufactured to be
interchangeable with the most common slurry pump designs, and features an extensive range of material
and configuration options to suit the most demanding slurry pumping applications, including mining,
heavyindustryandmineralprocessing.Featuresincludeahigh-strengthpumpconstructionwithreinforced
ribs for high-pressure strength and safety; a replaceable wear liner; a sturdy cast iron, single-piece bearing
frame with four through bolts for easy maintenance and adjustment; an impeller that features pump-
out vanes as standard to prevent recirculation and extend seal life; and an external impeller adjustment
mechanism provided below the bearing housing for adjustment of impeller clearance. 888/416-9513;
www.southerncross.pentair.com.
COMPACT PROGRESSIVE CAVITY PUMP
Compact BN truck or trailer-mounted progressive cavity pumps from seepex can be mounted to a
truck or trailer and are ideal for oil and gas completion, water well drilling and grouting rig applications.
They can be combined with the company’s Smart Conveying Technology (SCT) for hydraulic powered
installations, are available with explosion-proof motors, and have conveying capacities up to 500 gpm and
pressure capabilities up to 360 psi. They can produce the same pressure as four-stage pumps with a smaller
footprint, and use a standard hydraulic motor for minimal downtime. 937/864-7150; www.seepex.com.
SEMI-TRASH PUMP
Suitable for handling water with small solids and light debris, semi-trash pumps from Subaru
Industrial Power Products offer a heavy-duty overhead cam gasoline engine and large volute discharge
opening. The 2-inch PKX201ST is powered by the Subaru EX13, a 4.5-hp engine, and provides a delivery
volume of 153 gpm. The 3-inch PKX301ST offers a delivery volume of 246 gpm and is driven by the EX17,
a 6.0 hp engine. 847/540-7300; www.subarupower.com.
TRANSFER PUMPS
ALL-PURPOSE PORTABLE PUMP
The Yakka150i from AllightPrimax is an all-purpose portable pump that features replaceable wear-
plates and impellers in stainless steel materials as standard, as well as the capability to pass 3-inch solids.
Built with an acoustic enclosure and designed for maximum sound attenuation, it emits only 65 dBA at 23
feet. The panels are easily removed for maintenance and can be designed with any custom color. The body
is impact resistant and requires little or no maintenance due to its poly outer shell. The tubular frame design
provides side and end protection and lockable gull wing doors wrap over the body for added security and
easy access. All controls are situated inside the lockable module. 877/477-4629; www.allightprimax.com.
VACUUM-ASSISTED PUMP
The Prime Aire Plus “PAH” line of vacuum-assisted pumps from Gorman-Rupp Company feature
sizes from 3 through 8 inches, and are suitable for both clear liquids and liquids containing large solids.
They are available coupled to the latest EPA Tier (IT4) compliant engines or premium efficiency (EISA)
electric motors, and employ the same venturi/compressor priming system as the Prime Aire line. Increased
head, flow and enhanced maintenance features are additional benefits. Features include externally ad-
justable running clearances, integral seal oil chamber, ductile iron body and impeller, two lip seals and
atmospheric vent to assure bearing protection, oil-lubricated bearings, backwards retro-fit capability to
competitor’s installations and fuel level monitoring system. 419/755-1011; www.grpumps.com.
DIAPHRAGM PUMPS
PORTABLE DIAPHRAGM PUMP
The WDP30X diaphragm pump from Honda Power Equipment Group moves wastewater contain-
ing up to 2.4-inch-diameter solids, and is designed for industrial applications, including construction,
agriculture, mining, and any application where muddy water, sludge or water with a high percentage of
solids might be encountered. Features include a GX120 OHV 118 cc commercial-grade engine, pumping
capacity of 80 gpm, 3-inch suction and discharge ports, a die cast aluminum case, air cushion chamber,
seepex
SubaruIndustrial
PowerProductsAllightPrimaxGorman-RuppPentair/MyersHondaPowerEquipment
36. 36 GOMC www.gomcmag.com - SEPTEMBER 2013
special rock channel that allows solids to easily pass, spring-protected connecting rod to prevent case dam-
age, rugged neoprene diaphragm with nylon insert and a standard wheel kit for easy transport. Each model
is protected by Honda’s Oil Alert system. 678/339-2600; www.powerequipment.honda.com.
METERING PUMP
Milton Roy’s mRoy Series metering pump offers application flexibility for efficient performance at
capacities from 0.46 to 170 gph. The pump features a design life of 30 years for the drive and 96,000 hours
for the pure PTFE diaphragm. Turndown flexibility and the ability to accept process signals enable the
technician to tune the pump to the specific application. Its standard advanced powder coat system gives
it durability in harsh conditions. Its compact design and high durability standards make it a fit for critical
treatment processes. 215/441-0800; www.miltonroy.com.
POSITIVE-DISPLACEMENT DIAPHRAGM PUMP
Positive-displacement diaphragm pumps from Mr. Pumper are ideal in reducing pumping costs for
oil and gas operations. Benefits include an environmentally friendly design that has no water leaks, no
external power usage (unless electrically driven), extended-run oil reservoir (NG only); production ranging
from 50 to 1,200 barrels per day and pressures ranging up to 1,000 psig; and completely automated con-
trol features. They are capable of disposing water using natural gas on location without electricity required.
They feature a remote start function utilizing EPS 3-12 controls. 877/566-7867; www.mrpumper.net.
AIR DIAPHRAGM PUMP
The rugged, lube-free 1/2-inch All-Flo air diaphragm pump from Mum Industries features non-stall/
freeze air systems. Engineered for maximum fluid and chemical compatibility, the bolted design offers
ease-of-maintenance and leak-free operation. It is available in a variety of materials and options, including
a Max-Pass valve system that allows operation under a variety of conditions ranging from clean fluids to
slurries, to solids applications. Pumps are offered in sizes ranging from 1/4 to 3 inches, and can be custom-
ized to meet requirements. 440/354-1700; www.allflo.com.
HYDRAULIC PUMPS
ROTARY LOBE PUMP
The Rotary Lobe Pump from Boerger is a valveless, self-priming, positive displacement pump offered
in 19 pump models in six series with flow rates up to 5,000 gpm. The screw rotor design enables a
pulsation-free and smooth flow operation. Each pump incorporates reversible flow capabilities for loading
and unloading operation. It can be driven with a hydraulic motor or PTO. It features optional elastomer
choices for O-rings and rotor designs. The pump housing is made from a choice of cast iron, ductile
iron, stainless steel or in duplex quality. The different sizes of housings and rotors are manufactured in a
single-piece construction. Applications include water-like and viscous, abrasive and corrosive fluids. The
maintenance-in-place feature means all wetted parts can be quickly maintained or replaced without the
removal of the pipe or drive system. 612/435-7300; www.boerger.com.
INLINE-DRIVE VACUUM PUMP
The RFL100DV(L)I inline-drive vacuum pump from Gardner Denver Wittig provides a different
drive arrangement than the standard right angle gear drive or hydraulically driven vacuum pump. It is
driven directly by the PTO shaft from the transmission of the truck without the need for a right angle
gearbox. Removing this component reduces installation costs and eliminates pump damage due to shaft
misalignment. The mounting bracket is included with the pump, and allows mounting between the frame
rails, saving space on the exterior of the frame. The discharge flange can be rotated to provide discharge in
any direction, allowing for flexible piping arrangements to fit various applications. 217/222-5400; www.
gardnerdenverproducts.com.
SAND SLURRY PUMP
The S6CSL submersible 6-inch hydraulically driven sand slurry pump from Hydra-Tech Pumps
includes a built-in agitator designed to stir up heavy solids. It has hardened wear components and is
intended for use in applications where settled solids must be put into suspension and pumped away
Mr.PumperMumIndustriesBoergerGardnerDenverWittigMiltonRoyHydra-TechPumps
37. SEPTEMBER 2013 - www.gomcmag.com GOMC 37
with the discharge water. Its primary applications include de-silting, dredging and moving driller’s mud;
other uses include filling sand bags to prevent beach erosion, tank and digester cleaning or pumping
sediment from caissons. The small size allows the pump to fit through a 22-inch opening. It requires
hydraulic inputs of up to 28 gpm at 2,900 psi and is capable of output flows to 1,200 gpm. It will pump
up against head pressure up to 130 feet. 570/645-3779; www.hydra-tech.com.
CENTRIFUGAL PUMPS
NON-CLOG PUMP
The Dri-Prime NC150 6-inch pump from Godwin, a Xylem brand, features flow capabilities up to
1,767 gpm and discharge heads up to 195 feet. Its Flygt N-technology has a self-cleaning hard-iron (60
HRC) impeller. Its Dri-Prime automatic self-priming system primes and re-primes from dry up to 28 feet
without operator assistance or foot valve control. It has a dry-running high-pressure oil bath mechani-
cal seal with abrasion-resistant silicon carbide faces. The close-coupled centrifugal pump is mounted to
a diesel engine or electric motor for easy pump-end or engine/motor changeover in the field. It can be
highway trailer or skid-mounted, or installed in a quiet enclosure. It is also available as a Godwin DBS
for pump station backup. 800/247-8674; www.godwinpumps.com.
SCREW CENTRIFUGAL PUMP
The Triton screw centrifugal pump from Vaughan Company features an open-channel impeller,
making it ideal for handling thick sludge, large or stringy solids, shear-sensitive fluids and delicate or
highly abrasive materials. Other features include steep performance curves, non-overloading power
characteristics, heavy-duty power frames and a flushless mechanical seal design to eliminate water
flush requirements. A water-flushed mechanical seal or packing is also available. 888/249-2467; www.
chopperpumps.com.
TRIPLEX PUMPS
WATER JET PUMP
The 225 Series water jet pump unit from NLB Corp. is a diesel-powered, triplex plunger pump unit
that is easily convertible to any of seven operating pressures (up to 40,000 psi). The series offers flows
from 6 to 82 gpm. Each unit can be ordered with a choice of heavy-duty diesel engine. Conversions
with a simple kit can be completed in about 20 minutes; the conversion to 40,000 psi takes about 30
minutes. Customers who already have an NLB 225 Series unit can add the 40,000-psi capability with a
conversion kit instead of buying a new unit. 800/441-5059; www.nlbcorp.com.
VALVES/BLOWERS
FOOTPRINT INTERCHANGE BLOWER
KAY Blowers from BRUDON Air Vac / Kay International offer robust housing design and an
impeller profile that substantially reduces pulsation, noise and slippage. They increase service life and
reduce overall maintenance and operational costs, and are designed with footprint interchange capabil-
ity that allows ease of installation without major retrofit or modification to the existing airflow system.
780/440-1634; www.brudonairvac.ca.
HEATED VALVES
The Metaltecnica Arctic heated valve series from CEI Chandler Equipment were designed
specifically for the industrial waste transportation sector and to eliminate the need for any electric or
add-on heating collars or devices. The design incorporates stainless steel tubing with 1/2-inch stainless
steel female NPT connections molded within the brass valve body, completely eliminating issues with
the valve freezing. It has the ability to use the heated liquid from a truck engine’s radiator/heat exchanger
to heat the valve and maintain a constant temperature without having multiple plumbing or electrical
connections. 800/342-0887; www.chandlerequipment.com.
GodwinVaughanCompanyBRUDONCEIChandlerEquipment
Email your ideas to editor@gomcmag.com
Is there a product you would like to see
featured in a GOMC Product focus story?
Let us know!
NLBCorp.
38. 38 GOMC www.gomcmag.com - SEPTEMBER 2013
MULTI-PORT FOUR-WAY VALVES
Heavy-duty cast iron 4- and 6-inch multi-port four-way valves from Moro USA Inc. can be used
in vacuum and pressure airflow applications, including mixing, blending and diverting applications.
Valves can be operated by handle, hydraulic or pneumatic automation. They allow toggling between
vacuum, pressure and neutral, and feature direct-mount actuator capabilities and live loaded stem seals.
The 4-inch four-way valve is available in standard NPT threads and weld flanges, while the 6-inch four-
way valve has mounting studs. A full line of heavy-duty forged brass and cast iron valves are available.
800/383-6304; www.morousa.com.
BOTTOM-LOADING COUPLERS
OPW Engineered Systems’ 1004D4 API bottom-loading couplers have been designed to combine
easy maintenance with a spring-loaded sleeve design. They utilize a sleeve that is spring energized to
automatically “jump-on” the API adaptor. The coupler also features a special fluorocarbon seal com-
pound that is compatible with most fuel blends, including gasoline, diesel, biodiesel and ethanol. It has
no drive pins to improve serviceability, and a shaft stuff box design that provides easy maintenance with
no special tools required. In addition, the D4’s five-cam design ensures tight connections and security
at all times. It also utilizes a stainless steel “ergo” handle design that provides easy, smooth operation.
513/932-9114; www.opw-es.com.
VACUUM TRUCK BLOWER
RB-DV Hi-Vacuum truck blowers from Robuschi USA feature an airflow range from 400 to 6,200
cfm. Its air injection manifolds allow it to operate at 28 inches Hg continuously without the need for a
vacuum relief valve. The lightweight manifolds and low-pulsation technology ensure lower noise attenu-
ation and less vibration by 10 dBA. The fabricated and cast manifolds and feet assemblies can be custom
made to suit PTO angle and lower blower between chassis rails, as well as providing handy lifting hooks
for safe and easy assembly and removal. Rubber mounting feet are included with custom-made feet
assemblies to ensure any chassis flex doesn’t affect durability. 877/424-1020; www.robuschiusa.com.
INSTRUMENTATION
MACHINERY SHAFT ALIGNMENT TOOL
The ROTALIGN SMART EX from LUDECA is a high-end laser, intrinsically safe system for
machinery shaft alignment in potentially explosive areas such as mining and petrochemical. It is certified
for use in hazardous areas in accordance with ATEX and IECEx regulations. Just enter machinery
dimensions, rotate the shaft in one continuous sweep less than a quarter turn from any starting position
and view alignment results at coupling and feet. Built-in soft foot expertise suggests corrections for soft
foot, not just measurements. It features machinery thermal growth computation plus machine train
alignment of up to six machines with specified tolerances, targets, names and icons for each machine.
305/591-8935; www.ludeca.com.
SCALABLE SCADA SYSTEM
The wireless ScalableSCADA system from Revere Control Systems provides flexibility for growth
and communication technologies. Non-proprietary hardware and communications protocols eliminate
common restrictions on growth, application and supplier. Available protocol choices include cellular,
radio, modem and landline. Standard features include built-in serial and Ethernet ports, webpages and
data logging with FTP transfer to a server. Options include I/O, modems, cellular modems and key-
pad. NEMA 4X fiberglass, NEMA 12, and NEMA 4X stainless steel enclosures are available, as is radio
path testing, ISA certified technicians and CSIA certified systems integrator. 800/536-2525; www.
reverecontrol.com. GOMC
MoroUSAValvesOPWEngineeredSystemsRobuschiUSA
For Environmental &
Support Service Professionals
SAFETYSchooledin
Tech Perspectives:
Above-ground
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PAGE 24
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Hydroexcavators open new profit center
PAGE 32
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39. SEPTEMBER 2013 - www.gomcmag.com GOMC 39
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SUMP PUMPS USED TO CONTAIN GOLD MINE SODIUM METABISULFATE SPILLS
Problem
A Burkina Faso-based gold mining operation needed to replace their aging and failing metallic sump pumps after just a few years of use. The company accepted
the routine corrosion-related problems they were experiencing in reactive areas of the gold mine when pumping sodium metabisulfate and in dealing with the tail-
ings remaining after the extraction of the precious metal. For environmental reasons it was critical to contain and neutralize the highly caustic fluid.
Solution
After reviewing several options, the company selected the SGK cantilevered Sump Gard vertical centrifugal sump pump from Vanton Pumps. All of the
pump’s fluid contact parts are made of homogeneous polypropylene, promising a long service life. They include a balanced, closed impeller on a large diameter
steel shaft constructed of 304 stainless steel completely sleeved with polypropylene. All wet-end components are made of thermoplastic materials, which are inert
to corrosive chemicals.
Result
With no immersed bearings or bushings, the pumps were capable of run-dry operation for extended periods, an ideal benefit considering the mine’s remote
location, and the increased cost and impact of pump malfunctions and re-installation. Mine operators reported a longer service life and increased level of operation
since installing the pumps several years ago. 908/688-4216; www.vanton.com. GOMC
Case Study
By Craig Mandli
Pumps, Valves and Instrumentation
SUMP PUMPS USED TO CONTAIN GOLD MINE SODIUM METABISULFATE SPILLS
Problem
A Burkina Faso-based gold mining operation needed to replace their aging and failing metallic sump pumps after just a few years of use. The company accepted
the routine corrosion-related problems they were experiencing in reactive areas of the gold mine when pumping sodium metabisulfate and in dealing with the tail-
ings remaining after the extraction of the precious metal. For environmental reasons it was critical to contain and neutralize the highly caustic fluid.
Solution
After reviewing several options, the company selected the SGK cantilevered Sump Gard vertical centrifugal sump pump from Vanton Pumps. All of the
pump’s fluid contact parts are made of homogeneous polypropylene, promising a long service life. They include a balanced, closed impeller on a large diameter
steel shaft constructed of 304 stainless steel completely sleeved with polypropylene. All wet-end components are made of thermoplastic materials, which are inert
to corrosive chemicals.
Result
With no immersed bearings or bushings, the pumps were capable of run-dry operation for extended periods, an ideal benefit considering the mine’s remote
location, and the increased cost and impact of pump malfunctions and re-installation. Mine operators reported a longer service life and increased level of operation
since installing the pumps several years ago. 908/688-4216; www.vanton.com. GOMC
Case Study
By Craig Mandli
Pumps, Valves and Instrumentation
40. 40 GOMC www.gomcmag.com - SEPTEMBER 2013
FileName:DDC7836_HardworkingQR16R_GOMContract.inddTitle:HARDWORKINGQR16R...
Client:DetroitDieselPub:Gas,Oil,MiningContractor
Job#:DDC8185TrimSize:9x10.875”
App:InDesignCS6BleedSize:9.5x11.375”
Colors:4cpCloseDate:6/17/2013
www.rideragrisales.com
JUROP PN155R
VACUUM PUMP
• 538 CFM • Built-in oil reservoir
• Automatic Lubrication
• Continuous duty pumping @ 21"
• Ballast port cooling
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• LC-300 300 CFM
• LC-420 425 CFM
• 27" Continous Duty
• 29 PSI
• Automatic Oil Lubrication
• Built-in Final Filter
UNMATCHED PERFORMANCE
JUROP R260
VACUUM PUMP
• Automatic lubrication
• 364 CFM • Built-in oil reservoir
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• 92% vacuum efficient
RV360 360 CFM - 3"
RV520 520 CFM - 4"
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JUROP LIQUID COOLED
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42. 42 GOMC www.gomcmag.com - SEPTEMBER 2013
Money Machines
educing customers’ expenses by improving their operating efficiencies
goes a long way toward attracting loyal customers. Davey Graham, the
owner of Gonzo LLC in De Beque, Colo., knows this from experience,
thanks to the dozen submersible S6CSL pumps his company owns.
These workhorses, made by Hydra-Tech Pumps and driven by Hydra-Tech
power units, were instrumental in helping Graham establish his business in
2008. Gonzo provides an array of water-management services to oil- and gas-
drilling companies in Colorado.
“We tried regular vacuum-assisted pumps, but their performance
was inconsistent,” Graham says. “For continuous operation, we found that
submersible pumps are the only way to go.”
The Hydra-Tech pumps provide several benefits to Gonzo customers. First
of all, they save money by helping operators recycle drilling mud. Set in the
cellar ring, or cellar box, the pumps circulate fluid and cuttings/shavings from
the well bore to filtering screens that separate solids from the mud, which can
then be reused. Moreover, recycling mud minimizes the use of fresh water
required to mix new batches of mud, Graham says.
“That way, they don’t have to keep accessing local water resources …
and using freshwater on a continual basis,” he points out. “It’s one way to
minimize the environmental impact.”
The pumps also help reduce costs when drilling companies bore multiple
holes in well pads, he notes.
“The Hydra-Tech pumping system allows for much cheaper operation
when they batch their surface holes,” he explains. “The savings come from
eliminating the need for a flow line, or nippling up, as they call it. That, in turn,
makes for a quicker cementing and casing process.”
This technique also benefits the drilling companies because it further
minimizes the chances of contaminating the mud system with cement. If
cement gets into the mud, it ruins it, he says.
“Then it costs a considerable amount of money to clean out the mud
tanks and rebuild your mud,” he says.
R
PUMPINGUPPROFITS
Hydra-Tech equipment helps Colorado contractor improve efficiency for drilling companies
By Ken Wysocky
<< Gonzo LLC uses Hydra-Tech power
units, shown here on a drill site in
Colorado, to power the Hydra-Tech
pumps. Gonzo provides an array
of water-management services to
drilling companies, and the pumps
were instrumental in establishing the
business.
Gonzo LLC, De Beque, Colo.
MACHINES: 12 S6CSL submersible pumps and 12 power units,
all made by Hydra-Tech Pumps
FUNCTION: Pumping drilling mud and fracking water on well pads
FEATURES: Variable-speed, hydraulic-drive operation; 6-inch discharge;
flow of 1,250 gpm at 135 feet of head
COST: $12,000 per pump; $60,000 per power unit
43. SEPTEMBER 2013 - www.gomcmag.com GOMC 43
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The pumps, which weigh 495 pounds and can
generate flow of 1,250 gpm at 135 feet of head,
cost about $12,000 apiece. The power units go for
roughly $60,000. They only require one person for
operation, which is controlled by a throttle on the
power unit. Other features include variable-speed,
hydraulic-drive operation; a 6-inch discharge port;
hydraulic input flow of 28 gpm; and hydraulic
operating pressure of 2,800 psi.
Graham lauds the pump’s design, which features
a built-in, high-chrome agitator that’s attached to the
impeller. The agitator helps keep solids suspended in
the slurry, which maximizes the removal of cuttings
and shavings.
“As a result, you’re not filling up your cellar with
cuttings,” he says. “If you have too many cuttings
sitting at the bottom of the hole, then you have to
over drill … which costs a significant amount of time
and money for a drilling rig and its employees.”
Gonzo also uses the pumps to more efficiently
remove water and debris – rock, sand and trash, for
example – from pits used to store water for fracking;
this is part of the process of reclaiming the land by
backfilling the pits when drilling is finished.
“These pumps help save thousands of dollars
because they’re so fast and they don’t leave a lot of
debris behind,” Graham says. “They pump the water
into a series of tanks where the solids separate and
then are disposed of.”
Overall, Graham says the Hydra-Tech pumps
help him provide efficient solutions for improving
operating efficiencies.
“Depending on how many wells a company is drilling, it can save them
$2,500 a well in terms of increased productivity and efficiencies associated with
drilling surface wells,” he says. “Without these pumps, it would take them a
lot longer to drill wells, and it would be riskier in terms of the environmental
impact.” GOMC
“These pumps help save thousands of
dollars because they’re so fast and they
don’t leave a lot of debris behind. They
pump the water into a series of tanks
where the solids separate and then
are disposed of.”
Davey Graham
44. 44 GOMC www.gomcmag.com - SEPTEMBER 2013
he CVS line of liquid-ring and water-cooled VacuStar vacuum pumps
from Fruitland Manufacturing proved popular with visitors at this year’s
Pumper & Cleaner Environmental Expo in Indianapolis.
“We just brought this line on,” says Keith Myers, business development
manager for Fruitland Manufacturing. “We contracted with a company in
Germany called CVS [Engineering GmbH] with over 30 years of experience. It’s
a liquid-cooled pump at 765 cfm [model W 3100; model W 900 delivers 530
cfm and model W 1600 delivers 942 cfm]. The application for the pump is
industrial, for refineries, chemical plants and paper mills, so a lot of the exhibitors
at the Pumper show this year use this type of product for their end-users,” he
says. “Most of the customers were getting 10, 15 years before they have to do
any rebuild on it.”
The liquid-cooled pumps deliver 506 (W 900) to 924 (W 1600) cfm at
18 inches Hg, have an operating pressure of 29 psig and maximum operating
volume of 27 inches Hg, depending on cooling water temperature. The pumps
have a speed range of 1,000 to 1,500 rpm. Power requirements range from 35.5
hp (W 900) to 63 hp (W 1600). The model W 900 weighs 485 pounds, the W
1300 weighs 615 pounds and the W 1600 weighs 747 pounds.
Myers says the pumps are easy to install. “We have what’s called the
Eliminator Series. These are comprehensive packages. All you have to do is
literally bolt it up, hook up the plumbing and the PTO and you’re ready to go.
Drive types vary from hydraulic right-angle to belt drive.”
The pumps can be used with multiple truck types. “They can be used on
hydroexcavators or a regular vacuum truck,” he says. “In an application, you’re
looking at refineries and chemical plants where they have ponds, pits, separators
and lift sumps that collect liquid waste. Companies would go to the site, use
this pump to load their tank, then take it to a disposal site and use the pump to
unload the tank.” Tank sizes can range from 1,000 to 8,000 gallons.
Toby Jones, director of sales for Fruitland, predicts the CVS liquid-ring will
be the pump of the future. “We sold out of them before we got the next container
on its way,” he says. “It’s refining, mining and OSHA friendly because there is
no spark.” The model line includes the WR 2500 (1,470 cfm maximum volume
flow), WR 3100 (1,825 cfm) and WR 4000 (2,393 cfm).
“The other big feature is you can make a mistake and suck product into the
pump,” he says. “Once you contaminate it, it’s as simple as dumping that water
and putting freshwater in. So it’s forgiving.”
Maximum volume flow is 1,470 cfm for the WR 2500 and 1,825 cfm from
the WR 3100. The WR 4000 has a maximum operating pressure of 14.5 psig and
maximum operating vacuum of 27 inches Hg; the WR 2500 and WR 3100 have
a maximum operating pressure of 21.3 psig and maximum operating vacuum
of 26 inches Hg, depending on cooling water temperature. The WR 4000 has
a speed range of 800 to 1,300 rpm; the WR 2500 and WR 3100 have a speed
range of 800 to 1,600 rpm.
The WR 2500 weighs 385 pounds, the WR 3100 weighs 422 pounds and
the WR 4000 weighs 657 pounds. Maximum horsepower requirement for the
WR 2500 is 105, 128 for the WR 3100 and 176 for the WR 4000.
Pump features include face seals for extended service life and internal
cooling with cavitation protection.
“It resists chemicals, rust and corrosion,” Jones says of the pumps’ anodized
aluminum design. “It’s also very truck friendly. You can mount it at a 22.2-degree
angle to go around a vacuum tank. The connection flanges that go from the
pump to the vacuum tank are extremely flexible and adaptive to wherever you’re
plumbing.” 800/663-9003; www.fruitland-mfg.com. GOMC
Expo Spotlight
Pump of the Future
New line of liquid-cooled, liquid-ring pumps proves popular at Expo
By Ed Wodalski
T
“The other big feature is you can make a mistake and suck
product into the pump. Once you contaminate it, it’s as simple as
dumping that water and putting freshwater in. So it’s forgiving.”
Toby Jones
Keith Myers (left), business development manager for Fruitland Manufacturing, describes
features of the VacuStar W 1300 water-cooled compressor vacuum pump to a visitor at the
Pumper & Cleaner Environmental Expo.
Pumper & Cleaner Environmental Expo
Education Day: Feb. 24, 2014 Exhibits Open: Feb. 25-27, 2014
Indiana Convention Center - Indianapolis | pumpershow.com
