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

Hose Pumps vs Tubing Pumps

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?