Dewatering pumps installed at Colombian nickel mine
Problem: In 2011, a nickel mine located in the Northern Andean region of Colombia sought an effective dewatering option.
Solution: Mine operators selected three Cornell Pump Company 8NHTA-RP-EM18-3 units and provided the engine and pontoon locally to keep the packaged price to a minimum. The pumps have a Cycloseal system designed to reduce seal maintenance, as a typical dewatering application experiences over 15,000 hours of operation before any seal maintenance is required. At an average cost of $5,000 per seal replacement (including drive time, crane rental, labor and seal price), the additional operational time is a windfall for mines.
Result: Three years later, the pumps have been running flawlessly for over 4,500 hours. Not a single spare part has been required, which prevents any additional costs and allows the mine to operate without any downtime, avoiding any disruption of nickel production. 503/653-0330; www.cornellpump.com.
Lift station controls needed for remote camp
Problem: A mining camp accommodations contractor in Alberta’s Oil Sands area north of Fort McMurray needed a lift station control panel for a remote, 800-person camp. The panel had to withstand environmental extremes, address power and pump-compatibility concerns, and interface with the communications network.
Solution: Horizon North Camps and Catering approached Michael Schmalz of S2M Consultants for help with its wastewater system. Schmalz suggested an Orenco Controls OLS control panel. They are modular, programmable, remote telemetry control panels used to regulate sewage, influent, effluent and stormwater lift stations. They provide full remote connectivity and include color touch screens with built-in programming and real-time data acquisition and control over an Internet, cell or phone line connection. They combine the functions of relays, timers, alternators, elapsed-time meters and cycle counters, resulting in a compact panel. This lift station included a 5 hp Muffin Monster grinder that the panel had to incorporate along with the system’s heater/blower.
Result: The custom panel met the lift station’s requirements, including environmental considerations and a tight timeline. It was designed, built and supplied in four weeks. 877/488-3594; www.orenco.com.
Auto-prime diesel pump set increases efficiency at roofing-slate quarry
Problem: Welch Slate, one of the world’s leading manufacturers of high-quality roofing slate and architectural and aggregate slate products, was dissatisfied with the cost of dewatering at its largest quarry, Penrhyn at Bethesda near Bangor in North Wales. Operating from four quarries, the company has been supplying the world with high-quality roofing slate and other materials for over 200 years. Quarry operators looked into replacing their submersible pumps with higher-efficiency models.
Solution: The quarry installed a diesel-driven PP86C17B submersible pump package from Pioneer Pump. The package uses an 8- by 6-inch centrifugal pump powered by a 224 hp diesel engine. It is capable of a maximum flow rate of 2,300 gpm.
Result: The package resulted in an approximately 30 percent fuel reduction, at an estimated annual savings of $150,000, and reduced the carbon footprint by 411 tons per year. Improved pump reliability also reduced downtime. 503/266-4115; www.pioneerpump.com.