Innovative Valving Solution Solves Over-Pressure And Turbidity in Tight Space For Poultry Processor
Ken Johnson of Hulsey Environmental and Plumbing Services knows pressure. When he was asked to troubleshoot a backflow prevention problem at a poultry processing plant earlier this year, he quickly diagnosed that incoming pressure was the major problem, but it wasn’t the only problem. Water turbulence, space constraints and the need to keep the plant online compounded the problem and put the real pressure squarely on Johnson.
The number one check valve on the 8-inch backflow preventer at the Pilgrim’s Pride plant in Gainesville, Ga. had failed several times due to incoming pressure surges of up to 180 psi.
Poultry processing uses large volumes of water. The Pilgrim’s Pride plant is fed by two four-inch lines that enter the backflow device through an 8-inch flanged connection. Downstream from the backflow device, the plant piping changes to 6-inch stainless steel. Johnson knew that turbulence added to the pressure problem, but he also knew he’d need an innovative solution.
“The traditional way of dealing with turbidity is to install additional piping between the supply and the backflow. The formula is to multiply the diameter of the unit times five and add that much piping.” Johnson explained. “But there was no way we could add another 40 inches of pipe. We didn’t have that much space.” A lengthy shutdown to reconfigure the plant’s incoming lines was out of the question.
“That plant runs 24/7, 365 days a year, except for washdowns. A washdown was our window to get this fixed,” he said.
Johnson contacted the engineering department at Apollo® Valves, makers of the backflow unit, for their advice. After several conversations and a thorough examination of the options, Johnson and the Apollo team settled on the solution. A 90˚ angle configuration Apollo A127 Automatic Pressure Valve (APV) would be attached directly to the backflow. A short connector line would be fabricated to connect the APV to the water supply.
Apollo® A127 Series APV’s are available in nine sizes, ranging from 1-1/4 inches (32 mm) to 12 inches (300 mm). They're designed for managing water over-pressure and for zone pressure control in municipal, commercial and industrial water systems. Depending on size, the valves are equipped with threaded, grooved or Class 150 and Class 300 flanged end connections.
“It was a very creative approach. Based on the specs, it looked like it would work, but we didn’t have any history to go on. We’d just have to install it and see what happened,” Johnson recalled. “We all had a lot riding on this.”
Johnson and Hulsey Environmental had the APV and connector line ready for installation during a normal washdown in February. The results were impressive.
“The Apollo APV did exactly what we were told it would do in terms of reducing the pressure and the turbidity. We were able to do it within the existing space and within the customer’s time requirements. The water pressure stabilized at 95 psi, and they’ve had no further problems,” Johnson said.
Outlet pressure on the Apollo A127 is controlled and adjusted with a single screw. The standard setting is 25 to 75 psi. A low setting for 10 to 35 psi and a high setting, such as on the valve used by Hulsey at Pilgrim’s Pride, for 75 to 125 psi are available as options.
With constant water demands at the plant ranging from 35 to 3500 gallons per minute, the pressure was on for a fast solution. Hulsey Environmental Services and Apollo Valves came through.
ABOUT APOLLO® VALVES
The Apollo® Valves brand is manufactured by Conbraco Industries, founded in 1928 in Detroit, Mi. The company moved its headquarters to Matthews, N.C. in 1955. Today it is one of the world’s largest producers of ball valves, pressure reducing valves, backflow preventers, safety relief valves, actuators and other flow control devices.
ABOUT HULSEY ENVIRONMENTAL SERVICES
Serving North Georgia since 1918, Hulsey Environmental And Plumbing Services is a full service plumbing and environmental company serving industrial, commercial, and residential customers with a 97% customer approval rating.