MPT - 062015 PDF

JUNE 2015
MPT
Modern Pumping Today
Providing Solutions for the Worldwide Pump Industry
www.modernpumpingtoday.com
Repairing Earthquake
Damage in Nepal
The Global Impact of
Motor Drives
Protecting Shaft Seals
in Hydraulic Systems
CONTENTS
12
MPT

P.O. Box 660197 | Birmingham, Alabama 35266

@ModPumpMag
JEFF FLETCHER Associate Publisher

jeff@modernpumpingtoday.com
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28
40
LISA AVERY Assistant Art Director

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JAMIE WILLETT Circulation Consultant
INGRID BERKY Administrative Assistant
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TIM GARMON
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RUSSELL HADDOCK
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CHRIS GARMON
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means, electronic or mechanical, including photocopy, recording, or any information
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views expressed by those not on the staff of Modern Pumping Today, or who are
not specifically employed by Highlands Publications, Inc., are purely their own. All
Industry News material has either been submitted by the subject company or pulled
directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
jay@modernpumpingtoday.com.
EDITORIAL ADVISORY BOARD: Terry Bell Product Manager, Baldor Electric Company Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting
Robert G. Havrin Director of Technology, Centrisys Corporation Michael Mancini Consultant and Trainer, Mancini Consulting Services John M. Roach Engineering
Manager for New Product Development, Trebor International, Inc.: A Unit of IDEX Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos Trey Walters, P.E. President, Applied Flow Technology
JUNE 2015
INDUSTRY NEWS
TRADE SHOW PROFILE
10
ASHRAE 2015 Annual Conference
CASE STUDIES
12
14
Protecting a Blue Flag Seaside Town
WATER & WASTEWATER SOLUTIONS
18
Hose Pump Reduces Labor Costs at Anheuser-Busch

InBev China
The Path to Water Innovation
A policy brief for water utility reform from the Hamilton Project
Part 2 of 2
24
Repair of Quake-damaged Wastewater Plant

Is Life-saving Work
Aid group arche noVa provides emergency intervention in Nepal
MAINTENANCE SOLUTIONS
28
Curing a Raw Water Pumping Facility's Unremitting

Driveshaft Failures
Part 1 of 2
PUMP SOLUTIONS
34
Blue Angel Pumps Provide Peace of Mind

for Geiler Plumbing
Pre-assembled back-up and primary cuts down installation time
36
What Is Your Zero?

Knowing your zero can reduce costly mistakes
Part 1 of 2
DEWATERING SOLUTIONS
40
Stormwater Chambers Go Super-Sized

CULTEC introduces new, ultra-high capacity Recharger 902HD
MOTOR SOLUTIONS
42
Why Motor Drives Impact the World So Dramatically
POWER GENERATION SOLUTIONS
44
Surviving Hazardous Duty in a Hot Fly-Ash Pit

BJM's KZN Pump takes on a coal-fired power plant near Denver, Colorado
PROCESSING SOLUTIONS
48
Safe Conveyance of Sour Crude Oil Despite Demanding

Process Conditions
VALVES & CONTROLS SOLUTIONS
50
Monitoring Energy Flows for Saturated and Superheated

Steam or Hot Water
Optiswirl 4200 vortex flowmeter provides advanced energy measurement
SEALING SOLUTIONS
52
Protect Shaft Seals in Hydraulic Systems
MODERN PUMPING PRODUCTS
54
Featured Product Release: FEDERAL PUMPS

Series VSPV Triplex Variable Speed Booster System
PUMPING TRENDS
56
Building Relationships in the New Century

ThomasNet.com's Ed Edwards on providing free product sourcing
and supplier discover
INDUSTRY NEWS
ACLARAS NEW THROUGH-THE-LID ANTENNA
ON DISPLAY AT ACE 2015
Aclara, a world-class supplier of smart infrastructure solutions
to electric, gas and water utilities globally, introduces a robust
through-the-lid antenna that provides a solution for every
meter site, reaching 100 percent of meters in pits and vaults
while providing exceptionally high read rates.
Aclaras through-the-lid antenna offers utilities a flexible
and complete solution for installing communications modules
in meter pits and vaults. With the units exclusive design and
advanced technology, utilities can elect to reuse their existing
metal lids or replace them with lids that radio frequency
signals can penetrate. Modules installed with Aclaras
through-the-lid antenna provide equivalent communications
performance to those mounted under composite-material
lids.
The through-the-lid antenna installs easily through an
industry-standard-sized hole drilled in the pit-lid. It attaches
seamlessly to the Aclara STAR network meter transmission
unit, which, in turn, is connected to the meter.
The unit complies with the Americans with Disabilities Act
and delivers road- and traffic-rated performance. The antenna
operates with single- or dual-port, standard- and extendedrange meter transmission units. For more information about
the Aclara through-the-lid antenna, visit Aclara at ACE 2015,
Booth 438.
AZIMA DLI EXPANDS U.S. PRODUCT DISTRIBUTION

NETWORK WITH CASCADE MACHINERY VIBRATION
SOLUTIONS
Azima DLI, the leader and premier provider of predictive
maintenance (PdM) solutions, today announced that
Cascade Machinery Vibration Services has joined Azima
DLIs expanding network of Authorized PdM Service
Agents who sell and support Azima DLI products and
services.
Under the agreement, Azima DLIs solutions will be
available through Cascades product distribution network
in Texas and the Gulf Coast, with expansion to Cascades
other U.S. markets expected to follow. Cascades highly
skilled engineers will also be available for local support to
Azima DLIs customers, including vibration data collection,
balancing, and on-site troubleshooting.
Cascade will add Azima DLIs line of TRIO portable
vibration analyzers, WATCHMAN Online Systems, and
the ALERT family of vibration diagnostic software to its
product offerings.
Cascade is also authorized to sell Azima DLIs routebased, remote condition-based vibration analysis under
WATCHMAN Services, which is backed by Azima DLIs
team of 40+ expert analysts. As an Authorized PdM Service
Agent, Cascade will manage the customer relationships
and data collection, and Azima DLI will perform remote
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Cascade cites Azima DLIs unmatched technology,
experienced analysis team, and infrastructure as the driving
factor in deciding to join. The ability to easily customize a
solution for in-house, outsourced, or hybrid programs makes
Azima DLIs offering extremely attractive.
BIONOMIC INDUSTRIES
INTRODUCES NEW
PACKED TOWER
SCRUBBER
Bionomic Industries,
Inc., an industry-leading
manufacturer of proven
air pollution abatement,
product, and heat recovery
technologies, has announced
availability of their latest
concept, the high efficiency
Series 5000 Counter Current
Packed Tower Scrubber with
increased versatility.
Series 5000 Packed Towers incorporate Bionomic's
maximum throughput Hi-Flow random or structured packing,
high efficiency mist eliminator designs, and a variety of clog
June 2015
resistant liquid distribution systems match engineered to

more precisely meet specific application requirements. An
optional dual packed bed arrangement enables removal of
multiple contaminants using different scrubbing reagents
within the same unit.
Engineered for use with water, reactive chemical reagents,
or special solvent scrubbing liquids to reduce costs and
recover or minimize liquid waste, the scrubbers provide
up to 99.9 percent removal efficiency and are available in
a full range of sizes for gas flow rates from 30 cfm through
300,000 cfm.
SPI PARTNERS WITH UMASS LOWELL TO SECURE

EQUIPMENT FOR PLASTICS RECYCLING AND
SUSTAINABILITY LAB
SPI: The Plastics Industry Trade Association joined the
University of Massachusetts Lowell (UMass Lowell) Plastics
Engineering Department recently on the show floor of
NPE2015: The International Plastics Showcase in Orlando,
Fla., to launch the UMass Lowell Plastics Sustainability
Research Lab. SPI has been instrumental in procuring
equipment for the comprehensive industry-university
collaborative laboratory that will be used for studying
plastics recycling and sustainability.
The willingness of SPI member companies to contribute
to the UMass Lowell Plastics Sustainability Research Lab is
INDUSTRY NEWS
testament to the industrys support of education and the
future of the plastics manufacturing industry, says William
R. Carteaux, SPI president and CEO.
Because of the lab, students who study at UMass
Lowell, one of the nations top programs for plastics
engineering students, will not only receive a world-class
education in prime plastics, but will become versed in the
technologies and processes related to recycled plastics.
UMass Lowells effort to add the lab to its curriculum and
research capabilities demonstrates that the university is
truly ahead of the curve in plastics engineering education
and sustainability, Carteaux says. I hope this success
encourages other member companies to consider similar
partnerships with our nations educational system.
Robert Malloy, chairman of the UMass Lowell Plastics
Engineering Department, echoed Carteauxs statement
adding that industry partnerships are critical to plastics
engineering programs.
As educators, we rely on industry to provide advice
and guidance to help ensure that our program remains
relevant and produces the necessary supply of trained
plastics engineers. We could not do this effectively without
the generous support of the plastics industry, Malloy
adds.
So far, SPI members have donated hundreds of
thousands of dollars in state-of-the-art recycled materials
June 2015
handling and reprocessing equipment and instrumentation.

The effort to secure the necessary equipment critical
for plastics recycling is ongoing. Member companies
interested in participating should contact David Palmer at
dpalmer@plasticsindustry.org or 202.974.5527.
Jim Holbrook, president of the ACS Group, stated that
although he is relatively new to the plastics industry, he is a
strong proponent of recycling and sustainability. Holbrook
says, ACS Group is a leader in the auxiliaries market for
plastics processing equipment and is very pleased to be
able to donate five different pieces of equipment for the
Sustainability Research Lab at UMass Lowell, both for the
advancement of the state of the art in plastics recycling
technology and for the training of the next generation of
plastics industry leaders.
In addition to the ACS Group, which donated $40,000 in
equipment under its AEC, Cumberland, Sterling and Carver
brands, other companies that donated equipment include
Bay Plastics Machinery, Hi-Tech, Davis-Standard, Dynisco,
Thermo Scientific.
After being displayed during NPE in the first-ever Zero
Waste Zone, all equipment was shipped to UMass Lowell
and will be installed for use after the lab renovations
are complete. Those interested in sponsoring recycling
research should contact Bob Malloy at UMass Lowell at
robert_malloy@uml.edu or 978.934.3435.
T R A D E S H OW P R O F I L E
ASHRAE 2015
Annual Conference
The Need for Real Engineering
Has Never Been Greater
scheduled. Also, a Laboratories

mini-conference scheduled within
ASHRAE 2015 AT A GLANCE
the technical program addresses
Where: Atlanta Hilton
current practices in this area.
Atlanta, Georgia
Mobile, moisture, data centers,
weather
data and BIM are
When: June 27July 1, 2015
topics covered in the Modeling
Website: www.ashrae.org/atlanta
throughout the Building Life
Cycle Track, and the Advanced
Energy Design Guides have been
available for ten years. The Moving
the conference focus on advanced
Advanced Energy Design Guidance to
design guidance, modeling, operation
the Mainstream Track presents sessions
and optimization, and Indoor Air
describing some of the work in this
Quality, which are key aspects of high
area.
performance buildings.
The third annual Research Summit
The need for real engineering
brings together researchers to present
as applied to operation, maintenance
and discuss the latest research. Papers
and operational optimization or
and presentations describing ASHRAEcommissioning can bring increased
related research as well as papers from
comfort
and
offers
huge
financial
DIVERSE TECHNICAL PROGRAM
societies and associations worldwide
returns.
And,
the
technical
program
The Technical Program features a
are presented. The technical program
meets that need as the Building
strong focus on the design, construction
rounds out with core programs
Operation, Maintenance, and
and operation of High Performance
on HVAC&R systems, equipment,
Optimization/Commissioning Track
Buildings, Refrigeration, and the annual
fundamentals and applications.
has the highest number of sessions
Research Summit. Programs within
ith more than

53,000 members
from over 132
nations, the American Society
of Heating, Refrigerating and
Air-Conditioning Engineers
(ASHRAE) is a diverse
organization representing
building system design
and industrial processes
professionals around the world, and
this year the society hosts its annual
conference in its hometown of Atlanta,
Georgia. As always, the ASHRAE Annual
Conference presents an unparalleled
opportunity for engineers to advance
both their technical knowledge and
their professional goals.
10
June 2015
FULL-DAY PROFESSIONAL
DEVELOPMENT SEMINARS
Led by ASHRAE member Jim Kelsey,
P.E., the seminar Commercial Building
Energy Audits provides guidance on
how to perform commercial building
energy audits. Best practices and
other information relevant for building
owners, managers and government
entitles are covered. The seminar
includes a summary of materials
essential for performing ASHRAE Level
1, 2 and 3 audits, time-saving tips for
every auditor, how to hire an auditor,
what to ask for in a comprehensive
audit report, and how to build a
successful energy efficiency retrofit
team.
Operating and maintaining
high-performance buildings often
requires different actions than a
typical commercial or institutional
building. After defining what a highperformance building is, Operations
and Maintenance of High-Performance
Buildings, led by ASHRAE member
Laurie Gilmer, P.E., will provide
practical insights about operations and
maintenance practices for both typical
and high-performance buildings. The
course includes an interactive group
project to reinforce concepts such as
how to identify and define energy and
maintenance management metrics,
and how to make the business case for
changes to an existing building and its

systems.
HALF-DAY SHORT COURSES

The course Design of Commercial
Ground Source Heat Pumps describes
the best design practices of ground
source heat pump systems to achieve
maximum customer benefit. The course
examines the economic analysis of
ground source vs. more traditional
systems and what is necessary to
design an effective and efficient
ground source system. The course
covers energy analysis, equipment
selection, drilling technologies, testing
requirements, hydronic system design
and system controls. Participants
will learn all that is necessary for the
design and installation of a successful
ground source heat pump system.
Based on Standard 189.1-2011,
Standard for the Design of HighPerformance Green Buildings Except
Low-Rise Residential Buildings,
Understanding Standard 189.1-2014
for High-Performance Buildings
provides the minimum requirements for
the design, construction, and plans for
operation of high-performance, green
buildings, including new buildings
and their systems, new portions of
buildings and their systems, and new
systems and equipment in existing
buildings. Water use efficiency,
indoor environmental quality, energy

efficiency, site sustainability, and a
buildings impact on the atmosphere
are covered. The course presents
the goals of establishing mandatory
criteria in all topical areas, providing
simple compliance options, and
the complement of green building
rating programs for Standard 189.1.
Upon completion of this course,
participants will understand the basic
requirements of Standard 189.1;
understand the background that led to
the development of these requirements;
and become familiar with how to apply
the requirements in the Standard to
new commercial buildings and major
renovation projects.
A comprehensive overview of
HVAC design for laboratories is
examined in Laboratory Design:
The Basics and Beyond. The course
focuses on the essential elements
of the design process that are
unique to laboratory HVAC systems.
Topics include: planning steps; risk
assessment; determining exhaust/
supply requirements; load calculation;
pressure mapping; evaluating system
options; layout of ducts and rooms;
sizing primary air systems; designing
exhaust stacks; sustainability in
laboratories and control strategies.
Example problems and case studies
will be presented.
June 2015
11
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CASE STUDIES
Protecting a Blue Flag

Seaside Town
By Lucy Ogden, Hidrostal Ltd.
idrostal Ltd., the UK sales

division of specialist pump
manufacturers for the
wastewater industry, has provided
Yorkshire Water with a reliable
solution for a sporadically performing
sewage treatment works in Whitby.
INSUFFICIENT PUMPING
PROBLEM AT WHITBY
The scenic seaside town of Whitby
located on the UKs North Yorkshire
coastline is a renowned tourist
destination as well as home to a
population of 13,000. Boasting one of
the highly acclaimed Blue Flag awards
for its town beach, Whitby is fully
committed to its sewerage system and
after suffering insufficient pumping at

the sewage treatment works at Whitby,
Yorkshire Water utilized Hidrostals
expertise to solve the problem.
IN NEED OF AN UPDATE
The original pumps installed at
Whitby STW had become obsolete
so Hidrostal was asked to provide
a competitors pump for hire as a
standby unit. The selection was made
by the customer as a like for like
unit but suffered from blockages
and was incapable of handling the
incoming flow. Hidrostal attended
the treatment works to undertake a
thorough site evaluation, including
discussing the pumps performance
with the operators to fully understand

the requirements. Following this
process, Hidrostal selected four of
their transfer pumps to provide the
necessary performance at the site.
The Hidrostal pumps were selected
due to their excellent solids handling
performance. The Hidrostal screw
centrifugal impeller can comfortably
handle all types of sludge up to 8
percent DSC without blocking and
is renowned for its rag handling
capabilities.
A GOOD AND TIDY JOB

The transfer pumps were installed
by Yorkshire Waters supplier, S&B
Utilities, in close collaboration with
Imported sludge application at Whitby Sewage Treatment Works
14
June 2015
WHAT IS
BLUE FLAG?
The Blue Flag Program
works towards sustainable
development of beaches
and marinas through strict
criteria dealing with water
quality, environmental
education and information,
environmental management,
and safety and other
services. Over 4000
beaches and marinas in 49
countries across Europe,
South Africa, Morocco,
Tunisia, New Zealand,
Brazil, Canada and the
Caribbean have earned
this award, a voluntary
eco-label. The program
is owned and run by the
non-government, non-profit
organization the Foundation
for Environmental Education
(FEE).
Hidrostal. The installation into a wet

well included a new lowering device,
pedestal bend, guiderails, chains and
lifting devices.
Sam Peacock, treatment operator
at Whitby STW, is delighted with
the performance of the new pumps.
They are good, reliable pumps which
keep up with the flow demand and
have never failed or blocked since
installation, he states. We were very
impressed with the installation and it
has been an all-round good and tidy
job.
Hidrostal were delighted to project
manage this contract from problem
through to solution. Due to their close
collaboration with S & B Utilities,
Wet Well installation at Whitby
Yorkshire Waters input requirement

was minimal and resulted in a stress
free solution to their pumping
problem.
With over thirty years of experience and having deployed thousands of pumping systems,
Hidrostal fully understands the needs and technical requirements of todays pump
users. For more information, email Lucy Ogden at lucy.ogden@hidrostal.co.uk or visit
www.hidrostal.co.uk.
June 2015
15
CASE STUDIES
Hose Pump Reduces

Labor Costs at
Anheuser-Busch
InBev China
By Chuck Treutel, Watson-Marlow Fluid Technology Group
hen Anheuser-Busch InBev was

seeking to reduce labor costs at
one of its thirty-six Chinese brewing
facilities, it turned to Bredel hose pumps
from Watson-Marlow Fluid Technology
Group (WMFTG). The pump automated
previously manual operations, reducing
manual labor and filter press
downtime, offering considerable cost
savings. At the same time, the new
pump technology also offers an
improved environmental solution.
The company now has plans to
modify three additional filter
presses to use the hose pumps.
PRODUCTION METHODS
RESULT IN HIGH MANUAL
LABOR COSTS
Since Anheuser-Busch InBev first
entered the Chinese market in
1984, the company has established
thirty-six plants and hired around
25,000 employees. One of the
largest is the Putian brewery in Fujian
province, with annual beer output of
about 1,000,000 tons (907,185 tonnes).
The plants production method still relies
largely on manual processes, including four
plate-and-frame filter presses for filtration
of diatomaceous earth. These presses
added considerably to labor costs. First
of all, it took workers to collect waste
diatomaceous earth after it was emitted
into stainless steel boxes under the filters.
Secondly, two workers were needed to
16
June 2015
A custom install with this Bredel hose pump has saved Anheuser-Busch InBev labor cost and improved
overall efficiency.
shovel the diatomaceous earth into

bags, which were then carried to a
truck for appropriate disposal.
Not only was the process laborious
and time consuming, but because
shoveling the diatomaceous earth
into bags relied on human judgment,
some of the material always ended up
on the brewery floor. Workers would
have to spend extra time washing down
the area, which had a big impact on
production planning and scheduling,
particularly in peak season periods.
set to run at the same time as diatom

unloading in the press, thus reducing
filter downtime and helping to maintain
production schedules. The pump
has also reduced the impact to the
environment since there is no longer
any requirement for cleaning water.
In addition, there have been no

maintenance requirements since
the pump began operations. As a
result, the Putian facility of AnheuserBusch InBev is now finalizing plans to
modify its three other filter presses
on site.
HOSE PUMPS PROVIDE SOLUTION

For a solution to the problem, the
facility turned to WMFTG, which
already had fourteen successful
applications in the diatomaceous earth
and PVPP (polyvinylpolypyrrolidone)
dosing process using Bredel hose
pumps.
An application engineer suggested
that the customer install a coneshaped tray with a screw propeller
underneath the filter to feed the waste
diatomaceous earth to a Bredel hose
pump. From there the diatomaceous
earth could be pumped to a collection
tank stand outside of the plate and then
loaded onto a truck for transfer to the
designated disposal point.
The idea was implemented on one of
the filter, and proved to be successful.
Operations personnel estimate that the
Bredel hose pump has saved the efforts
of two workers and the associated labor
time. Furthermore, the pump can be
Chuck Treutel is sales manager for

Watson-Marlow Fluid Technology
Group and can be reached at
608.883.6851 or via email chuck.
treutel@wmftg.com. WMFTG is the
world leader in niche peristaltic and
sinusoidal pumps and associated
fluid path technologies. Founded
on nearly sixty years of supplying
engineering and process expertise
and with over one million pumps
installed worldwide, our pumps
are tried, tested and proven to
deliver. For more information, visit
www.watson-marlow.com.
June 2015
17
The Path to
Water Innovation
A policy brief for water utility reform
from the Hamilton Project
Part 2 of 2
nnovation in the U.S. water industry

is incremental and fragmented.
In the second half of this policy
brief, Ajami, Thompson, and Victor
propose increasing innovation in
the water sector by addressing the
challenges presented by inadequate
water pricing, obstructive regulations,
and the lack of public-sector financing
to raise capital for new projects.
Addressing these challenges would
unlock new funding sources and
opportunities for the water industry,
while also establishing a regulatory
environment more conducive
to innovation, prerequisites for
addressing the nations water needs.
WATER PRICING
To strengthen innovation in the water
sector, the authors call for three
targeted reforms. First, they advocate
pricing schemes that capture the full
price of delivering water to better
support the financial health of water
suppliers. In particular, they argue
that rates should recover all the costs
of utilities services, including the
costs of replacing infrastructure over
time as well as needed research and
development. Full-cost water pricing
would help utilities recover the fixed
costs of their infrastructures, granting
them greater stability in funding
innovative projects.
Second, they call for consumers to
face the full marginal cost of each unit
of water consumed, including costs to
20
June 2015
society in the form of environmental

damages. For example, water utilities
that charge flat fees for water, under
which all users pay the same price
no matter how much water they use,
would move to a metered pricing
structure; utilities that charge a
uniform unit rate to all consumers
would move to a pricing structure that
charges more per unit as consumption
rises. These pricing reforms would
encourage greater conservation by
end users and incentivize them to
adopt water-conserving technologies.
Third, the authors propose
decoupling utility revenue from the
quantity of water sold by setting
fixed revenue targets that do not
vary with sales. Decoupling can
be achieved by allowing utilities to
issue a surcharge or a refund if the
quantity of water sold lands below or
above the target quantity, respectively.
For example, the California Public
Utility Commission ordered investorowned utilities to decouple prices in
2006, using a water rate adjustment
mechanismthe ability to issue a
surcharge or refundto lower utilities
risk of falling revenue resulting from
increased conservation, unexpected
weather conditions, or an economic
recession. Decoupling would remove
the incentive from water utilities
to maximize the amount of water
sold, instead giving them a stake in
the development of more-efficient
technologies.
REGULATIONS
Regulation in the water sector can
both promote and inhibit innovation.
To ease the negative impact of
regulations, Ajami, Thompson, and
Victor propose a two-pronged
approach to regulatory reform. First,
they propose that state legislators
and regulators undertake a review of
regulatory practices along several key
criteria, such as minimizing variation
across geographic jurisdictions and
across related sectors (e.g., water and
wastewater, water and energy) and
providing sufficient flexibility to avoid
blocking the timely adoption of new
technologies. Second, they propose
that certain states create water
innovation offices to better coordinate
and support innovation efforts across
the industry and to recommend
regulatory reforms to the respective
states water sector.
The regulatory review would
seek to:
Reconcile regulations that are
inconsistent between state and
local government and among local
governments, with state regulations
always taking precedence.
Coordinate regulations across
sectors (e.g., water and
wastewater, water and energy)
to ensure consistent treatment of
new technologies and to reduce
obstacles to the development and
adoption of new technologies.
ROADMAP
Local water utilities would
initiate three reforms to pricing.
First, utilities would raise the
price of water to capture its full
cost, including environmental
costs. Second, utilities would
employ tiered pricing structures
that charge users more per
unit consumed as consumption
increases; in some places,
this reform would also require
the addition of water meters
where they are not already
utilized. Third, utilities would
decouple target revenue from
the actual quantity of water sold,
using surcharges or refunds
to consumers to make up the
difference. The exact method of
instituting these reforms would
vary by utility. As water utilities
can be public or privately
s
low
F
n
ere
Wh
Inn
o
ati
ov
For
Handling
owned, the council or agency

overseeing the water utilities
pricing reforms would vary.
Executive bodies and/or state
legislators would authorize
regulators of the principal
water agency (or interagency
team where no principal water
agency exists) to conduct a
review of regulatory practices.
Certain states would establish
innovation offices to develop
a vision of water sector
innovation. In some cases this
would involve the legislature
or governor first creating
a commission or task force
comprising policymakers,
academic experts, and
stakeholders to examine
specific water challenges and

opportunities in that state.
The legislature or governor
would then decide whether an
independent innovation office
or an existing office within a
principal water agency would
carry out the vision.
Water authorities would impose
a public benefit charge (PBC) in
addition to normal water bills. In
some cases the PBC would be
collected and run by local water
utilities, while in others it would
be administered directly by
a statewide entity such as the
principal water agency. The size
of the PBC would vary based
on the funding objectives of the
water utility in question.
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21

Shape regulations to encourage
utilities to meet performance
standards, rather than force them to
adopt fixed technology mandates.
Enact regulations that drive, rather
than inhibit, the development of new
technologies.
The authors propose that select

states establish offices of water
resources innovation and development
(called innovation offices) to develop
a vision of water sector innovation. In
some cases the legislature or governor
would first create a commission or
task force comprising policymakers,

academic experts, and stakeholders
to examine specific water challenges
and opportunities in the state. The
legislature or governor would then
decide if an independent innovation
office is necessary to carry out the
vision, or if an existing office within the
principal water agency can implement
the plan.
Statewide water innovation offices
would be well-positioned to support
regulatory, as well as pricing and
financial, reforms. Potential first
adopters of water innovation offices
include California, Florida, and Texas,
which have the existing administrative
capacity and most-pressing water
supply challenges. These states
may wish to employ their innovation
offices to carry out or assist in the
systematic review of water regulations.
The innovation offices would also be
positioned to support water pricing
and utility financing reform and to
promote research and development to
a level seen in the energy industry.
The authors also suggest that the
federal government play a supportive
role to the first innovation offices,
especially for states that lack the
expertise or funding to promote
innovation on their own. Utilizing the
resources of the U.S. Environmental
Protection Agency, the federal
government would supply expertise
and enable information sharing of best
practices among the states. It could
reward best practices with race-to-thetop funds and a periodic innovation
report card. It would also engage
organizations such as the National
Association of Regulatory Utility
Commissioners to promote adoption of
innovation-driving regulations.
PUBLIC-SECTOR FINANCING
Finally, Ajami, Thompson, and Victor
propose that authorities either local
water utilities or a statewide entity such
as a water innovation officeinstitute
a surcharge on water usage, called a
public benefit charge (PBC), to create
a stable and sustainable source of
funding to finance innovative projects.
The surcharge would create a pool of
22
June 2015
monies that could be used to invest in

research and development, to pay for
adoption of new technologies, and to
attract private capital. The authors also
suggest that the federal government
act as a catalyst to investment by
continuing to provide low-interest loans
and grants to pilot and implement
innovative projects.
Experience already shows how
the administration of the PBC can be
tailored effectively to state and local
circumstances. One example is the
water stewardship rate levied by the
Metropolitan Water District of Southern
California, which added a fixed charge
to water bills to fund conservation
programs and support research.
Another successful illustration of how
PBCs can promote innovation includes
the California Solar Initiative, which
used the funds levied from Californias
PBC on electricity usage to promote
renewable clean energy, successfully
bringing down the prohibitive cost of
rooftop solar power through the use of
subsidies. Implemented in stages, the
subsidies started at a high level and
then declinedbroadly in line with
improvements in technology.
The primary benefit of instituting a
PBC is that it would confront the water
sectors fundamental public-sector
challenge to raise sufficient capital to
support innovation. For the 80 percent
of the water market that is supplied
through state-owned enterprises,
a public surcharge on water users
is perhaps the most economically
efficient mechanism for raising new
capital while tying the costs to users.
The PBC would help reverse the longstanding trend of exceptionally low
public investment in water innovation.
that consumers do not face the full

cost of their consumption, and water
systems struggle to fund infrastructure
renewal projects, let alone research
and development of new technologies.
Water systems are also subject to
regulations that vary by jurisdiction
and often emphasize implementation

and use of status quo rather than
next-generationwater technologies.
Furthermore, water systems lack
access to the capital needed for
innovation due to a dearth of public
funding and difficulty obtaining
PREPARING FOR THE FUTURE

In order to prepare for nations
anticipated increased vulnerability to
water scarcity, the water sector must
confront its historic lack of support
for innovation. The authors stipulate
that three factors in particular present
barriers to greater innovation, and
that these could be addressed with
smart policy reforms. First, water
is typically underpriced, meaning
June 2015
23

low-yield bonds. Taken together,
these factors limit the innovation in
an industry predisposed to utilizing
existing technologies over pioneering,
but possibly riskier, alternatives.
The policy reforms called for by
Ajami, Thompson, and Victor can
help to break down some of these

barriers to innovation. Price reforms
would incentivize both utilities and
consumers to conserve water and
increase funding for innovation.
Conducting systematic reviews of
water regulations at the state and
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24
June 2015
local levels would make regulations

consistent and help drive the water
industry to reach new performance
standards through innovation and
adoption of new technologies. Finally,
instituting a PBC would provide utilities
with a dedicated revenue stream and
increase their access to capital to fund
research for new technologies.
QUESTIONS AND CONCERNS

1. Would states need to build
additional capacity or provide
additional funding for these reforms?
Most of the reforms presented in this
paper, including reforms to pricing,
regulations, and public financing, do
not require significant new capacity
or funding from state governments.
The only reform that could require
additional capacity or funding is
the establishment of an innovation
office. A task force or commission
in each state would initially evaluate
the steps needed to promote
innovation, including the potential
value of an innovation office. As part
of this evaluation, the task force would
examine the capacity needs of such
an office and how the office might be
financed. The exact needs of an office
would depend on its mandate and
activities. In some cases, a state might
be able to create the office without a
significant investment of new resources
by reallocating resources within an
existing state agency.
If the innovation office would need
new resources, the state may be able
to fund the office and its activities
either by allocating a portion of the
funds collected from the public benefit
charge or through contributions
from the local water agencies who
would benefit from the office. States
could require local agencies to fund
the office, or they could institute a
membership model in which local
agencies could voluntarily decide
whether to provide funding. In the
energy sector, the Electric Power
Research Institute (EPRI) successfully
relies on voluntary subscriptions
to support its activities. Like the
Institute, a state innovation office
could open its membership not only
to local water agencies, but also to

businesses and other governmental
agencies interested in promoting
innovative water technologies.
EPRI estimates that, by pooling the
resources of its members, it provides
them with ten dollars in research and
development for every one dollar
received in contributions. Under this
model, members would presumably
receive benefits, such as the ability to
formulate research goals and access
research results, that are not available
to nonmembers. However, other
activities, such as regulatory reform,
would benefit all water agencies.
2. Should there be a mandate for these
pricing reforms?
In many cases, state or federal
mandates may not be necessary. Water
suppliers will often want to develop
larger and more-reliable revenue
streams in order to respond to the
multiple water challenges facing them.
Moreover, some reforms, such as
decoupling revenue from the quantity
of water sales, may not increase
water consumers rates and therefore
not engender significant political
opposition. Other reforms, such as
full-cost pricing and tiered pricing
schemes, may threaten consumers
budgets and therefore attract political
opposition. Many water suppliers,
nonetheless, have successfully raised
rates or reformed their pricing
structures. Education of customers has
often been the key to success in these
cases. Consumers are much more
likely to accept higher rates if they
understand the necessity of the rate

increase or the benefits of reform.
Both the federal government and
state governments, moreover, can help
encourage pricing reforms without
resorting to mandates. First, these
governments can provide information
and programs designed to help water
suppliers explain the necessity of the
reforms to their customers. Second,
where state governments require
water suppliers to adopt efficiency or
conservation policies, the states can
make pricing reforms such as those
recommended above meet those
requirements. The pricing reforms not
only would help promote innovation,
but would also encourage conservation
and more-efficient water use.
Where pricing reforms prove
impossible, water suppliers or states
might be able to adopt other policies
that mimic the effect of the reforms
but with less political opposition. For
example, if a water supplier is unable
to raise its rates because of consumer
opposition, the supplier might use a

shadow price (i.e., a price equal to
the full cost of the suppliers water,
including environmental and other
costs) to determine what investments
to make in new technology. Innovation
opportunities that may be costineffective when based on actual
water rates could actually be costeffective when shadow prices are used
instead.
This policy brief is based on the

Hamilton Project discussion paper,
The Path to Water Innovation, which
was authored by Newsha K. Ajami,
Stanford Woods Institute for the
Environment; Barton H. Thompson
Jr., Stanford Woods Institute for the
Environment and Stanford Law School;
and David G. Victor, University of
California, San Diego. To learn more
about this proposal, read the full
paper at www.hamiltonproject.org.
June 2015
25
Repair of
Quake-damaged
Wastewater Plant
Is Life-saving Work
Aid group arche noVa provides
emergency intervention in Nepal
By Alexandra Klengel, VSX - Vogel Software
Inhabitants of the camp in Bhaktapur are using the water from the arche noVa tank (photo: arche noVa Initiative fr Menschen in Not e.V.).
26
June 2015
erman-based association arche

noVa specializes in the provision
and restoration of drinking
water supplies in disaster areas. The
devastating earthquake in Nepal claims
humanitarian workers in these days in
particular. According to the association,
this is due to, besides the rescue of
buried people and medical care, an
enormous need in the field of water
supply after catastrophes with such large
destructive power.
field of water, sanitation and hygiene

in the province of Nuwakot and in the
historical royal city Bhaktapur.
HOPE OUT OF CONFUSION

"The confusing phase directly after
the earthquake thins out gradually.
Our explorations have led us to two
locations where the need for assistance

is particularly high," explains project
manager Friedrich Machein.
In Bidur the earthquake has left
behind severe damage, among other
things the water supply. Also damaged
is the local wastewater treatment plant.
After the work at the hospital arche noVa
SIXTY SECONDS OF TRAGEDY

The 7.9 magnitude earthquake
occurred on April 25, 2015, at 11:56
a.m. near the capital Kathmandu. The
earthquake is said to have lasted
more than one minute. It is supposed
to be the worst earthquake in Nepal
for 80 years. The earthquake and
numerous aftershocks were also felt in
the neighboring countries India and
Pakistan. Nepal has declared a state of
emergency in the affected areas and
asked the international community for
humanitarian assistance.
Nepal, one of the poorest countries
in Asia, faces major challenges, not
least because the affected area in and
around the capital is extremely densely
populated. Immediately after receiving
the news arche noVa has sent a team to
the disaster area to estimate the extent
of the damage better and to locate
possible operation sites.
DRINKING WATER NEEDED

Meanwhile, the installation of two
drinking water treatment plants at the
District Hospital in Bidur, in the province
Nuwakot, which was hit hard by the
earthquake, is in full progress, securing
the supply of approximately 170 patients.
The two hospital buildings have
overcome the earth shocks, but the
water supply has since then been
catastrophic. Patients and doctors have
to revert to heavy polluted water even
during ongoing surgical procedures,
says Konrad Menzel, describing the
situation prior to the commitment of
the intervention team. The trained
mechanical engineer is a member of
the arche noVa intervention team onsite,
which carries out emergency aid in the
June 2015
27

will focus on the repair of the drainage
system. The team works closely together
with the responsible authorities.
"The city engineer is very happy
about our commitment and pleased
that we contribute locally," says Konrad
Menzel. The numerous small and major
rivers in the region are very dirty since
the earthquake; it is about time that
the wastewater treatment plant can
go into operation again. More plans
for the province Nuwakot from arche
noVa include repair of spring tapping,
pipelines, and water distribution points
in the more remote mountain villages.
WATER WHERE IT IS NEEDED

In the second operating area of arche
noVa in Bhaktapur is a water tank built
at an emergency shelter a few days ago,
in order to secure the water supply of
1500 people affected by the earthquake.
Previously, the inhabitants of the camp
had to wait and rely on the delivery
by tankers. arche noVa is currently in
discussion with government agencies
which want to set up five official
28
June 2015
temporary settlements on public land in

Bhaktapur.
"7200 families who have lost their
homes are supposed to find shelter in
these settlements. Planned are simple
buildings made out of bamboo and
corrugated iron. We want to install pipes,
storage and if necessary filters for water
supply as well as toilets and washing
facilities for personal hygiene in these
settlements," says Friedrich Machein.
Already, arche noVa has positive
experiences with the drinking water
treatment plants, which were flown into
Nepal, in countries like Haiti, Pakistan,
the Philippines and Vanuatu. One plant
can produce up to 132 gallons (500
liters) of water per hour. Ideally, six
systems can supply up to 12,000 people
a day.
A CONTINUOUS NEED
"The supply of clean drinking water
in crisis areas that have been ravaged
by natural disasters is one of the most
important aid supplies," summarizes
Jens-Uwe Vogel, managing director
of VSX - Vogel Software. "In many

cases pump technology is used for
the installation of such plants. As a
provider of software solutions for the
pump selection, VSX is not only linked
to the association concerning the
content of their aid supplies, another
decisive aspect why we support the
arche noVa helpers regularly is the
regional proximity. Due to the current
acute situation, we did not hesitate and
triggered a donation. In addition, we also
asked our employees to donate."
Alexandra Klengel is marketing

specialist for VSX - Vogel Software,
which specializes in software and
Internet solutions for the fluid handling
industry and develops applications
for sizing, selecting, configuring
and selling engineered systems and
components like pumps, valves and
pipes. For more information, visit
www.vsx.net. For more information on
the emergency intervention of arche
noVa, visit www.arche-nova.org.
Curing a Raw Water

Pumping Facilitys
Unremitting
Driveshaft Failures
Part 1 of 2
By Maki Onari and Juan Gamarra, Mechanical Solutions, Inc.
ne of the major pump OEMs had invited

Mechanical Solutions, Inc. to resolve an
occurrence of multiple pump driveshaft failures for
one of their most important customers, a well-established
international ore mining company. The operation of the
relatively new pump systems at the mining companys raw
water pumping station in East Africa frequently had been
accompanied by objectionable vibration levels. Recently
two of the three large pump systems had sustained
catastrophic failures, which had occurred roughly one
month apart. What phenomena had caused both of the
driveshafts to fail in rapid succession? And once its true
source was identified correctly, what actions and how
much effort would be required to correct this acute
machinery problem permanently?
Typically this station pumped river water for slurry
production through a pipeline to a separate mining and
processing facility, which was located several miles
away from the station. However, the lack of pumping
capacity temporarily had shut down the whole ore mining
operation. The unanticipated outage had penalized the
facilitys owners upwards of $100,000 per week in lost
production revenue. Out of necessity the company planned
to restart the mining operation without delay. Unfortunately,
the prior efforts of others had failed to identify the true
source of the broken pump driveshafts, which placed the
operation at considerable risk. Therefore, the objectives
of this testing project were to identify the root cause of
the driveshaft failures, and to devise a practical solution
that would eliminate the recurrence of the costly and
potentially dangerous pump system breakdowns.
30
June 2015
Figure 1: One of the three pump systems at the station is depicted in the figure,
viewed in the direction toward the prime mover. Because the coupling guard had been
removed to perform the repairs, the massive driveshaft which connected the prime
mover and the right angle drive is visible.
Section sponsored by Azima DLI www.AzimaDLI.com
THE STATION HAD

RESUMED OPERATION
After MSI arranged a detailed
evaluation plan, two MSI engineers
journeyed to the remote site
with an array of comprehensive
instrumentation, to perform extensive
vibration testing of the pump
systems. In each of the three pump
systems, a 1200 horsepower diesel
prime mover was connected to a
large vertical turbine pump through
a welded, hollow driveshaft and a 1:1
right angle gearbox.
Figure 1 shows one of the three
pump system installations at the
station. Each of the multistage
pumps when in operation moved
over 24,000 cubic feet (680 cubic
meters) of water per hour, and
featured a column pipe which
extended approximately 40 feet (12
meters) below grade. To satisfy the
unique geometric and dimensional
requirements of these particular
installations, the massive steel
driveshafts which connected the
prime movers to the pump gearboxes
had been welded together from
smaller subsections, and they also
had been equipped with large
constant velocity joints at both ends.
Notably, both of the mechanical
failures had occurred at the locations
of the welded joints in the fabricated
driveshafts. One of the two massive
pump system driveshafts which had
failed is depicted in figure 2.
The pump systems at the station
immediately had been returned to
service by the mining company,
once the replacement driveshafts
were fabricated and installed. At the
suggestion of others, supplementary
structural steel bracing, steel
cladding, and steel plates had been
welded to the existing pump system
support structures. Considerable
amounts of extra grout also had been
put in, and this included the packing
of the new voids in the structures
which were formed by the addition of
the cladding. Based on the continued
elevated vibration which was present
as the pump systems operated,
however, the modifications apparently
had little influence on the actual

machinery problem that was at hand.
It also was evident that the diesel
prime movers ran very roughly, and
in fact instances of backfiring were
observed relatively frequently while
the pump systems were in operation.
COORDINATED TESTING AND

ANALYSIS WAS PERFORMED
Sufficient data was recorded at
the test site over several days to
accomplish a competent diagnosis
of the puzzling machinery problem.
Experimental modal analysis (EMA)
June 2015
31
testing was performed to identify the
actual structural natural frequencies
and mode shapes of the three pump
systems. Using accelerometers, the
response frequencies of vibration
were recorded both parallel
and perpendicular to the pump
discharge piping. The data was

logged at many locations on the
gearbox top, the column pipe,
the pump shaft, and the top of the
diesel prime mover, and also in the
vertical direction at the top of the
gearbox.
Figure 2: The figure presents several views of one of

the two failed driveshafts from the pumping station.
The welded, hollow construction of the driveshaft
clearly is evident, as is the complete failure through
the cross section of the driveshaft. In the upper left
hand view, the massive size of the driveshaft also is
apparent.
32
June 2015
Section sponsored by Azima DLI www.AzimaDLI.com
Figure 3: The figure shows a plot of typical experimental modal analysis (EMA)
frequency response test data that was recorded from one of the pump shafts, in the
direction perpendicular to the pump discharge piping. The test data indicates that
the pump shaft has a natural frequency of 42Hz, which is adequately separated from
the 1xrpm speed, 30.3Hz, but close to 1xrpm.
Figure 4: Illustrated in the figure are the ODS plots of the data which was recorded
at the top of one of the pump systems diesel prime movers. The FFT spectra at
the top, for the direction parallel to the crankshaft and the pump discharge piping,
shows a response of 0.067in/s rms at 1xrpm, and of 0.322in/s rms overall. The FFT
spectra for the perpendicular direction, bottom, shows a response of 0.041in/s rms
at 1xrpm, and of 0.244in/s rms overall. These values are considered elevated, but
do not by themselves necessarily indicate a serious problem.
Figure 3 presents a typical plot of the EMA data, which

was recorded at the pump shaft of one of the pump systems
at the station. Also, the separation margins in percent
between these natural frequencies and the maximum
response frequencies of 1x rpm and 1.5x rpm speeds of
both the pump and the prime mover were calculated and
reviewed.
At strategic locations on each pump system, the
operating deflection shape (ODS) test data was acquired
during steady state operation, and all of the test data
points were tied to consistent, three dimensional, spatial
reference coordinates. In the directions both parallel
and perpendicular to the pumps discharge piping, Fast
Fourier transform (FFT) spectra were recorded at roughly
the same locations on the pump systems as were the EMA
data. For each pump system, the recorded overall vibration
amplitudes, as well as those at 1xrpm of the pump and
at 1.5xrpm of the prime mover, were summarized and
compared. Figure4 illustrates as an example typical plots
of the ODS data, which was recorded at the top of the prime
mover of one of the pump systems at the station.
Further, the recorded ODS test data was processed
with proprietary computer software, to create graphical
animation files of the vibration mode shapes and torque
oscillations of the pump systems. Each resulting ODS file
was a computer animation that displayed in an exaggerated
manner the amplitude and also the phase of each portion of
the pump systems structure. The ODS files were created for
each of the pump systems key vibration frequencies. Shown
in figure5 is a plot of a
still frame from the ODS
animation file for one of
the pump systems.
Strain gages in
conjunction with RF
telemetry systems were
attached to the driveshaft
of one of the pump
systems. During the
pump systems operation,
the strain gage outputs
were monitored and the
axial and torque loads
on the driveshaft were
calculated continuously
from the recorded data.
Figure6 illustrates a plot
of this data for one of the
Figure 5: A still frame from an ODS
pump systems. Working
animation file for one of the pump systems
is depicted in the figure. At a vibration
in parallel, engineers
frequency of 41Hz, the right angle gear
back at the U.S. office
drive at the top of the pump has been
displaced from the vertical, in the direction
evaluated the test results,
parallel to the pump discharge piping
and also performed a
and the driveshaft. Clearly visible in the
ODS animation, this movement confirmed
finite element analysis
the existence of the large oscillating
(FEA) of the welded
compression load in the driveshaft, should
the driveshaft splines not slide.
driveshaft design using
June 2015
33
the measurements that were taken directly
at the pumping station.
A LOOK AHEAD
In next months conclusion, we will present
how analysis of the data unlocked the
solution to the puzzle and the practical
resolution to prevent the damaging
combined mechanical stress condition
from recurring in any of the three pumping
system driveshafts.
Figure 6: Dynamic strain gage data which was recorded from the driveshaft of one of the operating pump
systems appears in the figure during a load transient, where the bottom two plots are magnifications of
the highlighted bandwidth in the overall data plots which appear in the top half of the figure. The test
data displays the unusually large oscillating longitudinal load that existed, which when combined with the
oscillating torsional load created an environment that would promote crack growth in the driveshaft.
34
June 2015
Maki Onari is manager of turbomachinery

testing and Juan Gamarra is senior staff
engineer at Mechanical Solutions, Inc. (MSI).
MSI performs consulting and R&D, as well
as provides design, analysis and testing
services for organizations throughout the US
and overseas. MSI is proud of its outstanding
track record in solving some of the world's
most difficult technical problems. For more
information, call 518.320.8552 or visit
www.mechsol.com.
PUMP SOLUTIONS
Blue Angel Pumps

Provide Peace of
Mind for Geiler
Plumbing
Pre-assembled back-up and primary system
cuts down installation time
By Tyler Lusebrink, Wayne Water Systems
eiler Plumbing found that

using Wayne Water Systems
Blue Angel Pumps cut down
their installation time, improving
overall productivity. The new Blue
Angel Pumps pre-assembled back-up
and primary system combines all the
components needed for a sump pump
with a high-quality backup pump and
an auto dialer that can notify up to five
numbers.
for third- party security system

notification, while the auto dialer
allows the plumber to input up to five
numbers (including their own) to be
alerted in the event flooding occurs.
CUSTOMER FOCUSED
Is this beneficial to the consumer?
I think it is, for quite a few reasons,

Varos says. People never go down
and look at their sump pump, Ive
gone out on inspections and its full to
the drain tile, where its been running
for who knows how long.
A bright LCD screen that displays
the time, date, and various messages
EASE OF INSTALLATION
Its definitely easier (the installation):
youre not playing with acid, you
dont have to put prongs in anywhere
and make sure you have everything
wired up correctly, says Jose Varos,
technician for Geiler Plumbing. With
the old ones, youd have about fifteen
lead wires coming over and each one
has to be hooked to a certain side. Its
nice that they (Blue Angel) color-code
all of them.
The cast-iron primary pump
pushes 60 gallons (227.13 liters) per
minute, while the fully submersible
thermoplastic back-up pump pushes
47 gallons (177.91 liters). The backup
system includes connection ports
36
June 2015
Section sponsored by Smart Turner Pumps www.smartturner.ca
about the current state of the primary

and back-up pumps. The system is
also extremely quiet while it runs.
It is super quiet, its very nice,
the only thing I hear is the checkvalve when it closes, and thats how I
know its actually working. When he
first installed a system, Varos says, I
expected to go downstairs and see
water everywhere because of how
quiet the sump pump was.
Varos continues, Its just really
nicefor ease of installation, the
simplicity, and how user-friendly
it is.
CONSTRUCTION SPECS
Microprocessor controller self-tests the battery status, float switch
and pump operation every seven days and sends voice alerts in
advance of a problem
Fully submersible back-up pump for an easy addition to any sump
system
Auto dialer notification calls up to five (5) telephone numbers you
program in to alert the homeowner to a problem before flooding
occurs (auto dialer requires standard telephone service, a landline
or digital telephone service like DSL or cable telephone - product
will not work with a PBX or internet phone system)
Includes connection port for third party security system notification
Corrosion-resistant thermoplastic construction for long life in tough
sump applications
Corrosion-resistant thermoplastic impeller for maximum water flow
Tyler Lusebrink is the social media

marketing coordinator for Wayne
Water Systems, a Scott Fetzer company.
Wayne Water Systems provide people
with worry-free water handling
solutions. For more information, visit
www.waynewatersystems.com.
Protective battery case included with LCD screen display

1- inch (38.1 millimeter) NPT discharge for easy installation and
compliance with building codes
For use in 14 inch (355.6 millimeter) diameter or larger sump basins
Drop in the pit ready, complete with two (2) 1- inch (38.1
millimeter) check valves already installed.
June 2015
37
PUMP SOLUTIONS
What Is Your Zero?

Knowing your zero can reduce costly mistakes
Part 1 of 2
By Jeff Sines, Engineered Software, Inc.
n all aspects of life, numbers are

used to describe the amount of
something, whether its the cost
of a product, the distance between
two cities, how fast you are driving,
or how old your children are. But a
number is meaningless unless it has
two things: a unit and a zero reference
datum. In science and engineering,
miscommunication, confusion, and
costly mistakes can occur when
numbers are used without proper
attention to units or their relationship
to a reference point.
In September 1999, the $325
million NASA Mars Climate
Orbiter disintegrated in the upper
atmosphere of Mars because the
navigation software produced output
in Imperial units of pound-seconds
(lbfs) instead of SI units of newtonseconds (Ns). This error caused
Trajectory Correction Maneuvers to
place the orbiter on a path to enter
the Mars atmosphere at an altitude of
37 miles (60 kilometers) instead of the
intended altitude of 140 miles (225
kilometers). A minimum altitude of 50
miles (80 kilometers) was required for
safe orbit around Mars.
Not all miscommunication is as
costly as the Mars Climate Orbiter.
However, expensive mistakes are
commonly made here on Earth.
When designing, installing, operating,
and maintaining piping systems
these mistakes often result in lost
production, off-quality product,
excessive downtime, environmental
excursions, and re-work. It is crucial
that communications be as concise
38
June 2015
as possible for all who are involved

in any aspect of operating a process
system, particularly those involved
in extremely hazardous fluids and
energy levels.
FLUID PROPERTY UNITS

There are numerous fluid properties
that are used in the design and
analysis of piping systems: pressure,
temperature, density, viscosity, and
specific heat capacity to name a few.
Each property has a numerical value
and unit that gives meaning to that
property and allows it to be used to
determine the operating conditions
for the system. Understanding
what the unit means, and when a
unit conversion must be applied, is
crucial to the appropriate use of the
property.
For example, when is a foot
not a measure of distance? The
pump industry characterizes the
performance of a pump by how many
feet of Total Head it produces. Head
and feet in the study of fluid flow does
not refer to distance or parts of your
body, but instead is used to quantify
the specific energy, or energy content
per unit weight (or mass), of the fluid.
But even the definition of head has

some nuances that are not obviously
apparent and must be taken into
account in order to properly use the
numerical values associated with it.
COMPARING VALUES OF HEAD

A key concept with head is that
its numerical value is referenced
to the density of the fluid under
consideration. One foot of head of a
given fluid is not the same energy
content as one foot of head of a
different fluid. Consider two site
glasses containing two different fluids
separated by a liquid/liquid interface
at Points 1 and 2, as shown in figure
1. In order for the two fluids to be in
equilibrium at the interface, the total
fluid energy at Point 1 (H 1 due to the
height of the column and density of
Fluid 1) must be equal to the total
fluid energy at Point 2 (H 2 due to the
height of the column and density of
Fluid 2).
Figure 1: Fluid Pressure Head is a function of pressure

and density
But its obvious that H1 does not

equal H2, so how can the two values
represent the same amount of fluid
Section sponsored by Smart Turner Pumps www.smartturner.ca
energy? To reconcile this apparent discrepancy, its important

to understand that H1 quantifies the amount of fluid energy
at the interface in reference to the density of Fluid 1, while
H2 quantifies the same amount of fluid energy but uses the
density of Fluid 2 as the reference.
If the two fluids are in equilibrium with no flow, the static
pressure at Point 1 must equal the static pressure at Point 2.
This density compensation adjusts one fluids numerical

value of head so that it can be directly compared to another
fluids head, in essence putting them on the same zero
reference datum.
An example where this distinction may have an impact on
the sizing and selection of a pump can be seen in figure 2.
A pump must add sufficient energy to the fluid to overcome
two aspects of fluid flow: energy lost due to friction (Dynamic
Head Loss) and Static Head due to elevation and pressure
differences between where the fluid is pumped to and where
it is pumped from.
The pump itself does not know how much of its Total Head
is used to overcome the Head Loss or how much goes to
compensate for the Static Head. The pump feels a pressure
at its inlet due to the configuration and Head Loss leading
into its inlet as well as pressure at its discharge due to the
configuration and Head Loss of the system at its outlet. In
other words, the piping system tells the pump how much
Total Head it must produce at a given flow rate.
The static head that Pump 1 must overcome in System 1
can be calculated:
In System 2, a heat exchanger located at the 25 foot

elevation heats up the water from 60 to 200 degrees
Fahrenheit, resulting in a change in the density of the fluid
from 62.38 to 60.14 pounds per cubic feet. Does Pump 2 feel
the same amount of Static Head as Pump 1?
Because the density of the fluid from the outlet of the
heat exchanger to the liquid surface in the Product Tank in
System 2 is less than System 1, the pressure felt at the 25
June 2015
39
PUMP SOLUTIONS
This difference of 3 percent in Static Head
between System 1 and System 2 may not be
significant enough to result in over-sizing the pump
in System 2, especially if a design margin of 15 to 25
percent is added prior to pump selection. But every
unnecessary foot of head means that the pump is
adding more energy than the system needs, which
results in the additional flow or throttling to dissipate
the energy that must occur at a control valve. That
equates to higher energy cost, more wear and
tear on the control valve, a greater susceptibility
to cavitation and choked flow and potentially
more downtime for maintenance and equipment
replacement.
Figure 2: Systems with different values of Static Head modeled in PIPE-FLO Professional.
foot elevation due to this 85 foot column of water will be less

than the pressure at the same location in System 1. The Static
Head felt by Pump 2 must include a portion of the system that
is density compensated because the water flowing through the
pump is at 60 degrees Fahrenheit:
40
June 2015
Jeff Sines is product engineer at Engineered Software,

Inc., the leading software developer for piping systems
worldwide. With over thirty years of experience in
the software development industry, ESIs portfolio
includes award-winning PIPE-FLO, PUMP-FLO, and
ESI Learning product lines. For more information, visit
www.eng-software.com.
DEWATERING SOLUTIONS
Stormwater Chambers
Go Super-Sized
CULTEC introduces new, ultra-high
capacity Recharger 902HD
By CULTEC technical staff
ntroducing its Contactor and Recharger

chambers to the industry in 1986, CULTEC
helped begin a revolution toward using
plastic construction products. Since then, several
product developments and strategic alliances
have made CULTEC a cutting-edge manufacturer
focused on research and development. The
companys Contactor and Recharger plastic
septic and stormwater chambers were designed
to provide a lightweight stormwater management
solution compared to heavier concrete
structures. A wide variety of sizes ensure there
is a chamber to meet virtually any installation
requirement.
THE RECHARGER 902HD

The newest chamber CULTEC provides to the
stormwater market is also its largest offering
yetthe Recharger 902HD. This ultra-high
capacity model offers the benefit of minimizing
project costs by maximizing storage volume
in a given footprint. The Recharger 902HD is
an ideal solution for high-volume stormwater
management systems due to its lightweight
maneuverability, shipping and stockpiling
benefits and design flexibility.
When compared to smaller, lower capacity
chamber sizes or comparably sized large
diameter pipe, clients achieve the required
storage volume in a condensed footprint using
the Recharger 902HD and require less labor and
excavation, resulting in a lower cost per cubic
foot. Additionally, the chambers shorter length
and light weight (78 pounds [35 kilograms])
allow for easier handling and reduced heavy
equipment time when judged against competitive
models.
42
June 2015
The Recharger 902HD provides more than 20 percent greater storage per foot than the closest
competitor chamber size.
The Recharger 902HD is open on both ends and requires a separate end cap to cap chamber rows.
QUICK ASSEMBLY ON SITE

Units are shipped on pallets at twelve
pieces-per-skid, fourteen skids-pertruckload and stockpile neatly on
site in a compact area. The installing
contractor and heavy equipment
operator experience less downtime
when receiving CULTEC Recharger
902HD material shipments than when
waiting for several truckloads of
heavy concrete structures or loose
pipe to arrive and to be unloaded.
Chambers are joined using an
overlapping rib connection. Each
902HD chamber includes CULTECs
unique side portal feature which
allows connections to take place
at any point within the system for
maximum design flexibility. Smaller
chamber-type cross feeds called
HVLV FC-24 Feed Connectors
are inserted into the side portal
openings to create an internal
manifold. Having the manifold
incorporated within the system
reduces the required bed area and
related excavation costs. A customfabricated external pipe manifold
is eliminated by using this internal
manifold feature.
To support the engineering community, CULTEC is modeled in Bentley Systems' PondPack

V8i, HydroCAD, Autodesk Storm and Sanitary Analysis and Streamline Technologies' ICPR
and can assist with any design by performing preliminary calculations and supplying jobspecific AutoCAD layouts free of charge. A free Stormwater Management Design Guide is
available upon request. For more information, call 203.775.4416 or visit www.cultec.com.
GREATER STORAGE PER FOOT

The model has an installed length
of 3.67 feet (1.12 meters) long, 78
inches (1981 millimeters) wide and
48 inches (1219 millimeters) tall. The
bare chamber storage capacity of
the Recharger 902HD is 17.66 cubic
feet per foot (1.64 cubic meters
per meter)more than 20 percent
greater storage per foot than the
closest competitor chamber size.
The chamber boasts a minimum
installed storage of 27.27 cubic feet
per foot (2.53 cubic meters per
meter) when installed with stone. The
Recharger 902HD shall be designed
to withstand AASHTO HS-25 defined
loads when installed according to
CULTECs recommended installation
instructions. The company currently
offers the largest variety of chamber
sizes ranging from 8.5 to 48
inches (216 to 1219 millimeters)
high to fit almost any installation
requirement.
June 2015
43
MOTOR SOLUTIONS
Why Motor Drives

Impact the World So
Dramatically
By Ulrich Spiesshofer, ABB
UNDERSTANDING ENERGY USE

ABB recently tallied what the company's
drives saved the globe in 2014, for
example. In energy consumption, the
installed base saved 445 TWh (terawatthours), which is equivalent to what 110
million households use in energy, when
each home consumes, on average, 4000
kilowatt-hours annuallyan average
for 2005, the year for which the latest
statistics are available.
If that amount of energy would have
been generated by fossil-fuel-powered
electricity plants, these drives reduced
CO2 emissions by 370 million tons. The
visual of how ABB's installed base of
drives impacts the world looks like this:
ENERGY REDUCTION
FOR PUMP USERS
Pumps are one of the most common
motor applications and offer the biggest
potential for saving energy because,
at half the speed, only one-eighth of
the power is needed. Drives' ability to
reduce energy consumption between
30 and 50 percent is commonand
44
June 2015
in some cases by up to as much as

90 percent. Intelligent motor control
methodssuch as use of variable
speed drivescan help in solving the
energy challenges all pump users face.
Variable speed drives regulate the
speed of a motor and can cut energy
consumption as much as half in many
pumping applications.
However, the truth is that most motors
around the globe still are awaiting
control via a drive, and most are
controlled with mechanical braking/
speed devices, rather than electronic
control. This means that as great
as the projected savings in current
applications are, the real potential for
savings occurs when the majority of
motors benefit from drive control and
users begin sharing their experiences
on how to maximize performance while

minimizing energy costs with real-world
results.
ACCELERATING THE GLOBAL

SHIFT TO ENERGY EFFICIENCY
Energy efficiency is not a localized
concern for just the pump industry.
In fact, electric motors account for
about 28 percent of global electricity
consumption. Many motors are bigger
than they need to be and most are
running at full speed, even when they
dont have to. Energy savings quickly
add up when high-efficiency motors
are used in combination with devices
such as variable speed drives that
adapt their speed to the task at hand
because the energy used to run a motor
over its lifetime costs 100 times more
Energy saved with ABB drives

500
450
400
350
300
TWh
otor drives, which act exactly

like an accelerator pedal that
speeds up or slows down a
vehicle in exact proportion to driving
conditions, are the unsung heroes of the
energy world. Because they regulate
motors so precisely, and because
motors are the major consumers of
energy produced for industry, the
installed base of drives save energy and
keep CO2 emissions out of our Earth's
atmosphere in dramatic proportions.
250
200
150
100
50
0
Y92 Y93 Y94 Y95 Y96 Y97 Y98 Y99 Y00 Y01 Y02 Y03 Y04 Y05 Y06 Y07 Y08 Y09 Y10 Y11 Y12 Y13 Y14
In 2014, the installed base of drives saved the earth the equivalent of the energy consumed by 110 million households .
Section sponsored by WEG www.weg.net/us
than the motor itself. Investing in a

high-efficiency motor typically has an
internal rate of return that is more than
100 percent higher than for a standard
motor.
Recognizing the opportunity for
reducing energy consumption while
maintaining performance, ABB joined
the United Nations Environment
Programs global action on improving
appliance and equipment efficiency.
The company will provide expertise
on energy efficient motors and
transformers to help governments
devise policies that accelerate energy
savings.
Many cost- and energy-efficient
technologies are already available. The
biggest contribution that governments
and businesses can make to fighting
climate change in the short term is to
drive the implementation of existing,
tested and often low-cost technologies
for using energy more efficiently.
For example, transformers account
for about 3 percent of global electricity
consumption and their number in

emerging markets is set to almost
triple by 2030. Since the most efficient
transformers consume 80 percent less
electricity than the least efficient, the
opportunities for savings are vast.
In a first phase, ABB will share knowhow related to energy efficiency in
motors and transformers, including
its experience with current policies,
regulations and standards, and advice
on potential applications for the best
available technologies.
ABB is one of the worlds largest
makers of transformers, electric motors
and variable-speed drives. The installed
base of ABB drives saved more than 400
terawatt-hours (TWh) of electricity in
2013, equal to the annual consumption
of about 37 million households in the
United States.
The United Nations Environment
Program expects that the global
transition to efficient appliances and
equipment would reduce global
electricity consumption by about 1500
TWh by 2030, which is equivalent to 8

percent of todays global electricity use.
A WINNING SCENARIO
When you get an opportunity to speak
with, or help, users of motors, let them
know how dramatically they can impact
the earth, and their pocketbook, via the
addition of drives. It's a truly perfect
win-win-win for the earth, the user,
and companies like ABB who help with
these automation solutions.
Ulrich Spiesshofer is the chief

executive officer of the ABB Group,
a leading power and automation
technology company. Boasting a
record of innovation, ABB is the largest
supplier of industrial motors and drives,
the largest provider of generators to the
wind industry and the largest supplier
of power grids in the world. For more
information, visit www.abb.com.
June 2015
45
P OW E R G E N E R A T I O N S O L U T I O N S
Surviving
Hazardous Duty
in a Hot Fly-Ash Pit
BJMs KZN Pump takes on a
coal-fired power plant near
Denver, Colorado
By Suzette Gibson, BJM Pumps
he most challenging place for a pump at a coal-fired power

plant is the hot fly-ash pit. Fly ash is a heavy and abrasive
powder produced during the combustion of coal. Power
plant operators recover fly ash from their combustion gas flues to
remove particulate pollutants from air emissions, and they store
fly ash in outdoor piles or pits.
A RIGOROUS CHALLENGE
Fly ash has a number of commercial uses, among them as
a binder in concrete manufacturing and road construction.
Comprised of small, glassy particles with sharp edges, fly ash
is heavy and has a tendency to compact and harden, making it
difficult to pump.
A power plants fly ash pits or piles are typically served by
sumps that collect rainwater runoff. The sumps thus contain
slurry that can exceed 30 percent by weight, some six times
the amount that can be handled by the submersible sewage
pumps that traditionally have been used by power plants in this
application.
A DANGER TO PUMPS AND THE BOTTOM LINE

These misapplied pumps come with high maintenance costs and
a high failure rate. The operators of a Colorado power station
were told by one leading pump manufacturer that their pump
needed to be shut down and pulled from the fly ash sump every
three months to change the seal oil.
Such costly and labor-intensive shutdowns at the Colorado
power plant turned out not to be necessary. Plant operators
replaced their submersible sewage pump with a BJM KZN55,
7.5-horsepower heavy-duty slurry pump, turned it on and all but
walked away.
46
June 2015
DURABILITY MEETS PERFORMANCE

Constructed especially for the thick
and abrasive slurries unique to the coal
industry, the KZN is an extremely durable,
top-discharge pump with a mechanical
agitator and wide clearances. Because
it has a straight path from intake to
discharge, the KZN uses the pumped
liquid to cool the motor, and because it
does not have an elbow joint like a sidedischarge pump, it has fewer surfaces
that can wear and potentially fail. Because
the pumping components of the KZNthe
agitator, impeller and wear plateare
constructed with abrasive-resistant,
high-chrome iron, the pump has been a
workhorse at the Colorado plant.
MORE THAN SURVIVAL: SUCCESS

The KZN ran flawlesslytwenty-four
hours a day, for two yearsuntil a piece
of rebar jammed in the impeller, causing
a built-in overload protector to shut down
the motor. The pump was pulled, the
rebar was removed, and the agitator and
impeller vanes were replaced because
of minor wear. It has now back in service,
well into its third year of pumping hot fly
ash. The operators initially looked for a
pump that could merely survive these
harsh conditions, but are now extremely
pleased to find a solution they can count
on for some time to come.
Suzette Gibson is the marketing

coordinator for BJM Pumps, LLC.
Headquartered in Old Saybrook,
Connecticut, BJM Pumps has been
serving the industry since 1983 by
supplying quality pumps at a modest
price. For more information, call 877.
BJM.PUMP (877.256.7867) or visit
www.bjmpumps.com.
June 2015
47
48
June 2015
PROCESSING SOLUTIONS
Safe Conveyance
of Sour Crude Oil
Despite Demanding
Process Conditions
By Sriram Iyer, Lewa GmbH
our crude oil contains a high

amount of impure sulfur.
To convert sour crude oil
into valuable and refined fuel the
impurities occurring as elemental
sulfur in solution and as hydrogen
sulfide gas need to be removed. Due
to the presence of hydrogen sulfide,
sour crude oil is toxic, hazardous and
extremely corrosive which makes
its transportation to the preparation
system challenging.
it was possible to supply sixteen

mechanically identical pumps of the
Lewa Ecoflow series, driven by 55
kW electric motors, measuring 8.9
by 6.2 feet (2.7 by 1.9 meters), 6.2
feet (1.9 meters) high, and weighing
9259.4 pounds (4200 kilograms).
SELECTING THE RIGHT PUMP

To ensure high reliability in
operating the system, despite the
project's difficult conditions, the

customer defined a series of strict
selection criteria. The critical
fluid characteristics that had been
taken into consideration while
designing the pumps are: high
content of sulfur of about five
percent, high chlorine content,
high temperatures and highly
humid conditions under which
even stainless steel corrodes.
THE VALUE OF EXPERIENCE

Critical applications of conveying
mixtures of acidic hydrocarbon/
water to the washing system have
always been a challenge for any
pump manufacturer. This was also
the case in one recent project
Lewa handled in the Emirate of
Abu Dhabi. Lewa has designed and
supplied sixteen pumps to a major
construction company in Abu Dhabi
specifically designed to handle this
critical application.
On the project, Lewa was asked
to provide a solution to pump
liquid hydrocarbons from the flare
knock-out drum, or the blow-down
drum respectively, and convey the
acidic hydrocarbon/water mixture
back into the oil line to the washing
system. Since the differences in
these processes are only minor,
50
June 2015
In all, sixteen mechanically identical Ecoflow pumps were delivered to the customer. There, they work under difficult
process conditions to convey a highly volatile mixture of hydrocarbons and hydrogen sulfide conveying water back
into the oil line to the washing system.
Section sponsored by GEM www.gemu.com
Since the medium conveyed

is very volatile and extremely
hazardous, Lewa selected
hermetically tight diaphragm pump
heads made of superduplex stainless
steel. The diaphragm itself, due to
the eroding effect of the particles in
the corrosive liquid, is made of wearresistant PTFE.
valves to keep the suction pressure

requirements low and satisfy all
process conditions.
According to the customer, since
commissioning, the installed Lewa
pumps have been running smoothly
and with high reliabilityfulfilling
the expectation of the maintenance

and operating personnel. The oncall time agreement that permits
uninterrupted work at the plant
even when one of the pumps
needs maintenance is also working
seamlessly.
SPECIAL SUCTION VALVES

ENSURE A LOW NPSHR VALUE
While designing the pumps, it
was also necessary to take into
consideration that the mixing ratio of
water to hydrocarbons in the liquid
phase varies significantly and that
the pressure can vary between 20
and 45 bar.
Lewa designed the pumps to
handle a flow rate between 17.7
and about 529.7 cubic feet (0.5 and
15 cubic meters) per hour of the
acidic mixture. To ensure that the
pumps work reliably despite the
changing flow rate, the net positive
suction head of the system (NPSHa)
also had to be kept higher than
that required at the pump suction
(NPSHr). When pure hydrocarbons
are conveyed on hot summer days,
their vapor pressure rises and the
risk of cavitation increases. Various
options were analyzed with the
customer to tackle this issue. Lewa
offered integrated special suction
Sriram Iyer is managing director at

LEWA Middle East. As a researching
and productive company, LEWA
develops technologies and works
out solutions for a wide variety
of its customers' applications.
Products are primarily used in the
oil and gas industry, in the area
of gas odorization, refineries, and
petrochemistry, but also in the
manufacture of plastics, detergents,
and cleaning agents. LEWA currently
has approximately 1000 employees
and has 16 subsidiaries worldwide
as well as representatives and sales
offices in over 80 countries. For more
information, visit www.lewa.de.
June 2015
51
V A LV E S & C O N T R O L S S O L U T I O N S
Monitoring Energy
Flows for Saturated
and Superheated
Steam or Hot Water
Optiswirl 4200 vortex flowmeter
provides advanced energy measurement
By Sandy Olley, Krohne, Inc.
perators searching for

reliable flow measurements
in advanced energy
management systems have a new tool
at their disposal. Used to measure
both conducting and non-conducting
liquids, gases and steam, the new
Optiswirl 4200 vortex flowmeter
can be used for internal monitoring
of energy flows for saturated and
superheated steam or hot water, and
heat metering applications. It is also
a perfect choice for such applications
as steam boiler monitoring, burner
consumption measurement, or
compressed air network monitoring,
including free air delivery (FAD)
applications.
temperature sensor in the return line.

The gross and net heat calculation
can be fed into a distributed control
system (DCS) to support advanced
energy management.
FLEXIBLE OPTIONS
FOR VARYING NEEDS
The all-in-one solution features
integrated pressure and temperature
compensation, and can perform both

gross heat calculations for steam and
net heat calculation for steam and
condensate (hot water). The Optiswirl
4200 is available in a remote version
equipped with a field housing
converter with a connection cable up
to 164 feet (50 meters). Temperature
and pressure compensation options
are also available, which enable
IN WITH THE NEW

Equipped with comprehensive
communication options, and designed
in accordance with international IEC
61508 functional safety standards,
this flowmeter is a major update to
the original 4070 model. With one
temperature sensor integrated as
standard, the device can be installed
as a heat meter in the feed line
directly connected with an external
52
June 2015
Monitoring of compressor
output
calculation of standard flow volume

under fluctuating pressures and
temperatures. By measurement of
flow, temperature, and pressure in
one 2-wire-device, the line has to be
opened only once for installation.
In addition to the standard sensor
range, another available option
features an integrated reduction of
nominal diameter up to two sizes,
ideal for space-saving installations
and large measuring spans. A dual
version with two independent sensors
and two signal converters is also
available for multiproduct pipelines,
redundant measurement or increased
safety demands.
Evaluation of Free Air

Delivery (FAD)
ENHANCED ACCURACY
TYPICAL
APPLICATIONS
Measurement of saturated
steam and superheated steam
Steam boiler monitoring
Heat metering of steam and
hot water
Measurement of consumption
of industrial gases
Measurement of consumption
in compressed air systems
The Optiswirl 4200 also includes a

variety of electronics enhancements.
The device is now equipped with
a new advanced vortex frequency
detection (AVFD) function, as
well as a newly developed signal
SIP and CIP processes in

the food, beverage and
pharmaceutical industries
Safety-related measurement
in SIL applications (SIL2)
converter (VFC 200), with advanced

signal processing and filtering
that suppresses interferences and
disturbances in the pick-up signal
and filters out signals other than the
relevant frequency band. Redundant
data management prevents loss
of calibration and configuration
data when changing electronics or
display.
Sandy Olley is marketing

communications manager
for Krohne, Inc., a worldwide
technological leader in the
development, manufacture and
distribution of accurate, reliable and
cost-effective measuring instruments
for the process industries. For more
information call 800.FLOWING,
email info@krohne.com, or visit
www.us.krohne.com.
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ModernPumpingToday.com
June 2015
53
SEALING SOLUTIONS
Protect Shaft Seals in

Hydraulic Systems
By Bob Mainz
perators looking to protect shaft

seals in hydraulic systems now have
another option in Zero-Max Overhung
Load Adaptors, which provide an extra layer
of protection to hydraulic actuated functions
helping to ensure trouble-free operation. They
provide an intermediate mounting platform
between a motor and pump to absorb both
internal and external stress conditions in a
hydraulic system.
EXTRA PROTECTION
WHERE IT IS NEEDED
Designed to provide an extra layer of
protection to hydraulic actuated functions,
Overhung Load Adaptors prevent shaft seal
breakdown, a condition often unseen until
system damage occurs. Replacing damaged
shaft seals is laborious and costly because
multiple hydraulic components usually must
be disconnected to get at the seal failure.
Now, these conditions can be eliminated using
Overhung Load Adaptors for protection.
Designed for either face or foot mounting,
standard Overhung Load Adaptors are
available in over fifty models with input
bore sizes that range from 5/8 inch to 3-1/2
inch (15.88 to 88.9 millimeters). SAE mounts
available include A, B, C, D, E, and F mounts
with 2 or 4 bolt mounting flanges. Overhung
Load Adaptors are available with many shaft
variations including splined, threaded, tapered
and extended output shafts, all now available
with the special Zero-Max corrosion protection
process. Special input bores and housing
modifications are also available.
Hydraulic system seal protection is ensured when an intermediate connection and mounting platform
called an Overhung Load Adaptor (OHLA) is positioned between the motor and pump in a hydraulic
system.
CORROSION PROTECTION
The corrosion protection shaft option is
another addition to over 1300 custom designs
offered by Zero-Max to meet new and unusual
overhung load system requirements. These
specials include custom inverted bearing
54
June 2015
Cutaway close up shows robust seal design in the OHLA that safely absorbs both internal and external
stress conditions to the hydraulic system.
designs and multiple lubrication ports that increase

the Overhung Load Adaptors load capacity, bearing
life and smooth system performance. Manufactured to
ISO 9001:2008 quality standards, Zero-Max Overhung
Load Adaptors are ruggedly built with shafts precision
machined from high quality 130,000 PSI Stress-proof
steel. All custom Overhung Load Adaptor designs
include a detailed CAD approval drawing submitted
prior to manufacture.
VARIED APPLICATIONS
Overhung Load Adaptors are used in workboats,
recycling systems, forestry shredders, cold planers
for road paving, industrial conveyor drives and many
others where hydraulic systems require shaft seal
protection.
For over sixty years, Zero-Max, Inc. has created

innovative solutions to servo motion control problems
worldwide such as shaft couplings, adjustable speed
drives and keyless lock bushings. For more information,
call 800.533.1731, email sales@zero-max.com, or visit
www.zero-max.com.
Overhung Load Adaptors (OHLAs) are available in over fifty models to fit most applications.
June 2015
55
MODERN PUMPING PRODUCTS
Featured Product
FEDERAL PUMPS
Series VSPV Triplex Variable Speed Booster System
Federal Pump VSPV Triplex
variable speed booster system
combines over eighty-seven
years of Federal Pump product
reliability with new designs
that reduce energy costs,
extend product life and provide
innovative solutions where water
pressure challenges exist. The
VSPV Triplex meets SDWA and
NSF standards for potable water
use.
Applications:
Mechanical equipment
Roof tank fill systems
Booster systems
Irrigation systems
Chemical feed systems
Marine vessels
Apartment/Condo Use
Cooling tower
High Rise
Hospital
Universities
Hotel/Casino
Water-TI
Water fountain
display
Specifications:
Capacities to
900GPM
Pressure Boost to 300PSI
Sizes 2 to 6 inches
HP to 50 each pump
Available in single and three
phase power
Benefits:
Low Installed Costs
Built-In-Reliability
Energy Saver
Quiet Operation
Certified and Tested
Backed by Federal Pump
eighty-seven year tradition
Supported by USA
Distribution Network
Automatic Operation 24/7
Three year extended
warranty
For more information, call 718.451.2000 or visit www.federalpumps.com.
MIKI PULLEY
BXR-LE Electric Brake
The BXR-LE was specifically designed for use on robotic arms to reduce
the cantilevered load and has found value in other applications as well. The
unique compact and lightweight design optimizes machine design efficiency.
With accompanying voltage controller, power consumption is stepped down to
7VDC after a split second of 24VDC for brake actuation. When compared to the
other BX brakes in the Miki lineup, this revolutionary BXR-LE design provides
just one-third power consumption and heat generation in one-half the overall
size thickness. For more information, call Jon Davidson at 800.533.1731, email
jdavidson@mikipulley-us.com, or visit www.mikipulley-us.com.
VICTAULIC
Style 31 AWWA Coupling
The Victaulic Style 31 AWWA coupling assures quick, easy installation when joining
ductile iron piping systems of AWWA dimensions. The coupling can be installed in rigid
or flexible configurations, creating rigid joints comparable to a flanged joint or flexible
joints that permit controlled movement and attenuate system vibration. The Victaulic Style
31 AWWA coupling is assembled by positioning the gasket and coupling housings on
the pipe ends and tightening the bolts and nuts with standard hand tools or an impact
wrench. Installation is completed up to 5 times faster than other pipe-joining methods,
permitting systems to start up sooner. For more information, visit www.victaulic.com.
56
June 2015
KSB
Ecochem Non-Seal Canned Motor Pump
The Echochem Non-Seal series will be available in four standard variants to be used for
standard chemical applications, heat transfer fluids, polymerizing or ferrite-containing
fluids, and for low-boiling fluids and liquefied gases. he new series of pumps combines
two of its predecessors to deliver superior performance. KSB's MegaCPK, a standardized
chemical pump used in process engineering for years, and innovative canned motors from
Japanese cooperation partner, Nikkiso, combine to create this ground-breaking product. The
low-noise motor is made with a corrosion-resistant Hastelloy (2.4610) can and the pump's
dimensions are compliant with ISO 2858. They also meet the requirements and standards of
DIN/EN/ISO 15783 and API 685. For more information, visit www.ksb.com/ksb-en.
ELECTRO-CHEMICAL DEVICES
T80-S80 Analyzer System
Aquaculture operators in search of a better way to automate testing for dissolved
oxygen (DO), pH, ammonia and other parameters will find the modular plug-nplay T80-S80 Analyzer System from Electro-Chemical Devices (ECD) simplifies
operations and lowers total operating costs. While many operators rely on portable
sensors, they require staff time to manually complete the testing on a fixed
schedule that can be hard to maintain consistently during their busy work day. The
challenge and expense of dedicating staff time to testing becomes incrementally
problematic in larger or remote operations. The T80 Transmitters highly intelligent
digital protocol simplifies installation set-up and process measurements while
also reducing maintenance costs. For more information, contact Steve Rupert at
800.729.1333 or sales@ecdi.com, or visit www.ecdi.com.
GE POWER & WATER

KlarAid CDP2727 and CDP2724 Coagulants
Through extensive jar testing, KlarAid CDP2727 and CDP2724
have shown that they are capable of reducing the turbidity and
TOC in low turbidity raw water to levels less than other singlecontainer products previously offered by GE. KlarAid CDP2727 is the
concentrated product whereas CDP2724 is a diluted version that may
be a convenient solution in circumstances where low volumes and
dosages are proven effective. These products can be used alone or
in conjunction with anionic flocculants. For more information, contact
Angie Hansen at 215.942.3511 or angie.hansen@ge.com.
METALLIZED CARBON
Carbon-Graphite Vanes, Rotors, and End Plates
Metallized Carbons carbon-graphite vanes, rotors, and
end plates are used in such dry running applications as
automotive anti-smog pumps and gasoline vapor pick up
pumps, breathable air pumps and vacuum pumps. Inliquid applications include vending machine beverage
pumps, fuel and liquid chemical pumps, and medical liquid
pumps.With dimensionally stability and high strength
to weight ratio, the components are available in several
grades of Metcars proprietary carbon/graphite material,
says Matthew Brennan, chief operating officer of Metallized
Carbon. Our engineers assist in selecting the optimum
grade based on application, environment, housing materials,
rpm and other parameters. For more information, visit
www.metcar.com or call 914.941.3738.
June 2015
57
PUMPING TRENDS
Building Relationships
in the New Century
ThomasNet.coms Ed Edwards on providing free
product sourcing and supplier discovery
uilding relationships with reliable,

high-quality suppliers is critical
to the success of the engineers,
maintenance and operations professionals,
and others in the pumping industry.
Ed Edwards, manager, audience
outreach with ThomasNet.com, offered
a tour of their free supplier discovery
Ed Edwards
and product sourcing platform for
Modern Pumping Today readers. He can be reached at
eedwards@thomasnet.com or 212.629.2177.
Modern Pumping Today: How long has ThomasNet been
serving engineers and other buyers?
Ed Edwards: Weve been in business for nearly 120 years,
and have always had the same missionto connect buyers and
suppliers. Many of your readers will remember the Thomas
Register of American Manufacturers, or the Big Green Books,
but about twenty years ago, the Thomas Register migrated
online as ThomasNet.com. Being online, it can provide more
resources than the printed Thomas Register could.
MPT: What are the main features that our readers should
know about?
Ed Edwards: Two applications are particularly relevant for
Modern Pumping Today readers: The first is Supplier Discovery,
which provides a gateway to suppliers of everything from
centrifugal pumps to brushless pump motors. It features
over 700,000 North American manufacturers, distributors
and service providers, indexed according to 67,000 product/
service categories. The application has guided search
capabilities; once users type in what they need, theyre
prompted to add qualifiers like location (i.e., within 50 miles)
and quality certifications (i.e., ISO, ANSI, etc.). This helps them
build a list thats targeted to their individual requirements.
In-depth supplier profiles let them dig deeper and research
companies of interest. The profiles include capabilities,
equipment, product lines, brand names carried, product news,
and more.
Second is Product Sourcing, an entry point for searching
millions of products, including raw materials, equipment,
58
June 2015
MRO (maintenance, repair and operations) supplies and

finished products. Items are featured in line-item detail, and
user manuals and exploded view diagrams are provided for
many products. Engineers can search for pumps according to
specifications such as maximum discharge head height, port
type, or pump media.
MPT: Can engineers also access CAD drawings through the
platform?
Ed Edwards: Yes; we provide access to millions of 2-D and
3-D CAD drawings and models right from Product Sourcing.
Users can download a 3-D model and insert it directly into their
designs. The underlying technology works with all major CAD
systems, so this is a seamless process.
MPT: What if a company is seeking suppliers with particular
certifications or registrations?
Ed Edwards: This is something that many of our users asked
about, and weve updated our platform in response. Our
new Certification/Quality application includes more than 80
certifications/registrations that are important to engineers and
buyers, such as ISO, ANSI, Nadcap, ITAR, FDA and C-TPAT.
Were listing thousands of companies with these credentials,
and many offer downloadable certificates.
MPT: What else is new on the platform?
Ed Edwards: We recently launched a Custom Quotes
application to help users locate the right job shop. It works like
a matchmaking service. Users indicate what they need, such as
casting, fabrication or finishing, and our engineers identify up
to five shops that can help them.
MPT: Speaking of suppliers: How do they get listed? Do they
have to pay?
Ed Edwards: We make listings available for free to all
suppliers. Id also encourage engineers and buyers to go to
www.ThomasNet.com and check out the Video Tour. They can
also sign up for ThomasNet Onsitea free, customized service,
available on-premise or via webinar, to help users address
their sourcing challenges.

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JUNE 2015

Modern Pumping Today

P.O. Box 660197 | Birmingham, Alabama 35266

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Monitoring Energy Flows for Saturated and Superheated

Protect Shaft Seals in Hydraulic Systems

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