Verderflex General Training
Paul Nelsen – Managing Director
Introduction
Verder, Inc.
• Main stocking facility located in Macon, GA
• Master Distributor for:– Alfa Laval / SSP Industrial
Rotary Lobe Pumps– Verderflex Peristaltic Hose
Pumps– Verderair Air Operated
Diaphragm Pumps• Large stocking/Repair
facility for all product lines
Who is Verder, Inc?
– Part of the Verder Group, founded in 1959, international headquarters located in Holland
– North American headquarters (warehouse, sales, & assembly) through Verder, Inc., Macon, GA
– Offices located in 14 countries across the globe (UK, Netherlands, France, Germany, Belgium, Poland, China, Czech Republic, South Africa, Norway, Romania, Austria, Slovania)
– 450+ direct employees worldwide, 60 in the US branch
The Verder Family….
Who is Verderflex?Largest Peristaltic Pump manufacturer in the world
• Smallest size is 5mm ID• Largest size is 125mm (5”) ID
Leader in product innovation• Dura product line• Smart tubing pumps
Superior Hose life• Longest lasting in the industry• Color-coded for easy recognition
Verderflex “Factory”
VA 8 VA 10 VA 15 VA 25
VA 40 VA 50 VA 80
Who is Verderair?Air-Operated Double Diaphragm Pumps
VA 20
VA-P08
VA-P10 VA-P15 VA-P25 VA-P40 VA-P50
Who is Verderair “PURE”
• Solid design: machined from solid material• 100% Pure materials are used : PE1000 and PTFE• Best abrasion resistance : PE• Best chemical resistance : PTFE• No material stress points• Absorption of mechanical movement: mounted on feet
FUTURE: Verder HUS
Screw Centrifugal pumpsSolids Handling Pump
©SSP Pumps Slide 15
Verder, Inc. – Macon, GA
Sales Office - Service Facility - Warehouse
© Alfa Laval Slide 16
Dual Disc Single Disc
Cast Iron & Elastomeric
High Capacity S.S. & C.I.
Series S Range
Stainless Steel
Series X Range
Series A & G Ranges
Cast & Ductile Iron
Series N Range
SSP Brand Products
Series D
Series L
Master Distributor for SSP Alfa LavalSuper Heavy Duty Rotary Lobe Pumps
• Founded in 1958 as Stainless Steel Pumps, LTD (SSP)
• Acquired by Alfa Laval in 1987• Alfa Laval - $5 Billion in sales
worldwide, transcending several industries & equipment
• SSP located in Eastbourne, UK
©SSP Pumps Slide 18
SSP Factory – 130,000sq.ft.
©SSP Pumps
CU - Components
©SSP Pumps
Rotorcase Machining
©SSP Pumps
Shaft Machining
©SSP Pumps
©SSP Pumps
Shaft Machining
©SSP Pumps
Rotor Machining
©SSP Pumps
©SSP Pumps
©SSP Pumps
Rotor Machining
and checking…
©SSP Pumps
SU - Supply
©SSP Pumps
©SSP Pumps
©SSP Pumps
Short term focus
Supply focus
Process stability
Processes• MES• AviX• VMI• Tactical forecast• Complex Orders• One4AL• Manufacturing system/
PULSEImprovement• Six Sigma pre-study and
realisation Leadership• Team reviews• 360o performance
development for managerslevel 4
• Succession planning• Salary system• Competence dev. plan
Processes• Customer
Segmentation and requirements
• Gap analysis of current supply chain capabiliites and customer req:s
• End-to-end forecastingprocess
• Complex Orders• Control TowerImprovement• Voice of the Customer • TTM -Design for Six
Sigma• Six Sigma in Supply
Chain (risk management)
• ISO 14001 and OHSAS 18001
• Performance Driven Supplier Cooperation
Leadership• Rotation between
Operations and other functions
• Benchmarking• Competence network
Best in ClassCustomer Value
New Concepts and Methods
World class
Processes• Process mapping • Basic IT/IS systemImprovements• Housekeeping• Operational plan• StargoalsLeadership• Build management
team
Processes• CU-SU concept and
flow oriented principles
• ISO 9000• Basic Inventory
Management• Supplier Development• Preventive MaintenanceImprovement• PROMAL• Six Sigma Feasability• 5SLeadership• WC yearly appraisal
talks• Mgrs performance
development• Org. Planning• Clear roles and resp.• Prof. recruitment
Processes• DPMO trend > 25 %
year-on-year• Customer configurated
supply chainsImprovement• Virtual Networks
(internal and external as ONE AL)
Leadership• AL Operations leaders
candidates for any position within Alfa Laval
• Knowledge management
TTM / New Product Introduction Structural Change / Business Plan
Six Sigma preparations Six Sigma realisation
Color legend:• Established • Ongoing implementation• To be developed• Not Apply
Operations World Class JourneyStatus Eastbourne 2007 Q1
©SSP Pumps
Series D Ranges
SSP Brand Pump Products
DD SD
Cast Iron & Elastomeric
High Capacity St.St. & C.I.Series S Range
Stainless Steel
Series X Range
Series A & G Ranges
Cast & Ductile Iron
Series N Range
7 minute overview - Verderflex
Who is Verderflex?
– Largest Peristaltic Pump Manufacturer in the world • Smallest size is 5mm ID• Largest size is 125mm (5”) ID
– Leader in product innovation• Dura product line• Smart tubing pumps
– Superior Hose life• Longest lasting in the industry• Color-coded for easy recognition
Advantages of Peristaltic Pumps
• Abrasion resistant– Hose life is not related to a product’s abrasive qualities– The hose fails due to fatigue or chemical action, not abrasion
• Solids Handling– Able to pump liquids containing up to 80% fine inorganic solids
(Slurry)– Up to 10% sludge capabilities
• No moving parts in the liquid stream – No contamination of product, pump or gearbox– No metal to metal contact– Smooth liquid passage (no valves, dead corners, or mechanical parts)
More Advantages• Self priming / Dry Priming
– Up to 95 % vacuum or 31’ lift of water
• Dry-Running– The hose is lubricated from the outside– Able to pump air or products that “off-gas” (NaOCl, Yeast)
• Reversible rotation– The pump can be used to empty lines or clear blockages
• No internal backflow– Accurate Dosing (true positive displacement)– Rotary pinch valve– repeatability ± 1%
More Advantages
• Shear sensitive products – Suitable for handling Flocculent/Coagulant, Polymers– Product is not damaged, Process Performance Improved
• Easy maintenance– Low cost of ownership (hose is only wearing part)– Easy and completely cleanable without disassembly– Reduced down time (maintenance in place)
Pump Terminology
Tubing Pumps• Capacities range from 0.25 gph –
7 gpm• Discharge pressures up to 30 psi• Many consist of integrated drive
units with built in controls (4-20mA, RS232)
• NEMA 4 washdown enclosure• Use non-reinforced extruding
tubing– Verderprene, Silicone,
Fluoroelastomers (Viton, Chem-sure)
• Tubing life ranges up to 5000-6000 hours depending on material & pump speed
Hose Pumps• Flow rates from .05gpm – 395gpm• Pressures up to 232psi across full range• Uses Nylon-reinforced hose to achieve
pressure• Four Basic Hose materials, one size per pump
(range from 5mm ID to 125mm ID):– Natural Rubber– EPDM– Buna– Hypalon
• Hose life generally lasts 2000 hours, depending on application details
• Speed is key – slower is better!
Pump Selection / Pump Sizing
Key Questions to Ask
• What am I pumping ? – Affects the chemical resistance of the hose type
and inserts
• How am I operating the pump ?– Intermittent or continuous duty
– Hose life and / or a smaller pump
• What is the product temperature ?– Limits hose type, hose life or pump size
Key Questions to Ask
• What is the discharge pressure and flow rate ?– Pump type, power requirement and pump speed
• What is the length of the suction and discharge lines ?– Determines impulse and friction losses
• What is the product’s working viscosity ? – Determines friction loss – Adequate NPSHa?
• What fittings do I need ?– ANSI flanges, threaded NPT, etc.
How Do I Size A Pump ?
• A pump’s capacity is determined by :
a) The hose’s swept volume
b) The pump’s speed
c) Operating conditions that may restrict the pump’s ability to self-prime
* Several pumps that can deliver the same flow. Must consider factors such as solids handling capabilities, ability to self prime, etc.
Volume Displacement per Revolution
Pump Capacity per rev (Gallons)
10mm 0.0066
15mm 0.022
25mm 0.0749
32mm 0.1585
40mm 0.33
50mm 0.705
65mm 1.5
80mm 2.93
100mm 4.835
125mm 8.8
Maximum Flow Rates
Pump Continuous Intermittent
10mm 0.45 GPM 0.72 GPM
15mm 1.65 GPM 2.64 GPM
25mm 8 GPM 9.6 GPM
32mm 14.8GPM 19.8GPM
40mm 26.3GPM 35 GPM
50mm 42 GPM 56GPM
65mm 76 GPM 112GPM
80mm 117GPM 175 GPM
100mm 146 GPM 242 GPM
125mm 242 GPM 395 GPM
Discharge Side Considerations
• The maximum discharge pressure is 16 bar or 232 PSI
• What does discharge pressure consist of?• Absolute Pressure • Hydrostatic Head • Frictional Losses• Impulse Losses (the one most forget)
• Tip: When pumping products that tend to settle, such as heavy slurries, some will engineer in an under-sized pipe diameter. Therefore, for long lines, pulsation dampers are generally needed
HYDROSTATIC HEAD LOSSESPressure associated with moving a fluid with or against gravityPs = S.G. x gravity x height
FRICTIONAL HEAD LOSSES
Different equations for type of flow
Based on flow, viscosity, pipe length, pipe ID, pipe type,
pipe layout
ABSOLUTE PRESSURE
Atmospheric 14.7 PSI (or absolute containment pressure)
Discharge considerations
Suction Lift Considerations• Flooded Suction Preferred• Hose Pumps Can Lift 30’ Water Column • Give Hose Time to Restitute
– Consider Pump and hose size– Consider Pump Speed (run slow)– Consider Piping Arrangement
Viscosity Considerations• Newtonian - viscosity unaffected by motion or agitation
(Water), i.e. doesn’t change moving through the pump
• Non Newtonian - Viscosity affected by motion– Thixotropic: Shear thinning (Yogurt, Mayonnaise)– Dilantant - Shear thickening (Kaolin Clay, Corn flour)
• Units are typically measured in centipoise– Common liquid viscosities:
• Water (68F) 1 cp• Egg Yolk (40F) 1,600 cps• Honey (65F) 11,000 cps• Honey (100F) 1,400 cps
Viscosity Considerations
• Under viscous conditions, hose cannot restitute to its full size, causing a decrease in volumetric efficiency
• Flow to the pump is generally key to application
• Running at slower speeds allows more time for hose to restitute at a given flow rate
• Use larger piping, shorter pipe runs, and few elbows/connectors to keep from restricting flow
Pulsation Effect• When the upper shoe leaves the hose, product will try to flow
back into the pump and it collides with product being pushed ahead of the lower shoe.
• The causes a hammering effect or pulsation
• SOLUTIONS include resizing pipe work or installing flexible hoses or fitting pulsation dampers
IMPULSE LOSSES - What Increases Pulsation?
Pi = c1* (La * F * n * s.g.)D2
Pi = impulse losses
c1 = constant
La = actual pipeline length
F = pump capacity n = pump speed sg = specific gravityD = diameter of the pipeline
Minimize Impulse Losses
• Short Piping Runs• Oversize Piping (Where Possible)• Minimize Restrictions & Elbows• Run Pump at a Slow Speed• Use Flexible Lines• Use pulsation dampeners where
needed• Consult factory to review system
General Installation Tips
• Pipework should be as short and direct as possible
• Piping should be over-sized, especially the suction line
• Include a short, removable section next to the pump for easy access (hose changes etc). Preferably this should be a flexible hose
• Lines should include valves and a discharge line pressure relief device (closed valve protection). They should also include a product drain down capability
HOSES
the soul of Peristaltic Pumps
Hoses – The Soul of a Peristaltic Pump
• Hoses are custom produced to very tight specifications – Cannot put a standard reinforced hose into a Peristaltic Pump. Must be specifically made for this duty.
– Natural Rubber (NR)– Nitrile Buna Rubber (NBR) – Ethylene Propylene Diene Monomer (EPDM) and– Chlorosulphonatedpolyethylene Monomer (CSM or
CSP) or Hypalon ®
• Hoses have been developed for increased fatigue resistance – the most likely cause of normal failure
• Some hoses interchangeable in other hose pumps – make sure you know which ones!
Not all EPDM Hoses are the same…
• Some made with EPDM liner, Verderflex hoses made with 100% EPDM• EPDM is used when chemical attack is the likely cause of hose failure
– A solid hose will last longer : there is more chemically resistant rubber – A lined hose allows small quantities of chemicals to leach through the outer
cover once the resistant liner is breached• A pure EPDM hose has better thermal resistance
– The weak point of a liner hose is the bonding between the dissimilar rubbers, which typically melts at 105°C, giving a max continuous working temperature of 80°C.
– A pure EPDM hose is good for 115 – 120°C when bonding between homogenous layers of EPDM starts to melt, allowing a higher maximum continuous limit of 100°C
EPDM
Natural Rubber
Factors Influencing Hose Life
• Speed• Discharge pressure• Temperature• Chemical compatibility• Duty cycle
Hose Manufacturing
Cross-sectional views of standard Peristaltic Hoses
Competitor Hose Verderflex Hose
Hose Distinctions
• Verderflex hoses have a larger number of reinforcement layers than others– During the manufacturing process, rubber is
pressed into the reinforcing fibers, trapping the rubber for greater strength
– The compressing load (to close the hose) is spread across these reinforcing fibers
– The higher the number of fibers, the better the load distribution and reduction of load per fiber
– Hence, better fatigue life
• Most other hoses’ reinforcement layers are spun into place during manufacturing– The spinning process limits both the
number of fibers and the size of reinforcements that can be built into a hose
• Verderflex hose does not use a spinning process, so it can use more fibers to equalize the compressive load and this gives the Verderflex hose it’s superior fatigue strength
Hose Distinctions
Extruded/Machined Hoses vs. Vulcanization
•Extrusion does not permit close diametrical tolerances to be maintained •Extruded hoses must be ground to meet these tolerances, typically 2mm to 3mm from the surface
•Vulcanized hoses are hand made which achieve tolerances w/o grinding or surface abrasionSurface Roughness:•“Ribbed” exterior of Verderflex hoses actually aides in lubricant distribution to top of hose, allowing for cooler running•Radial load more on machined hoses than on Verderflex Hoses
Verderflex VF-Series Close-Coupled Hose Pumps
Anatomy of a Hose Pump
Reinforced Hose
Suction / Inlet Port
Discharge/ Outlet Port
Cast Iron Housing & Rotor
Pressing Shoe
Rotor and Pressing Shoe Assembly
• Aluminium Rotor Shoe
• Stainless Steel Shims: – These allow hose
compressing force to match discharge pressure
• Cast Iron Rotor with Taper Lock Bushing
• No Shoes on VF10 or VF15 or Dura
– These have low or high pressure rotors only
Port Flange Assembly – VF
• Shows the sealing ring, the port flange and the hose insert
• Sealing ring is supplied as part of port flange assembly or as a flange sealing kit for service use
4 Build Positions
Hose Pump Types• There are two styles of hose pumps –
• Close Coupled –The pump’s rotor is mounted directly onto the gearbox’s shaft and the drive is bolted directly onto the pump’s drive flange
• Long Coupled –The pump’s rotor is mounted onto the drive shaft of a bearing assembly. The stand alone gear motor unit is connected to the pump by a flexible coupling
Advantages of the VF-Series
Simplicity…. Due to the simplicity and flexibility of a close-coupled configuration, only 3 parts needed to change a rotor (Rotor, shaft, & taper-lock bushing)
Multiple pieces, special tools, bearings, presses, and spline alignments required with other hose pumps
VF Series vs Competitor
Verderflex Fail Safe Hose Clamping Assembly
• The insert sits inside the hose
• The sealing ring fits over the hose & as the flange is tightened into the casing, the machined taper in casing forces the sealing ring to tighten onto the hose securing the insert in place
• The assembly will withstand pressures in excess of 30 bar / 435 PSI
• The hose to be pushed onto the discharge port & the pump action tries to pull the hose off the suction port – this is why the suction side sealing rings always “bite” harder into the hose
Safety & Reliability
• The Verderflex hose connection safely and securely contains the hose entirely within the pump casing.
• Some competitors have an exposed hose connection.
• Chemicals have a leak path that can lead to workplace contamination.
• These pumps also have exposed band clamps that can rust and corrode, becoming difficult to remove.
Safety & Reliability
Dependability / Longevity
• Stronger more robust rotor design prevents cracking in overload / stalled conditions
• Higher strength Aluminum shoes hold up to better to higher loads and withstand harsher conditions than Epoxy shoes, which tend to crack under high stress
Summary of Verderflex VF Series
• Widest range of peristaltic hose pumps in the world, from 5mm to 125mm
• Robust industrial pump designed to withstand the harshest process conditions
• Simple and safe clamping system contains all product within the casing
• Simplified, maintenance-friendly close coupled design
• Hoses are unmatched in performance, life, and reliability
Long Coupled Pump w/Close-coupled Advantages!
• A genuine advance in hose pump design combining advances in hose design, rotor profiles and component design to provide a true performance advancement while reducing the overall package size
• Increased hose life compared to existing hose pumps• Vertical gearbox & more compact casing dramatically reduced footprint• Gearbox is totally isolated from pump head → zero possibility of contamination• Specially designed hose reduces radial load → lower power consumption• Modified rotor profile generates less heat• Rotor locates directly over bearings, removing radial load from gearbox• Sealed for life bearings press fitted into casing• 316 stainless taper fit universal port flange, disaster-proof design, suits ANSI
150# standard, also available in polypropylene and PVDF• No shimming – standard rotor is good for 6 bar / 90 PSI, high pressure option to
12 bar / 175 PSI• Carbon steel front cover with viewing window
Verderflex Dura
Dura 35 Dura 25 Dura 15Dura 10
15 gpm 6.6 gpm 1.7 gpm0.50 gpm
Rotor Supported by Bearings
No shimming requirement : Standard and high pressure rotors
Rotor couples directly onto the shaft and locates over the bearings removing overhung load
Gearbox is totally isolated from pump head – zero possibility of contamination
Internal Bearings
Sealed-for-life bearings press fitted into the housing
Bearings protected by Viton lip seal
The Dura Port FlangeTapered insert section of port flange compresses the hose against the casing for secure hose clamping
Withstands pull off pressures of 430+ psi
ANSI 150 lb standard flanges
Speeds up hose changes but still maintains hose enclosed in casing
Cast 316 Stainless FlangeOption: Polypropylene
Gearbox Mounting
Torque arm mounts to PCD of gearbox
Gearbox slides onto shaft and over shaft key
Gearbox is free to sway slightly, dissipating energy away from pump
Compact right-angle design allows for significantly smaller footprint
The D10 only takes up ¼ of the footprint of Typical 10mm Hose pump
VF10 / Comp. 10mm
The D15 requires 30% of the floor that a Typical 15mm Hose Pump
VF15 or Comp. 15mm
The D25 requires ⅓ of the space of a Typical 25mm Hose Pump
VF25 or Comp 25mm
Dura Hoses
•Dura hoses are available in natural rubber, Buna, EPDM and Hypalon•New hose construction with thinner wall
– Reduces torque requirements – Limits Pressure capability
VF10 & D10 Hoses End View
Hoses are shorter than standard hoses and are unique to Verderflex DURA – D15 is shorter than VF10
Reduced Operating Temperature
Back to back tests show the Dura runs cooler, helping maximize hose life
Running Temperatures
0
5
10
15
20
25
30
35
40
45
Dura 15 VF 15
Tem
p in
Deg
rees
Cel
siu
s
Increased Hose Life
Back to Back Test Dura 15 & VF15 – 45psi, 25 rpm
Back to Back Hose Life Comparison
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
D15 VF15
Ho
se L
ife
in H
ou
rs
Competitive Comparison
The D10 only takes up ¼ of the footprint of Bredel SPX 10
The D15 requires only 30% of the SPX15 footprint
The D25 requires ⅓ of the space of a Bredel SPX 25
Other Competitive Advantages
Pressure Capabilities:
All Dura pumps have 2 rotor options – Standard pressure (90psi) and high pressure (175psi).
SPX 10 and 15 can only achieve 115 psi.
Safety and Ease-of-use:
All Dura pumps have a small cutout at the flange to allow for visual confirmation of hose clamping. Hose is still contained entirely within the pump casing.
Proven Durability in the Field
Over 2200 Dura pumps now installed in North AmericaPicture shows Verderflex Dura pumping Enamel
Summary of Verderflex Dura
• The Verderflex Dura is a proven advance in hose pump technology
• It combines the best features of long coupled and close coupled designs
• Significant Increase in hose life over standard hose pumps due to reduction in temperature, power consumption, hose design, and rotor configuration
• Simplified and reliable one-piece clamping system makes hose changes simple
• Small compact design greatly reduces floor space
Smart Pump Classifications• S-Series:
– Cased drive series of pumps including fully integrated motor, drive, and control panel
– Available with multiple control feature options, including analog or digital speed control and dispensing programming
• F-Series:– Close-Coupled design, assembled to a standard
gearbox and motor– Operate at constant flow rate– Or, use customer’s preferred VFD for limitless
control options
• Backlit illuminated display is easy to read from all angles
• Menu designed for simple and logical navigation
• Pump head, illuminated display and touchpad are all on front of unit for easy to use control
• Buttons are large enough to be operated with gloved hands
• In-line tubing placement allows for “kink free“ pumping
• Fixed rollers ensure linear output flow and accuracy
SMART Features and Benefits
• NEMA 4 enclosure rating for all pumps• Brushless DC motor for longer life time• The pumphead has its own bearings,
removing the load from the motor for reduced radial load
• An optional leak detector improves process control
SMART Features and Benefits
• The Easy-Fit tube saddle, like a ski boot fastener, for quick tube change with no tools required
• Unique top-loading design keeps changing tubes easy when more pump heads are mounted
• Tube saddle is interlocked with drive for immediate shutdown• Self adjusting clamps ensure no further action after changing a tube• Up to 400 GPH per head with up to a 100:1 turndown
SMART Features and Benefits
• 3-rollers: Standard High Flow Design
• 6-rollers: Low Pulsation, reduces the flow’s standard deviation by 50%, also giving enhanced dosing accuracy (less angular uncertainty). Flow drops by ~50% compared to 3 Roller Head. Pumps can be easily converted from 3 to 6 Rollers in the field. For maximum accuracy the 6 roller head should be used.
SMART Features and Benefits
• Modular pumpheads – stack up to 4 per pump• Low pulsation 6-roller pumphead option (or split-channel 2-pump
head to offset pulses)• Flow rate calibration available• SCADA compatible I/O interface • UL and CSA certification • Dosing program includes several preset batches/ programs which
can be activated on demand• Timer option in dosing program offers the possibility to preset batch
intervals which can be activated when needed• Anti-drop function prevents extra drops after dosing applications (eg
filling of bottles)
SMART Features and Benefits
• B Model – Manual start/stop, forward/reverse
• C Model – All manual features PLUS – auto/manual function – remote follower (4-20 mA or 0-10 VDC)
• SCADA – Includes 4-20 follower with manual overide– Leak detection and leak detector status output– Pumphead direction status output– Auto/Manual status output– 4-20 mA speed feedback signal
• L Model – All features of B and C models PLUS:– RS485 operation– Calibration– Anti-drop– Programmable dosing schemes
Four Control Options
An Industrial Style Close Coupled Tube Pump that operates well in the hard industrial world, ideal for process plants.
F-Series key strengths are:
• Design Simplicity• Ease of Integration• Multiple Head Options• Rapid Tube Changing• No electronics• Economic Alternative
SMART F-Series
• Simple pump head design - uses the same pumphead as S-Series
• No external controls - no fingers to adjust process parameters
• External panel mounted inverters can be locked away – the process runs as designed
• 3rd party inverters have industry standard modules for PROFIBUS®, MODBUS®, and other network protocols
• VFD manufacturer and/or model may be a site standard, so technicians are experts on programming it & as it is a site standard there are usually spare inverters in the central store. Both of these help kill downtime.
F-Series Features and Benefits
• Suitable for industrial and municipal applications– Nema 4 enclosure, Brushless DC motor
• Unique design– In-line tube load system, easy to use keypad
• Simple and multifuntional / modular– Easy Tube loading, multiple / stacking head
options, low pulsation• Able to be adapted to changing processes
– Analogue or digital control, F-Series, Dispensing capabilities
SMART Summary
VF series – Hose Installation
Questions?