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PUMPSANDSYSTEMS.COM
SYSTEMS
NITROGEN
REMOVAL
Wastewater Treatment
Safeguards the Potomac
COMPLETE SOLUTIONS
PRODUCT
Mi Process Pumps & Equipment is proud to offer a complete
line of:
Process Pumps
Process Pump Parts
Liquid Filtration
Pump Electrical Drives & Controls
Pump Types:
ANSI
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Boiler
Boiler Feed
Centrifugal
Centrifugal
Diaphragm
Diaphragm (AOD
(AODD)
DD)
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n late July, members from the Pumps & Systems team as guests of the Submersible
Wastewater Pump Association (SWPA) visited the Metropolitan Water Reclamation
District of Chicago. The areas population and its myriad of industries generate 1.4
billion gallons of wastewater every day or half a trillion gallons per year (page 88).
Demand for water treatment equipment and service continues to grow. Regulatory
mandates and the drive to lower operating costs are being met by equipment innovations
and new treatment methods. Advancements in design and related ancillary equipment
such as chemical feed systems, instruments and controlsplay an important role.
This months issue focuses on advancements in wastewater processing and water
management technologies, including a municipal redevelopment project in an Italian
community of 72,000 near Rome (page 72). The series outlines technology used to reduce
one facilitys wastewater sludge by 43 percent. Another case study from a utility near
Melbourne, Australia, shows how a 19th century wastewater disposal system upgraded
with a low-pressure sewer system and grinder pumps controlled by telemetry (page 48).
These articles represent Pump & Systems growing international coverage.
For details on metering and dosing pumps, see our special section (page 32), which
discusses of metering-pump technologies. Frost & Sullivan provides an analysis of how
the volatile oil and gas industry could impact the metering pump market (page 46).
Also, be sure to review the timely report on the aging workforce and how
demographics are affecting the immediate and long-term future of our industry. The
times are always changing, but it seems that major forces are now converging to quicken
the pace, even faster than we thought possible (page 28).
To meet the Pumps & Systems team, drop by our booth (#4256) at the McCormick
Center during WEFTEC in Chicago later this month (Sept. 26-30). We are looking
forward to seeing many of you there.
Best regards,
Senior Technical Editor, Mike Pemberton
mpemberton@cahabamedia.com
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com 205-278-2843
SENIOR TECHNICAL EDITOR: Mike Pemberton
mpemberton@cahabamedia.com
205-314-8279
MANAGING EDITOR: Amelia Messamore
amessamore@cahabamedia.com
205-314-8264
MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com 205-278-2839
ASSOCIATE EDITOR: Amy Cash
acash@cahabamedia.com 205-278-2826
CONTRIBUTING EDITORS: Lev Nelik,
lfreeman@cahabamedia.com 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
lmasaoay@cahabamedia.com 205-278-2840
ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody
dmoody@pump-zone.com 205-345-0784
ACCOUNT EXECUTIVES:
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Garrick Stone
gstone@pump-zone.com 205-212-9406
MARKETING ASSOCIATES:
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the
right to determine qualications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and
possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and
form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2015 Cahaba Media Group, Inc. No part of
this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the
factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the
authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba
Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements
contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any
medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be
returned. Volume 23, Issue 9.
Increased efficiencies and UNMATCHED RELIABILITY allow the Vaughan Chopper Pump
to handle tough stringy solids often with the same motor size as a non-clog pump. Also
included is a back-pullout casing design, allowing external adjustments of clearances and
ease of maintenance.
- Advanced engineering, efficiency, maintainability and performance
- Handles tough stringy solids with the same motor size as a non-clog pump
- New larger sizes, configurations, and cutting-edge flushless seal design
WEFTEC
BOOTH
#2362.
This issue
COVER
SERIES
SEPTEMBER
Volume 23 Number 9
WASTEWATER
56
COLUMNS
PUMPING PRESCRIPTIONS
The Italian wastewater plant reduced required man-hours and saved more than
170,000 annually in landfill costs.
SSPECIAL
PECIAL
REPORT
2
8
89
122
123
124
128
1-800-231-1412
toshiba.com/tic
This issue
SSPECIAL
PECIAL
SECTION
SEPTEMBER
DEPARTMENTS
94 EFFICIENCY MATTERS
5 Key Metrics that Affect
Operational Efficiency
By Anurag Garg
DATTUS
98 MAINTENANCE MINDERS
Remote Monitoring
Minimizes Outage &
Lost Production Costs
By Cynthia Stone
GE Intelligent Platforms
SSPECIAL
PECIAL
SECTION
WATER MANAGEMENT
S E P T E M B E R 2 0 15
PUMPSANDSYSTEMS.COM
SYSTEMS
CONSERVES ENERGY IN
MULTIPLE-PUMP SYSTEMS
By Kurt Bihler
Bihlertech, Inc.
NITROGEN
REMOVAL
Wastewater Treatment
Safeguards the Potomac
Image courtesy
of KSB
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
DENNIS RAWLE, GRAPHITE METALLIZING CORPORATION
YONKERS, N.Y. (Aug. 3, 2015) Dennis Rawle has been appointed
European director of sales for Graphite Metallizing Corporation.
Rawle has more than 25 years of experience in the marine and
industrial industries. Most recently, he was general manager and
technical sales manager for pump products at Exalto UK. Rawle will
be responsible for coordinating sales and marketing activities for
Graphite Metallizing in the UK and Europe and will be based out of
the UK office. graphalloy.com
JUSTIN SNOWDON,
METALLIZED CARBON CORPORATION
OSSINING, N.Y. (July 21, 2015) Metallized Carbon Corporation
(Metcar) appointed Justin Snowdon as sales manager, responsible
for driving sales initiatives and expanding markets for Metcar
products and services. Snowdon has more than 13 years of sales and
management experience. An insightful and consultative leader with
strong customer engagement skills, Snowdon was previously regional
sales manager at Thermatool Corporation and a senior sales manager
for Hoffman Engineering. metcar.com
COLLEEN LAYMAN,
THE SOCIETY OF WOMEN ENGINEERS
CHICAGO (July 17, 2015) The Society of Women
Engineers (SWE) installed Colleen Layman, vice
president and power-water management director
of HDR, as president through June 2016. Layman
brings a 20-year career in engineering. She has
a bachelors degree in mechanical engineering
Colleen Layman
technology from Thomas Edison State College, a
masters in water resources and environmental
engineering from Villanova University, an MBA in management of
engineering and technology from North Central University, and is a
registered professional engineer. swe.org
general manager for the Business Unit in 2013. In his new role, he will
drive the companys agenda to generate value by helping customers
improve throughput at lower cost. nskamericas.com
Jonathan
Hamp-Adams
JEFF PEETERS,
WEF & WERFS LIFT PROGRAM
WASHINGTON (July 8, 2015) GEs Jeff
Peeters was appointed a member of the Water
Environment Research Foundations (WERF) and
the Water Environment Federations (WEF) LIFT
Program Steering Committee. LIFT is a WERFWEF program that promotes the adoption of new
Jeff Peeters
technologies in the wastewater sector. Peeters
is a professional engineer with specific knowledge of biological
remediation techniques and membrane technology for water and
wastewater treatment challenges. werf.org/lift
JOSH WATERS,
AUTOMATION PRODUCT GROUP, INC.
LOGAN, Utah (July, 13, 2015) Automation Products Group,
Inc., (APG) named Josh Waters as the new director of sales for
Reid Jajko
DO YOU HAVE A
SPECIFIC NEED...
MIKE SMITH,
HAYWARD GORDON ULC
HALTON HILLS, Ontario (July
1, 2015) Hayward Gordon
ULC appointed Mike Smith
as its new vice president
sales and marketing. In this
role he will be responsible for Michael Smith
the sales and promotion of
Hayward Gordon industrial pumps, mixers and
engineered systems globally. Smith has a
Bachelor of Science and Liberal Arts from
the University of Southern Mississippi, with
continuing education at Michigan State
University, Odessa College and the University
of Alabama. haywardgordon.com
203.268.7513 |
10
NEWS
Grundfos Restructures to
Reinforce Position in Asia
SINGAPORE (July 6, 2015) Given that
Asia Pacific accounts for the bulk of
the worlds population and some of the
fastest-growing economies, Danish
pump manufacturer Grundfos has
announced a new structure to reinforce
its market position for sustainable and
profitable growth in the region.
The Asia Pacific operations will now
come under four geographical clusters:
East Asia, South Asia, Oceania and
Indochina. The reorganization aims
to improve customer centricity with a
stronger focus on local requirements,
strengthen business efficiencies with
better resource allocation, and increase
market competitiveness with better
economies of scale.
The new structure considers the
commonalities in technological
requirements, as well as cultural,
demographical profiles that exist within
each geographical cluster.
grundfos.com
11
Endress+Hauser to Strengthen
Operations in Finland by
Starting New Sales Company
REINACH, Switzerland (July 1, 2015)
In the future, Endress+Hauser Oy
will be the exclusive provider of
Endress+Hauser field devices and
related solutions and services in the
Finnish market. The new company
began operations July 1 and resumed
12
NEWS
EVENTS
TPS 2015
Sept. 14 17, 2015
George R. Brown Convention Center
Houston, Texas
979-845-7417 / tps.tamu.edu
Pumps & Systems Webinar
Presented by Baldor
Impact of Amended Motor Eiciency
Rules on the Pump Industry
Sept. 24, 2015
pumpsandsystems.com/webinars
WEFTEC
Sept. 26 30, 2015
McCormick Place
Chicago, Ill.
240-439-2554 / weftec.org
Pack Expo (PMMI)
Sept. 28 30, 2015
Las Vegas Convention Center
Las Vegas, Nev.
703-205-0480 / packexpolasvegas.com
Lift Station
13
www.dynamatic.com/win
14
PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Diameter of
Rotating Member at
Clearance (inches)
Minimum Diametral
Clearance
(inches)
Diameter of
Rotating Member at
Clearance (inches)
Minimum Diametral
Clearance
(inches)
<2
2.000-2.499
2.500-2.999
3.000-3.499
3.500-3.999
4.000-4.499
4.500-4.999
5.000-5.999
6.000-6.999
7.000-7.999
8.000-8.999
9.000-9.999
10.000-10.999
11.000-11.999
0.010
0.011
0.012
0.014
0.016
0.016
0.016
0.017
0.018
0.019
0.020
0.021
0.022
0.023
12.000-12.999
13.000-13.999
14.000-14.999
15.000-15.999
16.000-16.999
17.000-17.999
18.000-18.999
19.000-19.999
20.000-20.999
21.000-21.999
22.000-22.999
23.000-23.999
24.000-24.999
25.000-25.999
0.024
0.025
0.026
0.027
0.028
0.029
0.030
0.031
0.032
0.033
0.034
0.035
0.036
0.037
15
References
1. L. Nelik, Pumps & Systems magazine,
March, 2007, page 18, How much
Energy is wasted When Wear Rings are
Worn to Double Their Initial Value?
2. PREMS-2A Pumps Reliability and
Efficiency Monitoring System, rev. 2A,
March 2015: www.doctorpump.com
www.pumpingmachinery.com/pump_
school/pump_school.htm (PVA module
10A)
16
Understanding the
Connections
Every piping system consists of
three elements: the pump, process
and control elements. The pump
adds energy to the fluid; process
elements make the product or
provide the service while control
elements improve product or
service quality. Working together
these elements meet the systems
design objectives.
The key to understating the
interaction between the
equipment in the system, as well
as its operation, is energy usage.
Since we know that energy must
be conserved in any system, we
can develop an equation for
energy usage:
Figure 1. This open loop piping system will be used in the series of columns dealing with
troubleshooting piping systems. (Courtesy of the author)
17
hPU = hPR + hC
Equation 1
Where:
hPU = Pump gain (feet)
hPR = Process losses (feet)
hC = Control losses (feet)
We will use head in feet of fluid
as our energy units. Every system
must have a known reference for
comparing energy measurements
so all values are made in reference
to a common datum; i.e., 0 feet of
elevation in this case.
Innovative Pass-Through
Technology
For more details, please contact the address of the right note.
ShinMaywa(America), Ltd.
6135 Park South Drive Charlotte, NC 28210 Phone: 704-945-7112 Fax: 704-945-7101
www.shinmaywa.co.jp/america/ E-mail:pump@shinmaywaamerica.com
18
WEFTEC
Booth
#916
Control Elements
The control elements consist of the
instrumentation and controls used to improve
the quality of the product by maintaining a
given process parameter (PV) at a set value
(SP). The purpose of the control element is
to remove any excess energy supplied by the
pump elements that is not required by the
process elements.
19
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21
22
Conclusion
We now have an understanding
of how the energy flows within a
physical piping system. Knowing
how energy is being utilized
by the various elements of the
as designed system and then
knowing how the energy is actually
used in the physical system is the
key to troubleshooting how the
system is operating.
In the next part of this series,
we will discuss how energy is being
utilized in a system with installed
plant instrumentation. It is often
said that most plants do not have
sufficient instrumentation to
perform these calculations. Much
of the necessary information is
readily available. You just need to
know where to look. As always, feel
free to contact me with questions
about any of my columns.
References
1. ASME Performance Test Code PTC 8.2
Centrifugal Pump and ANSI/HI 3.6 Rotary
Pump Test
2. ASME MFC-3 Measurement of Fluid Flow
in Pipes Using Orifice, Nozzle, and Venturi
3. ISA Standard S75.01 Flow Equations for
Sizing Control
23
UnitedRentals.com/pmp | 800.UR.RENTS
24
25
Performance Mastered
The Chesterton 442C Cartridge Split
Mechanical Seal
The 442C is the latest innovation in split seal technology, combining
superior seal performance with the ease of installation of a cartridge
split seal. Our patented split seal technology addresses the inherent
limitations found in conventional cartridge split seal designs,
minimizing installation complications.
Cartridge design simplifies
installation and provides
superior sealing reliability
Enhanced performance
capabilities
Broadest equipment fit
of any split seal
Easy field repair
Visit us at www.chesterton442c.com
26
Conclusion
The pump performance must
be de-rated for higher elevation
changes (less absolute pressure
less NPSHa). If the pump is engine
driven in lieu of an electric motor,
the resulting intermittent torque
10. Flex pipe normally has a
introduces limitations to the shaft
reduced internal diameter (ID). design capabilities.
Non-collapsible flex piping is
Jim Elsey is a mechanical
commonly used on portable units.
engineer who has focused on
Normally the ID of flex pipe and
rotating equipment design and
adaptors are smaller than standard
applications for the military and
pipe. Think of the dimensions
several large original equipment
as tubing rather than pipe.
manufacturers for 43 years
Determination of the pipe friction
in most industrial markets
for the NPSHa calculations will be
around the world. He is the
incorrect if the reduced ID
general manager for Summit
is neglected.
Pump, Inc., and the principal of
Avoid older or incorrectly applied
MaDDog Pump Consultants LLC.
flex pipes because sometimes the
Elsey may be reached at jim@
pipe ID liner will collapse under
summitpump.com.
suction (vacuum) and block the line.
FRANKLIN ELECTRIC
KNOWS PUMPS AND SYSTEMS
After all, weve been moving water for more than 7 decades,
consistently offering breakthrough innovations, robust
products, and unmatched technical service. Weve leveraged
that expertise to develop reliable solutions for a number of
residential, commercial, and industrial applications.
Visit us at WEFTEC Booth #3652
27
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* See our Web site for details and restrictions. Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
3/:22/855/2627
28
SPECIAL REPORT
29
30
SPECIAL REPORT
SEE UESC:
WEFT 405
Booth 3
31
What makes the BHAT*LNK a Superior Peristaltic Metering Pump?
Exceptional Innovation.
IP
P66
NE
EMA
A 4X
]GY
GY
YN"J
N JU]
N"JU]
U]T
TUBING MATERIAL
OPTIONS
Norprene, Tygothane
and Norprene Chemical.
CHEMICAL
RESISTANT FITTINGS
Natural PVDF for
optimum chemical
resistance and fluid
purity.
EXCLUSIVE! NEW
www.blue-white.com
pu
mpsa
ndsyst
ems.c
ompsfreeinfo.com.
| Sept emb er 2015
Circle
104
on card
or visit
32
SPECIAL SECTION
33
Image 1. Metering pump users must consider many factors when designing
a system (Images courtesy of Neptune Chemical Pump Company)
34
SPECIAL SECTION
35
Safety
standards
change.
When is the last time
you raised yours?
Introducing the new Eaton SC9000 encapsulated
powerpole (EP) arc-resistant medium voltage (MV) drive.
The new standard in medium voltage drive safety.
At Eaton, its important to keep
workers and equipment safe. Arc
flashes can cause injuries, lawsuits,
fines, equipment damage, facility
downtime and lost production. As
the new standard in MV drive safety,
the SC9000 EP is the industrys first
fully integrated arc-resistant MV drive
www.eaton.com/SC9000
Circle
110 on
card om
or visit
psfreeinfo.com.
pu mpsa
ndsyst
ems.c
| Sept
emb er 2015
36
SPECIAL SECTION
WEF T
2-STAGE SCT
HAS ARRIVED
2-stage SCT is for applications up to 120 psi
but with all the same benets as 1-stage SCT.
Smart Conveying Technology offers:
Reduced downtime, extended stator
life and fewer maintenance needs
Reduced energy use compared to
conventional progressive cavity pumps
EC 2
0 15
Visit
us at
boot
h 24 3
7!
SEEPEX Inc.
sales.us@seepex.com
www.seepex.com
37
38
SPECIAL SECTION
39
40
SPECIAL SECTION
Easy Adjustment
The piston displacement (or volume pumped per stroke) is
variable and controlled by the angle of the pump head to the
drive. When the pump angle is zero, the pump head is in straight
alignment with the drive, and the flow is zero. In this situation,
no reciprocation occurs and only the piston is rotating. As the
angle of the pump head increases above zero, in either direction
with respect to the drive, the piston reciprocates, and fluid is
moved through the pump (see Figure 3). The greater the angle,
the greater the displacement (piston stroke) per cycle.
Adjustment is infinite between zero and 100 percent, and
a flow rate indicator allows for accurate and simple linear
calibration. The pump is designed so that at any angle and
flow rate, the piston always bottoms for maximum bubble
clearance. This is especially important at small dispenses
and flow rates, as the presence of even a minute bubble will
significantly affect accuracy.
Accuracy & Precision
Monitoring both the accuracy and precision of the dispenses
can help end users measure dispensing consistency. Accuracy
is a comparison of the average value of the dispense volume
compared to the desired or target value. Precision is the range or
degree of variation from dispense to dispense. Comprehensive
testing has proven that some valveless piston pumps can
maintain a precision of 0.5 percent or better for millions of
cycles without recalibration (see Figure 2).
Valveless piston pumps are also available in several
configurations including standalone production dispensing
systems and miniature original equipment manufacturer
(OEM) models for medical, analytical and process
instrumentation. The pump technology is used in a broad
range of precision-fluid control applications including
adding vitamin D to milk, producing adhesives for medical
apparatus assembly and handling monomers that form
contact lenses.
S P O N S O R E D
C O N T E N T
41
No Close Tolerances
he Disc pump is not a centrifugal pump,
positive displacement, gear or lobe pump.
Unique in design, the Disc pump bridges
the performance gaps of conventional
pumps and is capable of out-performing
all of them in many applications.
No Radical Loads
he Disc pump uses a new and patented
technology that isnt available in any
other pump. he technology of the Disc
pump harnesses the natural power of the
boundary layer and viscous drag.
No Impingement
A boundary layer of luid molecules collects and rotates with the discs. his
creates a natural, protective bufer that separates the pump from the luid.
Non Pulsating, Laminar Flow
hrough viscous drag, the luid is pulled through the pump without
impingement. he boundary layer attracts and drags successive layers of luid
molecules into layered lows of parallel streams. his is the simple principle
of viscous drag and in the Disc pump it is a powerful dynamic force that
pulls the luid through the pump in a smooth laminar, non-turbulent low.
VISIT US AT
WEFTEC
Booth 3415
disclo.com 619-596-3181
Circle 108 on card or visit psfreeinfo.com.
42
SPECIAL SECTION
Pumping Options
Municipal wastewater plants engage in various treatment
activities from removing solid material such as sludge
and sediment to dissolving suspended organic material
such as nitrogen and phosphorus to disinfecting water by
killing disease-causing microorganisms.
The processes used to clean water also vary widely
depending on the intended use of the final product.
Drinking water requires more intensive cleaning than
industrial process water or water that is to be reused
for irrigation.
Each process involves a series of steps, including
coagulation and flocculation, pH control, de-chlorination,
chemical precipitation and oxidation, ion exchange,
chemical neutralization and stabilization, and taste
and odor control. Each step requires an assortment of
chemicals that are used in different combinations until
the desired water standard has been achieved. Several
types of pumps can be used to meter the correct dosages
of the chemicals used in these processes.
The two proven technologies that continue to dominate
the industry are HAD and MAD metering pumps.
43
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pu mpsa ndsyst ems.c om | Sept emb er 2015
44
SPECIAL SECTION
The HAD design offers the longest life and the smallest
maintenance requirements with performance that exceeds
requirements in the water treatment industry.
pump drive moves the diaphragm back and forth. This
action causes suction from the supply tank, which pumps
fluids through the conveyance infrastructure. MAD
designs are suited for pressure peaks near 175 pounds
per square inch (psi). The maximum life of the pump is
achieved by replacing the diaphragm at recommended
service intervals.
As with any chemical that could cause gas binding,
a degassing valve is recommended to release off-gases
from the agitation or pressure changes experienced by
a liquid that has off-gas characteristics. Like the HAD
design, MAD metering pumps offer the same features
that address vapor lock and ensure consistent, accurate
delivery of chemicals.
For added assurance that the pump is operating as
expected, an air-fi lled chamber on the drive side of the
liquid end facilitates leak detection.
Because many of the chemicals used in water treatment
are hazardous, a leak-free environment is required.
Liquid ends (which come in contact with the process
fluids) are designed to be leak-proof and highly durable.
In some applications, a redundant, double-diaphragm
rupture-detection system can further protect the pump
from hostile chemicals and contamination by hydraulic
fluids. This system consists of two separate diaphragms,
a hollow intermediate ring and a pressure gauge. During
normal operation, the two diaphragms are pushed tightly
together and are separated only around their outside
edge by the intermediate ring. The rupture-detection
system senses pressure only when a diaphragm ruptures.
Otherwise, the system is not affected by changes in pump
discharge pressures.
MC r
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Chicago,, Illinois
C
45
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Barnes SH clog-resistant
l
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pumps outperforms the competition.
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pu mpsa ndsyst ems.c om | Sept emb er 2015
46
SPECIAL SECTION
47
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Trust
You Can
Wh
At Neptune, we offer design and manufacturing expertise all under one roof! No matter
the size of the project from a single metering pump to the most advanced custom
chemical feed systems Neptunes products are backed by an experienced engineering
team ready to serve and support you.
Hydraulic Diaphragm Metering Pumps backed by a 3-year warranty
Self-priming Mechanical Diaphragm Pumps with excellent
suction-lift capabilities
Electronic Metering Pumps with 300 strokes per minute providing
more even distribution of chemical and greater turn down
Peristaltic Hose Pumps available from 10mm to 100 mm sizes
offer heavy-duty design for reliable operation
Engineering capabilities include custom and semi-custom
systems to fit your needs
For more information, please go to: psgpumps.com/ps915n
See Us At
WEFTEC
Booth 4656
PSG
295 DeKalb Pike
North Wales, PA 19454
USA
P: +1 (215) 699-8700
F: +1 (215) 699-0370
info@neptune1.com
neptune1.com
48
WASTEWATER
Intelligent Pressure
Sewers Transform
Australian Wastewater
System
South East Water combines grinder pumps and
a remote control telemetry network to improve
groundwater quality and the economy in
Mornington Peninsula.
First of Two Parts
BY JOSEPH HARMES
FOR PUMPS & SYSTEMS
49
50
COVER
SERIES
WASTEWATER
51
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lab
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No
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Superior-quality products.
Comprehensive reliable solutions.
pu mpsa ndsyst ems.c om | Sept emb er 2015
52
COVER
SERIES
WASTEWATER
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Circle 151 on card or visit psfreeinfo.com.
Se p t e mb er 2015 | Pum ps & S y st e m s
in a jam
US Patent #
7,159,806
8 0 0 . 5 4 3 . 2 5 5 0 libertypumps.com
14 416
53
54
COVER
SERIES
WASTEWATER
55
The cycle of
solutions - Water
technology by KSB
Water is crucial for our survival. Clean water supplies and
efficient sewage treatment have never been more important. KSBs
know-how and extensive product range help you meet all water
supply and treatment requirements, efficiently and effectively. We
offer end-to-end solutions addressing all stages of the water cycle
from water extraction to sewage treatment. Visit us WEFTEC
booth #4853.
www.ksbusa.com
56
COVER
SERIES
WASTEWATER
Dual-Shafted Grinders
Save Illinois Lift Station
$20,000 Per Year
The design and function of this equipment provide
distinct benets for wastewater processing.
BY TROY HEIMERL
JWC ENVIRONMENTAL
57
Pump Genius
Pump Process Control Software
Pump Genius is designed to reduce system operation and maintenance costs
while increasing process accuracy and protection. The software provides
multiple pump control and protection, as well as system monitoring and
protection. Pump Genius can be applied to any system that requires constant
ow or pressure.
Reduce your pump system operation and maintenance cost
Increase accuracy and protection
Control up to 6 pumps dynamically alternated and controlled
To learn more about Pump Genius or to locate
a WEG Distributor near you, please contact
1-800-ASK-4WEG or visit www.weg.net/us
58
COVER
SERIES
WASTEWATER
59
Case Study
The Otter Creek Water Reclamation District in South
Elgin, Illinois, faced ongoing maintenance and cleanup
costs at their Thornwood lift station due to a buildup of
rags, wipes, trash, wrappers and other debris clogging the
system and forcing pump shutdowns.
Thornwood is the largest of the districts three lift
stations, with an incoming flow of about 490 gallons per
minute (gpm) or 110 cubic meters per hour (m3/h). The
stations three 40 horsepower (HP) (30 kW) pumps must
move sewage at about 600 gpm (136 m3/h) at 36 feet
(11 meters) total dynamic head (TDH). Incoming debris
would clog the pumps and force the district to take the
system offl ine.
Operators would then have to disassemble the
pumps to clear the buildup by hand, reassemble them
and restart the system. The district engineer noted that
the facility was seeing higher volumes of polyesterreinforced rags, which seemed to be a significant factor
increasing clogging.
This buildup was so massive that, beyond regular
cleanings by the operators, the station was forced to hire
a Vactor truck four times each year at $4,900 a visit to
remove rags and wipes from the wet well. The weight from
the debris buildup would disconnect the cables leading
to the submersible pumps, inadvertently shutting off
and short-circuiting them. Altogether, the cost to deal
with these maintenance and repair issues was costing
the district nearly $20,000 a year in hard costs plus the
additional maintenance time.
The district engineer suggested a dual-shafted grinder
unit. Since the installation of the grinder in 2012, the lift
station has experienced zero pump maintenance issues
and has eliminated the previous costs associated with
clogging problems.
Long-Term Investment
As the Thornwood Lift Station example demonstrates,
properly selected equipment can provide pump stations
with exponential cost savings and reduce unscheduled
60
COVER
SERIES
WASTEWATER
DC Facility Employs
High-Capacity Pump
Station for Nitrogen Removal
Optimization of the selected submersible propeller pumps saved the
facility up to $200,000 per year.
BY BRYAN ORCHARD
KSB
Reducing Nitrogen
Nitrogen is an odorless, tasteless, colorless non-metallic chemical
element that occurs naturally in the earth and atmosphere. It is a vital
component of life for many organisms, but too much nitrogen can be
harmful. In waterways, excessive nitrogen can deplete the oxygen that
fish and other aquatic life need to thrive.
The latest ENRF process expansion of Blue Plains was designed to
reduce nitrogen levels before the water is discharged into the Potomac
River. The goal was to meet or exceed the new U.S. Environmental
Protection Agency (EPA) requirement to reduce effluent nitrogen
production to 4 million pounds per year.
Se p t e mb er 2015 | Pum ps & S y st e m s
Demand Reliability
61
Energized testing
ALL-TEST Pro instruments provide
complete electric motor system
health analysis in minutes!
Predictive Maintenance
Troubleshooting
Route-Based Testing
Trending
Quality Control
Complete Stator and
Rotor Analysis Detect early
faults in AC & DC motors,
transformers and generators.
De-energized
testing
Comprehensive Reporting
Includes bad connections, winding & turn faults, air gap,
broken bar, contamination, ground faults and more.
Motor
Testers
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www.alltestpro.com
pu mpsa ndsyst ems.c om | Sept emb er 2015
62
COVER
SERIES
WASTEWATER
63
64
COVER
SERIES
WASTEWATER
4 Steps to Determine
Equipment SCCR
Wastewater treatment facilities can take advantage of the latest
calculation tools to ensure NEC and OSHA compliance.
BY DAN NEESER
EATON
65
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71
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WEFT
7
3
42
508A
www.seewaterinc.com
Phone: 888-733-9283
66
COVER
SERIES
WASTEWATER
67
68
COVER
SERIES
WASTEWATER
CASE STUDY
flow velocity of the medium. Transittime is the preferred mode of operation
for relatively homogeneous liquids and
is highly accurategenerally up to 0.5
percent of flow.
Doppler measurement relies on the
reflection of transmitted sound waves by
particulates to create a measurable shift
in frequency (see Figure 2). Commonly
referred to as the Doppler effect, this
shift can be used to calculate flow rate.
Doppler mode is ideal for applications
containing a high proportion of
suspended solids or entrained gas, but
it produces less accurate readings
typically up to 1 percent of flow.
THE CHALLENGE
The flow instrumentation used by a municipal wastewater treatment plant
in Louisiana experienced repeated electronics failures that prevented
maintaining an accurate effluent flow signal. The facility needed a more
reliable method of monitoring flow to ensure continuous compliance with
regulations imposed by the Louisiana Department of Environmental
Quality (LDEQ), so they contacted a global process instrumentation
supplier for support.
THE SOLUTION
Because the plant expressed the need for minimal interruption of effluent
flow to avoid interfering with reporting to the LDEQ, a local service partner
of the supplier arrived at the site with a portable clamp-on ultrasonic flow
meter demo unit. Since the sensors could be mounted externally, the meter
was installed on the line within a few hours, and no downtime was necessary.
Once the meter was turned on, the effluent flow signal was immediately
restored and the reading remained accurate.
Thanks to the immediate success of the portable unit in responding to a
months-long operational issue, the plant elected to purchase a permanent
version of the clamp-on ultrasonic flow meter with dual transit-time and
Doppler capabilities. Several years later, the meter continues to measure
effluent flow with the same combination of accuracy and versatility
demonstrated on the day of purchase.
69
70
COVER
SERIES
WASTEWATER
PROTECT
your Pumps,
Mechanical
Seals and
Bearings
Summit
Industrial Products
800.749.5823
www.klsummit.com
Circle 147 on card or visit psfreeinfo.com.
Se p t e mb er 2015 | Pum ps & S y st e m s
Booth 4062
Accurate, versatile
chemical pumps
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qdospumps.com
info@wmftg.com
71
72
COVER
SERIES
WASTEWATER
Ozone Technology
Reduces Sludge by
43 Percent or More
The Italian wastewater plant dropped required
man-hours and saved more than 170,000 annually
in landll costs.
BY WIEBKE RAND
XYLEM WEDECO PRODUCTS
The Problem
Idrica aimed to maximize the efficiency of the
facility. A growing populationwhich placed a
load on the plant that was 25 percent higher than
73
TFSEALSUSA .COM
TF-P214
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metal bellow cartridge
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74
COVER
SERIES
WASTEWATER
The Solution
Idrica worked with a major water and
wastewater technology company to
develop an efficient and cost-effective
solution that would meet the systems
requirements. The solution had to deliver
consistent and stable treatment service
throughout the year despite more intense
use during summer months.
The utility provider chose an ozone
system and set up a pre-configured,
containerized test unit that would operate
at full plant capacity for six months to
determine the solutions effectiveness at
different periods of the seasonal cycle.
The sludge oxidation demonstration
system includes an ozone generator and
a proprietary contact system. These two
main components are housed inside a
40-foot container and can be easily moved
from site to site.
This sludge oxidation demonstration
system includes an ozone system, which is
intentionally sized larger than necessary
at the final installation. In this particular
case, the test unit was providing three
times the capacity needed at the full scale
plant in Ardea.
This test delivered positive results
and showed that the facility required a
system smaller than the test solution. The
ozone system was pre-configured for this
particular application, which minimized
the time required for setup and reduced
the time needed for certifications.
The Benefits
Ozone is one of the most powerful
commercially available oxidants and
is often used for municipal water and
wastewater treatment. In addition to its
oxidizing capabilities, it is a sustainable
method of treatment. Oxidation destroys
pollutants, colored substances, odors and
microorganisms without creating harmful,
chlorinated byproducts, unpleasant
75
up to
50%
energy savings
with variable
frequency drive
technology
ENGINEERING
TOMORROW
76
COVER
SERIES
WASTEWATER
The Results
One year after installation, the ozone solution successfully
reduced the amount of sludge produced by the Ardea
wastewater treatment plant by 43 percent or 1,300 tons
annually. This significant reduction saved the facility more
than 170,000 per year in landfi ll costs. It has also led to a 30
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COVER
SERIES
WASTEWATER
Energy Eciency in
Water & Wastewater
VFDs can reduce energy consumption and water loss in
variable pumping systems.
BY JEFF BERGMAN
DANFOSS VLT DRIVES
78
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()
79
80
COVER
SERIES
WASTEWATER
Nanomaterials Promote
Eective Water Reuse
These technologies allow membrane-based distillation components
to be used to produce high-purity drinking water from heavily
compromised water sources.
First of Two Parts
BY TIM TANGREDI
DAIS ANALYTIC
81
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82
COVER
SERIES
WASTEWATER
Final
1511653
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83
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A
YA S K A W A . C O M
84
COVER
SERIES
WASTEWATER
Disposable
Wipes Threaten
Wastewater Systems
New shredder pump technology can prevent costly
clogging and minimize damage to equipment and
municipal reclamation facilities.
BY MIKE BJORKMAN
BJM CORP.
86
COVER
SERIES
WASTEWATER
Case Study
FoxRock Properties owns and operates two massive
office and medical complexes in Norwell, Massachusetts.
The first of the neighboring properties is Longwater
Place, a 27,000-square-foot office building, part of a
larger 26-acre campus that includes 84,000 square feet
of corporate offices and a 160,000-square-foot wellness
center. Longwater Place incorporates a full cafeteria, and
fitness center, featuring a gymnasium with squash courts
and locker/shower facilities.
The adjoining property is South Shore Medical Center,
an 85,000-square-foot facility comprised of 100 medical
examination rooms, 70 medical offices and a complete
range of diagnostic equipment.
Because of the expansive size of these buildings,
property management faces major wastewater handling
challenges. The complex has 30 bathrooms and 64 toilets
that pass flow content consisting of sanitary waste, wipes
and feminine hygiene products
flushed by staff, patients and
visitors. All of it travels through
the sewer lines of both properties
and is funneled into an outside
10,000-gallon overflow tank.
The wastewater is then pumped
through a 4-inch PVC discharge
pipe more than one-eighth of
a mile from the tank into the
municipal sewer system. Two
solids-handling submersible pumps
are at the heart of the system.
Although not required by local
regulations, FoxRock Properties
maintains this pumping system
to ensure that discharges to the
municipal sewer system can be
handled effectively by the local
treatment facilities.
Given the buildings
populations, professional range
of clients and types of services
provided, it is expected that we
would see more than our fair share
of flushables, said Dan Snyder,
property manager for FoxRock.
In the past, we experienced
87
Image 4. The new pump was placed in the sump without a screen,
alongside a shredder pump.
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88
COVER
SERIES
WASTEWATER
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Circle 134 on card or visit psfreeinfo.com.
Visit us at
booth
4256
Sept. 28 30
McCormick Place
Chicago, Ill.
89
90
SPECIAL SECTION
WATER MANAGEMENT
91
PROTECT PUMPS
PUMP POWER
AMPS
POWER
VALVE CLOSING
PUMPING
FULL LOAD
No Sensitivity
For Low Loads
NO LOAD
VALVE OPENING
NO FLUID
FULL LOAD
92
SPECIAL SECTION
WATER MANAGEMENT
93
Future Requirements
Each pump station has three bays, but only two are in
use. The Sabine River Authority had the manufacturer
refurbish the original 1970s eddy current drives and
purchased new digital controls. They plan to install them
in each pump stations third bay to use as a backup. Well
be able to decrease wear on the drives by running two in
parallel at half capacity. Asked if they would choose eddy
current drives again, Istres reply was, Hands down.
Gary Patterson holds a B.S. in electrical engineering
from Michigan Technological University, specializing
in rotating machinery and electrical power. He has
served as an application engineer, field sales
engineer and regional sales manager for
various manufacturers of variable speed drive
equipment for more than 40 years. He is
the national water/wastewater application
specialist for DSI/Dynamatic.
94
EFFICIENCY MATTERS
of temperature, vibration,
lubrication, loads, pressures and
other parameters. Analytics enable
engineers to move from an original
equipment manufacturer (OEM)
specified maintenance regimen to
one that is defined by actual usage
and observed failure intervals.
Prescriptive maintenance takes
predictive maintenance to the next
level by unlocking intelligence not
only about when a machine will fail
but about how it will fail. This allows
engineers to prepare for specific
failure modes and gather the
necessary replacement parts. This
knowledge also enables facilities to
better learn and understand their
equipment and to reduce unplanned
downtime. These analytics focus
Percentage Yield
Manufacturing companies
often measure operational
efficiency by percentage yield.
This strategy involves optimizing
equipment and processes to
produce the greatest number
of quality products possible.
95
Capacity Utilization
Capacity utilization is ensuring
a facility operates at maximum
production capacity by improving
equipment availability. If a facility
uses a predictive and prescriptive
Overall Equipment
Effectiveness
Operational efficiency is often
measured by overall equipment
effectiveness (OEE), which
breaks a manufacturing facilitys
performance into three measurable
components: availability,
performance and quality.
Continuous data gathering and
analytics are key to understanding
how assets are functioning in real
time. Continuous monitoring offers
96
EFFICIENCY MATTERS
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Pulsafeeder, Inc.
2883 Brighton Henrietta Town Line Rd.
Rochester, NY 14623
Phone: +1 (585) 292-8000
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97
Downtime in Proportion
to Operating Time
Unplanned downtime requires hours spent diagnosing
the issue, ordering parts, conducting the repair, getting
the system back online and waiting for operating
parameters to normalize. By getting ahead of the
failure, a facility can eliminate several of those steps. If
plants can predict maintenance, they can diagnose the
problem and have parts ready ahead of time.
A simple 3 percent improvement in uptime or
operational efficiency can result in a $2 million
impact on any continuous manufacturing operations
bottom line (assuming the cost of unplanned
downtime is more than $20,000 an hour). This does
not factor in the savings from the avoidance of other
downtime-related lossesproduct losses, injuries or
equipment damages.
The article Achieving Effective Lubrication in
Reliable Plant and Lean Manufacturing Journal reports
that contamination causes 70 to 85 percent of
hydraulic system failures. Preventive maintenance
does not take into account usage conditions or failure
from improper handling. Intermittent maintenance
schedules may not catch these inadequate conditions
until it is too late. If a maintenance program is to
be successful, a company should experience zero
unplanned downtime. Continuous monitoring can
make that a reality.
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These five metrics, which can be improved by
continuous machine monitoring, directly affect
operational efficiency. The return on investment can
often be achieved in less than two years.
The key is enabling solutions that reduce the
cost and complexity of adoption, work well with
IT departments, and are an easy retrofit option for
existing infrastructure.
98
MAINTENANCE MINDERS
Wiped Bearing on a
Feedwater Pump
On July 14, a remote monitoring
software solution detected
changes in the mechanical profi le
of the outboard bearing of a
feedwater pump at a combinedcycle power plant.
Vibration on the outboard
bearing increased to 7.55
millimeters per second (mm/s)
from an expected value of 3.98
mm/s. At the same time, the
temperature in this outboard
bearing jumped to an actual value
99
100
Product Utility
The DOE studies product utility
when evaluating changes
to regulated products. They
determine if the new motor
will have the same form, fit and
function as the motor currently
being used. In other words,
does the motor have the same
mounting footprint, speed and
torque characteristics so that
it can be used on existing older
equipment without modification?
In this case, the answer is
not completely.
Original equipment
manufacturers (OEMs) are
encouraged to work with their
motor suppliers and source
samples to be ready for production
conversion when non-compliant
motors are discontinued from
manufacture next year. Because
these higher efficiency motors
101
Conclusion
The DOE has chosen to regulate
pump, fan and compressor
systems. Th is extended product
approach covers the motor and
driven load, including any power
transmission devices or adjustable
speed drives that are used.
The coming years will require
the pump industry to adapt and
end users to understand and work
with these new regulations. The
U.S. has lower energy costs than
Europe and does not currently
have a carbon tax. If the nations
energy costs increase and states
begin to add carbon taxes, the
industry will need to evaluate
old inefficient extended product
systems and replace them with
higher efficiency solutions.
Utilities are likely to incentivize
such conversions as they have in
the past. The American Council
for an Energy Efficient Economy
(ACEEE) is organizing an
Extended Motor Product Label
Initiative (EMPLI) that will offer
incentives based on using the
DOE extended product rules as
a baseline. Products above the
baseline would be eligible for an
incentive from the utility program
based on deemed savings.
The pump industry can expect
to see a lot of activity surrounded
energy efficiency, and OEMs and
end users should stay informed
about ongoing changes.
HV 3 Ball Valve
> 416 GPM
> Passes 1.3 Solids
Please join
Pumps & Systems and
Baldor for a free webinar
about this topic.
SEPTEMBER 24 AT 1 P.M.
Register at
pumpsandsystems.com/webinars
HV 4 Slurry Valve
> 540 GPM
> Passes 3 Solids
www.pumps2000america.com
Worlds First
High Volume 3 & 4
Diaphragm Pumps
102
SEALING SENSE
103
Table 1. Piping plans for dual unpressurized seals (Tables courtesy of FSA)
Piping Plan
52
55
72
75
76
Liquid Buffer
Gas Buffer
Description
104
SEALING SENSE
Table 2. API piping plans for dual pressurized seals
Liquid Barrier
Gas Barrier
53A
53B
53C
54
74
Seal Type
Emissions (ppm)
Single seal
200
Dual
Unpressurized
50
Dual Pressurized
Conclusion
Over time, the seal industry has developed
a variety of innovative solutionssingle,
dual, wet and dryto continuously reduce
fugitive emissions. Emissions control
has come a long way, from high-balanced
single seals that keep emissions below
500 ppm to dual pressurized liquid seals
allowing true zero emissions. Each type
of sealArrangements 1, 2 and 3are
viable options for low-emissions sealing,
but the sealing option selected will depend
on the application. When selecting a seal
for a zero emissions application, users
must define the zero emissions criteria.
Acceptable emissions can take on a
different definition depending on location
and process fluid, as local government
defines the acceptable VHAPs emission
limit. Sealing solutions may become more
elaborate as the total allowable emissions
limit trends toward zero, but they are fully
able to achieve the goal.
Next Month: Valve tolerances for lowemission packing
We invite your suggestions for article topics as well as
questions on sealing issues so we can better respond to
the needs of the industry. Please direct your suggestions
and questions to
sealingsensequestions@
fluidsealing.com.
105
Impact of Amended
Motor Ef ciency Rules
on the Pump Industry
SEPTEMBER 24, 2015
1 P.M. EASTERN
pumpsandsystems.com/2015/baldor
FOR MORE INFORMATION AND TO REGISTER
FRE E
106
HI PUMP FAQS
107
108
Sealing Challenges
The sealing approaches of various
manufacturers differ significantly.
Sealing devices in chopper
pumps are highly integrated,
which means the equipment
manufacturer designs the seal
to act as part of the equipment.
Aftermarket seal designs are
rare and may not consider the
key elements of the equipments
overall design.
109
Quench Fluids
A quench fluid is a low-pressure
liquid introduced between the
rotating shaft or sleeve and the
stationary seal face (also known
as the seat) inside diameter. Th is
fluid will flow in and out of this
cavity to remove an accumulation
of solids that may occur as the
sealed liquid lubricates the narrow
space between the seal faces. Once
the sealed fluid evaporates, solids
remain and could potentially
clog the springs or O-ring
grooves. A spring loaded lip seal
could prevent this fluid from
leaking from the back of the
mechanical seal.
Dual Seals
A dual seal uses two sets of seal
faces with a clean fluid sealed
between them. The fluid can be
pressurized above the barrier
fluid or below the actual sealed
fluid known as the buffer fluid.
Hydrodynamic Grooves
One especially innovative
approach to sealing chopper
pumps is the incorporation of
hydrodynamic grooves etched
into a seal face. These grooves use
the energy of shaft rotation to
expel solids and sealed fluid from
between the seal faces. They are
described by manufacturers as
micro-pumping grooves because
the depth of the groove may be
on the scale of ten-thousands
of an inch. The shaft rotates the
grooves, which then channel
leakage back in the direction of
the sealed fluid.
The Right Selection
All approaches will deliver
different levels of performance
depending on the concentration
and hardness of the solids in
the flow stream. If the pumped
fluid often causes dewatering,
then the dual approach may be
more successful because some
lubrication is provided by the
110
Pumping Basics
Pumps move water or other fluids
from point A to point B. They
come in different types, including
diaphragm pumps and positive
displacement pumps. Diaphragm
pumps work like the human heart,
where valves allow blood to flow
into a chamber. From there, the
muscle flexes and forces the blood
out through the arteries. Positive
displacement pumps are similar to
a water cannon toy and consist of a
cylinder and a plunger. The plunger
forces the water out.
The most common type of pump
is the centrifugal pump. These use
an impeller that spins and adds
energy to the fluid by centrifugal
force and directs the water to
the discharge point. Just as fans
contain fan blades that speed the
Se p t e mb er 2015 | Pum ps & S y st e m s
Above-Ground
or Submersible?
All pumps are bound by the laws
of physics. If the pumped fluid
is below the pump, a centrifugal
pump must be able to create a
vacuum to allow atmospheric
pressure to fi ll the void and
push the fluid to the impeller.
At sea level, the theoretical
maximum suction lift for water is
approximately 33.9 feet; however,
other factors limit pumps to a
practical pumping suction lift that
is closer to 25 feet of suction lift
with a maximum of approximately
28 feet. The volume diminishes
as the suction depth increases, so
users should consider submersible
options as suction lift increases.
For most installations, aboveground pump setups are more
desirable because of their ease of
installation and access to the pump
for maintenance. An above-ground
installation will include the pump
placed near the fluid, a hose or pipe
connected to the suction side and
placed into the fluid, and hose or
piping connected to the discharge
of the pump to direct the fluid
to the discharge point. This setup
requires minimal space on the
suction side since the only item
going into the fluid is a hose or pipe.
Priming Systems
If the pumping level of the fluid
is below the pump, a standard
centrifugal pump requires a
priming system to evacuate the air
and allow atmospheric pressure
111
112
Dewatering, Stormwater
Typical dewatering or contractor
pumps deal with water, dirty water
or trash-laden effluent, which could
come from pumping out a pond,
Clean Water, Solids Handling
ditch or other source. These are not
Impellers are constructed of
to be confused with groundwater
vanes that add velocity to the
dewatering, which is a more
pumped fluid. When the impeller
specific type of pump and system.
is spinning, the length of the vane
A dewatering pump can be a small
generally controls the pressure
gasoline-driven self-priming pump
the pump can produce, while the
depth or width of the vane controls or electric submersible pump. They
can also be more sophisticated
volume. The most common types
dry-priming pumps or larger
are enclosed standard centrifugal
submersible pumps that will
impellers for clean or semi-clean
generally only be available from a
non-solids fluid, semi-open and
pump specialty store (Image 2).
enclosed non-clog impellers.
Stormwater pumps are generally
The impeller design and its pump
larger. Sometimes they will be of
casing are the difference between
higher pressure than a standard
a standard centrifugal pump and
dewatering pump, since they may
a solids handling pump. Typically,
the impeller for clean water will be need to pump the fluid further.
a highly efficient enclosed impeller Stormwater pumps may be
that will be thinner and have more submersible or diesel-driven and
will likely need automatic controls
vanes than an impeller meant for
for automatic startup. Since they
solids handling. The impeller of a
solids-handling pump is wider with are likely handling large volumes
and may have to pump debris along
fewer vanes to allow passage of a
solid. The solids-handling impeller with water, they are nearly always
solids-handling pumps.
has a capacity sized in inches of
Mining pumps are more
spherical solids that it will pass.
specialized than dewatering
Semi-open trash handling
or stormwater pumps. They
impeller designs have an open face
on one side of the vane and require a may be required to handle high
wear plate on the other. This design pressure and high volumes, and
the pump end may also need to
will require periodic adjustment.
be constructed of abrasive or
The wear plates are replaceable,
which is a cost benefit as long as the corrosive-resistant materials, such
as hardened iron or stainless steel.
impeller is not also worn.
Depending on the application and
The enclosed non-clog impeller
access at the site, the pumps could
design combines the efficiency of
an enclosed impeller and the solids- be submersible or diesel-driven.
The term jet pump usually refers
handling capability of a semi-open
impeller. It can include replaceable to a higher pressure pump that uses
the pressure to jet piles, wells
wear rings to increase its useful
or caisson into the ground. They
life. The non-clog impeller pump
Se p t e mb er 2015 | Pum ps & S y st e m s
Conclusion
Whether the pump is used for
dewatering, stormwater, mining or
other applications, several factors
designate which is the proper
pump. These include the material
being pumped in combination
with the distance from the pump
and the elevation difference from
the source to the discharge point.
Many times, it pays to consult
with a pump expert to make sure
the best pump is chosen. Only
those companies that routinely
use pumps of all types will have
the experience to see beyond the
request for a six-inch pump.
Jerry Soto has more than 30 years
of experience in pumps and welldrilling applications. He is involved
in installations, testing, design,
estimating, project management
bypass pumping operations
and landfill, soil and gas vent
installation systems, and the
coordination of Griffins
fleet of pumps. He
may be reached
at jerry.soto@
griffindewatering.
com.
113
weftec
booth #
5627
Circle 120 on card or visit psfreeinfo.com.pu mpsa ndsyst ems.c om | Sept emb er 2015
114
KNOW
115
Instrumentation Recommendations
In fluid dynamics, once the piping size and suction
and discharge friction loss calculations have been
taken into account and all the above check points
have been analyzed, the next objective is overall
Circle 171 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | Sept emb er 2015
116
Pump Station
d
i
r
Hyb Level Controller
Comprehensive
Industry Coverage
Conclusion
A properly selected and engineered pump system
can provide longer pump life, reduce downtime, offer
indications of pump conditions and help users to
plan upcoming maintenance. Basic fluid dynamics
technology and instrumentation can significantly
impact savings and reliability in pump applications.
Gerardo A. (Tito) Gomez is a mechanical designer
and instrumentation specialist. He operates his own
consultancy, DAT Sales and Consulting, LLC, and
is associated with Titan Manufacturing, Inc., as a
consultant. He may be reached at tag9@swbell.net
or 713-569-1761.
Rodney D. Oquinn has more than 17 years of pump
and pumping systems experience in industrial,
municipal and petrochemical applications. Oquinn
has been technical sales for Titan Manufacturing for
past three years. He may be reached at roquinn@
titanpumpsinc.com or 979-299-4779. For more
information, visit titanpumpsinc.com.
117
118
nstrumentation and
monitoring technologies
have become instrumental
in improving plant productivity
and efficiency. While these
tools provide great value to the
industry, the importance of the
field workforce in the overall
effectiveness of a plants reliability
strategy cannot be dismissed.
Instrumentation and remote
monitoring software must be
combined with tools that empower
employees to manage and maintain
systems reliably and efficiently.
This comprehensive strategy can
help field workers increase their
knowledge of system processes,
analyze equipment data, and make
well-informed decisions.
Remote access to standard
procedures is something every field
worker needs, whether he or she is
an operator, mechanic, inspector or
other facility employee. Employees
may not know they need a specific
procedure until they are at the
equipment that needs immediate
attention. One procedure may
reference several more procedures
that need to be used. Employees
cannot be expected to carry a
library of paper binders every
time they are in the field. In
these situations, mobile decision
Se p t e mb er 2015 | Pum ps & S y st e m s
Vendor recommendations
Industry specific best practices
Regulatory requirements
(commitment tasks)
Asset specific design and/or
operating parameters
Planned outages (to asset,
system, operating area)
Accessibility to the asset
Field workers ability to
execute task
PdM monitoring
Environment that asset is
installed in
119
Process historians
o Manually collected data is sent back to the process
historian where it is made available to trend along
with instrumented data.
Centralized maintenance management systems (CMMS)
o Mobile work order execution (preventive maintenance
and corrective)
o Automatic updates to work order history, time and
status
Laboratory information management systems (LIMS)
o Positive sample identification and accurate sample
times are sent back to the LIMS system. This ensures
samples were not mislabeled.
Reliability management systems (RMS)
o Manually collected data is sent back to the RMS where
it can be used to analyze and predict failures.
o Other systems including custom built applications.
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120
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flow
pressure
power
speed of impeller
Simplifying Control
If controlled from a common
external analog signal, a minimum
value of 0 percent will cause all the
pumps to run at the minimum set
point. The same is true at a value of
100 percent, where pumps will run
at their maximums. Each change
in set point will affect linear flows
and pressures and non-linear
frequencies and amp draws.
When the frequency is changed
in standard ASDs, the output
is non-linear. Energy is wasted
searching to find the appropriate
speed to satisfy the control loop.
121
Figure 1.
Determining how
to meet amp draw
based on virtual
linear pumps (VLPs)
(Courtesy of Toshiba)
Yes
Increase
frequency
to meet amp
draw
VLP
Number
current <
VLP?
No
Decrease
frequency
to meet amp
draw
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
(EZMH%/EOEVIOE
Managing Principal
GN$NSVHEROREYJJGSQ
Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ
122
PRODUCTS
Matrix Drive
Blue-White announced
the newest diaphragm
metering pump in their CHEMPRO M series, engineered
and designed for precision
liquid injection in municipal
water treatment applications.
Features include NSF 61 listing, 200:1 turndown, a
large LCD screen that displays the pumps output rate, a
4-20mA output is standard on all models, a robust #316
stainless steel pump head cover for added strength, and
a comprehensive 3-year warranty. The CHEM-PRO M
also features Blue-Whites exclusive DiaFlex Diaphragm.
Optional advanced communications include: Industrial
Ethernet, Modbus TCP, ProfiNet, Modbus, and Profibus.
Circle 202 on card or visit psfreeinfo.com.
Heavy-Duty
Process Pumps
Solids
Measurement
KSB Pumps has introduced
updated versions of its RPHbseries pumps for process
applications in refineries and
chemical plants. The new
pumps meet the American
Petroleum Institute (API)
Standard 610 (11th edition)
for BB2-type pumps. The
new RPHb API 610 11th Edition pumps are two-stage,
long-coupled machines suitable for the most demanding
refinery and chemical process environments. They are
rated for heads of up to 650 meters and flow rates as
high as 875 cubic metres per hour (3855 USgpm). The
operating temperature range is from -80C to 450C.
Circle 205 on card or visit psfreeinfo.com.
To have a product considered for our Products page, please send the information to Amy Cash, acash@cahabamedia.com.
123
Submersible Wastewater Pumps
he Grundfos line of SL
submersible wastewater pumps
are designed to handle raw,
unscreened sewage, eluent, large
volumes of surface water and
process water in municipal, utility
and industrial applications. he
solids-handing pump series,
in motor ranges from 1.5 to 15
horsepower (HP), is available in two types of impellers. he SLV/
SuperVortex impeller provides the free passage of solids up to 4
inches in diameter, making it ideal for liquids with a content of solids,
ibers or gassy sludge. he SL1/S tube impeller also accommodates
solids up to 4 inches, but is designed particularly for large lows of
raw sewage.
Circle 208 on card or visit psfreeinfo.com.
Circle 252 on card or visit psfreeinfo.com.
Adve r t ise rs
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Page
RS#
Advertiser Name
130
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254
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109
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133
134
248
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175
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169
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77
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124
Solve
dry start
problems with
Vesconite Hilube
bushings
Increase MTBR
No swell
Low friction = reduced
electricity costs
Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite@vesconite.com
www.vesconite.com
Circle 268 on card or visit psfreeinfo.com.
Circle 267 on card or visit psfreeinfo.com.
EXECUTIVE SEARCH/RECRUITING
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Specializing in placing:
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DAN BOLEN JASON SWANSON
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125
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univeRsalPoweRCell
PumPCondition
dRyRunning
Cavitation
1.800.731.7325
www.ppcmechanicalseals.com /cryogenic.html
28 - 30, 2015
The Cryogenic
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A seal that can handle liquids, gas, and
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GRUNDFOS
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BOOTH #1400
REMOVABLE,
LIGHTWEIGHT
INSPECTION
COVER
AGGRESSIVE,
SELF-CLEANING
WEARPLATE
Flushable wipes, rags and other stringy material can wreak havoc on pumps. Thats why your plant
needs a dependable solution for handling solid waste. Gorman-Rupp Super T Series pumps equipped
with the NEW EradicatorTM Solids Management System offers just that. The new aggressive selfcleaning wearplate is designed to handle clog-prone material with an obstruction-free flow path,
keeping your pump operating at peak efficiency. A lightweight inspection cover allows for easy
access to the inside of the pump without affecting wearplate-to-impeller clearance.
Trust Gorman-Rupp pumps to keep your operation running smoothly month after month, year after year.
Multiple Patents Pending
GORMAN-RUPP PUMPS l P.O. BOX 1217 l MANSFIELD, OHIO 44901-1217 l USA l 419.755.1011 l GRSALES@GORMANRUPP.COM l GRPUMPS.COM
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Gorman-Rupp Pumps USA is an ISO 9001:2008 and an ISO 14001:2004 Registered Company