screens INNOVATIVE SOLUTIONS IN SCREEN TECHNOLOGY A Weatherford Company

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1 screens A Weatherford Company INNOVATIVE SOLUTIONS IN SCREEN TECHNOLOGY

2 JOHNSON SCREENS HAVE 100 YEARS OF PROBLEM-SOLVING SUCCESS We offer a combination of economy, innovation and flexibility to provide a wide variety of industrial screen solutions. Johnson has a history of providing efficient, long lasting, maintenance free products that will work in a variety of situations. Our engineering staff is fully capable of precision design to ensure that each requirement is met. Now with our broadened line of screen products you can specify the perfect, most cost-effective screen no matter how challenging your application or process. Custom Designed and Engineered Each project is specifically designed to ensure complete satisfaction. We provide guidance and support from project concept to completion. Longer Lasting Johnson manufacturing standards are the most stringent in the industry. The screens utilize the patented Vee-Wire technology. They are extremely durable and have high resistance to abrasion, corrosion and impact damage. Lower Maintenance The rugged construction and high quality of materials make possible a product that lasts longer and requires less maintenance. Less Costly Superior operating efficiency, extended service life and reduced maintenance needs combine to reduce the true cost of Johnson screens to plant operators. 2

3 JOHNSON SCREENS HAVE BECOME THE FIRST CHOICE OF INDUSTRIES ALL OVER THE WORLD. Architects specify Johnson screens for column and wall covers, floor grating, light fixtures,sun screens and various decorative applications. Corn Wet Milling uses a variety of Johnson screens ranging from looped wire to fine wire mesh. Food Processors favor Johnson screens because they re heat and corrosion resistant and make it easier to secure FDA approval. Malting Plant Operators find our flat panel screens provide a more thorough mixing during the turning phase, and better ventilation in the kilning phase. Pulp and Paper Plants use our screens in the wood yard, paper machines, recycling, dewatering, debris removal, fiber fractionalization, drying, water purification and other processes. Mineral Processors rely on Johnson centrifuge baskets, sieve bends and flat panels for multiple operations. Refiners use our massive centerpipes and baskets or scallops for catalytic reforming, isomerization, ammonia conversion and other processes. Water and Waste Water Treatment benefit from high flow capacity, dependable media retention and excellent corrosion resistance. Water Supply Systems use Johnson surface water intakes and custom-engineered water well screens and system maintenance chemicals. Sugar Processors use our easy-to-install one-piece baskets and other washing, dewatering and solids retention screens. 3

4 JOHNSON VEE-WIRE SCREEN PANELS THE INDUSTRY'S BROADEST LINE. 4 Support grids in downflow vessels retain treatment media and offer more durability and reduced pressure drop resulting in lower operating costs. Johnson Screens' second generation 120-degree DSM screens have 33% more open area than current 120-degree DSM screens. This increased open area can increase your screening capacity 33%, with out adding capital equipment. This increased screening capacity also provides your screening and fiber washing systems with greatly enhanced operating flexibility. Increased operating flexibility allows you to fine tune your process and optimize your profits, beyond anything previously possible. This breakthrough technology utilizes the smallest profile wire ever manufactured. The solid face of this wire is a mere inches wide. Current 120- degree DSM screens are manufactured with a wire size of inches, or 50% more solid area. The dewatering capacity of the 120-degree DSM screen is determined by the amount of open area, not the amount of solid, or dead area. Increased screen open area benefits the screening and fiber washing systems by providing increased production capabilities, allowing lower nozzle pressures and reducing the moisture content of screened solids. Johnson flat screens can be used in food processing, malting, floor grating, wall covers and ventilating systems. Johnson's flat machines are unequalled in their ability to produce a screen that will meet specific requirements. The wire size can be as small as.020 inches with.001 inches slot openings on the fine side, to 1/2 inch wire and 1/2 inch slot opening for larger screens. Flat screen panels

5 JOHNSON BASKETS ARE VERSATILE AND DURABLE Patent pending sugar basket. Johnson screen baskets are most often custom products installed in centrifuges or similar machines. They can be designed as screen liners to be installed in existing frameworks or they can be built with integral support structures. In some applications such as pulp and paper and mineral processing they need to be particularly strong to resist the high centrifugal stresses and temperatures. They also require exceptional abrasion resistance. In other applications, such as sugar processing, greater importance may be placed on close-tolerance and fine-slot design. In all cases, our design engineers seek out the optimum combination of strength, capacity and wear life to help you increase your through-put at the lowest cost. Patented Generation Three pulp and paper basket. Conical and cylindrical baskets are used in a variety of industries. 5

6 JOHNSON CYLINDRICAL SCREENS CAN BE DESIGNED FOR SPECIAL PROBLEM SOLVING Johnson cylindrical screens can be built with diameters as small as 1/2 and as large as 36 in a single pass. With sectional construction, we ve built screens up to 24 ft in diameter and 50 ft long. Each Johnson screen can be up to 20 ft in continuous length. A wide range of external wrap wire and internal support rod shapes and sizes lets our design engineers build you a screen that s the perfect fit for your application. Our screen cylinders are used for a variety of filtration, media retention and dewatering applications. Screen slots are sized to admit fluid flow while excluding solids. Johnson screen laterals manifolded to a central header allow very efficient flow distribution and collection. 6

7 JOHNSON SPECIALTY SCREENS REPRESENT UNLIMITED POSSIBILITIES Nozzles can be used for flow collection and distribution. Specialty steel screens can take nearly any form, and fit nearly any liquid/solid separation need or architectural concept. Other materials such as polyurethane are used in making Johnson screens for abrasive environments. In addition, we offer economical, efficient spherical plastic nozzles, PVC laterals, custom-designed resin traps and inline filters, carbon septa, distributor baskets and header lateral screens. Our steel screens can also be custom-treated with powder coating, annealing or stress relieving, aluminizing, electropolishing, chrome plating and many other processes. Johnson screens make a dramatic room divider in a New York hotel. 7

8 AT JOHNSON, R&D IS A CONTINUOUS PROCESS Cable screen: a flexible new direction in screen technology. (patented) Even though the first Johnson screen was produced 100 years ago, the product continues to evolve. This process has led to several product designs that are standards within their industry. We follow a formal program of continuous improvement in which we: Search for and test new materials Refine wire and rod shapes and sizes Look at ways to improve current products. Develop new products for new markets Architecturally, it can be used as column covers and flexible wall separators in building construction Centrifugal baskets that require self-forming posture to existing fixtures Conveyor belts and vacuum processing belts Convoluted shapes without special shaping requirements Flexible structures for thermal expansion management and rebounding Our most recent patent is flexible cable screen. It s constructed with unique flexible support rods to achieve a significant level of flexibility, useful in a variety of applications. It is also constructed to be very rigid in one direction, while flexible in the other direction. The following uses have been identified, but your imagination can further expand its potential. 8

9 Standard Construction Axial Wire Construction Channel Rod Construction Internal Circumferential Wire Construction Internal Axial Wire Construction Inverted Wire Construction MULTIPLE CONSTRUCTION OPTIONS ARE AVAILABLE Our welded cylindrical screens can be categorized as designed with the media retention surface either on the outside or the inside of the screen. EXTERNAL RETENTION SURFACE (Outside-in flow) Standard Construction features external circumferential wire and internal support rods. Axial Wire Construction produces vertical slots which allow beds of media to move up and down without abrading the individual grains. Channel Rod Construction uses perforated channels as the internal support elements and flow control surface. When used as a collector, flow is outside in; as a distributor, flow is inside out. INTERNAL RETENTION SURFACE (Inside-out flow) Internal Circumferential Wire Construction uses external support rods to create an unobstructed internal screen face. Internal Axial Wire Construction creates long, parallel slots. In vertical applications, media can move up and down with abrading. In horizontal rotating applications, flow moves across the wire edges for efficient dewatering. Inverted Wire Construction presents the wire face to the cylinder interior and uses internal support rods. 9

10 TECHNICAL DATA JOHNSON VEE-WIRE PROFILES (shown approximately 3x size) STANDARD WELDED CONSTRUCTION JOHNSON ROUND AND STRIP SUPPORT RODS NAME IN WIDTH MM HEIGHT SECTION AREA RELIEF IN MM IN 2 MM 2 ANGLE o 13 o 10 o 13 o 7 o 13 o 13 o 8 o 8 o 5 o A = Width B = Depth C = Relief Angle Round rods available in diameters ranging from.125 in. to.500 in. Strip rods available in widths ranging from.070 in. to.188 in and heights raging from.375 in. to 2 in. JOHNSON SHAPED SUPPORT RODS SR 93 XJR 156 NAME WIDTH IN. HEIGHT IN. SECTION AREA IN. SECTION MODULUS IN. 3 X XJR SR A Tri-Wire A Iso-Grizzly Wire C B A 3 /32'' 1 /8'' 3 /16'' 1 /4'' B 5 /64'' 7 /64'' 11 /64'' 7 /32'' C C B A B C A Iso-Wire A Grizzly-Wire C B A 1 /32'' 3 /64'' 1 /16'' 3 /32'' 1 /8'' B.048''.074'' 7 /64'' 5 /32'' 13 /64'' C C B A 5 /64'' 3 /32'' 1 /8'' 5 /32'' 3 /16'' 1 /4'' 3 /8'' B 9 /64'' 11 /64'' 7 /32'' 7 /32'' 11 /32'' 3 /8'' 1 /2'' C

11 LOOPED WIRE CONSTRUCTION D Wire Number PERCENTAGE OPEN AREA Width* 20 D Height* OPEN AREA OF JOHNSON SCREENS 30 WT Wire Number Width* WT Height* LO-PRO Wire Number Width* 191 Height* *Dimensions are based upon a specified opening. Larger openings can be obtained for each respective wire size by the use of spacers between each wire. Calculation of open area is straightforward: Open Area (%) = Slot size x 100 Slot size + Wire width FINE SLOT PERCENT OPEN AREAS WIRE SLOT OPENING SIZE (IN) NO COMMON EQUIVALENTS INCHES MILLIMETERS MICRONS U.S. STD. MESH in SLOT OPENING WIDTH 11

12 CUSTOMER SUPPORT TECHNICAL SUPPORT Technical Support We do more than make the world s best screens. We also supply you with technical support that s like having your own in-house engineering team with no overhead. Our lab facilities can perform metallurgical, corrosion, chemical and failure analysis, pressure and flow testing and other physical property evaluations. Customer Service Our experienced customer support personnel will work with you during the entire manufacturing process. They will keep you informed of the status of your order and work hard to keep it on schedule and on budget. Field Services We maintain teams of engineers, technicians and welders to provide on-site technical direction for installing or repairing screens. We can also supply labor for the actual installation or repair. ASIA PACIFIC JOHNSON SCREENS - Australia Tel. : +61 (0) Fax : +61 (0) salesaus@johnsonscreens.com.au EUROPE - AFRICA - MIDDLE EAST JOHNSON SCREENS - France Tel. : +33 (0) Fax : +33 (0) jseurope@johnsonscreens.com NORTH & SOUTH AMERICAS JOHNSON SCREENS - USA Tel. : Fax : sales@johnsonscreens.com 2006 Weatherford JS-BR WFT