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S E P T E M B E R 2 0 15

PUMPSANDSYSTEMS.COM

SYSTEMS

The Leading Magazine for Pump Users Worldwide

NITROGEN
REMOVAL
Wastewater Treatment
Safeguards the Potomac

How to Size & Select


Metering Pumps
Exclusive: Solving the
Skilled Labor Shortage
WEFTEC 2015
Trade Show Preview

Circle 112 on card or visit psfreeinfo.com.

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From the Editor


I

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

in memory of jagdish jay shah


The Pumps & Systems family was saddened to learn of the death in early
August of Jay Shah, president of Hydro International. Jay was a tireless
ambassador for his company and for the pump industry and helped open
offices in Canada, Korea, Australia, United Arab Emirates, France and Vietnam.
A long-time friend of Pumps & Systems, he was a member of our MENA editions Editorial
Advisory Board and was a frequent contributor to our pages. I personally learned a lot
from Jay over the years, most important, the value of his philosophy friends and family
first, then business. His generosity of spirit and easy smile will be missed.
Wally Evans, Publisher
Pumps & Systems
is a member of the following organizations:

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,

Ray Hardee, Jim Elsey


CREATIVE SERVICES

SENIOR ART DIRECTOR: Greg Ragsdale


ART DIRECTOR: Melanie Magee
WEB DEVELOPER: Greg Caudle
PRINT ADVERTISING TRAFFIC: Lisa Freeman

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

PUBLISHER: Walter B. Evans Jr.


VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore

P.O. Box 530067


Birmingham, AL 35253
EDITORIAL & PRODUCTION

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.

S e p t e mb er 2015 | Pum ps & S y st e m s

1900 28th Avenue South, Suite 200


Birmingham, AL 35209
205-212-9402
ADVERTISING SALES

2126 McFarland Blvd. East, Suite A


Tuscaloosa, AL 35404
205-345-0784

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WEFTEC
BOOTH
#2362.

This issue
COVER
SERIES

SEPTEMBER

Volume 23 Number 9

WASTEWATER

48 INTELLIGENT PRESSURE SEWERS TRANSFORM AUSTRALIAN


WASTEWATER SYSTEM
By Joseph Harmes, for Pumps & Systems
South East Water combines grinder pumps and a remote control telemetry network to improve
groundwater quality and the economy in Mornington Peninsula.

56 DUAL-SHAFTED GRINDERS SAVE ILLINOIS LIFT STATION $20,000 PER YEAR


By Troy Heimerl, JWC Environmental
The design and function of this equipment provide distinct benefits for wastewater processing.

60 DC FACILITY EMPLOYS HIGH-CAPACITY PUMP STATION FOR NITROGEN REMOVAL


By Bryan Orchard, KSB
Optimization of the selected submersible propeller pumps saved the facility up to $200,000
per year.

64 4 STEPS TO DETERMINE EQUIPMENT SCCR


By Dan Neeser, Eaton
Wastewater treatment facilities can take advantage of the latest calculation tools to ensure NEC
and OSHA compliance.

67 CLAMP-ON FLOW MEASUREMENT INSTRUMENTATION IMPROVES


WASTEWATER TREATMENT
By Marisa Fedele, Siemens Process Industries and Drives
Proper flow measurement provides an accurate and cost-effective solution for
challenging operating conditions.

72 OZONE TECHNOLOGY REDUCES SLUDGE BY 43 PERCENT OR MORE

56
COLUMNS

By Wiebke Rand, Xylem Wedeco Products

PUMPING PRESCRIPTIONS

The Italian wastewater plant reduced required man-hours and saved more than
170,000 annually in landfill costs.

14 By Lev Nelik, Ph.D., P.E.


Pumping Machinery, LLC

78 ENERGY EFFICIENCY IN WATER & WASTEWATER

Efficiency Monitoring Saves


Plants Millions

By Jeff Bergman, Danfoss VLT Drives


VFDs can reduce energy consumption and water loss in variable pumping systems.

80 NANOMATERIALS PROMOTE EFFECTIVE WATER REUSE


By Tim Tangredi, Dais Analytic

PUMP SYSTEM IMPROVEMENT


16 By Ray Hardee
Engineered Software, Inc.

These technologies allow membrane-based distillation components to be used to


produce high-purity drinking water from heavily compromised water sources.

Troubleshooting Piping Systems


First of Two Parts

84 DISPOSABLE WIPES THREATEN WASTEWATER SYSTEMS


By Mike Bjorkman, BJM CORP.
New shredder pump technology can prevent costly clogging and minimize damage
to equipment and municipal reclamation facilities.

COMMON PUMPING MISTAKES


24 By Jim Elsey
Summit Pump, Inc.

88 SWPA MEETS IN CHICAGO

10 Common Self-Priming Pump Issues

Submersible wastewater professionals toured the worlds busiest sewer system.

SSPECIAL
PECIAL
REPORT

SKILLED LABOR SHORTAGE

28 By Alecia Archibald, Pumps & Systems


Pump industry insiders look for answers amidst this increasingly
difficult challenge.

S e p t e mb er 2015 | Pum ps & S y st e m s

2
8
89
122
123
124
128

FROM THE EDITOR


NEWS
TRADE SHOW PREVIEW
PRODUCTS
ADVERTISERS INDEX
PUMP USERS MARKETPLACE
PUMP MARKET ANALYSIS

P9 Pump Drive with

EQP Global Motor

Visit Us at Booth #3856

September 27th-30th, 2015

ONE CALL. ONE SOLUTION.


Toshiba International Corporation is proud to be a single-source
solution for your application demands, offering a complete
product lineup of electric motors, adjustable speed drives,
and motor starters. By pairing the P9 adjustable speed drive
with the EQP Global motor, we have set new pump control
standards in technology, efficiency, and ease-of-use that go
beyond the competitive demands of the evolving pump industry.
Circle 123 on card or visit psfreeinfo.com.

1-800-231-1412
toshiba.com/tic

This issue
SSPECIAL
PECIAL
SECTION

SEPTEMBER

METERING & DOSING PUMPS

32 HOW TO SIZE & SELECT THE


IDEAL METERING PUMP FOR
YOUR APPLICATION
By Tom ODonnell,
Neptune Chemical Pump Company

38 VALVELESS PISTON PUMPS


COMPLETE DENITRIFICATION OF
EFFLUENT WASTEWATER
By Herb Werner, Fluid Metering, Inc.

DEPARTMENTS
94 EFFICIENCY MATTERS
5 Key Metrics that Affect
Operational Efficiency
By Anurag Garg
DATTUS

42 DIAPHRAGM PUMPS IDEAL FOR


WATER TREATMENT & REUSE
By Jim Carling, Milton Roy

46 THE UNCERTAIN OIL & GAS MARKET

98 MAINTENANCE MINDERS

COULD IMPACT DEMAND FOR


METERING PUMPS
By Aida Paola Conti, Frost & Sullivan

Remote Monitoring
Minimizes Outage &
Lost Production Costs
By Cynthia Stone
GE Intelligent Platforms

100 MOTORS & DRIVES

SSPECIAL
PECIAL
SECTION

Review of the DOE


Final Rule for Integral
Horsepower Motors
By John Malinowski
Baldor Electric Company

WATER MANAGEMENT

90 MASSIVE VERTICAL PUMPS


PROTECT COMMUNITY ON
FLOOD-PRONE OHIO RIVER
By Thomas Morrison, Grundfos

92 EDDY CURRENT DRIVES PROVIDE


LONG-TERM WATER RELIABILITY
By Gary Patterson, DSI/Dynamatic

102 SEALING SENSE


Know Which Mechanical
Sealing Options
Meet Emissions
Requirements
By Ian Lincoln
FSA Member

PRACTICE & OPERATIONS


108 CHOPPER PUMPS REQUIRE
SPECIALIZED SEALING SOLUTIONS
By Ralph Merullo
A.W. Chesterton Company

110 FINDING THE RIGHT PUMP


By Jerry Soto
Griffin Dewatering

118 HOW REMOTE MONITORING


IMPROVES EMPLOYEE
HEALTH, SAFETY AND
KNOWLEDGE RETENTION
By Jason Vick & Jack Creamer
Schneider Electric

106 HI PUMP FAQS


Site Condition, Treatment
Stage & VFD Considerations
for Wastewater Pumps
By Hydraulic Institute

120 BALANCING SOFTWARE

114 BASIC PIPING & INSTRUMENTATION


TECHNIQUES OPTIMIZE
SELF-PRIMING PUMPS
By Gerardo (Tito) A. Gomez &
Rodney D. OQuinn
Titan Manufacturing, Inc.

S E P T E M B E R 2 0 15
PUMPSANDSYSTEMS.COM

SYSTEMS

The Leading Magazine for Pump Users Worldwide

CONSERVES ENERGY IN
MULTIPLE-PUMP SYSTEMS
By Kurt Bihler
Bihlertech, Inc.

NITROGEN
REMOVAL
Wastewater Treatment
Safeguards the Potomac

Image courtesy
of KSB

How to Size & Select


Metering Pumps
Exclusive: Solving the
Skilled Labor Shortage
WEFTEC 2015
Trade Show Preview

EDITORIAL ADVISORY BOARD


THOMAS L. ANGLE, P.E., MSC, Vice
President Engineering, Hidrostal AG
BRYAN S. BARRINGTON, Machinery
Engineer, Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy
Americas
R. THOMAS BROWN III, President,
Advanced Sealing International
(ASI)
CHRIS CALDWELL, Director of
Advanced Collection Technology,
Business Area Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment
Manager Pumping Equipment,
Square D by Schneider Electric

BOB DOMKOWSKI, Business


Development Manager Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA Flygt
WALT ERNDT, VP/GM, CRANE Pumps
& Systems
JOE EVANS, Ph.D., Customer &
Employee Education, PumpTech, Inc.
LARRY LEWIS, President, Vanton
Pump and Equipment Corp.
WILLIAM LIVOTI, Business
Development Manager/Energy
Efficiency Specialist, WEG Elctric
Corporation

S e p t e mb er 2015 | Pum ps & S y st e m s

TODD LOUDIN, President/CEO North


American Operations, Flowrox Inc.
MICHAEL MICHAUD, Executive
Director, Hydraulic Institute
JOHN MALINOWSKI, Sr. Product
Manager, AC Motors, Baldor Electric
Company, A Member of the
ABB Group

SCOTT SORENSEN, Oil & Gas


Automation Consultant & Market
Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump
Association (SWPA)
JERRY TURNER, Founder/Senior
Advisor, Pioneer Pump

WILLIAM E. NEIS, P.E., President,


Northeast Industrial Sales

DOUG VOLDEN, Global Engineering


Director, John Crane

LEV NELIK, Ph.D., P.E., APICS,


President, PumpingMachinery, LLC

KIRK WILSON, President, Services &


Solutions, Flowserve Corporation

HENRY PECK, President, Geiger Pump


& Equipment Company

JAMES WONG, Associate Product


Manager Bearing Isolator, Garlock
Sealing Technologies

MARIANNE SZCZECH, Director,


Global Marketing and Product
Management, Pump Solutions Group

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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

CHARLIE EVANS, EASA


ST. LOUIS (July 28, 2015) The Electrical Apparatus Service
Association (EASA) honored Charlie Evans as the 2015 recipient of
the EASA Exceptional Achievement Service Award. Established in
1997, this annual award recognizes an individual who has provided
exceptional service to the electrical apparatus sales and service
industry over a lifetime. Evans worked his way from sweeping a shop
floor to owning his own business to serving as EASAs international
president and chairman of the board. easa.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

REID JAJKO, NSK USA


ANN ARBOR, Mich. (July 15, 2015) NSK
Corporation announced the appointment of Reid
Jajko to vice president, Aftermarket Business
Unit, USA. Jajko joined NSK in August 2010 as
Aftermarket Business Unit director of sales,
later expanding his responsibilities to become

S e p t e mb er 2015 | Pum ps & S y st e m s

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, GRUNDFOS


BJERRINGBRO, Denmark (July 14, 2015)
Grundfos Pumps Corporation has elevated
Jonathan Hamp-Adams to managing director
for the Commercial Building Systems unit. His
responsibilities will include leading the sales and
production activities of Grundfos PACO brand,
based in Brookshire, Texas. This position will be
based at Grundfos Americas headquarters in
Downers Grove, Illinois. us.grundfos.com

Jonathan
Hamp-Adams

KAIRUS TARAPORE, XYLEM INC.


RYE BROOK, N.Y. (July 8, 2015) Xylem Inc. announced that Kairus
Tarapore has joined the company as senior vice president and chief
human resources officer. Reporting to Xylem President and CEO
Patrick Decker, Tarapore will lead the development and execution of
the companys human resources strategy. He will be based at Xylems
headquarters in Rye Brook, New York. xyleminc.com

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

MERGERS & ACQUISITIONS


Weir Minerals Acquired Delta Industrial Valves.
July 9, 2015
Watson-Marlow Fluid Technology Group Acquired MasoSine
Manufacturing & Pump Distributorship in Japan.
July 1, 2015

Reid Jajko

GEA Group AG (GEA) acquired Hilge from the Grundfos Group.


June 30, 2015

Quality You Can Believe In!

developing markets. His responsibilities will


include developing outreach and generating
new business. He will also be a leader in new
product development. Waters has a bachelors
in mechanical engineering from Trine University
and an MBA from Purdue. Waters will report to
APG President Stan Ronna. apgsensors.com

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

DR. CARL HAHN,


PENTAIR

MICHAEL SMITH, SEPCO


ALABASTER, Ala. (June 3, 2015) SEPCO
announced the appointment of Michael Smith as
its quality and safety manager. Smith will strive
to maintain SEPCOs excellent safety record.
He has been in quality service for 17 years and
has been responsible for the implementation
and conformance to QS 9000 and ISO 9001
standards for 13 years. sepco.com
To have a news item considered, please
send the information to Amelia Messamore,
amessamore@cahabamedia.com.

Stancor is leading the way to


customized solutions.
Depending on the size of your project, Stancor offers multiple
styles of submersibles, which includes, Stancor Oil-Minder,
dewatering pumps (MSHA approved), cast iron and stainless
steel, that can be used in a wide variety of applications. Our
products are designed and engineered to meet virtually
any specification.
Rugged with Proven Reliable Performance
Low Maintenance with Minimal Power Requriements
Introducing 2 and 3 Solids Pumps for Small Lift Stations
1/2-3HP with Guiderail Capability
To find a pump or control system that meets your projects
needs, stop by Booth #1691 during WEFTEC 2015.
www.stancorpumps.com |

203.268.7513 |

Select Distributorships Available

pu mpsa ndsyst ems.c om | Sept emb er 2015

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HOUSTON, Texas (June


24, 2015) Dr. Carl Hahn
has been named director
of international sales
operations focusing on oil
and gas separations for
Carl Hahn
Pentairs Flow & Filtration
Solutions segment. Hahn is responsible for
driving sales in fast-growth regions across
the globe, with a focus on the Middle East and
building the sales, customer service, engineering
and field service organization in Pentairs
Dubai office. Hahn, who holds multiple U.S.
patents, has a B.S. in chemistry from University
of Michigan and a Ph.D. in chemistry from
Princeton University. pentair.com

10

NEWS

AROUND THE INDUSTRY


LUDECA Becomes a
Reliability Leadership
Institute MSAT Provider
DORAL, Fla. (Aug. 4, 2015) LUDECA
has announced that they are now
an approved Reliability Leadership
Institute (RLI) Mapped Services and
Training (MSAT) Provider.
As such, LUDECA provides training and
services aligned with the Reliabilityweb
Uptime Elements for the alignment/
balancing domain under asset
condition management.
To support the MSAT program, LUDECA
recently certified 25 team members as
Certified Reliability Leaders (CRL) and
has embarked on a reliability journey
to educate end users on the benefits
of proactive precision alignment and
balancing as a key step on the road to
reliability excellence. ludeca.com

Water Associations Receive


Award for Water Infrastructure
Finance & Innovation Act
ALEXANDRIA, Va. (July 23, 2015) The
Water Environment Federation (WEF),
the Association of Metropolitan Water
Agencies (AMWA) and the American
Water Works Association (AWWA)
have received a 2015 Power of A Gold
Award from the American Society
of Association Executives (ASAE) for
their work on the passage of the Water
Infrastructure Finance and Innovation
Act (WIFIA).
WIFIA was passed in June 2014 to
provide loans to drinking water and
wastewater utilities at long-term U.S.
Treasury rates for projects too large or
beyond the usual scope of traditional
water loan instruments.
AWWA, WEF and AMWA coordinated
staff and member expertise and
grassroots lobbying efforts to educate
congressional members and other
imperative organizations about the
importance of WIFIA.
The U.S. needs to invest about $2
trillion in the next 30 years to maintain
current levels of water service, but we
must keep rates affordable at the same
time, said AWWA CEO David LaFrance.
WIFIA will provide access to low-cost
capital for water infrastructure projects
too large for traditional finance tools.
We are very proud of this work and
appreciate the acknowledgment from
ASAE. asaecenter.org

S e p t e mb er 2015 | Pum ps & S y st e m s

Extended Motor Product Label


Initiative Seeks Pump Data
PARSIPPANY, N.J. (July 16, 2015) The
Hydraulic Institute (HI) has announced
a new data collection effort on pumping
systems data. HI, working as part of the
Extended Motor Product Label Initiative
(EMPLI) consortium, is collaborating
on Designing a Program for Future
Incentives for Energy Efficient Pumps
and Pumping Systems.
Data will be used to support a new
voluntary labeling initiative for pumps
and extended pump products (defined
as the pump, motor, drive and controls).
The concept is to reflect the energy
savings potential of the equipment as
installed in motor and control system
applications. The development of an
extended-product label in combination
with the data collected will help form
the basis for easily implementable
prescriptive rebate programs.
Participation of end users in
submitting pump and load profile
data to the EMPLI survey will assist
the effort by utilities, working with the
pump industry through HI, to better
determine the energy savings potential
of new rebate/incentive programs. Any
other organizations with knowledge
of building services operating data for
pumps and pumping systems are also
welcome to participate.
Sept. 30 is the deadline for reporting
and organizations are encouraged
by EMPLI to promote and share this
opportunity with end users and others
who have access to building service
data. pumps.org

Schneider Electric & Applied


Instrument Technologies
Form Alliance
RALEIGH, N.C. (July 8, 2015) Schneider
Electric has formed a strategic alliance
with Applied Instrument Technologies,
Inc. (AIT), a provider of process analyzers
for online and real-time process
analysis in hydrocarbon, chemical,
pharmaceutical and steel-making
industries. The new partnership extends
the capabilities of both companies to
provide process automation solutions to
their respective global customer bases.
The combination of Schneider
Electrics Process Automation
portfolioincluding its Foxboro Evo
process automation system, Triconex

safety instrumented systems and


global delivery capabilitiestogether
with AITs portfolio of spectroscopy and
chromatography products, particularly
its real-time process analyzers, will
offer users more comprehensive
process analysis, control and advanced
operations management solutions in
one integrated automation solution
from a single vendor. schneiderelectric.com / aitanalyzers.com

Des-Case named a Tennessean


Top Workplace
GOODLETTSVILLE, Tenn. (July 7, 2015)
Des Case Corporation has been named a
Tennessean Top Workplace in an annual
competition that identifies companies
with the most desirable workplaces.
A national program orchestrated
by 30 regional daily newspapers
across the country and an employee
survey firm Workplace Dynamics, the
competition surveys the employees
of all participating companies that
have more than 35 regional employees
and grades them based on workforce
attributes that include leadership,
communications, career opportunities,
working environment, managerial skills,
pay and benefits, and organizational
health. descase.com

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

New Kaman Distribution Unit


Specializes in Automation,
Control & Energy Management

New Report Indicates that


U.S. Wastewater Market Could
Reach $11 Billion by 2025

ROCHESTER, N.Y. (July 6, 2015)


Kaman Distribution has announced
the formation of Kaman Automation,
Control & Energy, a new operating
unit that is said to be one of the only
fully integrated national providers of
industrial solutions serving original
equipment manufacturers, industrial
production plants and infrastructure
facilities throughout North America.
The organization, dubbed Kaman
AC&E, has been created through the
combination of existing resources of
Kaman Industrial Technologies along
with Minarik Corporation, acquired by
Kaman in 2010, and Zeller Corporation,
acquired by Kaman 2012.
Kaman AC&Es engineering offerings
include engineered process and
machine control solutions as well
as advanced energy management
systems for a variety applications.
kaman.com

BOSTON (July 2, 2015) Paralyzing


drought and environmental impacts on
water supplies across the U.S. sunbelt
from Florida to Californiahave thrust
wastewater reuse into the spotlight as a
critical solution to minimize long-term
risks to state water supplies.
According to a new report from
Bluefield Research, wastewater reuse
for municipal utilities will increase 61
percent by 2025, requiring $11.0 billion
of capital expenditures.
The lions share of the activity, or
94 percent, is expected to take place
in nine states, headlined by Florida
and California.
On the heels of this forecasted growth,
Bluefield Researchs analysis also
indicates a change in the markets
overall profile. Potable reuse currently
makes up 15 percent of the total
capacity but is expected to increase to
19 percent of total water reuse by 2025.

Irrigation and industrial off-takers


currently account for 69 percent and
16 percent of reuse, respectively. The
expected jump in potable reuse stems
largely from heightening pressure
on policymakers and utilities to stay
ahead of scaling urban populations,
anticipated future droughts, and
limited water supply alternatives.
These and other findings can be found
in the just released Bluefield Research
report, US Municipal Wastewater &
Reuse: Market Trends, Opportunities, &
Forecasts, 2015-2025.
bluefieldresearch.com

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

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pu mpsa ndsyst ems.c om | Sept emb er 2015

12

NEWS

all business responsibilities, which include maintaining the longstanding customer


relationships with companies in the Finnish process industries.
The company is a subsidiary of the internationally operating Endress+Hauser AG.
Previously Endress+Hauser and Metsos valve business shared operations under the
Metso Endress+Hauser joint venture company. us.endress.com
To have a news item considered, please send the information to
Amelia Messamore, amessamore@cahabamedia.com.

Mission SCADA Works Right Out


Of The Box, But Wont Box You In
Mission managed SCADA systems are
designed to get you up and running in
hours, not days. Our packages start at
around $1,000 with a maintenance fee of
less than $1 a day. Mission strives for
ease in doing business. Give us a try no
bureaucratic red tape, no huge commitment. If you like it, buy it. If not, send it
back. Its that simple.

Mission flexibility allows you to expand


your system as you are ready and on your
terms. Mix and match any of our products
one at a time or all at once, the choice is
yours. That is why you will find Mission
SCADA monitoring over 2,000 municipalities across the U.S. and Canada.

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

In Sewer Level Alarm

Lift Station

Tank and Well Control

Centrifugal And Positive


Displacement Pumps (Basics)
Oct. 28 29, 2015
Pumping Machinery Training Center
Norcross, Ga.
770-310-0866
pumpingmachinery.com/pump_school/
pump_school.htm
International Association of
Amusement Parks & Attractions
(IAAPA) Attractions Expo
Nov. 16 20, 2015
Orange County Convention Center
Orlando, Fla.
703-836-4800
iaapa.org/expos/iaapa-attractions-expo

Advanced Monitoring Low Cost Managed SCADA


(877) 993 - 1911 www.123mc.com
Circle 138 on card or visit psfreeinfo.com.
S e p t e mb er 2015 | Pum ps & S y st e m s

ALL-TEST Pro, LLC, Electrical


Reliability Training Seminar
Nov. 16-20, 2015
Fairield Inn & Suites-Chicago
River North
Chicago, Ill.
860-399-4222 / alltestpro.com

13

Dynamatic Variable Speed Drives and Controls


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you millions. And be sure to get entered for your chance to
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pu mpsa ndsyst ems.c om | Sept emb er 2015

14

PUMPING PRESCRIPTIONS
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board

Efficiency Monitoring Saves Plants Millions


Part 3
Editors Note: While running a pump at its best efficiency point saves money, reduces downtime and improves performance, many
plant managers are unaware of how their equipment is actually performing. This series, which began in the July 2015 issue of Pumps
& Systems, depicts a real-world scenario that is intended to illustrate the importance of monitoring pump efficiency.

ast month, Bob Sellers from


Duck Pump Company visited
Jim, a maintenance manager
at the Blue Creek Municipal Water
Plant. After completing some
testing, they discovered the plants
pumps were operating at reduced
efficiency. Bob recommended that
the plant repair the pumps and sent
Jim and his team a quote for the job.
To investigate the problem
further, Jim and his boss Charlie
visited the storeroom to inspect
the rotating assembly of the large
double-suction, split-case pump.
Grady, storeroom manager, and
Rusty, a plant mechanic, completed
the basic inspection and discovered
that the entire rotating assembly
was non-magneticwith the
exception of the wear rings.
They were concerned that what
they thought was a completely
stainless steel rotor was composed
of regular carbon steel wear rings.
That, they concluded, could be
causing rusting and wear, leakage
across the rings, and decreased
efficiency. Hoping to remedy the
problem, Bob requested that Sandy
from the Duck Pump engineering
department come to answer the
plants questions and help clarify
the situation.
Hi Sandy! Charlie greeted her
as she and Bob stepped out of the
car. Good to see you. Im glad Bob
brought some reinforcement to

Se p t e mb er 2015 | Pum ps & S y st e m s

help us troubleshoot these pump


problems we seem to be having.
Sure thing, Charlie. Thats why
Im here. Bob said you had some
questions on the metallurgy of the
pump rotors. Can we see the rings?
Of course. Weve got them in
the conference roomboth the
impeller ring and casing ring, along
with the magnet. It doesnt stick, so
we suspect theyre not 316 stainless
steel, as compared with the rest of
the rotor.
Sandy touched the rings with
the magnet.
You are right, guys. It doesnt
stick, but that doesnt mean it is
plain carbon steel. According to
our specs, these are 416 stainless
steel. The 400 series is called
martensitic stainless, and its not
magnetic. The 300 series is also

stainless but austenitic, and its


not magnetic. Both types are good
against corrosion, but the 300 series
is especially good against cavitation,
which is why your impeller is 316
stainless steel and the rings are 416.
Rusty was not convinced. But
look, Sandythe impeller is soft.
I just scratched it a bit with a knife
blade, and it cuts a groove in it like
butter. How can it resist cavitation?
True, Rusty. 316 stainless steel
is softbut only initially. Sandy
was flipping through her files. Once
in service and as it begins to get
bombarded by cavitation (which
is essentially a high energy of the
imploding water bubbles against
the impeller blades), the impeller
material work-hardens, and any
cavitation cant damage it from
then on. But the 400 series is better

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

for wear rings. Cavitation is not


really an issue there, but they need
to be hard enough to withstand
occasional contact or wear by
particulates like sand and grit.
But Bob did this testing in the
field and told me we are losing
efficiency. Jim pointed at Bobs
report. He told me it is costing us
a lot of money because the rings are
wearing. If they are so hard, how
come they wear so quickly?
Thats a good question, Jim.
Sandy handed him a chart on
recommended clearances and
pointed to the third column. Take
a look at this, and it may help clear
things up. So, in your case, the rings
are at 12.125-inch diameter. That
means the clearance should be about
0.023 inch, according to the chart.
Thanks, Sandy. Jim examined

the chart, glancing up at everyone.


So, what do we actually have? Can
we measure the impeller ring outer
diameter and subtract from the
casing ring inner diameter?
Sure, Rusty said. But we have
another meeting in a few minutes.
We can do the measurements and
email you results.
Sounds good, guys, Charlie
said. Thanks Sandy. Appreciate
you and Bob getting all this
information for us. It helps to learn
about how these pumps operate.
Youre welcome, Charlie.
Thanks for your time also. Talk to
you later.
Part 4 of this series will reveal the
measured wear ring clearances and
explain the efficiency problem Jim
discovered in Part 1.

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)

Dr. Nelik (aka Dr. Pump) is


president of Pumping Machinery,
LLC, an Atlanta-based firm
specializing in pump consulting,
training, equipment troubleshooting
and pump repairs. Dr. Nelik has
30 years of experience in pumps
and pumping equipment. He may
be reached at pump-magazine.
com. For more information, visit
pumpingmachinery.com/pump_
school/pump_school.htm.

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pu mpsa ndsyst ems.c om | Sept emb er 2015

16

PUMP SYSTEM IMPROVEMENT


A better understanding of complete system operation
By Ray Hardee
Engineered Software, Inc.

Troubleshooting Piping Systems


First of Two Parts

his series on troubleshooting


piping systems draws on
past columns in Pumps &
Systems discussing the operation
of individual components found
in piping system. Well use that
knowledge to establish the
connection between items with the
goal of developing a model of the
piping system. We will then see how
to use the model to determine if
the equipment is operating within
the confines of the model, and then
compare the model to the physical
piping system. This approach can
identify and isolate problems within
the piping system to arrive at a
course of corrective action. Piping
systems vary in size and complexity,
but the methods presented here
can break down even the largest
systems to troubleshoot and
improve system operation.

The Example System


Figure 1 shows the example
system. We will use this
example to build the model and
then demonstrate a variety of
troubleshooting techniques.
The system starts at supply
tank TK-101. The base of the
tank is located at 0 feet above our
common datum elevation and is
open to atmosphere. The tank has
a working level of 10 feet above
the tank bottom and is equipped
with a level indicator. The process
fluid is delivered to the supply tank
by a collection system outside the
boundary of our system example.
The process fluid has a temperature

Se p t e mb er 2015 | Pum ps & S y st e m s

of 60 F, a density of 62 pounds per


cubic foot (lb/ft3), a viscosity of
1.2 centipoise (cP) and a vapor
pressure of 1 pound per square inch
(lb/in2) absolute.
From the supply tank, the fluid
travels through a suction pipeline
to centrifugal pump PU-101. The
pumps suction and discharge
nozzles are at 0 feet elevation.
The pump is equipped with both
suction and discharge pressure
gauges PI-100 and PI-101. The
shell and tube type heat exchanger
maintain fluid at 100 F. The heat
exchanger has only an outlet
temperature gauge.
Flow control loop 101 has a flow
meter FT-101 for the process value
(PV), with the FCV-101 globe style
control valve as the final element.
The loop has a flow rate indicator
and a positioner on the control valve
showing the valve position.
The fluid is travels to the
destination tank. Tank PV-102 is
the outlet boundary of our piping

system. The tank bottom elevation


is 50 feet with a normal operating
level of 15 feet with pressure
maintained at 25 psi. The PV-102
tank provides the fluid to other
users within facility.

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.

The Pump Elements


A centrifugal pump adds energy to
the fluid by converting mechanical
from the pump shaft to fluid
energy. This is accomplished
by converting velocity head to
pressure head. The performance of
centrifugal pumps is documented

by the manufacturer in the form


of a pump curve, which shows the
pump head developed, and the
efficiency in converting mechanical
energy to fluid energy as a function
of flow rate.1

The Process Elements


The process elements consist of
the supply tank, interconnecting
piping, heat exchanger and
destination tank. The supply and
destination tanks represent our
systems boundary.
Since we are starting our system
at the supply tank, we must
determine the fluid energy content
at this point. This is determined by
calculating the energy due to the
elevation of the liquid surface in
the tank (referred to as elevation
head), and the energy due to the
pressure on the surface of the liquid

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(referred to as pressure head). The


combination of the elevation and
pressure head is referred to as the
static head. The amount of system
energy starts as the static head
of the liquid in the supply tank.
This calculation is outlined in the
Bernoulli equation described in
fluid dynamic textbooks.
The pipelines transport fluid
throughout the system. Due to the
friction between the stationary
pipe and the moving fluid, and the
change in fluid momentum due to
valves and fittings, energy is lost
in the system. This is referenced in
feet of fluid. The energy expended to
move the fluid through the pipeline
is called dynamic head, because it is
a function of the flow rate through
the pipe. Calculating head loss in
pipelines for Newtonian fluids is
performed using the Darcy formula.

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pu mpsa ndsyst ems.c om | Sept emb er 2015

18

PUMP SYSTEM IMPROVEMENT

Circle 141 on card or visit psfreeinfo.com.

The heat exchangers primary system function


is heating the process fluid. A heat exchanger
has two sides, one for the process fluid and
one for the service fluid. Thermal energy is
transferred from the hot service fluid to the
cold process fluid to meet the process heating
requirements. In the example system, the fluid
is heated from 60 F to 100 F. A heat exchanger
is designed to transfer thermal energy from
the service side to the process side, but as far
our piping systems is concerned, none of the
thermal energy is converted to fluid energy.
The process fluid moves through the heat
exchanger inlet via a series of small tubes, then
out of the heat exchanger. Just like in a pipeline,
energy is lost when the fluid moves through
the heat exchangers nozzles, tube sheets and
individual tubes. The hydraulic operation of
heat exchangers and other process equipment
is well understood, and performance data
indicating the head loss as a function of the flow
rate is supplied by the equipment manufacturer.
The outlet system boundary, tank PV-102,
is the final process element in our system. The
fluid at the destination tank has an energy
content that can also be determined using the
Bernoulli equation. The static energy at the
supply tank differs from the destination tank.
This difference is called the system static head.
It is calculated by subtracting the fluids static
head at the inlet boundary from the static head
at the outlet boundary. As long as the level
and pressures in the tanks remain constant
during system operation, the static head
remains constant, regardless of the flow rate
through the system.
The head loss due to the fluid flowing through
the process elements is a function of the flow
rate. This is often called dynamic head. The
energy used by the process elements is the sum
of the systems static head plus the dynamic
head for the given flow rate.

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Se p t e mb er 2015 | Pum ps & S y st e m s

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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pu mpsa ndsyst ems.c om | Sept emb er 2015

20

PUMP SYSTEM IMPROVEMENT

The control loop consists of a flow


meter (FT-101), a controller that
maintains a set process parameter (in
our example the flow rate) and the final
control element (FCV-101).

The flow meter FT-101 uses an orifice


device consisting of a metal plate with
a concentric hole sized to provide a
specific head loss for a given design flow
rate. A differential pressure or head

loss across the flow meter is required


for measurement. The head lost in the
flow meter can be calculated by the
various meter sizing standards.2 The
head loss across a control valve can be
calculated based on industry standards
as well the American National Standards
Institute (ANSI) International Society
of Automation (ISA).3 The control loop
maintains the set flow rate by regulating
the position of the control valve (FCV101) based on the outlet signal of the
control loop.

The Math Is Always Correct


The energy added by the pump elements
is well understood and documented
by various pump performance tests
as well as pump and motor standards.
The equipment manufacturers test the
pumps and motors using the applicable
standards and also provide operating
data to accurately calculate how
efficiently the energy is converted from
electrical to mechanical energy.
The amount of energy used by the
process elements can be determined
by calculating the static head and
dynamic head using fundamental
engineering principles.
The head loss associated
with process equipment is determined
from the manufacturers supplied test
data, especially the head loss vs. flow
rate curves.
The amount of energy used or lost by
the control elements is well documented.
Also, flow meters and control valves
represent mature technologies that are
well documented in industry standards.
As a result, motor input power and
the associated energy requirements
of the pump, process and control
elements is well understood. Once this
information is inserted into Equation 1
(Page 17), we have a very accurate model
of the total piping system.
The key to troubleshooting piping
systems is comparing the operation
of the piping system model with the
physical system. We can use this model
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21

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pu mpsa ndsyst ems.c om | Sept emb er 2015

22

PUMP SYSTEM IMPROVEMENT

to calculate how the system should


be operating and compare it to how
the system is actually operating. To
accomplish this we must:
1. Determine the amount of
energy each element in the
piping system model should
use based upon the systems as
designed parameters
2. Determine the amount of energy
each element in the physical
system is consuming based on
the plants operation data
Any differences in the energy
usage between the elements
in the piping system and the
elements in the physical system
indicate a difference between
the model and the actual system.
These differences are the basis for
effective troubleshooting of the
piping system.

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

Ray Hardee is a principal founder


of Engineered Software, creators of
PIPE-FLO and PUMP-FLO software. At
Engineered Software, he helped develop
two training courses and teaches these
courses in the U.S. and internationally.
He is a member of the ASME ES-2
Energy Assessment for Pumping
Systems standards committee and the
ISO Technical Committee 115/Working
Group 07 Pumping System Energy
Assessment. Hardee was a contributing
member of the HI/Europump Pump Life
Cycle Cost and HI/PSM Optimizing Piping
System publications. He may be reached
at ray.hardee@eng-software.com.

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Se p t e mb er 2015 | Pum ps & S y st e m s

23

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pu mpsa ndsyst ems.c om | Sept emb er 2015

24

COMMON PUMPING MISTAKES


By Jim Elsey
Summit Pump, Inc.

10 Common Self-Priming Pump Issues

ost experts agree that the


majority of centrifugal
pump problems occur
on the suction side of the pump.
Based solely on my experience, I
would state the percentage is at
least 80 percent, and in the case of
self-priming pumps I am sure the
percentage is higher.
I started a list of self-primer pump
field issues many years ago and
noted that almost all of them break
down to 10 fundamental areas.

25 feet due to factors such as fluid


temperature (think vapor pressure),
specific gravity, friction, system
leakage, pump inefficiencies and
elevation above sea level.

3. The pump is too far from


the liquid source.
Place the pump as close as possible
to the suction source. Usually
25 to 30 feet is the maximum
recommended distance. Prudent
system design dictates that the
suction pipe length be held to a
minimum to promote long pump
1. Even a self-primer pump
life. Every section of suction piping
has to be primed initially.
Even a self-priming pump has to be equates to a volume of air that must
be removed when the pump starts.
primed prior to the first operation.
Best practices say to reduce priming
No matter the manufacturer, there
time to a minimum.
is a priming chamber (integral or
Some system designers will add
external) or some portion of the
foot valves to mitigate the prime
volute that will require filling prior
time and strainers to preclude
to startup. Please read the manual
the introduction of solids into the
and/or contact the manufacturer
for details. There are other methods pump. A foot valve is in essence a
check valve placed at the beginning
to prime a pump, which include
(bottom) of the suction line. My
ancillary pumps, vacuum, vacuum
ejectors and/or eductors. This article experience is that foot valves add
undesired friction and will leak
only addresses liquid self-priming
or fail closed (or partially closed)
centrifugal pumps.
Sometimes the pump will require at some point. I typically do not
recommend foot valves for use on
manual re-priming after the initial
prime. There can be several reasons commercial and industrial selfprimer applications. For similar
for re-priming, one of the most
reasons I do not recommend suction
common is evaporation of the
strainers. If the pump cannot
fluid, and other reasons include
leakage, pump movement and other handle solids and a strainer is
utilized, monitor the differential
maintenance related matters.
pressure across the strainer. Most
2. The required lift is too high. industrial self-priming pumps are
of robust design and can handle
At sea level in a perfect world, you
passing solids, but check with
can theoretically lift 65-degree
the manufacturer. Note: A few
water 34 feet with a self-primer.
applications may perform better
I normally caution users to limit
with a foot valve.
their suction lift to a maximum of

Se p t e mb er 2015 | Pum ps & S y st e m s

4. There is a leak in the


suction line.
I frequently need to point out to end
users that the suction line on a selfprimer pump in operation is at less
than atmospheric pressure and so
there will not be a leak of the liquid
out of the suction line. There can,
however, be a leak of air into the
line. It is possible to have a suction
line at 20 inches of Hg (vacuum)
when the pump is operating. As
a tip for field problem solving, I
frequently use plastic wrap around
the flanges or suspected areas to
test for ingress leaks. Simply as
a general guideline, if your pump
takes more than four minutes to
prime than you should shut the
pump down and look for and correct
the cause of the problem.
5. There is no air vent.
The air in the suction side of the
system being displaced by the
liquid has to have somewhere
to go, otherwise the pump will
air bind. Centrifugal pumps
are not compressors. Water is
approximately 840 times denser
than air. As an example if a pump
was rated at a discharge pressure of
210 psig pumping water, the pump
could theoretically compress air
to approximately one quarter of a
pound (0.25 psig) (210 psig divided
by 840 is equal to 0.25). If the
pump discharge valve and/or the
discharge check valve are shut, the
generated pressure of 0.25 psig will
not be able to overcome the valves.
Within the confines of the article I
will simply state that the air must be
vented to an area of lower pressure
for the pump to properly prime.

25

There are many acceptable methods to


accomplish the process, please contact
your pump manufacturer or the author.

6. Consider the pipe size and


pump geometry.
Most experienced pump users know that
as a general rule you should always design
the suction line to be one size larger
than the pump suction. Selfpriming
pumps are an exception, and the suction
piping should be the same size as the
pump suction. The infraction of the rules
is encouraged because of the added air
volume that bigger suction lines require.
More air means more priming time.
The added friction loss from using the
same size pipe is just another reason
to eliminate the foot valve and suction
strainer mentioned earlier.
The suction pipe should rise
continuously to the pump and not higher.
In the field, I frequently see suction pipes
with high points before the pump suction
usually due to obstructions. These high
points become a place for the air and
other non-condensable gases to collect
and will bind the pump suction line.
Never install piping that is smaller than
the pump suction in any pump.
7. Watch the submergence
and NPSHA .
I covered net positive suction head
available (NPSH A) in last months article.
I strongly recommend calculating the
NPSH A for self-primers, as it is a great
method to identify potential problem
areas. For example, if the fluid is 160
degrees F, the vapor pressure of the fluid
alone will likely preclude you from this
application. For example, water at
160 F has a vapor pressure that equates
to a negative 11 feet.
The sump you are drawing from will
likely have operating levels that are
constantly changing. At some value of
minimum submergence it will be possible
for the system to create a vortex and air
bind the pump. I covered submergence in
the last article, but simply defined, it is

the minimum distance from the top of the


fluid to the center of the suction line that
will prevent a vortex from initiation. Even
if you do not completely air bind, the pump
performance can be affected.

8. Avoid freeze damage.


This problem occurs more often in
areas that have infrequent freezing
weather, but can happen anywhere the
temperature will drop below freezing

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pu mpsa ndsyst ems.c om | Sept emb er 2015

26

COMMON PUMPING MISTAKES

for an hour or more. The fluid in


the priming chamber of the pump,
usually water, will solidify if the
ambient temperature drops below
freezing for a sufficient period of
time. When water freezes it expands
and the casing will crack. The casing
will require replacement at a high
cost. Either drain the fluid out of
the pump or supply a heat source
when the ambient temperature is
predicted to be below freezing.

9. Avoid reverse rotation.


Unlike an ANSI pump, the impeller
will stay in place on most selfprimers for a period of time (unless
it is an ANSI self-primer. Eventually
the impeller may come loose and
damage the pump. The backwardrunning impeller generally will
create about 50 percent of the rated
flow and, depending on the impeller

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.

specific speed (NS), will generate


about 50 percent of the rated head.
Reduced efficiency of the wrong
rotation will likely prevent it from
priming or operating correctly but
in the simplest of suction lift cases.

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28
SPECIAL REPORT

Skilled Labor Shortage


Pump industry insiders look for answers amidst this
increasingly dicult challenge.
BY ALECIA ARCHIBALD
PUMPS & SYSTEMS

here is a shortage of skilled laborers in North


America and beyond. There is a need for workers
who build pumps and their systems, for those
who install and monitor them. The problem is
rampantcompounded as many older workers retire and
take their invaluable institutional knowledge with them.
In addition to retirements and economic expansion,
other factors contribute to the shortage of skilled
workforce, including loss of embedded knowledge due to
movement of experienced workers, a negative image of
the manufacturing industry among younger generations,
lack of STEM (science, technology, engineering and
mathematics) skills among workers and a gradual decline
of technical education programs in public high schools,
according to a study from the Manufacturing Institute
and Deloitte.
Industry leaders have fought to fi ll this gap for some
time. Efforts have been largely unsuccessful. Now,
companies and groups are banding together to draw
talented young people to professions that can provide
meaningful work and good pay without the requirement
of a college education.
One event that is attracting a lot of attention is
Manufacturing Day, set for October 2. Manufacturing
Day gives young people and their parents a chance to
learn about what kinds of jobs are available across the
country, according to Ed Youdell, president and CEO of
the Fabricators and Manufacturers Association.

By reengaging local communities to showcase their


manufacturing sector and demonstrate the contribution
that manufacturing makes to the local economy, we can
ensure a better future and way of life for our children and
grandchildren, Youdell said. Our future depends on our
ability to strengthen and advance this vital sector of our
nations economy.
Employers are getting creative in their efforts to attract
smart, motivated young people.
Were inviting schools to the NASCAR Sprint Cup
Series race at the Chicagoland Speedway this year on
September 20, said SKF Group CEO Alrik Danielson.
Ryan Blaney, who drives the No. 21 car and is 21 years
old, will help us promote youth in manufacturing.
SKF, a technology provider with employees in 130
countries, is taking the search for employees to a local
level. We are partnering with trade schools and high
schools, going to campuses to recruit youth. We think we
can do a little bit more, Danielson said.
Other employers are going even further to find
qualified workers. One industry executive with a U.S.
office said his company has gone as far away as India
to find skilled labor. Their recruitment program works
because employees have the chance to make more money
here and can receive additional training once they arrive.
While the shortage is felt acutely in the U.S., it extends
well beyond North America. Companies in the European
Union and the Middle East are struggling to fi ll jobs. The

Over the next decade, nearly 3.5 million manufacturing


jobs likely need to be filled. The skills gap is expected to result in
2 million of those jobs going unfilled.
- Manufacturing Institute and Deloitte

Se p t e mb er 2015 | Pum ps & S y st e m s

29

Australian Department of Employment reports that while


the demand for labor has decreased overall, there remains
difficulty recruiting for higher skilled jobs. All areas
report a skills gap in areas that include the pump and
rotating equipment industries.
Experts said that European
countries do a better job in
training than the U.S.
Schools in the U.S. need to
present the opportunity for
students that are strong in math
and science to go into the trades
and give them a vision of a career
path that will get them as far
as they want to go, said Henry
Peck, president of Geiger Pump
& Equipment Company. For
example, a world-class rotating
equipment specialist is not offered
by our schools as a vision for a
career path for a strong student,
when in fact it is indeed a high
level career alternative.
U.S. high schools promote
college preparatory programs
that do not necessarily include
mechanics or the related sciences
and skills. Schools are not
encouraging people, especially our
stronger students, to enter the
trades today. So, attracting strong
candidates is limited, Peck said.
Now the White House
is stepping in to ramp up
opportunities in the U.S. TechHire
is an initiative that allows
communities to take action,
working with each other and with
employers to expand access to tech
jobs, according to whitehouse.gov.
According to TechHire statistics,
America has more open jobs than
at any point since 2001. Many
require skills that can be learned at
community colleges and industrycertified training programs.
The recruitment efforts are going
to become even more important in
the future. The U.S. Department
of Commerce reports that the job
growth rate for STEM-related jobs

is almost double that of non-STEM occupations. There is


a movement to emphasize STEM education beginning in
elementary school. The National Education Association
endorses this move with resource recommendations for
curriculum enhancements and teacher training.

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pu mpsa ndsyst ems.c om | Sept emb er 2015

30

SPECIAL REPORT

SKILLS MOST DEFICIENT


IN MANUFACTURING EMPLOYEES
According to a U.S. Manufacturing Institute and
Deloitte study, executives cited the following skills
as those in which manufacturing employees are
most decient:
70 percent Technology/Computer Skills
69 percent Problem Solving Skills
67 percent Basic Technical Training
60 percent Math Skills
The study also discusses the challenges in dealing
with sensors, robotics, big data, controllers and
machine learning. In pumps manufacturing, this
means every aspect of the plant can be constantly
accessible, monitored and controlled, which
requires highly trained and nimble personnel.

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Meanwhile, schools and companies will celebrate


manufacturing next month with an eye on young people
who will choose skilled professions today.
Many industry groups and companies are participating
in upcoming events to promote manufacturing jobs to
young prospects.
Last month, Goulds Water Technology celebrated pride in
American manufacturing in a pre-Labor day event. Xylems
Auburn, New York, facility was open to tour.
Pump component manufacturer Lakeside Precision in
Dunkirk, New York, is offering plant tours and
demonstrations on October 2.
Ametek Motion Control will open its doors to students,
teachers and parents at its Harleysville Pennsylvania plant
on Manufacturing Day.
Baldor Electric is hosting an invitation-only event on
October 2 at its Fort Smith, Arkansas headquarters.
The Hydraulic Institute, a global authority on pumps and
pumping systems, has promoted Manufacturing Day
among its membership. The group helped its members
promote their company events around the country.
For a more complete list of pump industry participants, visit
pumpsandsystems.com. For more about Manufacturing Day,
visit mfgday.com.
Alecia Archibald is senior editor of the
Pumps Division, including Pumps & Systems,
Pumps & Systems MENA and Upstream
Pumping magazines. She may be reached at
aarchibald@cahabamedia.com.
Se p t e mb er 2015 | Pum ps & S y st e m s

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31
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32
SPECIAL SECTION

METERING & DOSING PUMPS

How To Size & Select


the Ideal Metering Pump
for Your Application
Chemical injection will only be successful if all variables are taken
into consideration and installation adheres to suggested protocols.
BY TOM O DONNELL
NEPTUNE CHEMICAL PUMP COMPANY

typical metering pump application in water


treatment, chemical process or agriculture can
deliver large amounts of chemicals during daily
operations. While the volumes may be large,
the metering also must be precise, with exact amounts
delivered according to strict injection schedules. The wide
range of injection pressures, from high to low, must also
be governed precisely. These demanding applications
require the use of a unique pumping technology, one that
can ensure successful, reliable adherence to the injection
schedule and fluid volumes.
Metering pumps have become a top choice for the
injection of chemicals in water treatment, processing
and agricultural applications. Many styles and modes of
operation are available, so users must understand the
different metering pump technologies in order to select
the ideal equipment for their injection applications.

Know The Parameters


When determining which metering pump is the best
option for a chemical injection application, users must
consider several variables:
Flow rate. Metering pumps should never be oversized,
so determining the exact flow rate required for the
application is paramount. A metering pump should be
sized so that the maximum expected flow rate is 85 to
90 percent of the pumps capacity.

Se p t e mb er 2015 | Pum ps & S y st e m s

Materials of construction. Metering pumps are


available in a variety of materials, most commonly
316 stainless steel, C-20 stainless steel, PVC and
Kynar polyvinylidene fluoride (PVDF). Users must
consider the corrosion, erosion and solvent action of
the chemical. For example, solvent-based chemicals
may dissolve plastic-headed pumps, while acids
and caustics may require stainless-steel models.
The effects of erosion must also be considered with
abrasive slurries.
Chemical makeup. Chemicals come in many
formulations, from thin to highly viscous, and they
can also be classified as a slurry or off-gas when
transferred. Standard metering pumps are typically
able to handle clear liquids with viscosities ranging
from water-like to 1,500 centipoise (cPs). Chemicals
with viscosities that approach 5,000 cPs or have light
suspensions will require special liquid ends. Those
with viscosities up to 20,000 cPs or that contain up
to 10 percent solids will require special diaphragms,
while ones that automatically vent accumulated gas
will need their own type of liquid ends.
Driver. Driverswhich can be powered by electricity,
water, gas, air or the sunmust be selected according
to the utilities that are available. Users must also
consider any environmental hazards that may be
found in the operating area, with the operator

33

Image 1. Metering pump users must consider many factors when designing
a system (Images courtesy of Neptune Chemical Pump Company)

realizing that pumps used in remote locations may


not be able to be inspected as often as those in
controlled environments.
Environment. Determine if the pump will be
operating indoors or outdoors. If used outdoors,
the pump must be sheltered from direct sunlight.
Any pumps that will be used in freezing
temperatures can only pump fluids that will not
freeze at that temperature.
Method of control. The operator must know if the
pump will be used in manual continuous operation,
on/off operation or operation that is governed by a
process signal.

Method of control is arguably the most important


variable when choosing a metering pump. Many
styles of metering pumps allow their flow rates to be
adjusted manually through the use of a micrometer dial.
Adjusting this dial changes the pumps stroke length
and allows the pump to be operated anywhere between
10 and 100 percent of its rated flow capacity. Metering
pumps with micrometer dials may also feature a variable
speed drive that allows adjustment of the pumps stroke
speed. Using the two in unison can allow additional

flexibility or turndown capabilities, over the range of


the drive, depending on the pumps stroking speed.
Flow rate set-point can be maintained automatically
by using electric or pneumatic positioners to adjust the
stroke length, which will deliver a full 10-to-1 turndown
ratio. In this method, the number of doses remains
constant with the size of each dose reduced, resulting
in doses that are uniformly distributed in a constantly
flowing line.
Metering pumps that use a variable speed drive will
deliver a turndown ratio that is determined by dividing
the pumps stroke speed by its minimum operating speed.
A variable speed drive will enable the pump to inject a
dose of the same size on each stroke, but because the
stroke speeds will change, the doses themselves will
be less frequent. Additionally, using a variable speed
drive with an induction motor-driven pump, which
normally operate at speeds less than 100 to 150 strokes
per minute (spm), is not practical because slowing the
motor causes each stroke to take longer to complete.
However, electronic metering pumps, which are pulsed by
a solenoid, can operate at less than one spm because the
timing of each stroke, from start to finish, is uniform at
every stroking speed.

pu mpsa ndsyst ems.c om | Sept emb er 2015

34

SPECIAL SECTION

METERING & DOSING PUMPS

Image 2. Method of control is arguable the most


important variable when choosing a metering pump.

Metering Pump Installation


When designing a pumping system, users must consider
any existing location or environmental concerns. Keep in
mind that metering pumps are able to push against high
pressures but will struggle to pull over longer distances.
This means that suction lift should be limited to no
more than 4 feet and that a foot valve should be used
in top-mount installations. Flooded suction is always
preferred in a metering pump installation to ensure
the pump is easier to prime, but the length of the
flooded suction should be limited to 6 or 7 feet. Other
components of the installation to consider include:
Suction piping. The traditional rule of thumb is
to use pipe that is one size larger than the pumps
suction connection, though using pipe that is the
same size as the suction connection is acceptable, if
the metering pump will be operating at a slow speed
when transferring low-viscosity chemicals. Generally,
do not use hard piping that is smaller than inch in
diameter or that is smaller than inch in diameter
for low-flow applications that use plastic tubing.
Discharge piping. The size of discharge pipe is not
as critical as that of the suction pipe, but the piping

Se p t e mb er 2015 | Pum ps & S y st e m s

must be suitable for the discharge pressure. Typically,


matching the pipe size to the discharge connection
should be sufficient.
Suction strainer. A suction strainer should always be
used, because it prevents foreign matter from entering
the pumps ball checks.
Flanges/unions/compression fittings. At least one
of these fittings must be installed at the suction and
discharge ports to facilitate maintenance procedures.
Isolation valves. Large-port, quick-opening isolation
valves should be placed at both the suction and
discharge ends of the installation as a way to ease
maintenance operations. Needle valves should not be
used because their design will create flow restriction.
Calibration column. Because metering pumps
often feature pulsed flow at low volumes, a drawdown calibration column is the most accurate and
convenient method to measure pump performance.
A tall, thin column should be used to ensure ease of
reading and reporting accuracy. Calibration columns
can also be helpful in determining if any wear has
occurred or dirt has accumulated in the pumps check
valves. If the liquid in the column bounces, that may

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

certified to CSA C22.2 No. 0.22-11 and witness


tested to IEEE C37.20.7 at a third-party high power
laboratory. The SC9000 EP is engineered to help
customers control, minimize and prevent arc
faults, leading to increased personnel protection
in global oil and gas, mining, utility, water,
wastewater and other critical applications.

www.eaton.com/SC9000

SC9000 EP arc-resistant medium


voltage adjustable frequency drive

Circle
110 on
card om
or visit
psfreeinfo.com.
pu mpsa
ndsyst
ems.c
| Sept
emb er 2015

36

SPECIAL SECTION

METERING & DOSING PUMPS

indicate that the valves are worn or dirty.


Relief valve. Though the metering pump may be
constructed with an internal relief valve, users should
consider installing an external relief valve. It should
be set at 50 psi (3.5 bar) or 10 percent above the
maximum operating pressure, whichever is greater.
Any chemical that flows through the relief valve is
piped back to the feed tank. Using transparent tubing
for the relief valve will allow the operator to observe
any returned fluid and identify any impurities. When
piping the relief valves return to the suction side of
the installation, the return must be upstream of the
pumps isolation valve so that the flow rate will not
become blocked.
Back-pressure valve. This component is only
necessary when the installation does not produce
adequate back pressure and the pump does not
contain a built-in back-pressure device. Back-pressure
valves are also required when a system has a lowpressure injection point that is hydraulically lower
than the feed tank.
Pressure gauge. The pressure gauge should be sized
30 to 50 percent larger than the maximum expected
pressure that is produced by the system.

Pulsation dampener. Pulsation dampeners are most


commonly required in systems that feature long
discharge lines where fluid acceleration can adversely
affect the pumps maximum pressure capacity or
relief valve setting. The pulsation dampener will
minimize the pressure spikes that these acceleration
circumstances may cause.
Injection quills/check valves. An injection quill that
is installed at the pumps injection point will serve as
a check valve while providing better dispersion of the
chemical. In low-pressure applications, an injection
quill that incorporates a corporation stop, which
allows the injection quill to be inserted or removed
without having to drain or shutdown the system, will
improve efficiency and overall performance.

Tom ODonnell is the director of business


development for Neptune Chemical Pump
Company and PSG. ODonnell may be
reached at 215-699-8700 or tom.odonnell@
psgdover.com. For more information, visit
neptune1.com and psgdover.com.

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2-STAGE SCT
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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

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Se p t e mb er 2015 | Pum ps & S y st e m s

37

Circle 102 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | Sept emb er 2015

38

SPECIAL SECTION

METERING & DOSING PUMPS

Valveless Piston Pumps


Complete Denitrication
of Euent Wastewater
For low-ow euent applications, a technology used for decades
in medical instrumentation has proven ideal for low and ultra-low
volume metering of methanol.
BY HERB WERNER
FLUID METERING, INC.

itrogen is present in untreated wastewater


effluent and can pose major environmental
concern in high concentrations, especially
when released into bays and watersheds.
Nitrogen is an end-product of the bacterial metabolism
of ammonia, which can act to deplete dissolved oxygen in
receiving waters. Nitrogen also stimulates aquatic plant
and algae growth, which causes hypoxia and, additionally,
blocks sunlight from reaching submerged marine life,
creating a condition known as eutrophication. Also,
nitrogen can exhibit toxicity toward some animals and,
in general, presents a significant public health hazard.
Furthermore, nitrate compounds are another primary
contaminant in drinking water that can cause a human
health condition known as methemoglobinemia, which
alters the oxygen-carrying capacity of hemoglobin.
The levels of nitrogen created during the wastewater
treatment process must be significantly reduced before
the effluent is discharged into the environment. The
primary challenge is to develop a practical method that
economically reduces the levels of nitrogen in the effluent.

Denitrification Using Methanol


Through denitrification, water treatment facilities convert
the excess nitrates into nitrogen gas, which is then vented
into the atmosphere. This process helps prevent an algal
bloom in watersheds thereby allowing oxygen and sunlight
to reach marine life below the surface.
Se p t e mb er 2015 | Pum ps & S y st e m s

Several commonly used methods, most of which use


pretreatment basins, aeration tanks and blowers, can
accomplish denitrification. For nearly 200 wastewater
treatment plants in the U.S., however, the process also
involves the addition of methanol into the effluent, which
accelerates the activity of anaerobic bacteria that break
down harmful nitrate.
Methanol is a colorless, volatile, flammable and
biodegradable liquid that is readily available in the market.
Methanol denitrification related costs are estimated
to be about one-eighth the cost of other commonly
used methods.
In most cases, a metering pump is used to add methanol
to the effluent stream. The type of pump can vary but
needs to meet certain application requirements, including
chemical compatibility of wetted parts and electrical safety
ratings for the area where the pump is being installed.
Because methanol is an alcohol that is classified as an
organic polar solvent, all wetted parts must have a high
degree of chemical resistance. Since methanol is both
volatile and flammable, the metering pump must meet
approvals for use in hazardous locations, especially Class 1
& II services.
Diaphragm pumps are often used for metering methanol
for wastewater treatment applications. However, when
metering in low flow treatment plants, such as small
facilities associated with universities, hospitals and rural
communities, pump designs that include valves can be

39

difficult to prime and often become


air-bound during operation. For
these low-flow applications, a
technology used for decades in a
type of medical instrumentation
has proven ideal for ultra-lowvolume metering of methanol
for denitrification.

Valveless Piston Pumps


Valveless piston pumps rely on
one moving part, a rotating and
reciprocation ceramic piston, to
accomplish both the pumping
and valving functions. With only
one moving part in the fluid path,
internal check valves, present in
diaphragm and other reciprocation
pump designs, can be eliminated.
The technology is precise
and works particularly well in
Image 1. An installation in a non-heated outdoor enclosure at a community college
low-flow wastewater treatment
wastewater treatment plant (Images and graphics courtesy of Fluid Metering, Inc.)
operations. The use of sapphirehard, dimensionally stable, ceramic
When metering methanol in the denitrification process,
internal components allows precision manufacturing
one valve-less piston pump is driven by a one-third
with tight clearances. The ceramic components for both
fractional horsepower (HP) hazardous-duty motor rated
the piston and mated liner are wear-resistant and
for Class I, Group C,D; Class II, Group E,F,G. Image 1 shows
chemically inert.
an installation in a non-heated outdoor enclosure, at a
As a result, the volume of the pumping chamber
community college wastewater treatment plant.
remains the same for millions of metered injections.
This, as well as the elimination of multiple check valves,
provides a metering pump that can self-prime down to the
micro-liter range and never lose prime. This is the result
of eliminating check valves that dont seal well enough to
prevent backflow.
Figure 1. The piston is designed with a flat cut
into the end closest to the inlet and outlet port.

How They Work


The metering pump uses a unique rotating and
reciprocating ceramic piston, moving within a precisionmated ceramic liner to accurately pump fluid in one
direction without allowing any backflow.
The reciprocation action of the piston
is similar to that of a standard piston
pump. As the piston moves back, it draws
fluid into the pump chamber. As it moves
forward, it pushes fluid out of the pump.
In addition to reciprocating, the piston
simultaneously and continuously rotates
in one direction. The piston is designed
with a flat cut into the end closest to the
inlet and outlet port (see Figure 1). As the
piston rotates, the flat cut is alternately
aligned with the inlet and outlet port,
essentially functioning as a valve. At
no time are the inlet and outlet ports
interconnected, eliminating the need for
pu mpsa ndsyst ems.c om | Sept emb er 2015

40

SPECIAL SECTION

METERING & DOSING PUMPS

check valves. One complete synchronous


rotation and reciprocation is required for
each suction and discharge cycle as shown
in Figure 1.
Diaphragm, bellows and traditional
piston pumps typically have four check
valves. Even during normal operation,
these will wear over time and not seal
properly, allowing backflow. When this
occurs, accuracy is compromised and the
pumps will need periodic recalibration.
Eventually, the check valves will need to
be serviced.

Figure 2. Some valveless piston pumps can maintain a precision of


0.5 percent or better for millions of cycles without recalibration

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.

Se p t e mb er 2015 | Pum ps & S y st e m s

Figure 3. As the angle of the pump head increases


above zero, the piston reciprocates, and fluid is
moved through the pump.

Herb Werner has been the marketing manager for Fluid


Metering, Inc., for 20 years. He has more than 35 years
of fluid control experience in the chemical process, water
treatment, medical and analytical instrumentation,
pharmaceutical and semiconductor
industries. He has a B.S in environmental
biology and is an active member of the
International Society of Automation,
American Water Works Association and Water
Environment Federation.

S P O N S O R E D

C O N T E N T

41

Harnessing the Power of


Boundary Layer
Viscous Drag
I

n severe applications where abrasion,


viscosity, entrained air, excessive wear
and corrosion problems wreak havoc on
pump systems and degrade products, Disclo
has developed a superior alternative that
dramatically reduces pump wear, is virtually
clog free and prevents product damage.
Disclo Corporation was founded in 1982
and quickly became an industry leader in the
hard-to-pump market and throughout the
world.
Our record of success in the highly
competitive pump market is a result of
breakthrough, state-of-the-art pump
technology and a commitment to providing
the most eicient and economical solutions
to the toughest pumping problems.

Disclos innovative Disc technology is a real revolution for hard-to-pump processes.

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.

Rotary discs provide non-impingement


pumping this means less wear and
greater protection for your product.

The non-impingement and laminar


low pumping of the Disc pump is
similar to low through an ordinary
pipe. The layers of luid at the
walls are stationary (relative to
the rotating discs), creating a
protective boundary layer. Viscous
drag pulls layers into lows of
smooth laminar streams.

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.

With no impingement device to damage your product and a boundary layer of


protection for the pump, the Disc pump effectively eliminates the root cause
of clogging, cavitation, excessive wear and product damage that plague the
performance of conventional pumps. Disclo is more reliable and eficient in
handling tough application and a lot more cost effective. It simply last longer,
requires fewer (if any) repairs and doesnt damage your product.

VISIT US AT
WEFTEC
Booth 3415

disclo.com 619-596-3181
Circle 108 on card or visit psfreeinfo.com.

pu mpsa ndsyst ems.c om | Sept emb er 2015

42

SPECIAL SECTION

METERING & DOSING PUMPS

Diaphragm Pumps Ideal for


Water Treatment & Reuse
These pump types oer longevity, precision and minimal maintenance
even when dealing with the harshest treatment chemicals.
BY JIM CARLING
MILTON ROY

ater is one of our most precious resources


andin drought-stricken areas such as
Californiais becoming more precious with
each passing day. The metering pump plays
a key role in treating water to make it suitable for reuse
or disposal. Depending on the processes and chemicals
required for treatment, hydraulically or mechanically
actuated diaphragm (HAD or MAD, respectively)
metering pumps may be the best option.

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.

Se p t e mb er 2015 | Pum ps & S y st e m s

Benefits of HAD Pumps


The HAD metering pump is a field-tested design that
has been around for decades, and it is built to last just
as long. HAD pumps have been proven to handle the
most aggressive chemicals at the full range of flow rates
required in a treatment process.
The HAD liquid end has a Teflon diaphragm, which acts
as a barrier between the piston and the process fluid. The
pistons pumping motion is applied to hydraulic fluid,
which causes the diaphragm to flex back and forth as
the piston reciprocates. The HAD operates with equal
pressure between the hydraulic and process fluids,
eliminating diaphragm stress, because the pressure is
essentially equal on both sides at all times.
This balance contributes to the longevity of HAD
pumps. With other types of diaphragm designs, the tube
or diaphragm contains the pressure. With no pressure on
the non-process side, the pressure is unbalanced and the
diaphragm (or tube) must withstand all of the process
pressure. With an HAD pump, however, the diaphragm
is balanced between two pressurized fluids and remains
under low stress. None of the moving parts in the pump
gets stretched or compressed, resulting in longevityup
to 96,000 hoursand minimal maintenance.
While the fundamental design elements of HAD pumps
have been around for decades, they continue to evolve.
Todays pumps feature advanced diaphragm materials,
efficient hydraulic system designs, enhanced control
interfaces, various motors and variable speed drives,
electronic capacity adjustments for remote control,
increased turndown (up to 1,000-to-1), and advanced
technology diaphragm leak detection systems.

43

The single biggest pump issue operators face during


water treatment is vapor locking. Gas bubbles from
chemicals such as sodium hypochlorite can form in
the head of the pump. Unless they are removed, the
pump will compress the gas, clog the pump and prevent
the chemicals from doing their intended job. Because
treatment plants run large-scale operations with highduty cycles over long shifts, ensuring continuous and
accurate distribution of chemicals is critical.
Properly selected HAD metering pumps eliminate the
problem of vapor locking by ensuring high fluid velocity
through the pump head. Front-scavenging technology on
the diaphragm evacuates the entire liquid end with every
stroke, cleaning it out and evacuating the head so that air
bubbles cannot accumulate and create vapor lock.
In addition to increased longevity and minimal
maintenance, HAD metering pumps provide a long-term
return on investment (ROI). According to Marc Sanchez,
vice president of Cortech Engineering, a California-based
distributor and solutions provider of pumps and process
equipment, numerous ROI examples demonstrate the
value associated with HAD metering pumps.

Our customers are large municipal water treatment


plants that process enormous volumes of water and
wastewater on a daily basis, Sanchez said. The cost of
downtime vastly exceeds the incremental cost of the
pump, and the peace-of-mind that comes from not having
to worry about repairs or extensive maintenance can be
priceless. Also, with a life expectancy of up to 30 years for
the pump and a 10-year life on the hydraulically actuated
diaphragm, its easy to stand behind this technology.
We install it. We let it run, and many customers will go
more than a year before they even need to think about
routine maintenance.

Benefits of MAD Pumps


MAD metering pumps have been specifically designed
for the water treatment industry, with features geared
toward lower pressure environments than those in which
HAD pumps operate.
Mechanically actuated pumps operate with a plunger
directly attached to the diaphragm. The direct attachment
of the piston to the diaphragm connects the pumps
drive and motor to the liquid end, and the motion of the

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8FMPPLGPSXBSEUPTFFJOHZPV
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pu mpsa ndsyst ems.c om | Sept emb er 2015

44

SPECIAL SECTION

METERING & DOSING PUMPS

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.

Turndown in Water Treatment


Traditionally, metering pumps were limited to a
turndown ratio of 10-to-1 while maintaining accuracy.
One manufacturer broke that barrier almost 30 years
ago with a design that increased turndown tenfold to
100-to-1 through variable speed technology controlling
the pumps output. Although many pumps today
boast similar capabilities, users must discern between
standard turndown claims and turndown with steadystate accuracy.
Se p t e mb er 2015 | Pum ps & S y st e m s

Turndown is important for water treatment because


the volume and quality of the incoming water varies
on a regular basis. For example, treatment plants
located on rivers deal with storms that can dramatically
alter conditions.
These conditions can result in different levels of
mud and accompanying sediment, which requires a
significant increase in coagulant dosage to remove the
resulting turbidity. Under normal operating conditions in
applications like this, metering pumps routinely operate
in the low end of the wide turndown range and still
need to repeatedly provide 1.0 percent accuracy at any
capacity setting.
Regardless of location, seasons also play a role in
requiring turndown flexibility. Seasonal changes can
alter influent water quality and impact chemicals such
as sodium hypochlorite, which loses concentration more
quickly in higher temperatures.
Both HAD and MAD pumps offer a variety of turndown
ratios as a standard. With the addition of variable
frequency drive (VFD) technology and remote stroke
control, turndown as high as 1,000-to-1 with precise,
steady-state accuracy can be achieved.
End users have a variety of choices that offer unique
advantages. In one corner, the HAD design offers the
longest life and the smallest maintenance requirements
with performance that exceeds requirements in the water
treatment industry. And in the other corner, MADdesigned metering pumps offer the same performance
and accuracy, targeted toward lower-flow requirements.
Regardless of the design, the metering pump must
deliver the performance, accuracy, reliability and
simplified maintenance needed to meet todays water
treatment challenges.

Jim Carling is the global product


manager for Milton Roy Municipal and
Industrial products. For the last 35 years,
Carling has served in numerous sales,
marketing and product management
roles for Milton Roy.

MC r
 e
Chicago,, Illinois
C 

45

September 26-30, 2015

Stop by booth 4626 at 10:00 A.M.


our
oon Monday September 28th for
o o
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Solids Handling Pump


The SH Series delivers excellent clogging
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IIn rigorous
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pu mpsa ndsyst ems.c om | Sept emb er 2015

46

SPECIAL SECTION

METERING & DOSING PUMPS

The Uncertain Oil & Gas


Market Could Impact
Demand for Metering Pumps
Manufacturers must develop a long-term market position
by diversifying.
BY AIDA PAOLA CONTI
FROST & SULLIVAN

robust specifications that allow equipment to withstand


fter a period of falling prices, from more than
high pressures and extreme temperatures.
$100 per barrel in late 2014 to $49 per barrel
The connection between unconventional drilling
in January 2015, a subsequent rise in oil prices
activities and its metering pump suppliers entered its first
indicated that supply and demand for crude oil
rocky stage with the oil crash in 2008 to 2009 and again
may be beginning to balance out.
in 2014. The falling prices resulted in a decline in the
In the best case scenario, oil prices could rise until
number of new oil rigs, presenting a difficult landscape
production grows and offset the decline in inventories
for suppliers.
from decreased drilling activities. In the worst case
scenario, the price of oil is expected
Figure 1. Total metering pump market in oil and gas industryrevenue
to fluctuate, which could lead to a
forecast by region (Courtesy of Frost & Sullivan)
structural change in the supply and
demand of crude oil. Given the role
metering pumps play in upstream
crude oil production, these two
scenarios could affect the demand for
metering pumps.
In the last decade, hydrocarbon
investments in remote shale oil and
gas areas and offshore activities have
fueled the demand for metering
pumps. As a result, a number of
suppliers found a niche market in
the individual shale plays. Similarly,
the development of offshore drilling,
which began near the coast and has
now turned into a race to conquer the
deep sea, created niche opportunities
for metering pump players with
specialization capabilities and more

Se p t e mb er 2015 | Pum ps & S y st e m s

47

With prices rising by nearly 40 percent in the last six


weeks of the year and inventories declining to nearly 3.9
billion barrels in the first week of May 2015, the market
may have been showing signs of recovery. Also, when
oil prices reached $60 per barrel, at least a portion of
the calculated 2,500 to 3,500 nonoperational rigs were
expected to enter operation. The current downward spiral
in oil prices closely resembles the downward trend of the
2008 to 2009 oil price crash, which suggests that a similar
upward trend can be expected after its bottom low.
Less optimistic views argue that the downward spiral of
oil prices is here to stay. Given the static and sometimes
declining demand for oil in the worldwide markets and
the growing trends toward the use of alternative sources
of power, the dynamics of the oil market are projected to
endure an integral change. The industry might continue
to trend downward.
Metering pump manufacturers are speculating whether
a definitive price increase is approaching or a prolonged
weak market from high price uncertainty. As old projects
begin to close, the ability to maneuver among the various
exploration activities and diversify into downstream

tio

s
low
F
n

a
ov

ere

activities will enable manufacturers to weather the storm.


While the total metering pump market is projected to
follow a slow-growth period, market application areas
such as anti-corrosion and anti-foaming processes are
seeing a demand in the short term. Use of energy-efficient
technologies and drilling equipment is influencing longterm purchasing decisions, which is projected to impact
the demand for metering technologies.
The challenge for metering pump manufacturers is to
develop a long-term market position by maneuvering
among different activities, diversifying into related lines
of business, and adopting energy-efficient technologies.

Aida Paola Conti is a research analyst for Frost & Sullivan,


North America. She has an international business
and marketing degree from the University
of Texas at San Antonio and Escuela de
Administracin de Empresas (EAE) in
Barcelona, Spain. For more information,
visit frost.com.

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pu mpsa ndsyst ems.c om | Sept emb er 2015

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

outh of the Equator, many Australians observe


Christmas, Boxing Day and New Years Day by
enjoying summers coastal heat on Mornington
Peninsula just south of Melbourne. For almost
two months, the population there surges from 155,000
to a quarter-million as revelers seek respite at a large
number of holiday homes.
According to South East Water, a utility in the state of
Victoria, the steady population growth of the peninsula
and the influx of residents during peak summer periods
have led to increasing pressures on septic tanks from
surges in use. Evidence shows that the aging, failing and
poorly maintained systems have been contributing to the
pollution of the regions groundwater and environment.
In November 2013, however, this 19th-century
wastewater disposal system graduated to the status
of intelligent sewer when South East Water began to
lay the fi rst pipe of an enormous project observers are
calling a game-changer.

Se p t e mb er 2015 | Pum ps & S y st e m s

Already named a fi nalist


in Australias 2014 Premiers
Sustainability Awards, the
approximately $297.5 million
pioneering approach to sewage
management combines a lowpressure sewer system (LPS) with the
iota OneBox, a proprietary remotecontrol telemetry network that
monitors and governs in real time
more than 16,000 grinder pumps in what will be one of
the worlds largest installations of its kind.
According to the award programs citation, South East
Waters innovative work represents the integration of a
novel approach to design, new technology and trenchless
drilling (which) has allowed the corporation to apply a
modern solution to address age-old issues.
As one analyst said, Were not only talking about
grinder pump technology and how thats solving an

49

As o Eptas illaborest la dolupid ut abor renimusamus di


cumquia di volorem fuga. Ercid molest, simustinciis eatur.

Image 1. The E/One grinder pump station


consists of a pump and holding tank.
Pump, motor controls and level-sensing
are integrated into a compact unit,
easily removable for service. (Courtesy of
Environment One Corporation)

immense problem; were also talking


about new technology and how thats
going to help people save money and
help the environment as well.

The Future of LPS


Environment One Corporation (E/
One) is under a multi-year contract
to provide the grinder pumps for
what E/One President Eric LaCoppola

Image 2. E/Ones Derek


Lachut providing in-depth
installation training on-site
(Courtesy of Environment
One Corporation)

pu mpsa ndsyst ems.c om | Sept emb er 2015

50

COVER

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WASTEWATER

From both an individual and


system-wide perspective, OneBox
users remotely monitor and control
a propertys pump unit in real time
using a desktop or smartphone to
transform a standard LPS into an
intelligent network.
refers to as the biggest opportunity for a grinder pump
driven low-pressure sewer system on the planet.
Two sewer pump stations will be connected by nine
miles of transfer main pipeline and 143 miles of sewerage
reticulation pipe to a single discharge pointthe Boneo
Water Recycling Plant.
The central component supervising everything is the
OneBox, a command system developed by iota, South
East Waters commercial arm. From both an individual
and system-wide perspective, OneBox users remotely
monitor and control a propertys pump unit in real time
using a desktop or smartphone to transform a standard
LPS into an intelligent network.
With this flexible and radically different approach
to designing an infrastructure system, operators are
able to smooth daily peak flows within the system,
simplifying the sewer infrastructure and creating greater
operational control.
Until now, pressure sewers operated autonomously
based on their given levels, a function of an individual
propertys wastewater generation. By incorporating
OneBox into the network, South East Water will now
be able to even out and control the flows of the entire
system, says Phil Thompson, CEO of iota.
This enables maximum optimization of our network
and treatment plant by reducing pressures caused by
variations in flow, Thompson says. In addition, iota was
able to develop smart commands, which changed how
the network was operated during times of high rainfall.
This is important for Mornington Peninsula where
the low-pressure sewer network connects to a gravity
network. When a high rainfall event comes through
and the catchment sewerage systems reach peak, the
pumps can be slowed or shut down to allow any inflow
and infi ltration to pass through the gravity system.
This increases capacity in the system by utilizing the
on-site storage of the low-pressure sewer tank. South
East Water needed a higher level of visibility over their
infrastructure, and OneBox provides that.
Se p t e mb er 2015 | Pum ps & S y st e m s

Image 3. Developed for utilities by South East Water Corporation, the


iota OneBox provides trend analysis, report generation, peak flow
demand determinations, flow smoothing and maximized efficiency of
downstream infrastructure with command and control from remote PCs
or from mobile devices. (Courtesy of South East Water)

Building a New Infrastructure


The Mornington Peninsula project could not have been
conceived even a decade ago, much less 1995, when
Australian officials began sounding alarms about
contamination of surface waters by septic tank systems.
Septic tanks are often associated with including leaching,
odors and contamination of groundwater. Septic tanks
are often more than 25 years old, and homeowners may
not be actively maintaining the systems.
The area needed an upgrade to a low-pressure sewer
system to maximize the value of the Mornington
Peninsula. Home to both full-time residents and
vacationers (by one estimate, unoccupied private homes
constitute 30 to 40 percent of total dwellings), the
peninsula also boasts 114 miles of coastline and a diverse
economy dependent on tourism and agriculture. Grapes
and olives thrive in the peninsulas maritime climate,
and dozens of wineries produce world-class pinot noir
and chardonnay.
South East Watera company with approximately
$2.91 billion in assets providing water, sewerage and

51

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Improved raceway surfaces for less friction
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Improved seal & shield designs for superior
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pu mpsa ndsyst ems.c om | Sept emb er 2015

52

COVER

SERIES

WASTEWATER

recycled water services to more than 1.65 million people


in the Melbourne regiongot to work to preserve this
regions beauty, economy and health. It helped develop
a backlog program, which by 2006 had compiled a list of
more than 20,000 high-risk lots in unsewered townships.
When they started to look at other options and the
scale of this project16,000 propertiesit certainly
justified some creative, outside-the-box thinking to
come up with some better solutions, says Derek Lachut,
Environment Ones Oceania regional manager.

The Birth of Intelligent Sewers


South East Water is unique amongst its contemporaries
with a high level of commitment to embracing in-house
research and development, Thompson says. We
developed a prototype (of OneBox) and manufactured
about 2,000 of those for our own internal use, and we
trialed and refined them for three years.
In 2012, the technology won a Global Honour Award at
the International Water Association Project Innovation
Awards in Korea.

"
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Image 4. The iota OneBox installed at each homesite provides


remote control and monitoring of individual grinder pumps and
can alert the utility before the customer becomes aware of any
faults. (Courtesy of South East Water)

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Se p t e mb er 2015 | Pum ps & S y st e m s

in a jam

US Patent #
7,159,806

The only patented V-Slice cutter technolog


gy.
Setting the new standard in grinder pump performance.
f

8 0 0 . 5 4 3 . 2 5 5 0 libertypumps.com

Copyright Liberty Pumps, Inc. 2015 All rights reserved.

14 416

Single stage and


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54

COVER

SERIES

WASTEWATER

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You can reason that the technology to do whats


being done existed 10 years ago, but it certainly wasnt
as prevalent, the market wasnt as accepting, and
the accessibility of the control interfaces werent as
ubiquitous as now, Lachut says.
The OneBox will interface with each grinder pump,
providing real-time data about individual or network tank
storage capacities, power failures, blockages and faults.
In the past, utilities lacked communication outside of
visual reports or customer contact regardless of the sewer
technology used. They sized pipes for peak diurnal flows
and based future designs on textbook standards and some
knowledge of daily and annual flows.
In the Mornington region, calculating this
information is critical, Lachut says, because its a holiday
area where flows fluctuate based on the demand from
holiday makers.

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Se p t e mb er 2015 | Pum ps & S y st e m s

Smart Sewer Rewards


The OneBox networks ability to smooth flow and
maximize efficiency of downstream infrastructure is the
benefit cited most by iota.
The benefit is not only at the individual property,
Lachut says. The benefit is what also occurs outside
the property boundaries. By precisely controlling
the flow, theyre able to right-size those downstream
infrastructure pumps and save a significant amount
of money.
Eamon Casey, design manager, asset creation at South
East Water, says this system provides the utility with
extra confidence.
It means that the utility can have a visibility of how
the low-pressure network is operating at any given
time, Casey says.
It provides additional confidence during a power
outage event. Smarts within the controller identify
pumps that are in the most compromised parts of the
network and allow them to discharge into the network
fi rst. The rest of the system is gradually brought back on
line over a period of time. Th is reduces the risk of sewage
spills, which is critical in such an environmentally
sensitive area.
Thompson says the ability to be proactive is also a
significant benefit. OneBox can identify individual
pump trends that could indicate a potential leak at
a property, allowing the utility to quickly notify the
customer before the next billing period.
It also enables a proactive response to pump failures.
Or, we can react. South East Water gets both SMS and
emails alerts where there is a pump failure. We can
come out, fi x it, and the customer doesnt even know

55

Image 5. Grinder pump startup inspection is a standard part


of the protocol ensuring maximum homeowner satisfaction.
(Courtesy of Environment One Corporation)

Part 2 of this series (November 2015) will discuss the


challenges South East Water faced when choosing a sewer
system suited for the distinct region and the benefits of lowpressure sewer systems.

South East Water is a state-owned corporation providing


water, sewerage and recycled water services to more
than 1.65 million people in the southeast of Melbourne,
Australia. Joseph Harmes has documented the evolution
and acceptance curve of grinder pumps and low-pressure
sewer systems for two decades. Besides Australia, hes
profiled overseas installations in Baja California, Mexico
and Turawa, Poland, as well as the Western Hemispheres
biggest LPS installation of more than 5,000 grinder pumps
in Twin Lakes, Indiana. *Special thanks to South East
Water for collaboration on this editorial project.

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
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they had a problem. Th is reduces irate customer phone


calls we have had to respond to. In the past, an alarm
went off, and the homeowner had to get out of bed and
call the water company and wait for them to come out,
Thompson says.

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

lushable wipes continue to inundate pump stations


throughout North America, clogging pumps and
pipes and often requiring operators to remove
the offending debris by hand. This deragging
process is time-intensive, hazardous and never-ending as
new debris continuously flows into pump stations. Total
shutdown, cleanout and rebuild of the pumps may be a weekly
requirement depending on the volume of wipes present in the
waste stream.
According to a 2013 report done by the Association of the
Nonwoven Fabrics Industry, wipes usage will grow 16 percent
year-over-year in North America alone (INDA; Cary, NC),
meaning wipes will continue to pose significant problems in
sewers, at water resource recovery facilities (WRRFs) and in
pump stations.
Chopper pumps and dual-shafted grinders both provide
economical, reliable solutions for preventing clogs and
equipment failure caused by wipes and nondispersible products. Pump station owners,
however, should fully understand the
differences between the design and function
of these two equipment types before making
a final design decision. Equipped with this
information, pump station owners can
minimize clogs and equipment failure caused
by wipes and non-dispersibles.

Design & Operation


Dual-shafted grinders employ low-speed,
high-torque grinding to break down
Se p t e mb er 2015 | Pum ps & S y st e m s

Figure 1 (small image). Environmental wipes ready cutter design


slices in two directions, creating smaller debris particles that easily
pass through pumps.
Image 1 (large image). Rag ball example (Images and graphics
courtesy of JWC Environmental)

57

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pu mpsa ndsyst ems.c om | Sept emb er 2015

58

COVER

SERIES

WASTEWATER

troublesome solids. This configuration handles tougher


items such as wood or rocks and is especially effective at
shredding rags and consumer wipes when compared with
single-shafted grinders or macerators.
As the name indicates, dual-shafted grinders comprise
two stacks with rows of hardened, steel cutters that
rotate toward one another. The cutter teeth actively grab
solids and pull them through the cutter stack, shredding
solids into smaller pieces. The shafts rotate at different
speeds, so the cutters interact like a pair of scissors
slicing the solids rather than crushing them. This slicing
action helps ensure a consistently small particle size;
most pieces are inch or smaller (see Figure 1, page
56). Dual-shafted grinders employ top and bottom shaft
bearings and robust mechanical seals to prevent shaft
deflection or seal failure when grinding high volumes of
solids, such as wipes, rags and organics.
An in-line, dual-shafted grinder system comes in two
parts, ensuring an efficient and streamlined installation.
The fl anged steel housing is bolted into the pipeline at
both ends, and a removable cutter cartridgeincluding
two shafts of cutters, the gear reducer and motorslides
down into the housing. This setup simplifies maintenance
inspections and repairs by allowing the pipeline to be put
back into service when the cutter cartridge is removed.
Chopper pumps are motor-driven, centrifugal pumps
that macerate incoming solids prior to pumping them.
This configuration
protects the pump
component from clogging
and maintains flow
through the system.
The chopper component
comprises a cartridge
seal to handle slurries a
nd reduce material
wrapping, impeller
vanes, auxiliary cutters
and impeller blades.
The auxiliary cutters
move against the sharp
impeller blades to chop
solids before they enter
the hydraulic parts of
the pump. To accomplish
this task, chopper pumps
employ high speed and
low torque to quickly chop
and move solids.
Some chopper pumps,
Image 2. Side view of Muffin Monster
however, may not be as
Se p t e mb er 2015 | Pum ps & S y st e m s

efficient at handling large volumes of tough solids. This


condition is common in a pump or lift station near the
end of a series of stations. Chopper pumps must operate
at a relatively high speed to maintain the ability to pump
fluids. This can reduce the maximum possible torque
required to grind through solid debris such as rocks,
wood, plastics and rag balls caused by wipes. The type
and volume of waste chopper pumps can handle also
may be limited by the equipments design. In other
words, if the chopper doesnt work, the unit cant pump
effectively, resulting in clogs. A dual-shafted grinder, on
the other hand, isnt required to maintain flow or move
material through the entire system. The main function
of a dual-shafted grinder is to grind any debris that
contacts it, allowing the continual flow of waste through
the pump station.

Selection Criteria & Positioning


Despite the limitations of chopper pumps, they can be
effective if placed at the first of a series of lift or pump
stations. If incorporated at an initial upstream point, the
chopper pump is only handling the onset of waste from
individual houses, buildings or apartment complexes
from a localized area. Most of this initial debris is easily
handled by a well-designed chopper pump.
As rags pass through collections systems in either long
trunk lines or in a series of pump stations, they tend to

Image 3. Installed in channel Muffin Monster

59

form ropes or rag balls as they recombine with hair and


grease (see Image 1). When chopper pumps are placed
further downstream in a series of stations, especially
last in a line of pump stations, the enormous volume of
rag balls and wipes that have accumulated can create
significant challenges.
Because of their construction and the torque of their
cutting force, dual-shafted grinders can overcome this
limitation, regardless of where one is placed within a line
of pump stations.

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

Image 4. In-line pump easily adapts to pipelines


or channels with little or no modification.

maintenance. The initial investment in a dual-shafted


grinder or chopper pump may deter some end users from
incorporating a solution within their system. But when
wastewater districts compare the up-front cost with the
long-term benefits of solving the wipes problem for their
pump or lift stations, the return on investment is difficult
to ignore.
While end users cannot completely eliminate the
impact of wipes and non-dispersibles on influent waste
streams in their pump stations, they can dramatically
improve the clogging and ragging situation with the right
waste-reduction equipment.

Troy Heimerl is the Midwest regional manager for JWC


Environmental with two decades of experience working
with pumps and process equipment for the water and
wastewater industry.

pu mpsa ndsyst ems.c om | Sept emb er 2015

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

overing more than 150 acres and serving an area of 725


square miles, the Blue Plains Advanced Wastewater
Treatment Plant (AWTP) in Washington D.C. is one of the
largest advanced wastewater treatment plants in the world.
Blue Plains has a design capacity to treat up to 370 million gallons per
day (mgd), meeting the needs of the metro-D.C. areas wastewater and
collection treatment needs. Because the treated effluent is discharged
into the Potomac River, the plant must meet some of the most stringent
nitrogen standards in the world. The District of Columbia Water and
Sewer Authority, also known as DC Water, has implemented a $3.8
billion, 10-year capital investment program for all its capital projects.
Part of this program has been the construction of the Enhanced
Nitrogen Removal Facility (ENRF). Submersible wastewater pumps are
central to the operation of this facility.

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

Image 1. One of five submersible propeller pumps for The Blue


Plains Water Treatment Facility in Washington, D.C. (Images
courtesy of KSB)

Demand Reliability
61

Because downtime is never on the schedule.


Electric Submersible
Pumps for Difficult
Wastewater Solids

Test All Electric


Motors, Regardless
of Location

The new SKG Series from BJM is


designed to obliterate flushable
wipes and other difficult solids in
wastewater applications.
Innovative features include:
Patent Pending RAD-AX
Dual Shredding Technology Radial and axial
shredding elements. System efficiency alleviates
potentially high surge load to the motor.
High Efficiency Motor High-torque,
4-pole motor - 2, 3 and 5HP.
Impeller Design High solids passage impeller
design expedites flow and hydraulic performance,
preventing clogs.
Robust Construction Chrome iron impeller
and suction cover. All shredding elements
are hardened 440C SS with a Rockwell hardness
of 55C+.
Superior Motor Insulation and SS Motor
Housing Class F insulation and SS motor
housing for superior corrosion resistance
and longer life.
Double Mechanical Seals
Oil-lubricated (SIC x 2), with separate
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Energized testing
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62

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Nitrogen removal at Blue Plains is a two-stage process


that involves nitrifying secondary effluent within
the existing 12 nitrification/denitrification reactors.
Complete denitrification occurs in the newly constructed
ENRF tanks.

Pump Station Requirements


A key element of the new ENRF process was the addition
of a new high-capacity pump station. The design
specifications mandated 24/7 operation, with a planned
life span of at least 20 years. The selected pumps had to
be robust and have a high degree of reliability. Blue Plains
chose several submersible propeller pumps designed
specifically for this type of application.
The selected pumps were factory-tested in accordance
with the operating conditions, and they had to pass
a stringent set of criteria. The pumps were optimized
specifically for the project, using the most suitable motors
for the application and hydraulics that exactly matched
project requirements.
The selected pumps are ideal for the wastewatertreatment and water-supply sectors and operate
in some of the most challenging water industry
applications worldwide. At Blue Plains AWTP, seven
submersible pumps are located at various locations in the
denitrification return sludge gallery sumps and are used
for pumping drainage, washdown, and potentially sludge
and chemicals if a pipe breaks. Four other submersible
pumps are located at two dewatering stations in the
denitrification return sludge gallery and are used for
liquor, pumping groundwater, pump/floor washdown
drainage and wet weather run-off duties.
In the Alternate Carbon Building, two submersible
pumps are used for sump pumping eyewash station
drainage, laboratory sink drainage, pump/floor washdown
drainage and potentially carbon chemicals if a pipe or
pump leaks. Portable submersible units can be moved
to various locations in the denitrification reactors and
post-aeration tanks to handle mixed liquor. Their primary
function is to dewater the denitrification reactors and
post-aeration tanks when they are taken out of service.
DC Waters new submersible motor denitrification
pumps are typically used for industrial and agricultural
water supply, stormwater and flood prevention stations,
and water and wastewater treatment. It is a close-coupled,
wet-installed, single-entry axial propeller pump with
the propeller located in a tubular casing immersed in
the water. To satisfy project requirements, the pump
manufacturer adjusted the pitch angle of the propellers
and specially wound the motors. Each of the seven pumps
has a maximum flow capacity of up to 179 mgd and a
Se p t e mb er 2015 | Pum ps & S y st e m s

Image 2. The largest submersible propeller pumps produced by the


projects pump manufacturer.

maximum head of 12 meters (m). Together they deliver a


total of 895 mgd. Low vibration hydraulics and a vortexfree flow resulting from the inlet ribs and wide bellmouth
ensure the pumps are hydraulically optimized. The slim
motor that minimizes discharge tube flow losses provides
improved operating efficiency.
For maximum versatility/flexibility, this type of pump
is available in a wide range of materials. Specially adapted
hydraulic systems with high operational reliability
resulting from wide free passages provide optimum
economic transport of all types of liquids. Unlike the
water supply pumps, the pumps used for the handing of
untreated and treated effluent operate all day long, which
places them under a considerable workload.

Adapting to System Needs


Having chosen these high-capacity pumps for this unique
application, DC Water took advantage of alternative
configurations. Optimizing the configuration resulted in
considerable power savingsas much as $200,000that
could be achieved every year. The manufacturer also has
the engineering resources to assist design engineers in
optimizing the design of the pump station. Reducing the
number of pumps also reduced the overall pump station
footprint. Less excavation, less concrete, less rebar and
fewer control panels contributed to lower operating,
capital and construction costs. Extensive hydraulic
calculations were also performed to develop a pump curve
required at various speeds.
Bryan Orchard is a independent journalist for KSB
specializing in pump and valve technology for the water
services and process engineering markets.

63

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pu mpsa ndsyst ems.c om | Sept emb er 2015

64

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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

key consideration in wastewater treatment


facilities is complying with the National
Electrical Code (NEC) and Occupational
Safety and Health Administration (OSHA)
requirements by determining if electrical equipment is
properly rated for the available short-circuit current. The
difficulty with compliance is that short-circuit current
levels can change as a result of modifications to the
electrical distribution system.
For instance, if the transformer supplying the facility
is increased in size (kilovolt-amps or KVA) or the
impedance is lowered, the short-circuit current will
increase. In addition, when equipment is relocated or
added, the available short-circuit current may be higher
than expected.
To assist end users with determining the availability
of short-circuit current, web-based tools and mobile
apps are available that can simplify fault current level
calculations and produce labels for fault current marking.

Short-Circuit Current Ratings Defined


Short-circuit current rating (SCCR) is the amount of
short-circuit current that electrical equipment is able to
safely withstand. SCCR applies to all electrical equipment,
such as panelboards, switchboards, motor control centers
and industrial control panels.
To protect equipment and personnel from certain risks
in the event of a short circuit, NEC and OSHA require
equipment SCCR to be sufficient for the available shortcircuit current at the point of connection.
Some of these requirements are:

NEC 110.10 requires that electrical equipment SCCR

Se p t e mb er 2015 | Pum ps & S y st e m s

is sufficient for the available short-circuit current.


OSHA regulation (1910.303(b)(5)) requires all
electrical equipment SCCR, new or existing, to be
sufficient for the available short-circuit current.
OSHA does not provide for any exemptions.
NEC requires industrial control panels that contain
power circuit components to be marked with the
equipment SCCR per 409.110 based on its listing and
labeling or per an approved method.
The marked SCCR of industrial control panels must
not be less than the available short-circuit current
per 409.22.

The NEC does not require industrial control panels to


be listed. It does, however, provide an informational note
in 409.110 that references Underwriters Laboratories
(UL) 508A, Supplement SB, as an approved method for
determining the industrial control panel SCCR. The
majority of industrial control panels are typically not
listed, but, to comply with the NEC, they must be marked
with the SCCR. Some industrial control manufacturers,
however, are less familiar with how to determine the
equipment SCCR of industrial control panels per UL
508A, Supplement SB.
Further, these entities are probably not verifying
the available short-circuit current during the customers
installation of the system.
They also may be unfamiliar with the methods to
increase the industrial control panel SCCR to be adequate
for their customers installation where the short-circuit
current is above the typical default SCCR of 5,000
amperes (A).

65

Adjustable speed drives as listed to UL 508C/UL 61800-5-1,


may require a special type of overcurrent protection devicein some
cases, a semiconductor fuseto achieve a high SCCR.

UL 508A, Supplement SB, is basically a weak-link


analysis of the industrial control panel power circuit
components. It can be broken down into a four-step
process. The first step deals only with power circuit
components (basically anything other than a circuit
breaker or fuse) that supplies a load (motor, heating,
lighting, appliance and typically receptacles). Per UL
508A, the component SCCR is marked on the component
or instructions.
This marking is typically based on proper overcurrent
protection by a fuse or circuit breaker. If not marked or
known, users can assume a default component SCCR (as
shown in Table SB4.1 of UL 508A, Supplement SB). The
four steps are outlined below.

Determine high-fault rating for power circuit


components. Most power circuit components
can be tested for an optional high-fault rating that
may require a specific circuit breaker or fuse. These
optional high-fault ratings can be found on ULs website
for combination motor controllers. Other types of
component SCCRs, including those of adjustable speed
drives, can be more difficult to find. Adjustable speed
drives as listed to UL 508C/UL 61800-5-1, may require a
special type of overcurrent protection devicein some
cases, a semiconductor fuseto achieve a high SCCR.
This required overcurrent protection device often is not
marked on the adjustable speed drive but instead in the
equipments installation and operation manual. Where

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pu mpsa ndsyst ems.c om | Sept emb er 2015

66

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To ensure compliance, the design engineers for wastewater


treatment facilities must determine the available short-circuit
current where the industrial control panels should be installed.
overcurrent devices are used with slash voltage ratings,
such as 480/277, or when combination motor controllers
that result in slash voltage ratings are used, the industrial
control panel must be marked with this slash rating
as well.

Verify whether a current-limiting device is


ahead of the branch circuit components (in the
feeder circuit). The branch circuit components would be
the components closest to the load but on the load side
of the branch circuit fuse or circuit breaker. The current
limiting device in the feeder would then be upstream of
the branch circuit fuse or circuit breaker.
The current-limiting device could be a transformer,
current-limiting circuit breaker or current-limiting
fuse.
If the device is a transformer, the process is relatively
simple, find the let-through of the transformer (Table
SB4.3 or SB4.4) if the let-through is less than the
branch circuit component and overcurrent device
ratings, then apply the primary overcurrent device
interrupting rating to the entire branch circuit.
If the device is a current-limiting fuse or circuit
breaker, the let-through is determined by Table SB4.2
for various classes of current-limiting fuses or by
published manufacturer data for marked currentlimiting circuit breakers.
If the let-through of the current-limiting fuse or
circuit breaker at a given fault current is less than the
branch circuit components, raise the component SCCR
to the fault current that was referenced.

Establish the interrupting ratings for all the


fuses and circuit breakers in the feeder and
branch circuits. This includes the fuses and circuit
breakers that supply control transformers and power
supplies. Fuses or circuit breakers that supply control
circuits on the load side of a motor branch circuit
overcurrent may be branch circuit overcurrent devices
or supplemental overcurrent protection devices, but the
interrupting ratings of these overcurrent devices affect
the assembly SCCR.

Se p t e mb er 2015 | Pum ps & S y st e m s

Find the lowest component or overcurrent


device rating in the assembly based on Steps
1, 2 and 3. This becomes the industrial control panel
SCCR. The UL 508A, Supplement SB, requirements and
component short-circuit current ratings can be difficult
to understand and apply. For this reason, most industrial
control panels are marked with the typical default rating
of 5,000 A. This can create problems with NEC and OSHA
compliance when the industrial control panel SCCR is not
sufficient for the available short-circuit current.
To ensure compliance, design engineers for wastewater
treatment facilities must determine the available shortcircuit current where the industrial control panels
should be installed. They should also consider that these
industrial control panels may be relocated where the
available short-circuit current is higher.
Often, a minimum industrial control panel SCCR,
such as 50,000 A, is determined to allow for flexible
application of industrial control panels in a given facility
regardless of location.
Complying with the latest national and local codes
and standards is vital for supporting personnel safety
and electrical system reliability. Wastewater treatment
facilities should consider tapping the latest tools to help
meet these requirements and simplify compliance.

Read more about


this topic online at
pumpsandsystems.com.

Dan Neeser is a field application engineer with Eatons


Bussmann Division. He specializes in training on
the design and application of overcurrent
protective devices and equipment
in electrical distribution systems in
accordance with the National Electrical
Code and equipment in accordance with
the various product standards.

67

Clamp-On Flow Measurement


Instrumentation Improves
Wastewater Treatment
Proper ow measurement provides an accurate and cost-eective
solution for challenging operating conditions.
BY MARISA FEDELE
SIEMENS PROCESS INDUSTRIES AND DRIVES

wastewater treatment plant is designed to


Different Methods of Measurement
protect the community it serves. However,
A clamp-on ultrasonic flow meter consists of at least
if the complex process of removing harmful
two sensors mounted externally to a pipe. The sensors
substances from wastewater is not carefully
measure flow by transmitting and receiving ultrasonic
managed, the plant may not be able to fulfi ll its purpose.
signals directly through the pipe wall and the medium,
Monitoring the flow of influent (incoming domestic,
but the method in which the flow rate is determined
commercial or industrial wastewater) and effluent
varies depending on the nature of the application.
(treated water that is discharged or repurposed) is crucial
Transit-time measurement calculates the difference in
for remaining in compliance with increasingly strict
arrival time between sound waves traveling in the same
legislation that holds treatment facilities accountable for
direction as flow and those traveling against it (see Figure
their impact on public and environmental health.
1). This difference is directly proportional to the mean
Several flow technologies
can measure wastewater
as it advances through the
treatment process, but
clamp-on ultrasonic flow
offers a combination of
benefits that should not
be overlooked. A properly
outfitted clamp-on flow
meter is suitable for most
wastewater applications. It
performs more accurately
than a traditional mechanical
meter and is often more
cost-effective than an
electromagnetic or inline
Figure 1. Transit-time measurement (Graphics courtesy of Siemens Process Industries and Drives)
ultrasonic meter.

pu mpsa ndsyst ems.c om | Sept emb er 2015

68

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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.

Accurate and Versatile


Transit-Time
Clamp-on flow technology is sometimes
perceived as a poor choice for wastewater
treatment applications because of
the misconception that transit-time
meters can only measure liquids devoid
of any particles or bubbles, leaving loweraccuracy Doppler meters as the
sole clamp-on option for most
wastewater applications.
In reality, a high-quality transittime meter is capable of tolerating
a sizeable amount of solids without
any compromise in performance. The
maximum concentration depends on
which type of sensor is used:
Shear mode or narrow beam. A
transmitting shear mode sensor
injects an acoustic signal into the
pipe wall, through the flowing liquid
and directly into the receiving sensor.
When fitted with shear mode sensors,
a transit-time meter will generally
retain its accuracy level with a total
solids content of up to 7 percent.
Lamb wave or wide beam. Lamb
wave sensors operate by broadcasting
a variety of frequencies through the
pipe to determine which most closely
resembles the pipe wall. The matching
frequency is then transmitted into
the liquid with the pipe wall serving
as a waveguide, allowing a broader
Se p t e mb er 2015 | Pum ps & S y st e m s

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.

Figure 2. Doppler measurement

69

In reality, a high-quality transit-time meter is capable of tolerating a


sizeable amount of solids without any compromise in performance. The
maximum concentration depends on which type of sensor is used.
swath of ultrasonic energy to cross the
pipe and increasing the probability
of a strong signal during times of
high particle content. The wider beam
produced by this method results in a
solids tolerance of up to 15 percent.
There are select circumstances in which
the solids concentration will be high
enough that even high-precision Lamb
wave sensors are not appropriate and
Doppler mode will become necessary.
By choosing a clamp-on ultrasonic
flow meter capable of switching
between transit-time and Doppler mode
depending on what is flowing through
the pipe, a wastewater treatment plant
is ensured maximum versatility while
avoiding the expense of purchasing
two separate clamp-on meters or an
electromagnetic meter.
A dual-mode clamp-on meter provides
sufficient flexibility for measurement
of most wastewater applications, including
raw sewage
primary sludge
return- and waste-activated sludge
(RAS and WAS)
mixed liquor
chemical additives
effluent

Lower Cost of Ownership


With the costs of wastewater treatment
and disposal rising annually in response to
more stringent governmental regulation,
investing in the right flow instrumentation
is one of the most cost-effective business
decisions a wastewater treatment plant
can make.
Clamp-on meters offer an overall lower
cost of ownership because they can operate
under a wide range of operating conditions
and due to their externally oriented
sensors and lack of moving parts.
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pu mpsa ndsyst ems.c om | Sept emb er 2015

70

COVER

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of the pipe with no necessary modifications to the


pipeline. This means meter setup is generally quick
and the plant can continue normal operations
throughout installation.
Additionally, because many wastewater applications
contain suspended solids and
flow through the pipe at high
velocities, meters that operate
by use of moving parts in direct
contact with the liquid will be
subject to substantial wear and
tear. Mechanical flow meters, for
example, require regular cleaning
since they are susceptible to
clogging, periodic recalibration
and repair of damaged parts.
Clamp-on sensors never touch
the flowing medium, thereby
preventing the formation of
deposits and virtually eliminating
the need for time-consuming and
costly maintenance.
A wastewater treatment
plant plays an important role in
safeguarding the public water
supply. Selecting proper flow
Free
measurement instrumentation
Technical Support &
is essential to ensure the plant
Used Oil Analysis
maintains tight control of every
step of the treatment process.
Clamp-on ultrasonic flow
Improve pump reliability, MTBF*, reduce downtime and energy
technology is well suited for the
consumption with Summit CentriPump PPO and SPO Series
challenging operating conditions
synthetic lubricants. Synthetics lubricants are resistant to oxidation,
that characterize the wastewater
enhance wear protection, and reduce friction. They keep your
industry and, with time, can save
plant operators a considerable
equipment running cooler, smoother, longer and more efficiently.
amount of money.

Installation of a mechanical, electromagnetic or


inline ultrasonic flow meter requires shutting down the
process and cutting into the pipe, potentially resulting
in lost productivity and revenue. This is not the case for
clamp-on meters, which are fitted on the outside surface

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Se p t e mb er 2015 | Pum ps & S y st e m s

Marisa Fedele is a senior


marketing communications
specialist for Siemens
Process Industries and Drives
in Hauppauge, New
York. She may be
reached at
marisa.fedele@
siemens.com.

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71

72

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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

he coastal area between the city of Anzio and the


commune of Pomezia in Italy is a popular holiday
destination, particularly for Italians living in
neighboring Rome.
Rapid development in the area in recent decades, resulting
in part from the availability of low-cost land, has outpaced
the advancement of local infrastructure. In fact, until just
15 years ago, most of the areas buildings and
facilities were not connected to sewer systems.
To address this problem, the municipality
of Ardea launched a significant redevelopment
program. At its core was the creation of an
efficient wastewater treatment service
capable of treating wastewater for the citys
population of 72,000.
To meet future population growth in the region,
the capacity of the existing plant needed to be
expanded. The municipality commissioned Idrica,
a utility provider, to build a sewage treatment
plant capable of serving the local population.

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

Se p t e mb er 2015 | Pum ps & S y st e m s

expectedmade this objective more complex. The project


required a technical solution that would minimize impact
on the environmenta key consideration when effluent
outflow into the sea could negatively impact tourism in the
area, which is a vital contributor to the local economy. Idrica
also aimed to reduce the public cost of running the treatment
facility. To decrease disposal costs and associated man

Image 2. Ozone container and chiller with


concrete aeration tank and pipe.

73

Image 1. Inside view of the sludge container. Pictured on


the left is instrumentation in front of the ozone generator.
(Courtesy of Xylem Wedeco Products)

hours, Idrica made it a priority to reduce the amount of


sludge produced.
Because of its low cost and ease of operation, the activated
sludge process is the most widely used method in municipal
and industrial wastewater treatment. However, it results in
the generation of excess sludge. Forty-five to 50 percent of
the costs of wastewater treatment are associated with the
handling, treatment and disposal of excess sludge.1 For this
reason, municipalities look for solutions that reduce the
mass and volume of sludge, improve its physical and chemical
characteristics, and minimize the impact on its destination.
Several European Union (EU) directives have resulted
in increasing the costs associated with the treatment and
disposal of sludge. Under the Urban Waste Water Treatment
Directive 91/271/EEC, most EU populations must be served
by wastewater treatment facilities, resulting in the generation
of excess sludge. The Sewage Sludge Directive 86/278/EEC
has led to restrictions on the agricultural application of
sludge from wastewater treatment processes, resulting in the
incineration of more sludge. In addition, the Landfi ll Directive
1999/31/EC limits the disposal routes for excess sludge,
leading to rising costs for sludge disposal.

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The use of increasingly effective treatment technologies


at the Ardea plant and population growth leading to more
intense use of the system caused an increase in the amount
of sludge in need of disposal.
Despite the use of centrifugal pumping, which can

eliminate most of the moisture produced, the plant at Ardea


produced 3,000 tons of sludge per year. The cost of disposal
was more than 130 per ton. Idrica aimed to reduce this
significant financial outlay.

A World Class Provider of


Fluid Sealing Solutions

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

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Se p t e mb er 2015 | Pum ps & S y st e m s

75

up to

50%
energy savings
with variable
frequency drive
technology

ENGINEERING

TOMORROW

is making efficient, reliable water a reality


Demand for an ecient, sustainable water supply will only increase as
infrastructure continues to expand, environmental challenges intensify, and
energy costs rise. From improving pumping eciency to handling uctuating
demand and maintaining constant pressure, Danfoss engineers innovative
solutions designed specically to help you reduce energy consumption and
water loss while meeting performance challenges.

Discover how we are Engineering Tomorrow


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pu mpsa ndsyst ems.c om | Sept emb er 2015

76

COVER

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WASTEWATER

chemical tastes or odors, or significant residues. It does


not involve the storage and handling of oxidants or other
chemicals and is generated safely on-site and controlled
on-demand from air/oxygen and power. By decomposing
to oxygen as it reacts, ozone provides a cost-effective and
ecological alternative to oxidation with chlorine, absorption
or other separation processes.
Ozone reacts quickly with a large number of compounds.
These compounds are attacked either directly by the ozone
molecule or indirectly by the intermediately occurring
hydroxyl radicals. The ozone is completely consumed in this
reaction process, releasing only oxygen. Any remaining ozone
residues in the off-gas are converted back into oxygen by a
residual ozone destructor.
The ozone Idrica incorporated is a completely integrated
system capable of producing 9.6 to 600 kilograms (kg) of
ozone per day or 400 grams (g) to 25 kg per hour.

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

Image 4. The recycling of ozone treated


RAS in the aeration tank.

percent reduction in the man hours required to remove and


dispose of the sludge produced.
The solution also reduced the amount of fi lamentous
bacteria produced, which is the main cause of sludge
bulking within secondary clarifiers. When bulking occurs,
large quantities of sludge can be carried out from the
wastewater treatment plant with the effluent water in
the form of suspended solids (SS), which can lead to legal
penalties. In most cases, a fi ltration step is required if the
bulking phenomena are frequent. Alternatively, a chemical
flocculation is required (with additional associated costs).
However, the use of ozone can eliminate the negative effects
caused by fi lamentous bacteria.
References:
1. Kroiss, Helmut (2014): Perspektiven von Schlammmanagement und
Schlammverwertung in Europa, Enduser Konferenz FP7 ROUTES;
Braunschweig 2.4.2014

Image 3. Contact system Lyso providing


defined reaction time and reaction
conditions to ozone treated return sludge
(RAS).

Se p t e mb er 2015 | Pum ps & S y st e m s

Wiebke Rand is an application engineer at Xylem Wedeco


Products. She studied civil engineering at the Technical
University Braunschweig, Germany, focusing on
sanitary and environmental engineering and
hydromechanics. She may be reached at +49
5221 930-184 or wiebke.rand@xyleminc.com.
For more information, visit xyleminc.com.

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77

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Circle 113 on card or visit psfreeinfo.com.

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

s the cost of energy and water and


wastewater services continues to
rise, operators are looking for ways
to reduce the costs of these basic,
yet crucial, utilities. Proposed energy efficiency
standards from the U.S. Department of Energy
(DOE) and other federal measures could help.
In the water sector, the DOE has a mandate
to develop and enforce national minimum
Figure 1. Water losses at different operational pressures (Courtesy of Danfoss)
energy efficiency standards for any product if
significant savings can be realized in a costjustified and technically feasible manner. During the past
energy consumption is the result of the three affinity
year, the DOE and stakeholders have been negotiating
laws, which describe the relationship between speed of
a regulation for pump efficiency. That rule, now in the
the pump (n), flow (Q), pressure head (H) and electrical
Notice of Proposed Rulemaking (NOPR) phase, would
power consumption (P) (see Equations 1-3).
apply only to clean water pumps of these types:
End suction close-coupled
Q1 n1
H1
n 2 P1
n 3
End suction frame-mounted/own bearings
=
= 1
= 1
n2
P1
n2
Q2 n2
H2
In-line
Radially split, multi-stage, vertical, in-line, diff user
casing
Equations 1-3
Vertical turbine submersible
Gallons

78

()

The energy efficiency of existing water distribution


systems is greatly impacted by pumps and motors.
Utilities are incentivizing facilities to install variable
frequency drives (VFDs) to reduce electrical surges caused
by starting and stopping equipment. These controls can
reduce water hammer and lower maintenance costs.
By operating a pump/motor system at constant pressure
or flow, a VFD can help reduce energy consumption. This

Se p t e mb er 2015 | Pum ps & S y st e m s

()

These calculations show that the power to run a pump


is relative to the cube of the speed. If a pump is slowed
by 20 percent, it will experience a nearly 50 percent
reduction in power or energy consumption. Even small
decreases in speed can result in energy savings. VFDs can
also regulate the pressure of water distribution systems.
Before VFDs were commonly used, water distribution
systems typically incorporated pressure switches to

79

control pumps. When the system hit a low pressure point,


the pump turned on; when it hit a higher pressure point,
the pump shut off. A facility may have used two pumps:
a smaller one for slow night hours and a larger unit for
during the day. While this type of control often causes
pressure fluctuations, it is common practice.
A VFD can maintain pressure at a constant set point by
increasing pump/motor speed. By maintaining constant
system pressure, a VFD can help reduce water leakage.
For example, a -inch hole in a distribution pipe can leak
as much as 4 million gallons per year at 50 pounds per
square inch (psi) or more than 5 million gallons per year
at 80 psi. By keeping the pressure more constant, VFDs
can help reduce non-revenue water losses (see Figure 1).
While VFDs can help reduce energy consumption,
which could lead to lower operating costs, some additional
savings may not be initially realized:
Protection of pumps and assets
Reduction of maintenance costs
Lower risk of bacteria/contamination of tap water
Lower risk of road breaks
Reduction in pipe repair cost
Extended service life of network
Postponed investment in system upgrades
Improved control performance
Increased redundancy
Reduced load on supervisory control and data
acquisition (SCADA) system because of dedicated VFD
software features
The wastewater side of the system requires more
processes and a greater number of motors and pumps. But
because wastewater pumps operate in different conditions
than clean water pumps, they have not been included in
the DOE rule. While the DOE could develop a rule for
wastewater pumps in the future, the schedule for efficiency
rulemaking under the current administration appears full,
and a federal initiative in the near term seems unlikely.
The U.S. Environmental Protection Agency (EPA)
through its Clean Air Act (section 111d), on the other
hand, will require states to develop compliance plans,
which could include state energy efficiency programs.
Wastewater treatment plants could be included in
these regulations. While states are unlikely to require a
minimum efficiency specifically for wastewater pumps,
the EPA could incentivize plants to reduce energy use.
Wastewater operations can begin to increase efficiency
by adding VFDs to motors and pumps in the same way
many clean water applications have. Utility rebates can
help with acquisition and installation costs, and the
resulting lower energy bill can reduce operating costs.

Additional VFD Features


For smaller facilities, using a larger SCADA system
may be out of the question. But todays VFDs typically
include integral controllers that can be used to maintain
level, pressure, flow, dissolved oxygen (DO), turbidity
or other monitored processes. An analog signal sent
from the monitoring equipment to the VFD allows the
VFD to maintain a constant process output. Internal
communication modules transmit data to other areas,
allowing end users to monitor the current status.
Integral cascade controllers can operate multiple
pumps simultaneously, allowing for better overall control.
When used in a variable pumping system, where pumps
of different flow capabilities are installed and staggered,
VFDs can increase system efficiency. This type of control
can offer the most efficient operation of a pumping
system and the highest system efficiency.
In almost any size system, the use of VFDs on pump
motors means greater flexibility and better process
control. By reducing the surges that a plant may see
during an event or normal loading, VFDs allow a plant to
more closely handle waste influx by regulating the flows
into the plant. VFDs can assist the existing SCADA or
overseeing system.
Drives can also offer featuressuch as a deragging
functionthat help maintain pump efficiency. This
feature will rotate the impeller backward (on a pump that
can be operated backward) to dislodge solids, stringy
materials or other debris, which can help the impeller
pump at optimum performance.
In addition to deragging capabilities, drives designed
specifically for the water/wastewater market tend to offer
additional features that facilitate motor/pump operation,
including initial ramp and/or check valve ramping, flow
counting, flow confirmation, and no-flow or low-flow/dry
pump protection. Additionally, analog and digital output
cards, communication cards and specific application cards
are available to assist in control functions.
As the water/wastewater industry continues to
modernize and expandand issues such as reducing
energy consumption and water loss become more
important and regulatedVFDs will become more
commonplace in many applications.
Jeff Bergman is global key account manager
for Danfoss. He received his Bachelor of
Engineering Technology in mechanical and
manufacturing engineering technology from
Clemson University. For more information,
visit vltdrives.danfoss.us.

pu mpsa ndsyst ems.c om | Sept emb er 2015

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

ecent developments in the field


of nanotechnology have resulted
in a positive impact on two of
the worlds largest industries
energy and water. These advancements
have allowed scientists and engineers to
develop new tools that work with pumping
systems to improve and streamline the
wastewater treatment process. Some
believe that the commercial use of
nanotechnology in key applications
will help meet the worldwide drive to
reduce carbon emissions and redefine the
energy-water nexus.
Image 1. Nanostructured polymer membrane (Images and graphics courtesy of Dais Analytic)

How Nanomaterials Work


Nanotechnology is broadly defined as
science, engineering and technology that is limited to a
length scale of 1 to 100 nanometers.1 One such material
is a family of nanomaterials created by the chemical
modification of styrene block copolymers that are widely
used in glues and gaskets. Modified copolymers can be
used to produce innovative membranes that provide
molecular pathways for the transport of water between
the surfaces without traditional porosity.
The block copolymer starting resin contains discrete
blocks of styrene that are interspersed in various
patterns and blocks of olefin polymers that are inherently

Se p t e mb er 2015 | Pum ps & S y st e m s

hydrophobic and provide elasticity to the polymer.


A variety of proprietary processes are used to
covalently bond an acidic functional group to the
styrene blocks of the copolymer without modifying the
hydrophobic regions. The acid group is extremely polar,
which makes that region of the polymer hydrophilic.
When a liquid solution of the polymer is cast onto a fl at
surface and the solvents evaporate away, the hydrophobic
and hydrophilic regions of the polymer exhibit different
wetting characteristics. This process causes selforganization of the polymer as the different blocks

81

attempt to minimize or maximize their


interaction with the remaining solvent.
Upon solidification, the polymer layer
contains a pattern of hydrophobic and
hydrophilic regions
that are 5 to 30 nanometer (nm) in
diameter, making the membrane a
nanostructured material.
These hydrophilic regions swell with
water molecules that force the polar
functional groups further from each
other, a spontaneous change that reduces
the electrostatic repulsion forces
between the functional groups.
These regions are contiguous with
the neighboring hydrophilic regions,
connecting one surface of the membrane
to the opposite surface with a continuous
chain of water molecules. The hydrophobic
regions of the material provide a strong,
flexible structure that keeps the material
from dissolving.
The polymer membrane is sensitive
to any differential in vapor pressure
between the two surfaces. As water
molecules evaporate from one surface

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pu mpsa ndsyst ems.c om | Sept emb er 2015

82

COVER

SERIES

WASTEWATER

of the membrane, they create local imbalances in the


electrostatic interactions between functional groups and
water molecules, resulting in the redistribution of water
molecules to replace the evaporated molecules.
When the evaporation rates at the two surfaces are
different, a net flow of water molecules through the
membrane results as the material tries to maintain a
dynamic equilibrium.
This electrostatic interaction acts as a solid-state
pump to preferentially move small polar molecules
through the material; nonpolar molecules such as
oxygen and nitrogen show low transport rates compared
with water molecules that interact with the polymer.
Membranes made of this nanomaterial are able to
selectively move water from one face to the other at a
higher rate than nitrogen, oxygen and other gases, as
well as dissolved ions and materials.
rapidly transport water molecules between surfaces to
allow a high flux rate of water molecules per unit of area.
demonstrate durability in a variety of environments.
use commercially available methods to achieve highvolume production.

Figure 1. Nanomaterial operation


References
1. http://www.nano.gov/nanotech-101/what/defi nition
2. http://www.pumpsandsystems.com/news/2015-05-20/droughtdriving-greater-reliance-wastewater-reuse-california#sthash.
q6UwEnrh.dpuf
3. Th roughout this document, the terms ppm, parts per million, and
mg/L are used interchangeably.

Tim Tangredi is the CEO of Dais Analytic,


a commercial nanotechnology materials
business that provides technology for the
worldwide energy and water markets. For
more information, visit daisanalytic.com.

KEEP PUMP & IRRIGATION CONTROL IN YOUR HANDS

Final

Developed for manual


or automatic control
Offers flexibility for
mechanical or electronic
engines
Designedd aand
nd ttested
ested
for hharsh
arsh eenvironments
nvironments

Take control now.


918-317-2630
www.fwmurphy.com/ps
08/15

1511653

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Se p t e mb er 2015 | Pum ps & S y st e m s

RTGUUWTG"("HNQY
83

The right amount of water pressure and flow is critical to


protecting pipes, preventing loss of prime and avoiding dead
head conditions.
Thats why you need the iQPump from Yaskawa. The most intelligent pump
controller available gives you complete control of your irrigation needs for water
land management resulting in lower installation costs, simpler operations and
greater energy savings. The iQPump can be easily integrated into any pump station,
or retrofitted into an existing system.
When the right amount of pressure and flow is critical, call Yaskawa.

Get personal with Yaskawa.


Call Scott Mathews today.
1-847-887-7144

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

2015 Yaskawa America Inc.

For more info:


http://Ez.com/yai804

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pu mpsa ndsyst ems.c om | Sept emb er 2015

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.

he problem of disposable wipes in the nations


sewer systems has been well-documented
in news coverage across the U.S. While
manufacturers claim these wipes are flushable,
they have been causing major problems for wastewater
facilities, and the problem has only worsened in recent
years. New York City alone claims that more than $18
million has been spent during the past five years to
remedy wipe-related problems in their 14 wastewater
treatment plants.
In the Southwest, a Tucson, Arizona-based news crew
visited a regional reclamation center and documented
that white wipes were everywhere. The operator
suspects the wipes are not biodegrading as fast as the
general public is being led to believe. The wipes cake the
walls and eventually get stuck in the sewers where they
clog pumps and pipes. When blockages occur, there is just
one way to clear themby hand.
In Vancouver, Washington, sewer officials performed
their own experiment after spending more than $1
million replacing 11 pumps that regularly became clogged
as a result of wipe ingestion. They dyed wipes labeled
flushable and sent them on a one-mile journey through
the system. They did not break up.
One major producer of flushable wipes claims that the
problem is caused by products not meant to be flushed.

Se p te mb er 2015 | Pum ps & S y st e m s

Image 1. Jae Wilson, service manager at Williamson New England Electric


Motor and Pump Company, consulted with the pump manufacturer while
reviewing the system and its requirements. (Images courtesy of BJM Pumps)

They explain that flushable wipes, when used as directed,


break up after flushing and clear properly maintained
toilets, drain lines, sewers, pumps, and septic and
municipal treatment systems.
Consumer Reports performed tests that dispute
these claims. The magazine ran vortex and mixer tests
on several major flushable wipe brands that claimed to
be safe for sewer and septic systems. After 10 minutes
of agitation, the wipes did not break down. Consumer
Reports states that the public must understand what is

Image 2. While manufacturers claim wipes are flushable,


they have been causing major problems for wastewater
facilities, and the problem has only worsened.

safe to flush and what is not. Their advice:


Do not flush flushable wipes.
Until industry standards for all wipes
meet wastewater handling equipment
requirements, the public must be informed
and responsive to minimize system
downtime and the resulting costs to
taxpayers. In the meantime, waste-handling
equipment must be upgraded to handle a
large volume of these wipes in the system.

Facing the Problem


Several pump companies have attacked the
problem by developing equipment that will
shred wipes and other solids to make
them safe for wastewater systems. The
engineers at one company have developed
dual shredding technology that features
radial and axial shredding elements. Th is
design obliterates wipes and other hard-tohandle solids.
Incorporating both radial shredding and
axial cutting achieves optimum results on
hard, to near impossible to pump liquids
containing fibrous solids like wet wipes,
said Brian Mitsch, the companys VP of
operations and engineering. The radial
shredding is achieved by a rotating cutter bar
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pu mpsa ndsyst ems.c om | Sept emb er 2015

86

COVER

SERIES

WASTEWATER

with serrated edges, which traps and shreds solids against


the sharp grooves of the radial cutting ring. Wipes
and other fibrous debris are efficiently ripped apart.
The complementary axial cutting utilizes dual cutting
elements operating in tandem to multiply the shearing
action. As the material exits the radial shredding area,
the axial cutting components shear any remaining pieces
using multiple cutting bars. The impeller design
expedites flow and hydraulic performance, preventing
wrapping and clogging.
These pumps feature shredding elements that are cast
in hardened 440C stainless steel
(Rockwell hardness above 55C),
and the patent-pending design
provides excellent solidspassage efficiency through
its impeller and volute.
Image 3 . This dual shredding
technology with radial and
axial shredding elements
provides solids passage
efficiency.

Available with 2-, 3- or 5-horsepower (HP) high-torque


four-pole motors, these pumps are ideal for smaller
wastewater stations.

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

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Se p t e mb er 2015 | Pum ps & S y st e m s

87

Image 4. The new pump was placed in the sump without a screen,
alongside a shredder pump.

frequent failures as wipes blocked screens protecting


the pumps and wrapped around impellers, clogging
the volute and eventually burning out the pumps
submersible motors. Even with a back-up pump in place,
the service interruptions and maintenance costs became
unacceptable.
The average pump service life was less than 1.5 years.
After one of the 460-volt submersible pumps failed
again, Snyder asked the water and waste equipment
specialists at Williamson New England Electric Motor and
Pump Company to examine the problem and recommend
a solution.
Jae Wilson, service manager
at Williamson New England
Electric Motor and Pump
Company reviewed the system
and its hydraulic requirements,
including the difficult-to-pump
wastewater content. Although
numerous solids-handling pumps
were available, none presented the
perfect solution.
Research indicated that the
heavy wipe content would still
tend to wrap and clog pumps with
traditional non-clog impellers. The
resulting failure meant lifting the
pump, disassembling and manually
clearing the blockage, and possibly
replacing the motor.
Wilson consulted with one of
his pump suppliers and decided
to install a shredder pump with
dual shredding technology.
Because it used both radial
shearing and axial cutting to pass
hard-to-pump items such as wipes,
this new design was ideal for
the application.

One important advantage of the new system was


immediately noticeable. Most non-clogs, including the
second wastewater sump on the FoxRock property, must
be surrounded by a screen. The solids and debris that get
caught in that screen must be routinely cleared by hand.
The installed pump does not require a screen. A postinstallation inspection showed no debris in the sump.
So far, I am very happy with the pump. It was installed
in July 2014 and continues to operate without clogging,
Snyder said.
While preventing non-flushable materials from
entering the wastewater system is impossible, FoxRock
Properties has a pump that can minimize the possibility
of clogging and improve downstream conditions.
Mike Bjorkman is vice president of BJM Corp. and has
more than 30 years of experience in the pump industry.
He serves as marketing and IT director for BJM Pumps
LLC and All Test Pro LLC, both subsidiaries of BJM
Corp. For more information, call 860-399-5937 or visit
bjmpumps.com.

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88

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WASTEWATER

SWPA Meets in Chicago

he Submersible Wastewater Pump Association


(SWPA) recently met in Chicago to tour several
facilities and plan upcoming events and training
opportunities for members.
The meeting included tours of the Stickney Water
Reclamation Plant (WRP) and the Tunnel and Reservoir
Plan (TARP), both part of Chicagos extensive sewer and
wastewater treatment district. While in the Windy City,
SWPA members also toured the local Grundfos facility.
The group saw portions of the Metropolitan Water
Reclamation District, which serves more than 5 million
residents of the Chicago area. The Stickney plant,
considered to be the largest in the world, has a capacity
of 1.2 billion gallons of water per day.
Parts of the facility were completed from 1930-1939,
and pumps from that era are still operational. Famously,
before that construction, the city reversed the flow of the
Chicago River to protect the waters from contaminants.
Some tanks are now being replaced. This project will
take about three years to go online and will ultimately
save about $1 million a year.

The sewer tour also


included a trip to the
bottom of the TARP
pumping station, located
350 feet below ground.
During SWPAs meetings,
the group discussed an
upcoming partnership with
Pumps & Systems magazine.
The two will launch a new
online Training Resource
Center this year. The center
will include webinars,
training videos, white
papers, articles and other
information for pump
Image 1. SWPAs Steve Doolittle (left)
professionals seeking
joins the tour of the Chicago sewers
continuing education
research greenhouse.
units (CEUs).
For more information, visit pumpsandsystems.com.
For more about SWPA, email swpaexdir@sbcglobal.net.

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Se p t e mb er 2015 | Pum ps & S y st e m s

TRADE SHOW PREVIEW

Water Environment Federation


Technical Exhibition and Conference

Visit us at
booth
4256

Sept. 28 30
McCormick Place
Chicago, Ill.

he Water Environment Federations Annual Technical Exhibition


and Conference (WEFTEC) is the largest annual water quality
exhibition and conference in North America. It ofers water quality
education and training for water quality professionals from around the
world. he show loor provides access to technologies in the ield, serves
as a forum for domestic and international business opportunities, and
promotes networking between its more than 22,000 attendees. he Water
Environment Federation (WEF), a not-for-proit technical and educational
organization, organizes the annual event.
Each year, WEFTEC ofers hundreds of educational and networking
events, from technical sessions and workshops to committee meetings
and celebratory receptions. Attendees can learn from peers about the
latest practices, technologies and services in the industry. WEFTEC ofers
a comprehensive list of training opportunities and facility tours that
attendees can choose from. hey can also earn continuing education credit
and network with water and wastewater professionals.
he exhibition features more than 1,000 exhibitors, displaying the
latest in water quality research technology and service. his years exhibit
loor includes an innovation pavilion dedicated to modern treatment
products and services, technical sessions, and mobile sessions that allow
attendees to compare similar technologies. Featured exhibitors include
Exhibition Hours
inalists and winners of the Imagine H2O Water Innovation Prize and
Monday, Sept. 28
the 2013 BlueTech Forum Showcase.
Tuesday, Sept. 29
he technical program provides water and wastewater
Wednesday, Sept. 30
professionals an opportunity to learn, network, discover new
products and services, and earn continuing education credits and
professional development hours. his years conference ofers tracks
including collection and distribution systems, municipal wastewater
treatment process and design, facility operations, leading edge research,
nutrient management, and utility management and leadership. he
2015 WEFTEC program also features the Stormwater Congress. his
specialized educational opportunity gives attendees access to more than
30 stormwater technical session and workshops. WEFTEC attendees have
the opportunity to earn up to 1.2 continuing education units (CEUs), 16.5
professional development hours (PDHs), and eight contact hours per day.

8:30 a.m. 5 p.m.


8:30 a.m. 5 p.m.
8:30 a.m. 5 p.m.

Photos courtesy of the Water Environment Federation

Top 5 Reasons to Attend WEFTEC


1

Learn from other industry professionals


about new practices and technologies

Network with more than 18,000 of the worlds


water and wastewater professionals

Earn Continuing Education Credits

View the cutting-edge technologies

Choose from technical sessions, workshops


and facility tours
pu mpsa ndsyst ems.c om | Sept emb er 2015

89

90
SPECIAL SECTION

WATER MANAGEMENT

Massive Vertical Pumps


Protect Community on
Flood-Prone Ohio River
Vertical mixed-ow, line-shaft pumps power a $20 million
ood control station.
BY THOMAS MORRISON
GRUNDFOS

ump reliability can sometimes be life or death.


That is true for Louisville, Kentucky, a city of
1.2 million people that is located at the widest
and deepest point of the flood-prone Ohio River.
The city is haunted by memories of a 1937 flood that put
70 percent of the community under water, causing $250
million in damage ($3.3 billion in todays dollars) and
leaving nine dead in the state of Kentucky. Since then, the
state has seen several other major floods.

Image 1. Jeff Lukemeyer at one of the control stations


for the pumps. (Courtesy of Grundfos)

Se p t e mb er 2015 | Pum ps & S y st e m s

To prevent future disasters, the U.S. Army Corps


of Engineers (Corps) decided in the early 1950s to
build a series of flood control stations in the region.
One of these, the Western Flood Pumping Station,
was completed in 1952 and equipped with seven massive
vertical pumps. The station protects about 138,000
residents against flooding.
By the first decade of the 21st century, the station had
seen more than 60 years of service, and Louisville city
officials were concerned about continued performance.
The pumpswhich only activate during routine
maintenance or a flood eventwere old, powered by
electrically outdated synchronous motors and lacked
monitoring capabilities. The city wanted the ability
to remotely monitor the pumps to maintain proper
condition, but the old pump technology would not work
with modern electronic controls.
A station upgrade was planned that would include
seven new vertical mixed-flow, line-shaft pumps: four
with 72-inch nominal diameter bottom casings and 1,250
horsepower (HP) motors and three with 48-inch casings
and 450-HP motors. This new flood control system would
yield a combined pumping capacity of one million gallons
per minute. The pumps would have the latest induction
motor technology, vibration monitoring, controls to
monitor bearing temperatures and an automatic grease
lubrication system (the old pumps used oil). The team
selected the same pump brand that had safeguarded the
city since 1952.
We have worked on many pumping station projects
over the years, but this was the biggest, says Hall

91

Contracting Vice President of Construction Tony Shade, the general


contractor on the project. In addition to the specs set by the Corps, which
owns the station, the pumps needed to meet the requirements of the local
Metropolitan Sewer District (MSD), which operates the Western Flood
Pumping Station.
Hall Contracting, along with the manufacturer and its local distributor,
Corporate Equipment Company of Cincinnati, worked for several years
with the MSD and the Corps to define the $20 million project before it
ever went to bid. In the end, the project took four years to complete: two
years for design, one for manufacturing and one for installation.
Among the teams most critical challenges was renovating the station
without a minute of downtime. That meant replacing the enormous
pumps one at a time, as well as bringing in two electrical feeds for
operational redundancy.
With the new pumps and controls, the Louisville Jefferson MSD can
now be confident in the Western Flood Pumping Stations reliability. The
people of Louisville can feel safe knowing their flood control station is
ready for the next 60 years.

Thomas Morrison is vice president for sales and business


development for the water utility market in North America for
Grundfos. He may be reached at tmorrison@grundfos.com.

Image 2. Inside the flood control station for


the Louisville, Kentucky, Metropolitan Sewer
District (MSD) showing the pumps installed.

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pu mpsa ndsyst ems.c om | Sept emb er 2015

92

SPECIAL SECTION

WATER MANAGEMENT

Eddy Current Drives Provide


Long-Term Water Reliability
Louisiana s Sabine River Authority incorporated this VFD alternative to
divert 141 million gallons of water per day.
BY GARY PATTERSON
DSI/DYNAMATIC

he Sabine River Authority of Louisiana created


the Diversion Canal System in 1970. The goal was
to decrease dependence on the sole area aquifer
and supply fresh, untreated surface water from
the Sabine River to industries in the Lake Charles and
West Lake area, which includes petrochemical plants and
an oil refinery. Because of their proximity to the Gulf of
Mexico, the surrounding surface water is brackish and
unsuitable for the process requirements of these plants.
The system consists of three pumping stations, five
level control gates, nearly five miles of underground
pipeline and more than 35 miles of channel canals. Pump
Station 1 draws water from the Sabine River into the
canal system. Pump Stations 3 and 4 pump the water
into the pipeline for delivery. It is used as utility water,
process water or steam generation by Air Liquide, Air
Products, Citgo Phillips 66, Eagle US 2, Entergy, Equistar,
LC Co-Gen, LA Pigment, Lyondell, Matheson Tri-Gas,
Westlake and Sasol. According to a 2014 report by the
Southwest Louisiana Entrepreneurial and Economic
Development (SEED) Center, the system is under contract
to deliver 141 million gallons per day (mgd) to these
thirteen major users, with a total capacity of 216 mgd.
Stations 3 and 4 were designed with two variable speed,
single stage, vertical turbine pumps using eddy current
drives, 250-horsepower motors, and analog controls. The
pumps discharge into a 36-inch pipeline and maintain the
pipeline pressure at about 12.5 pounds per square inch.
After 40 years of continuous operation, the Sabine
River Authority looked into upgrading the system. The
rotating mechanical equipment was still functioning well,
but the controls needed modernizing. An engineering
Se p t e mb er 2015 | Pum ps & S y st e m s

firm was brought on that was strongly in favor of


replacing the entire system with variable frequency drives
(VFDs), but Matt Istre, the electrician at the Diversion
Canal, fought in favor of keeping eddy current drives.
Our past experience with eddy current has taught us
theyre more robust and handle power cycling better,
Istre said. From an everyday maintenance standpoint,
I didnt want VFDsthey have to be in a climatecontrolled environment, and all of our pumps are housed
in a small metal building with no air conditioning. Eddy
current drives dont need that. We purchased new eddy
current drives and digital controls to ensure continued
reliability for the next 40 years.

Why Variable Speed?


Eddy current drives and VFDs provide controlled,
adjustable speed to alternating current (AC) motor-driven
pumps. By adjusting the speed of the pumps to match
the necessary capacity, the shaft load of the pump can
be reduced, resulting in significant energy savings in
the form of reduced electrical power input. With large
industrial pumps, the savings can be well over $100,000
per year for each unit in operation. Variable speed
operation also reduces wear on the pumps and reduces
possible hydraulic fluctuations in the pipeline system.
What is An Eddy Current Drive?
VFDs operate by electronically altering the input power
(frequency and voltage) to control the speed of the motor.
Eddy current drivesalso known generically as magnetic
drives, eddy current clutches or magnetic clutchesare
driven at a constant speed by an AC motor and use a

93

simple electro-magnetic device to control torque and


speed to the driven load. The power to the motorand
to the pumpis not manipulated electronically. Instead,
it comes directly from the electrical bus. This prevents
harmonic distortion and other power quality problems.
The electrical system sees only a constant speed motor
operating at a varying level of loading.
In a typical vertical configuration, an ordinary
induction motor is mounted on top of the eddy current
drive. The drive is built within a stationary frame of
fabricated or cast steel with a lower fl ange and shaft
similar to that of a vertical motor. Two concentric
rotating membersthe drum (sometimes called the ring)
and the magnetic rotor (sometimes called the magnetic
field)are also in the frame. The drum is a cylinder of
magnetically permeable steel coupled directly to the
motor shaft. It rotates at constant speed determined by
the speed of the motor. The motor shaft provides an axial
and radial support bearing for the rotating drum.
The variable speed magnetic rotor is mounted
concentrically within the drum. They are separated by
bearings, which maintain an air gap between the inner
diameter of the drum and the outer diameter of the
magnet to a specified tolerance. The outer surface of
the magnet consists of a series of magnetic poles with
alternating north and south polarity that are magnetized
at varying strength by a low-power direct current (DC), a
phenomenon known as excitation.
The excitation current flows to a coil that induces
magnetic flux to the pole pieces, or in some designs,
a series of individual windings on the individual pole
pieces. Some models use carbon brushes and slip rings to
deliver the current to the pole windings. As the rotating
drum passes through the magnetic flux field in the air
gap, a pattern of eddy currents is established in the
drums steel. In turn, these currents establish a magnetic
field of their own, causing an exchange of torque from the
drum to the magnetic rotor. It might be useful to envision
that the magnetic rotor chases the drum.
The available torque is proportional to the excitation
current flowing in the magnets coils. Speed is controlled
by increasing or decreasing this excitation current. A
tachometer-generator or other speed-sensing device is
provided for feedback to the controller and for external
reporting to a visible meter or central control system.
The excitation current is derived from an exciter/
controller, normally supplied as a package with the eddy
current drive. It derives power from a low-voltage, singlephase source and uses a silicon-controlled rectifier (SCR)
bridge to develop the DC used by the magnet coils.

Figure 1. In a typical configuration, an induction motor is mounted


on top of the eddy current drive (Courtesy of DSI/Dynamatic)

In general, this excitation requires less than 1 percent


of the power supplied to the driven pump load. The actual
power that reaches the pump comes from the AC motor,
not from this excitation.
The eddy current drive maintains a smooth consistent
torque so long as the excitation current and at least some
relative movement between the drum and the magnet
occur. The differential between motor speed and output
speed is called slip. In pumping applications, the drive
unit should provide sufficient torque at 96 to 99 percent
of motor speed, or 1 to 4 percent slip. This slip results
in an equivalent percentage of loss, manifesting itself
as heat in the drum dissipated into the cooling air. In
centrifugal pump and fan applications, this slip loss,
applied against a declining load as speed is reduced,
results in a net loss comparable to VFD performance.

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.

pu mpsa ndsyst ems.c om | Sept emb er 2015

94

EFFICIENCY MATTERS

5 Key Metrics that Affect Operational Efficiency


With the right implementation, continuous machine monitoring can improve production
and increase equipment effectiveness.
By Anurag Garg
DATTUS

ew deny that demands from


the manufacturing and
energy sectors will continue
to drive industry growth. In this
era of demanding conditions,
operational efficiency has never
been more vital. International
pressures require machine shops
to compete at a higher level, doing
more with less, and manufacturing
facilities have been forced into 24/7
operation. As a result, equipment
reliability has become a core
industry concern.
With increased competition
saturating topline revenue
growth, businesses are focusing on
improving operational efficiencies
and managing cost centers to
impact their bottom lines. To
achieve the coveted near-zero
downtime, companies begin by
evaluating their maintenance
programs. Preventive maintenance
had its place 20 years ago, but new
technological advances allow for
more refined and reliable methods
of tracking machinery health and
avoiding potential failures.
Predictive maintenanceas
the name suggestsleverages
data collection to enable users to
predict when equipment failure
might occur so they can implement
maintenance before equipment
breaks down. Several reliabilitycentered maintenance (RCM)
programs attempt to do this with
monthly or quarterly samplings

Se p t e mb er 2015 | Pum ps & S y st e m s

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

on asset efficiency, which helps


companies get ahead of failures and
increase uptime.
Asset efficiency is critical, but,
in order to fully thrive, companies
must improve their overall
operational efficiency. Five
key metrics define operational
efficiency, and continuous machine
monitoring could be the answer to
improving these metrics.

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.

Figure 1. Predictive vs. reactive maintenance (Graphics courtesy of DATTUS)

95

Continuous tracking and quality


testing are key to optimizing yields,
but monitoring machinery also may
help achieve this purpose.
Continuous machine monitoring
empowers engineers with a
real-time stream of information
regarding the status and health of
equipment. It unlocks (through data
analytics) real-time insights into
the slightest changes in operating
conditionschanges that directly
affect the quality of the products.
This varies from traditional
maintenance programs, which are
limited by intermittent information
and a lack of real-time insights.
Because parts rarely fail without
warning, the goal of continuous
monitoring is to identify weak or
poorly implemented controls so that
they can be corrected or replaced
before yield is affected. Consistency
in operation and smoothly running
machines directly contribute to a
higher percentage yield.

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

approach via continuous


monitoring, it will reduce the
amount and cost of downtime.
To achieve more uptime and
better capacity utilization, plants
should plan maintenance around
load rather than planning load
around maintenance.
Many plants face forced
shutdowns, failures and idle assets
as a result of equipment repair.
One facility, for example, follows a
two-production-shift followed by
one-maintenance-shift cycle every
day. These approaches lead to lost
productivity and underutilized
assets. Condition monitoring and
improved maintenance programs
can reverse these problems.

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

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Figure 2. Pump cost of ownership

pu mpsa ndsyst ems.c om | Sept emb er 2015

96

EFFICIENCY MATTERS

Figure 3. How continuous monitoring affects


operational efficiency

actionable insights that empower


operators to make better decisions. If
machinery does not meet its intended
level of performance, machine
operators must be alerted immediately,
not with uninterpretable numbers,
but with actionable information (i.e.
imbalanced loads, power mismatch,
over/under lubrication, etc.). This
information is especially imperative
given that 5 to 15 percent of machine
failures are a direct result of improper
maintenance and incorrect usage.
Timely identification of problems
combined with actionable data
provides an ideal solution for
improving operational efficiency.
planned maintenance rather than
incorporating it in an emergency.
Percentage Planned vs.
Planned downtime is one-sixth the
Emergency Maintenance
cost of unplanned downtime.
All facilities need maintenance.
Consider a continuous manufacturing
They can save money by scheduling
operation (assume opportunity cost

of unplanned downtime is $30,000 an


hour) that has 100 hours of planned
downtime annually and 200 hours of
unplanned downtime. Flipping that
ratio through the use of continuous
machine monitoring and predictive/

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Se p t e mb er 2015 | Pum ps & S y st e m s

UPSTREAMPUMPING.COM

97

prescriptive maintenance (200 hours of planned


downtime, 100 hours of unplanned downtime) would
result in $2.5 million in savings.

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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Conclusion
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.

Anurag Garg is the CEO of DATTUS.


He is a published researcher in
the field of reliability and micro/
nano devices. Garg may be reached
at agarg@dattus.com. For more
information, visit dattus.com.
Circle 175 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | Sept emb er 2015

98

MAINTENANCE MINDERS

Remote Monitoring Minimizes Outage &


Lost Production Costs
By Cynthia Stone

emote monitoring software


as part of a complete
preventive maintenance
plan can provide the insight and
data required to troubleshoot
pump system problems and prevent
total equipment failure. For many
facilities, these tools have been
instrumental in minimizing
downtime and costly repairs while
providing information necessary
for preventing future issues.

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

Se p t e mb er 2015 | Pum ps & S y st e m s

of 270 degrees F (132 C) before


quickly dropping to values around
170 F (77 C). The temperature
for this bearing was expected to
remain around 190 F (88 C). The
software provider sent a highpriority notification to the facility
and started closely monitoring
this issue.
The provider send follow-up
reports to the user on July 15
and 16. On July 16, the outboard
bearing temperature fell to around
115 F (46 C). At the same time, the
inboard bearing metal temperature
increased to 184 F (84 C) from an
expected value of 170 F (78 C).
Upon the initial notification,
the end user quickly confi rmed
that the mechanical system on
this feedwater pump was failing.
When the pump was fi nally
taken offl ine, the user confi rmed
that the pump was smoking.
Inspection of the pump revealed
that the bearing Babbitt had been
wiped. When the replacement
pump was brought online, it

experienced high-thrust bearing


temperatures so the plant shut
down and trimmed the balance
drum position. Th is caused the
thrust bearing temperature to
return to normal but caused
the motor outboard bearing
vibration to increase and an
abnormal sound to emanate
from the bearing.
The user and software provider
collaborated on a review of the
high-speed bearing data and
diagnosed a coupling alignment
issue that resulted from the
trimming of the balance drum on
the replacement pump that had
just been installed. The new pump
was taken offl ine and an axial
misalignment of approximately
0.05 inches (1.27 mm) resulting
from the trimming of the
balance drum was discovered and
corrected. Once the new spare
pump was returned to service,
the plant was able to verify motor
outboard bearing vibrations and
noise abated.

99

The user and software provider collaborated on a review of the


high-speed bearing data and diagnosed a coupling alignment
issue that resulted from the trimming of the balance drum on the
replacement pump that had just been installed.

In this particular case, running


this feedwater pump to failure
was more economical than taking
an outage and repairing the
pump. The early identification of
the issue allowed the user to have
a spare pump staged and ready to
install. This allowed the facility
to minimize the outage and lost
production costs. In addition,
collaboration between the user
and the software provider helped
identify a coupling alignment issue
on a newly installed spare pump
and prevented damage to the pump
and the lost production that would
have resulted if the plant had lost
the spare feedwater pump.

Lube Oil Pump


Operational Issue
Earlier in the year, the same
monitoring solution detected that
a boiler water feed pump for a heat
recovery steam generator started

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up with significantly higher lube oil


pressure than expected. Lube oil
pressure was expected to operate
around 22 pounds per square inch
guage (psig). When this pump
started up, the lube oil pressure
was at 35 psig.
The plant had rebuilt the boiler
water feed pumps shaft-driven
lube oil pump during a recent
outage. Prior to this work, the
plant had to operate with both
the shaft-driven lube oil pump
and the auxiliary lube oil pump
in tandem in order to maintain
proper lube oil pressure. With the
rebuilt shaft-driven lube oil pump,
this temporary measure was no
longer necessary, and normal
operation of the lube oil pumps
could be resumed.
The software notified the
user that the continued tandem
operation of both the shaft-driven
and auxiliary lube oil pumps was

over-pressurizing the lube oil


system. Th is could have caused
damage to the boiler-feed pump
seals, bearings and the pump
itself, and it could have resulted
in a trip of the boiler water feed
pump. After discussion on the
weekly call, the plant immediately
shut down the auxiliary lube oil
pump, and the lube oil pressures
returned to expected values.

Cynthia Stone is a product


marketing manager for Industrial
Data Intelligence at GE. She has
nearly a decade of experience
working in predictive analytics
for power, oil and gas,
mining and aviation.
Stone may be
reached at cynthia.
stone@ge.com.

pu mpsa ndsyst ems.c om | Sept emb er 2015

100

MOTORS & DRIVES

Review of the DOE Final Rule for Integral


Horsepower Motors
The Final Rule will take effect June 1, 2016.
By John Malinowski
Baldor Electric Company

t the end of May 2014, the


U.S. Department of Energy
(DOE) released the Final
Rule that amends the regulation
for integral horsepower motors.
Until the rule takes effect June 1,
2016, motor manufacturers will
continue to operate under rules
from the Energy Independence
and Security Act (EISA), which
took effect in December 2010.
Th is means that almost all
low-voltage, three-phase motors
sold for use in the U.S. will need
to be premium efficiency per
National Electrical Manufacturers
Association (NEMA) MG
1-2014, tables 12-12 and 20B.
Additionally, 56-frame enclosed
motors, including those with 56J
pump mounting, are covered.
Motors with close-coupled pump
mounting in JM, JP and WestCoast configurations will now
move from energy efficiency (table
12-11) to premium efficient levels.
All types of vertical hollow-shaft
and solid shaft P-base motors also

will be required to be premium


efficiency. Only submersible
motors will be exempt.

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

have less slip, their higher speed


may require some changes to the
impellers to adjust pump flow and
prevent motor overload.
Motors with higher efficiency
usually require additional
active material, including steel
laminations and copper windings.
Enclosed 56-frame motors were
not regulated for efficiency prior
to this rule, so they will be going
from exempt efficiency levels to
the premium level.
Most 56-frame motors use a
rolled-steel band for the frame, so
they are likely to get longer and,
in some designs, larger in
diameter. Many integral
horsepower open motors may
also use rolled-steel frames,
which increase in length as active
material is added. Cast-iron
enclosed or open frames usually
are made with one length per
frame size, so the additional active
material is added inside that frame
until it reaches a limit. Additional
material means more cost.

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.

Se p t e mb er 2015 | Pum ps & S y st e m s

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.

Produce Higher Volume


Over Longer Distances
High Performance - Longer Lasting Parts

The Yellow Series: General Purpose

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

More motors and drives at


pumpsandsystems.com/
tags/motors-drives.

John Malinowski is the senior


manager for industry affairs at
Baldor Electric Company in Fort
Smith, Arkansas. Malinowski is
a senior member of IEEE and is
a member of the IEEE Industry
Application Society. He also serves
as a member of the Pumps &
Systems Editorial
Advisory Board.
Malinowski may
be reached at john.
malinowski@baldor.
abb.com.

HV 4 Slurry Valve
> 540 GPM
> Passes 3 Solids

Our unique combination of in-house R&D


and manufacturing enables us to offer
pumps that are technically superior and
significantly higher quality than those
offered by competitors.

Learn more at:


info@pumps2000america.com

1721 Main St., Pittsburgh, PA 15215


Tel: 412.963.9200 1.800.245.6211
Fax: 412.963.9214

www.pumps2000america.com

pu mpsa ndsyst ems.c om | Sept emb er 2015

Circle 158 on card or visit psfreeinfo.com.

Small Motor Rule


The DOE issued a Small Motor
Rule in 2010, which took effect
March 9 of this year. Th is rule
covers 42-, 48- and 56-frame,
single- and three-phase 60 Hertz
(Hz) general-purpose motors in
open drip-proof (ODP) enclosures
rated at through 3 horsepower
(HP). Th is means motors with 56J
and pool pump mountings are
not included, but standard base
mounted and C-face designs are.
Enclosed designs and customized
ODP motors are not covered under
the Small Motor Rule.
At press time, a working group
that will review future changes
to the Small Motor Rule is being
organized. The next rule will likely
be more encompassing and may
be designed to reduce confusion
with the rules on integral
horsepower motors.

Worlds First
High Volume 3 & 4
Diaphragm Pumps

102

SEALING SENSE

Know Which Mechanical Sealing Options


Meet Emissions Requirements
By Ian Lincoln
FSA Member

n todays world, facilities face


the daunting challenge of
minimizing the environmental
impact of industrial processes.
A primary motivation for
industrial plants to control
their environmental impact is
government regulation. In the U.S.,
these regulations are issued at the
national level by the Environmental
Protection Agency (EPA) and similar
agencies at the state and local levels.
Before the U.S. government
passed the first Clean Air Act in
1963, no federal regulations on
gaseous emissions existed. The
Clean Air Act initiated research
to investigate techniques to
monitor and control air pollution.
During the 1970s and 1980s, the
government passed legislation that
established a limit on emissions of
10,000 parts per million (ppm) for
gases defined as volatile hazardous
air pollutants (VHAPs). Similarly
in Europe, a series of accidents
resulting in toxic chemical
release lead to adoption of the
European Commission directive
82/501/EEC targeting safety
measures to prevent the release of
hazardous chemicals.
This threshold came down to
1,000 ppm in the 1990s. In some
cases, these emissions restrictions
were driven even lower by local
authorities. The sealing industry
has always worked to provide
innovative solutions to meet
the goals of the regulations
and industry.

Se p t e mb er 2015 | Pum ps & S y st e m s

Low Emissions Sealing


Low-emissions mechanical seals
were first introduced to industrial
rotating equipment in the 1980s as
single seals with seal face designs
and balance ratios optimized to
reduce leakage. Th is design became
an effective low-emissions solution
that could limit emissions to a few
hundred ppm. Single seal reliability
typically depends on the process
fluid. With a life span of several
years, these seals can exhibit
leakage variability.

Because all seals depend on the


migration of fluid between the
seal faces for lubrication, true zero
emissions control is generally not
possible with a single seal. Single
seals also pose the risk of high
emissions resulting from seal failure
because they lack a secondary line
of defense to contain leakage. As
local emissions regulations became
stricter throughout the country (as
low as 50 ppm), the seal industry
searched for a sealing solution to
further limit emission levels. This

Figure 1. Dual unpressurized liquid buffer seal (Courtesy of Flowserve)

Figure 2. Dual pressurized liquid barrier seal (Courtesy of Flowserve)

103

led to the development and widespread


use of unpressurised and pressurized
dual mechanical seals, later defined by
API 682 as Arrangement 1 (single seal),
Arrangement 2 (unpressurized dual seal)
and Arrangement 3 (pressurized dual seal).
An Arrangement 2 dual unpressurized
seal (see Figure 1) uses a secondary set of
seal faces to prevent process fluid from
escaping. Arrangement 2 seals are two
single seals arranged in series and installed
into one seal chamber. The cavity between
the two sets of sealing faces is vented to
a flare or vapor recovery system, which
prevents the cavity from building pressure.
Table 1 lists support systems standardized
by API 682 and used to maintain the cavity
environment for Arrangement 2 seals.
An Arrangement 2 seal can run on a
liquid or gas buffer designs, also called
containment seals, that have either
dry contacting or non-contacting seal
faces. These dual unpressurized seals are
designed to contain and direct process
leakage to a waste area for recovery or
safe disposal. Dual unpressurized seals
provide a margin of safety because the
outer seal acts as a true backup seal,
while the inner seal sees the rigorous
operating conditions and high pressure
drop across the seal faces. Testing has
proven that dual unpressurized seals can
achieve emissions control below 50 ppm.
Although emissions into the buffer cavity
are low, plant operators must manage
vent and buffer systems properly to
ensure emissions are properly recovered.

heat generated by seal face contact.


Table 2 lists applicable support system
piping plans for dual pressurized seals
(see page 104).
Dual pressurized gas seals accomplish
the same zero emissions objective but
use a gas barrier in the seal cavity. This
technology, adapted from centrifugal
gas compressor seals, uses topographical

Dual pressurized liquid seals use a seal


support system with continuous pressure
control to maintain cavity pressure higher
than process pressure. End users must
give attention to barrier fluid selection,
ensuring the medium is compatible with
the process fluid, does not pose hazards
and provides good lubricity. The system
must also be able to remove unwanted

Table 1. Piping plans for dual unpressurized seals (Tables courtesy of FSA)

Piping Plan
52

Unpressurized buffer fluid circulation through a reservoir.


Fluid is circulated by a pumping ring in the dual seal
assembly.

55

Unpressurized buffer fluid circulation by a system


external to the seal.

72

Unpressurized buffer gas control system. Containment


seal support typically with nitrogen buffer gas.

75

Drain from containment seal cavity to liquid collector and


vapor recovery.

76

Vent from containment seal cavity to vapor recovery.

Liquid Buffer

Gas Buffer

Description

Zero Emissions Sealing


Arrangement 3dual pressurized
sealsclose the emissions gap left by
dual unpressurized seals. Similar to an
Arrangement 2 seal, dual pressurized
seals are comprised of an inner and outer
seal, but the cavity between the two is
always kept at a higher pressure than
the process fluid. An intermediate fluid
or barrier fluid in the dual seal cavity
prevents process emissions from reaching
the atmosphere while establishing a
stable environment.
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pu mpsa ndsyst ems.c om | Sept emb er 2015

104

SEALING SENSE
Table 2. API piping plans for dual pressurized seals

Piping Plan Description

features in the seal face to generate


hydrodynamic lubrication of the seal faces
with pressurized gas which keeps the seal
faces from contacting. Non-contacting
containment seal faces also employ
features for hydrodynamic support.
This revolutionary achievement led
to the implementation of gas seals in
a variety of applications. Compared
with dual wet seals, dual gas seals
generate little heat or wear because of
face separation, use simpler support
systems, and, in many cases, use an
inert gas such as nitrogen as the barrier
medium. In addition, the support
system does not require fluid circulation.
Dual gas seals also effectively use less
energy consumption than their liquid
counterparts because of the absence of
friction between the seal faces. Users
must implement proper instrumentation
to ensure the barrier gas is clean and

Liquid Barrier

Gas Barrier

53A

Barrier liquid pressurized by outside source, circulated in


the barrier cavity via a pumping device within the dual
seal assembly.

53B

Pressurized barrier circulation using bladder accumulator


and circulated in the seal cavity via a pumping device
within the dual seal assembly.

53C

Pressurized barrier circulation with piston accumulator.


Fluid is circulated by a pumping device within the dual
seal assembly.

54

Pressurized barrier fluid circulation by external system.

74

Pressurized barrier support for gas seal, usually using


nitrogen.

properly pressurized higher than the


process at all times.
Long-term reliability of any dual
mechanical seal and the achievement
of zero process emissions are strongly
dependent on the lasting reliability of
the support system. Dual gas seals also
effectively use less energy consumption
than their liquid counterparts because
of the absence of friction between the
seal faces.

Table 3. Lowest emissions capability by seal type

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.

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Se p t e mb er 2015 | Pum ps & S y st e m s

105

Impact of Amended
Motor Ef ciency Rules
on the Pump Industry
SEPTEMBER 24, 2015
1 P.M. EASTERN

This timely webinar will take a look at the Small


Motor Rule and the upcoming Integral Horse
Power Rule ef ciency requirements for motor
manufacturers as these requirements evolve and
change. The event will discuss how these rules
impact end users in the pump industry.

About the Presenters


John Malinowski is the Senior Manager for Industry Affairs at
Baldor Electric Company, A Member of the ABB Group, in Fort
Smith, Arkansas. He is chairman of NEMA 1MG Motor & Generator
Section and familiar with collaborating with CEMEP and ABB
IEC colleagues on global motor standards. He acts as company
advocate with government agencies, professional associations,
and industry standards committees.

pumpsandsystems.com/2015/baldor
FOR MORE INFORMATION AND TO REGISTER

FRE E

pu mpsa ndsyst ems.c om | Sept emb er 2015

106

HI PUMP FAQS

Site Condition, Treatment Stage & VFD


Considerations for Wastewater Pumps
By Hydraulic Institute

When dealing with


wastewater treatment
pumps, what concerns
pertaining to site
conditions are relevant?
The type of pump that can
be used depends on the location
of installation. These location
considerations include the size
of the installation space, discharge
piping alignments, wet-well depth,
interior/exterior installation
and power.
The area where the pump is
installed must allow space for
proper mounting of the pump and
driver assembly, for the inlet and
discharge piping and valves, and
for the necessary power wiring
and switches. Operators and
maintenance personnel must have
enough space to access the pump
and complete any required work
or removal of the pump. Because
their installation space is
significantly different than that
of other pumps, horizontal and
vertical pump assemblies require
special evaluation.
New designs allow designers
to create the space required to
meet the new pump requirements.
Retrofit designs may not afford this
ability. The existing structure, wet
well, hydraulics, control sequencing
or installation requirements may
become the primary considerations
when end users are choosing a
pump. The fluid being pumped
can create specific requirements

Se p t e mb er 2015 | Pum ps & S y st e m s

for the driver and/or the power


distribution components that
serve the pump assembly. These
requirements can change the sizing
of the components, so users should
also evaluate these factors when
installing the pump assembly.
For more information on
wastewater treatment pumps, see
HIs newest guidebook Wastewater
Treatment Plant Pumps: Guideline for
Selection, Application, and Operation.

What types of pumps are


recommended for the
primary treatment stage
in a wastewater facility?
The primary treatment step
physically separates insoluble
solids from floatable materials
contained in the wastewater. For
example, primary sludge consists
of the solids generated from the
primary sedimentation process.
The primary sludge may be
transferred to a solids-processing
system, such as a gravity sludge
thickener, where the solids are
concentrated and pumped to
the solids-handling facilities.
The primary sludge stage can
incorporate many types of pumps,
including horizontal and vertical
solids-handling rotodynamic,
submersible solids-handling
rotodynamic, piston, progressive
cavity (PC) and rotary lobe.
When incorporating a solidshandling rotodynamic pump

(see Figure 4.3), end users must


consider the change in consistency
because the most concentrated
sludge is pumped in the beginning
of a pumping cycle. When most
of the sludge has been pumped,
diluted sludge with consistency
and hydraulic characteristics
similar to water will be pumped.
To determine the required motor
power for a rotodynamic pump,
users should plot system curves
and pump curves for both the most
dense sludge and water.
A PC pump (see Figure 4.18) can
be used in the primary treatment
stage and will deliver constant flow

Figure 4.3. Vertical solids-handling


pump (Images courtesy of Hydraulic
Institute)

107

To minimize the risk of clogging the pump impeller, users should


consider alternating pumps to create back-flush and to bring them
to full speed before stopping or at the start of a pumping cycle.

regardless of pressure. The flow


is controlled by the pump speed.
For low-solids contents, full speed
is typically allowed. If sand and
grit are in the sludge, the speed
should be adjusted down to reduce
wear. Because of their design with
a metallic rotor in direct contact
with a stationary elastomeric
stator, PC pumps must not run
dry. If using a PC pump, install a
pressure guard that shuts the pump
off when it experiences a pressure
drop indicating dry run.
For more information on
wastewater treatment pumps, see
HIs newest guidebook Wastewater
Treatment Plant Pumps: Guideline for
Selection, Application, and Operation.

Figure 4.18. Progressive cavity solids-handling pump

What benefits result from


implementing variable
frequency drives (VFDs) in
a wastewater treatment
plant?
VFD units are used to vary
motor speed, which allows the
pump to provide different rates of
flow to meet system requirements.
They also provide an option to
reduce inrush current. They
have time-adjustable ramp-up
and ramp-down features to
control motor acceleration and
deceleration times. The controller
may be programmed to electrically
disconnect the motor on signal
shut-down. VFDs can provide
numerous functions in wastewater
pump applications, which include:
Regulate the operation of
pumps or the station in relation
to wet-well depth, discharge
flow or force main pressure,
which can potentially eliminate
the need for control valves
Provide energy-efficient
operation of pumps by
matching best efficiency
operating points and/or
matching pump operation to
varying demand loads
Ability to over-speed pumps to
meet certain specific short-term
application conditions
Provide power phase conversion
(producing three-phase
power from a single-phase
power supply)

Create power at a different


frequency (e.g., producing
60-Hertz [Hz] power when only
50 Hz is available)
Adjust the pump operational
speed (or torque) instead of
using a control valve to restrict
pump output, which reduces
downstream flow or pressure
Reduce mechanical stress of
conditions such as cavitation
and water hammer on both the
pump and pump system

To minimize the risk of clogging


the pump impeller, users should
consider alternating pumps to
create back-flush and to bring
them to full speed before stopping
or at the start of a pumping cycle.
Operating pumps at low speeds or
with slow increases and decreases
in speed can cause pump clogging.
For more information on
wastewater treatment pumps, see
HIs newest guidebook Wastewater
Treatment Plant Pumps: Guideline for
Selection, Application, and Operation.

HI Pump FAQs is produced by the


Hydraulic Institute as a service to pump
users, contractors, distributors, reps
and OEMs. For more information, visit
pumps.org.

pu mpsa ndsyst ems.c om | Sept emb er 2015

108

PRACTICE & OPERATIONS

Chopper Pumps Require Specialized


Sealing Solutions
Because of the substantial concentrations of solids that these pumps handle, end users
must understand the available sealing options.
By Ralph Merullo
A.W. Chesterton Company

hopper pumps are designed


with an element that
chops solids entering the
pump suction, allowing them to
pass through the volute.
Th is mechanism prevents
clogging of the impellers, which
can cause dynamic imbalance, poor
hydraulic performance, and what is
commonly called dewatering or
ragging out.
These terms refer to the
condition of flow interruption
caused by the accumulation of
fibrous material or solids in the
volute or impeller.
While they meet the unique
requirements of todays
wastewater flow streams, chopper
pumps are often difficult to seal
because many are submerged in
fluids that contain substantial
concentrations of solids.

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.

Se p t e mb er 2015 | Pum ps & S y st e m s

The difficult location and limited Approach 3: A dual seal that


uses the bearing lubricant as
space in this equipment usually
a buffer fluid. Hydrodynamic
prevent the use of traditional
elements may be incorporated
aftermarket seal approaches. For
into the seal faces to
example, barrier fluids provided
discourage contamination of
by reservoir tanks or clean
the bearing lubricant.
flush liquids are not possible in
these applications. As a result,
Designers select seal face
equipment manufacturers have
materials based on their
developed alternate strategies to
seal in this difficult environment. inherent lubricity, abrasion
resistance, corrosion resistance,
machinability and cost. Seal
Alternative Solutions
designers may select a softer
Manufacturers typically use
material for the narrow face and a
three main approaches to seal
harder material for the wide face
this difficult flow and prevent
contamination of the equipments to allow the narrow face to lap in
as it runs. Lapping in is defi ned as
bearing lubricant.
wear of the softer material as it
Approach 1: A single-face seal rubs against the harder material
with hard faces mounted below to obtain a fl atness that is better
than when the equipment was
a reservoir of lubricating oil
but above a chopping element. originally manufactured.
As the mating surfaces rub, they
Approach 2: A single-face
become more fl at in clean fluids,
seal with hard faces mounted
which increases their ability to
behind an impeller with
seal and minimizes visible leakage.
an integral quench port.
In dirty fluids, however, solids can
Th is seal is contained by a
secondary seal used to remove become embedded in a soft seal
face material, which can grind a
accumulated solids inside the
groove in the wide seal face and
seal. Th is type is described
allow visible leakage.
by the American National
To avoid this phenomenon,
Standards Institute (ANSI)
seal designers will select hard
as Piping Plan 62. It may
faces. Common seal face materials
be described as a flushless
include tungsten carbide or silicon
mechanical seal.

109

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.

carbide, which are technically


ceramic in nature. Once lapped
by the manufacturer, they will
maintain their fl atness. Lapping
in of a hard-face material against a
mating hard seal face takes many
days of service. Lapping in of a
softer material, on the other hand,
takes only hours.

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.

Chopper pump dual mechanical


seals typically use the bearing
lubricant as a buffer fluid to
protect and lubricate the outboard
seal. The fluid acts to buffer and
prevent leakage in order to avoid
immediate seal failure.

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

buffer fluid. If the solids in the


flow stream will crystallize inside
the seal, then the flushless or
dual seal approach may be
successful. If the flow stream
includes solids that are easily
broken down and do not crystalize
or cause dry running, then a
conventional seal with hard faces
mounted below a reservoir of oil
should be successful.
The key is to understand the
properties of the fluid and how
it will behave after the chopper
blades break it down in the volute.
Th is knowledge will lead to a
fact-based selection of the ideal
sealing solution.
Read more articles about
chopper pumps online at
pumpsandsystems.com.

Ralph Merullo has been in the


rotating equipment industry for
more than 25 yearsdesigning,
manufacturing and specifying
mechanical sealing devices.
He is manager of applications
engineering and
sales support at
A.W. Chesterton
Company in
Groveland,
Massachusetts.

pu mpsa ndsyst ems.c om | Sept emb er 2015

110

PRACTICE & OPERATIONS

Finding the Right Pump


End users must consider several factors to ensure the correct
pump for their specific needs.
By Jerry Soto
Griffin Dewatering

ump suppliers often hear


their customers say, I need
a six-inch pump. This is a
typical request but lacks the vital
information necessary for choosing
the correct pump for a particular
application. While the same pump
can be used for dewatering, mining
or other related applications, end
users must evaluate several factors
to determine the best fit for their
pumping needs. These factors
include the pumped material,
the distance from the pump and
the elevation difference from the
source to the discharge point.

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

air passing through them, impellers


are constructed of vanes that add
velocity to the pumped fluid.

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.

Image 1. Hydraulic submersible pumps and power units


(Images courtesy of Griffin Dewatering)

If the suction lift is 25 feet or


more, a submersible pump should
be used. This type of pump is
partially or entirely placed in the
fluid and pushes the fluid up. It
is not bound by a suction lift. A
hose or piping is connected to the
pump and lowered into the fluid,
and additional hose or piping is
connected to the discharge point.
While a submersible setup is not
limited by pumping depth, it may
create access issues. The entire
unit needs to be placed into the
fluid because of the pump size. If
maintenance is required on the
pump, it must be removed and
replaced. Some submersible pumps
have a maximum submergence
depth below watersome as
shallow as 50 feet or less below
the fluid level. Special precautions
are necessary to protect the
pumps under these conditions.
Users should check with the
manufacturers recommendations.

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

to push the fluid into the impeller. This


can be achieved by a hand primer
typically a manually operated diaphragm
pumpin combination with a foot valve
strainer on the suction hose or other
priming mechanism. Once primed, the
centrifugal pump will continue to pump
as long as the suction lift does not exceed
the suction lift capacity of the pump
or have an air leak that the pump itself
cannot overcome.
A self-priming pump is a specially
constructed centrifugal pump that will
prime itself as long as its casing is fi lled
with water. This type generally consists
of a pump and a driver, which could be an
electric motor, a gasoline or diesel engine.
These are typically the easiest to use.
When the pump chamber is fi lled with
water and the pump driverwhich spins
the impelleris turned on, the impeller
and casing create the vacuum and
evacuation of air necessary for priming
and pump the fluid out. Self-priming
pumps are typically used in applications
where priming time is not critical,
because the priming time is dependent
on suction length and lift and can take
several minutes.
A prime-assisted pump is a centrifugal
pump that has an automatic priming
device and will prime itself under dry
conditions. Priming can occur whether
the pump has water in it or not. Primeassisted pumps prime substantially
faster than self-priming pumps. The
priming time is highly dependent on the
volume of air that needs to be evacuated,
which is based on the size and length of
the suction pipe/hose. Prime-assisted
pumps include a pump, driver and
priming device. The priming device may
be a vacuum pump (using rotary vane,
liquid ring or other type of vacuum), a
diaphragm pump (which is connected
to the pump or engine shaft) or a
compressor and venturi combination.
All are installed in conjunction with
an air/water separation chamber with
its float or priming valve. In general, a

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112

PRACTICE & OPERATIONS

vacuum-assisted pump will be the


quickest priming pump, followed
by the diaphragm prime and then
the compressor with venturi setup.
Once primedor submerged in
the case of submersible pumps
the fluid is drawn into the casing
and is pumped out by the impeller.

has a higher efficiency and higher


price tag than other types, but it
will cost less to operate for a given
pump volume or head.

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

Image 2. Eight-inch diesel driven dewatering pumps

typically use clean water impellers


and may have multiple impellers
that increase the pressure capacity
of the pump. Most of the time,
these pumps are diesel-driven, but
some submersible pumps can be
used under certain conditions.

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

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114

PRACTICE & OPERATIONS

Basic Piping & Instrumentation Techniques


Optimize Self-Priming Pumps
System design and instrumentation decisions can impact the efficiency and maintenance
requirements of these pumps in wastewater applications.
By Gerardo (Tito) A. Gomez & Rodney D. OQuinn
Titan Manufacturing, Inc.

he concept of moving water


from point A to point B has
existed for thousands of
years. It was not until after 1851
that engines began powering pumps,
a hydraulic phenomenon known as
suction lift in a self-priming pump.
Ideas began to emerge about
using water as power for other
industries and as a tool to control
the growing populations sanitation
and food supply. The design of these
pumps improved with time, and
a large split volute, an open vane
impeller, a check valve assembly
and a strong drive assembly became
requirements for the success of the
self-priming pump revolution.
New technology has inspired
improvement to this simple
mechanical conceptincluding
submersible pumps with electric
motors, vacuum-assisted centrifugal
pumps and venturi systems with
compressed air. The energy used
by the pump to create a vacuum
(up to 28 feet) restricts the selfpriming pumps ability to create
high discharge pressure, but the
volumes can be as high as piping
allows. Many companies have
designed different versions of the
self-priming pump, but in 1933, one
manufacturer developed a pump
with features that many users still
rely on today. The combination of
low maintenance, above-ground
Se p t e mb er 2015 | Pum ps & S y st e m s

access, solids-handling capabilities,


the ability to pull a suction lift up
to 28 feet, and the large volute that,
if full of water, allows the pump to
prime and re-prime with use made
this technology an ideal choice for
wastewater facilities worldwide.

an open pit near the pumps, and


the sump is about 5 feet below the
suction center line of the pump.
A foot valve was installed at the
bottom of the suction sump pipe.
The pump manufacturer
specifies the pumps net positive
suction head required (NPSHR)
given on the performance pump
System Design
curve. The suction head should
Selecting a pump for a particular
be taken into account in order to
application can be difficult. The
provide ample suction and prevent
selection strategy will depend on
suction cavitation. In the case of
the application and the cost of the
proposed solution: the cost of pump, pumping water, viscosity factor
does not present a problem, and
motor and starter (if required),
the temperature does not have
simplicity of the piping design and
significant variations that could
associated cost of maintaining the
affect the application case study.
system. Once a facility determines
When designing the piping
the selection strategy, the next
system, end users must follow
step is to improve reliability of
the basic rule of keeping suction
the pump application by focusing
velocity below 15 feet per second
on the piping design and basic
implementation of instrumentation. by properly sizing the pipe, having
an adequate water supply, and
This concept is illustrated by
minimizing turbulence and water
a facility that uses self-primed
centrifugal pumps for cooling water resistance caused by valves, foot
valves and/or pipe fittings such as
circulation. The water source is
DID YOU

KNOW

OTHER SELF-PRIMING PUMP APPLICATIONS

While self-priming trash pumps are widely used within


wastewater systems worldwide, they are also becoming popular in portable
rental units usually powered by diesel engines. A high demand for portable
self-contained pumps has exploded during the past 15 to 18 years as general
rental companies add pumps to their fleets. Coastal cities keep portable
pumps on standby during hurricane/storm season to avoid flooding, as they
do with backup generators for electricity.

115

elbows. Calculating the suction friction loss is a more


comprehensive method and leaves a smaller margin
of error. With the addition of a basic instrumentation
apparatus, the pump system will provide important
process information that can lead to increased life
and reduced downtime.
During the startup of the pump system, check the
piping and instrumentation drawing and compare
with the field layout. Basic guidelines can help users
visualize possible problems. Checkpoints that may
help during a problematic startup are listed below.
The distance between the pump and the fluid
source should be as close as possible.
An adequate water supply must be evaluated prior
to implementation.
The pipe elbow should not be too close to the
pump suction.
If a filter or strainer is part of the piping, make
sure it is not clogged.
When a foot valve is used, make sure it is not
stuck, and check for leaks. A suction pressure
gauge can be used. Make sure the foot valve is
functioning properly by closing the discharge
valve, and then fill and charge the suction pipe.
If an eccentric reducer has been installed, check
for proper installation.
Ensure the proper orientation of the check valve.
Verify the suction lift is not too high.
If not enough NPSH is available for the pumped
fluid, consider a jockey pump or an inducer to
increase the suction pressure.
Check for possible air entering the system
through valves above the water line or gaskets in
the suction piping.
If the fluid is vortexing at the pump inlet, low
level at the sump may be the cause.
If two pumps are connected in series, make sure
that both pumps have enough capacity.
Check that the vapor pressure of the fluid is not
too close to the atmospheric pressure, especially
when it rains. This condition may cause a drop in
atmospheric pressure and can cause the inlet fluid
to vaporize.
Never throttle the flow of the pump at the suction
of the process fluid.

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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
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116

PRACTICE & OPERATIONS

Pump Station
d
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Hyb Level Controller

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PSL 5.0 Pump Station
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Comprehensive
Industry Coverage

Positive Displacement Pumps


Centrifugal Pumps
Specialty & Other Pumps
Industrial Valves
Pneumatic & Hydraulic Valves
Industrial Automation & Process Control
Electric Motors & Drives
Actuators
Compressors
Custom Research
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Se p t e mb er 2015 | Pum ps & S y st e m s

information processing. In the case of pumping water


for cooling processes, the basic instrumentation
recommendations are listed below.
Low water level switch. In an open water
reservoir, a low-level switch will provide
information when the water level has reached a
low indication, and corrective maintenance will
eliminate pump cavitation.
Flow monitor. A paddle type of flow switch can
provide basic indication of either flow or no flow
in the process. A flow meter will provide accurate
water flow and a more accurate process condition.
Several types of meters are available, including
a magnetic flow meter, a vortex flow meter, an
ultrasound and a paddle flow meter.
Pressure monitor. A pressure gauge is the
simplest way to check for proper inlet and outlet
pressure. Pressure transmitters can provide
instant information at remote locations.
Inlet and outlet water temperature gauges or
temperature transmitters. These can also be
used to indicate important system conditions.
Pump and motor indicators. Low-cost current
meters can remotely send the signal to the control
room to visualize current conditions. The current
can be converted into motor horsepower that
can indirectly be converted into a rough flow
indication based on the pump performance curve.

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

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118

PRACTICE & OPERATIONS

How Remote Monitoring Empowers


Plant Employees
Modern software provides plants with the data they need to improve reliability while
empowering pump operators to make well-informed decisions.
Last of Two Parts
By Jason Vick & Jack Creamer
Schneider Electric

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

support software can provide the


correct information in real time
while helping gather data, identify
defects, predict impending
failures and capture predictive
maintenance (PdM) related
activities. This is often far more
than paper- or experience-driven
tasks could accomplish.
Remote access to standard
procedures also heightens
situational awareness by providing
focused advice or guidance of
the corrective measures that
must be taken to prevent failures
based upon the assets as found
condition. For example, operators
cannot remember every safe
operating range of every gauge
they have to monitor, where each
step change in severity level is or
what corrective action is required
depending on that severity level.
If forced to act upon experience,
an operator will likely make a bad
decision at some point because they
lack all of the needed information
to make a well-informed decision.
Advanced scheduling offers users
the ability to schedule tasks such
as reliability programs. Some of the
input sources for task frequency
include the following:
Failure history
Condition monitoring history

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

Different tasks must be


scheduled at different frequencies.
Likewise, tasks may be considered
conditional, meaning they are only
needed when a certain condition
or event has occurred in the field.
This cannot be done without
mobile decision support software
applications and is a critical
component to ensure an efficient
field workforce.
Visibility to the noninstrumented data benefits the
organization in several ways. At
each point that must be monitored
or inspected, the field user has
access to historical readings, trends
and notes. This information helps
workers make well-informed
decisions about the equipment.

119

This visibility also provides access to gathered data through


emailed reports, desktop-based data review and auditing
applications. By pushing data to subject matter experts,
supervisor and managers, plants and facilities are able
to shorten the time it takes for information collected
in the field to be reviewed. This visibility also provides
integrations to other systems, including the following:

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.

While this only scratches the surface of what a


mobile decision support application can do, the return
on investment can be significant. By empowering the
field workforce to make better decisions faster, plants
and facilities can reduce safety incidents, maintenance
costs, unplanned shutdowns or slowdowns, backlogs and
inventory levels.
Modern remote monitoring technology can also improve
health, safety and environmental compliance, plant and
asset availability, maintenance efficiency and reliability, and
knowledge retention.

Image 1. Modern remote monitoring technology can improve health,


safety and environmental compliance, plant and asset availability,
maintenance efficiency and reliability, and knowledge retention.
(Courtesy of Schneider Electric)

Correction: The last paragraph of Part 1 in this series


(Pumps & Systems, August 2015, page 104-105)
referred to QBR coding. It should say QR coding.

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Jack Creamer is the segment manager of the


pumping equipment sector for Schneider
ElectricSquare D and a member of the
Pumps & Systems Editorial Advisory Board.
He may be reached at jack.creamer@
schneider-electric.com.
Jason Vick is the mobility technical sales
consultants manager at Schneider Electric,
where he is responsible for providing mobile
workforce enablement technical guidance
and best practices to customers.

912-466-0304

www.LOBEPRO.com

Made in USA

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120

PRACTICE & OPERATIONS

Balancing Software Conserves Energy in


Multiple-Pump Systems
Each adjustable speed drive can find its own set point independently without stressing
the entire system.
By Kurt Bihler
Bihlertech, Inc.

rocess control through


traditional adjustable
speed drives (ASDs)
with centrifugal pumps has an
inherent problem of attempting
to use a linear equation to solve
a non-linear problem. Common
ASD controller software provides
an estimated speed to achieve
a desired set point. But when
the target speed is reached with
this method, the set point is not
available because the answer is on
an unknown non-linear curve.
The software must again guess
the speed and decrease the error.
This process continues until a
reasonable deviation from the
set point is met. If one aspect of
the system curve changes, the
whole process must be restarted.
Searching for the speed costs
energy, even on a single machine.
On a system with multiple
machines operating either in series or
in parallel, a second and more serious
problem occursbalancing the load.
Even if the machines are built to
the same specifications, differences
in motor performance, impeller
clearances and other mechanical
design issues will change a specific
pumps speed.
Conventional frequency control
operates multiple devices at the
same speed. In parallel operation,
the pump with the greatest pressure
capture most of the output and
Se p t e mb er 2015 | Pum ps & S y st e m s

corresponding amperage while


the other pumps use a fairly high
amount of power and add little to
the total output. There is no way
to balance a load using frequency
directly, because the smallest of
physical differences will cause a
shift in power to the device with the
highest pressure.

Balancing the Set Points


Specialized balancing algorithms
start with a fi xed linear pump curve
number. If the output electrical
current is less than the number, the
frequency is increased. If the output
current is greater than the number,
the frequency is decreased.
On centrifugal pumps, the
frequency in Hertz turns into rpm
to meet the amp draw. Amp draw
is linear to both pressure and flow,
and non-linear to speed. This is in
contrast to the balancing algorithm,
which directly controls power to
meet pressure or flow.
Consider the pump affinity laws,
where the diameter of the impeller
is held constant:

Q
H
P
N

=
=
=
=

flow
pressure
power
speed of impeller

The fi xed linear pump curve


number is a percentage of available
amps of power of a specific ASD.
When the motor and pump are set
up, the motors full-load amps are
entered into the drive. The ASD
temporarily sets the maximum
variable to the entered motor
amps divided by the ASD full
output amps. The maximum can be
adjusted to achieve the desired set
point for flow or pressure.
The minimum value is set to
find the lower limit, or motor stall
point. In multiple-pump systems,
each machine repeats the same
operational set points. The software
then creates a linear pump curve
where each pump will run at the
required power to match other
pumps set points.

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

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guidance necessary to select
pump types, pump materials,
and auxiliary components so the
wastewater pumping system
performs effectively, efficiently,
and reliably in various plant
operations. Find out whats
inside by visiting the link below.

No

Decrease
frequency
to meet amp
draw

Because the software produces a virtual linear performance curve,


the first calculation from an external controller will most likely
be the most accurate calculation. The software changes the
power of the motor to produce the desired pressure or flow. No
time or energy is wasted accelerating and decelerating.
Each ASD can calculate what speed to run at in order to
independently hold the set point. This would be impossible for
separate drives running speed control because each drive would
fight the other with hunting errors until the whole system
became unbalanced. Because the software provides a virtual
line of performance, each ASD can select an individual point
that represents exactly the same pressure at flow point as every
other ASD. So, the overall control system is greatly simplified.

Balancing Multiple Pumps


Each pump is tuned during commissioning to produce a specific
result, such as a flow rate or pressure at both minimum and
maximum values. Each motor/pump combination is unique and
requires slightly different frequencies and power requirements
at both end points and every point in between. Because all
ASDs share the same common reference signal, they can
independently calculate the power needed to match the flow/
pressure of all the pumps online. In a series operation, this
effect is even more pronounced. If series pumps are run at the
same speed, they have different velocities. This is analogous to
a traffic jam on an expressway where the cars are stopping and
starting. With a balancing software, the cars are all moving
at the same velocity. Without this software, the difference in
velocities between pumps can result in pressure waves that
cause mechanical stress and wasted power.
Kurt Bihler has more than 30 years of experience in industrial
controls. Since 1993, Bihler was president of Bihlertech, Inc.
Bihler is now a consultant to Toshiba and is a co-inventor of the
VLP algorithm.

Attention Pumps & Systems Readers:


Take 15% off your purchase of this guide
by applying coupon code WWPS15GB
during checkout in the HI eStore at
eStore.Pumps.org/Wastewater

Circle 169 on card or visit psfreeinfo.com.

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

Jordan, Knauff & Company is a knowledgeable and


experienced provider of a comprehensive line of
investment banking services to the pump, valve and
PXVEXMSRMRHYWXVMIW *PS['SRXVSP 
Our lines of business include: selling companies,
raising debt and equity capital, and assistance
SREGUYMWMXMSRW
To learn more about Jordan, Knauff & Company,
contact any member of our Flow Control
XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX
[[[NSVHEROREYJJGSQS[GSRXVSP
+'SSO.SVHER.V

(EZMH%/EOEVIOE

Managing Principal
GN$NSVHEROREYJJGSQ


Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ


MEMBER FINRA, SIPC

Circle 170 on card or visit psfreeinfo.com.


pu mpsa ndsyst ems.c om | Sept emb er 2015

122

PRODUCTS

Matrix Drive

Diaphragm Metering Pump

Yaskawa announces its greenest


drive ever, the U1000 Industrial
Matrix Drive. Yaskawas Matrix
technology employs a system of
9 bi-directional switches that are
arranged in a matrix to convert
a three-phase AC input voltage
directly into a three-phase AC
output voltage. This eliminates the
need for a rectifying circuit and DC
smoothing circuit that are used in
traditional AC drive inverters. The
result is a compact drive with full
regenerative capability and reduced
harmonic distortion.
Circle 201 on card or visit psfreeinfo.com.

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.

Liquid Level Alarm

Variable Frequency Drives

The See Water HLA


Liquid Level Alarm
Series includes the HLA
type 1 indoor alarm,
HLA-4X robust outdoor
alarm, and the HLA4X-X a multiple alarm
point configuration. The
alarm panels are ideal
for tank monitoring,
sump pump basins,
and other liquid level
monitoring applications.
The See Water alarm systems are UL listed, made in the
USA, and include a three-year warranty.
Circle 203 on card or visit psfreeinfo.com.

Amtech Drives offers a line of


Axpert-Eazy variable frequency
drives (VFDs). These VFDs have a LCD
display and eight selectable parameters
on a single screen. The Axpert-Eazy
VFDs feature an ambient temperature
of 122 F (50 C). The drives have a open
loop/close loop V/F and vector control
modes. They provide true overload and
ground fault protection. The AxpertEazy VFDs include a built-in energy
meter and energy savings calculator. Other features
include: fault history with the last 10 faults and eight
dynamic parameters, user programmable 8 analog and 15
digital I/Os, and Modbus-RTU connectivity.
Circle 204 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.

Wireless Switch Control


Harwil Wireless switch
control eliminates the cost
of the wire, installation and
maintenance. The range can
cover distances of 1,000 feet
and includes a sending
unit attached to the switch
and receiving that attached
to the pump. Use to control
water levels in a tank,
detect moisture intrusion or
line breaks, remote control of
equipment during installation
or service. Th is system is ideal for temporary and
portable applications.
Circle 206 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.

Se p t e mb er 2015 | Pum ps & S y st e m s

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
Advertiser Name

Page

RS#

Advertiser Name

A.W. Chesterton Company


25
ABZ, Inc.
127
Advanced Technical Staing
Solutions
124
Advanced Engineered Pump, Inc.
123
American Braiding & Manufacturing 111
Amtech Drives
63
AutomationDirect.com
27
BASF Corporation
37
BJM Pumps
61
Blue-White Industries
31
Boerger, LLC
30
ChemWorld
127
ChemWorld
124
Continental Pump Company
127
Crane Pumps & Systems
45
Dan Bolen & Associates, LLC
124
Danfoss VLT Drives
75
Dickow Pump Company
20
Disclo
41
DSI/Dynamatic
13
Eaton
35
EMEC
11
Environment One Corporation
88
Equipump
127
Flomatic Corporation
87
Fluid Metering, Inc.
97
Franklin Electric
26
Frost & Sullivan
116
Fullo Specialties Co.
22
FW Murphy
82
Gorman-Rupp Company
BC
Greyline Instruments Inc.
116
Grundfos
IFC
Grundfos
127
Hydraulic Institute
121

130
250

Hyundai Heavy Industries


Jordan, Knauf & Company
KSB, Inc.
Liberty Pumps
Load Controls, Inc.
Load Controls, Inc.
LobePro
Magnatex Pumps, Inc.
Master Bond Inc.
Megator Corporation
Meltric Corporation
MERRICK Industries, Inc.
MISSION Communications
Motion Industries
Motion Industries
Motor Protection Electronics
National Electric Motor
& Supply Co.
Neptune Chemical Pump Company
NETZSCH
Nidec Motor Corporation
Pinnacle-Flo, Inc.
Pioneer Pump, Inc.
POWER-GEN International
PPC Mechanical Seals
Proco Products, Inc.
Pulsafeeder
Raven Lining Systems
Rosedale Products, Inc.
Salem Republic Rubber Co.
Scenic Precise Element, Inc.
Schaeler Group USA
See Water Inc.
SEEPEX
SEPCO
SERO Pump Systems

251
252
165
100
101
102
103
104
131
269
270
253
106
254
107
132
108
109
110
133
134
248
155
175
135
166
136
156
111
167
112
273
169

FREE PRODUCT INFORMATION


Visit www.psfreeinfo.com to request more
information from these advertisers.

Page

RS#

Advertiser Name

77
121
55
53
91
126
119
111
127
101
126
97
12
19
1
104

113
170
152
114
137
255
168
157
256
158
257
174
138
115
116
154

126
47
126
29
85
21
117
126
103
96
18
115
43
125
51
65
36
74
125

249
139
258
140
159
117
118
259
160
176
141
171
150
260
119
142
143
144
261

ShinMaywa (America), Ltd.


Simerics
Sims Pump Co.
Sims Pump Co.
Sims Pump Co.
Singer Valve
SJE-Rhombus
Skinner Power Systems, LLC
St. Marys Foundry
Stancor Pumps
Sulzer
Summit Industrial Products Dorsey Advertising
Summit Pump, Inc.
Swaby LOBELINE
TECO-Westinghouse
TF Seals
Titan Manufacturing, Inc.
Topog-E Gasket
Toshiba
Trachte, USA
Tuf-Lok International
United Rentals, Inc.
Varisco USA Inc.
Vaughan
Verderlex
Vertilo Pump Company
VescoPlastics Sales
Watson Marlow Fluid
Technology Group
WEG Electric Corp.
Yaskawa America Inc
Zoeller Company

Page

RS#

17
95
113
126
125
86
81
69
125
9
IBC

145
164
120
271
272
161
162
146
262
129
121

70
81
54
7
73
125
125
5
124
124
23
124
3
52
115
124

147
163
153
122
145
263
264
123
265
266
124
267
125
151
172
268

71
53
83
15

126
127
128
149

he Index of Advertisers is furnished as a courtesy, and no


responsibility is assumed for incorrect information.

pu mpsa ndsyst ems.c om | Sept emb er 2015

124

PUMP USERS MARKETPLACE

Solve
dry start
problems with
Vesconite Hilube
bushings





Circle 270 on card or visit psfreeinfo.com.

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

Serving the Pump &


Rotating Equipment, Valve,
and Industrial Equipment
Industry since 1969

U-iv>}}Eiv
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www.danbolenassoc.com

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Ynovh{orjotm"3"Ktmotkkxy5Vrgttkxy5Gxinozkizy

Circle 254 on card or visit psfreeinfo.com.

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Domestic & International

Specializing in placing:
General Management Engineering
Sales & Marketing
Manufacturing
DAN BOLEN JASON SWANSON
CHRIS OSBORN
9741 North 90th Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com

Tuf-Lok International
*i\ n{n U www.tuflok.com

Circle 266 on card or visit psfreeinfo.com.

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S e p t e mb er 2015 | Pum ps & S y st e m s

125

Circle 264 on card or visit psfreeinfo.com.

Circle 263 on card or visit psfreeinfo.com.


Circle 272 on card or visit psfreeinfo.com.

Circle 261 on card or visit psfreeinfo.com.

Circle 262 on card or visit psfreeinfo.com.


Circle 260 on card or visit psfreeinfo.com.
pu mpsa ndsyst ems.c om | Sept emb er 2015

126

PUMP USERS MARKETPLACE

NEMO Progressing Cavity Pumps


Designed for Full Service in Place!

NETZSCH Pumps North America, LLC


1-610-363-8010
PUMPS@netzsch.com
www.pumps.netzsch.com

Circle 258 on card or visit psfreeinfo.com.

MONITOR PUMP PERFORMANCE


FlowRate

univeRsalPoweRCell

PumPCondition
dRyRunning

Come out of the Cold and


see what PPC is all about.

Cavitation

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www.ppcmechanicalseals.com /cryogenic.html

28 - 30, 2015

Full Service in Place Sept


Service with out removing
the pump from the system
Rapid disassembly and assembly
Easy maintenance and cleaning
Upgradeable and compatible with
existing NEMO pumps
Long service life
Economical

The Cryogenic
Worlds next
generation of sealing
technology is here
A seal that can handle liquids, gas, and
phasing states. PPCs leap in technology
over the competition is the result of:
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Booth 1461
at WEFTEC
in Chicago,

BeaRingFailuRe

OneSizeAdjustsfor
AllMotors,FromSmall
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10timesmoresensitivethan
justsensingamps
4-20Milliamp,0-10Volt

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:63

PGOC"Rtgokwo"XUU"Rwor"Oqvqtu

MOTOR
PLUGS
QUICKLY CONNECT
& DISCONNECT POWER
OFF
Button

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Safety Shutter
S
(on receptacle
e)

Rated up to 200A, 75hp


Rjqpg"*:22+":99/9742"0"*447+"4;4/9:;7
Hcz"*:22+"494/9742"0"*447+"4;4/;465
3326:"Enqxgtncpf"Cxgpwg
Dcvqp"Tqwig."Nqwkukcpc"92:2;
yyy0PGOUEQ0eqo"0"kphqBPGOUEQ0eqo

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S e p t e mb er 2015 | Pum ps & S y st e m s

 Connector + Switch in 1 device


ce
 Maximizes Arc Flash Protection
 Minimizes PPE Requirements
meltric.com
800.433.7642

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127

WE
booth FTEC
#158
0

Need A Technical
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Adhesive Needs?

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Personal one-on-one assistance


Custom formulations
Latest technological developments
Available in small to large volumes

154 Hobart Street


Hackensack, NJ 07601 USA
+1.201.343.8983main@masterbond.com

www.masterbond.com
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THINK PUMP SOLUTIONS


THINK

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GRUNDFOS

GRUNDFOS PROVIDES COMPREHENSIVE


MARKET COVERAGE THROUGH OUR
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pu mpsa ndsyst ems.c om | Sept emb er 2015

128

PUMP MARKET ANALYSIS

Wall Street Pump & Valve Industry Watch


Figure 1. Stock indices from July 1, 2014, to June 30, 2015

By Jordan, Knauff & Company

he Jordan, Knauf &


Company (JKC) Valve Stock
Index was down 25.8 percent
over the last twelve months, while
the broader S&P 500 Index was up
9.3 percent. he JKC Pump Stock
Index also decreased 20.6 percent
for the same time period.1
he Institute for Supply
Managements Purchasing
Managers Index (PMI) fell to
52.7 percent for the month of July
compared to 53.5 percent in June.
he New Orders Index rose to 56.5
percent from 56.0 percent, while
the Production Index jumped 2.0
percentage points to 56.0 percent.
Lower raw materials prices were
indicated as the Prices Index fell 5.5
percentage points to 44.0 percent.
Inventories of raw materials fell
below 50 percent, registering 49.5
percent, a decrease of 3.5 percent
from June.
he irst estimate by the Bureau
of Economic Analysis showed that
U.S. gross domestic product (GDP)
increased 2.3 percent in the second
quarter of the year. he growth
includes increases in personal
consumption, state and local
government spending, residential
ixed income and exports.
Federal government spending,
private inventory investment and
nonresidential ixed investment
were all lower during the quarter.

he report also revised irst


quarter GDP. Instead of
contracting, the economy
expanded at a 0.6 percent rate
in the irst quarter of 2015.
According to the U.S. Energy
Information Administration
(EIA), the rolling four-week
average of U.S. gross reinery
Source: Capital IQ and JKC research. Local currency converted to USD using
inputs has been above the ive- historical spot rates. he JKC Pump and Valve Stock Indices include a select list of
publicly traded companies involved in the pump and valve industries weighted by
year range every week of this
year. Lower crude oil prices and market capitalization.
with an average of 0.6 million
strong demand for petroleum
Reference
barrels per day over the same
products, mostly gasoline, both in
1. he S&P Return
period last year, helped push oil
the U.S. and internationally have
igures are provided
prices lower. he EIA projects that
led to favorable margins. he total
by Capital IQ.
amount of gasoline produced in the Brent crude oil prices will average
$54 per barrel in 2015 and $59 per
U.S. is up 2.9 percent through the
barrel in 2016.
irst ive months of the year. Since
Jordan, Knauf
On Wall Street all indices were
early April, reinery utilization has
& Company is an
consistently been above 90 percent. up for the month of July. he Dow
investment bank
hese record high gross outputs are Jones Industrial Average was up
based in Chicago,
0.4 percent, the S&P 500 Index
the result of these high utilization
Illinois, that
rose 2.0 percent and the NASDAQ
rates and an increase in reinery
provides merger and
acquisition advisory
Composite increased 2.9 percent.
capacity of 18.0 million barrels
services to the
Despite weak second quarter
per day as of January 1. U.S.
pump, valve and
earnings,
the
Federal
Reserve
Bank
reinery runs typically reach their
iltration industries.
remains positive about the economy Please visit
peak in the second and third
jordanknauf.com for
and still expects to increase interest
quarters of the year.
more information.
rates at some point this year.
North Sea Brent crude oil prices
Jordan Knauf &
Overall, economic activity was
averaged $57 per barrel in July
Company is a member
mixed, with positive gross domestic
and fell to $48 per barrel at the
of FINRA.
product numbers and an increase in
beginning of August. Increasing
durable orders, while disappointing
global liquids inventories, which
data included initial unemployment
rose by an estimated 2.3 billion
These materials were
claims, pending home sales and
barrels per day through the irst
prepared for informational
purposes from sources that
seven months of the year compared consumer conidence.

Figure 2. U.S. energy consumption and rig counts

Source: U.S. Energy Information Administration


and Baker Hughes Inc.

Se p t e mb er 2015 | Pum ps & S y st e m s

Figure 3. U.S. PMI and manufacturing shipments

Source: Institute for Supply Management Manufacturing


Report on Business and U.S. Census Bureau

are believed to be reliable


but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or completeness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
deployment of capital.

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Visit us at

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
539

Copyright, The Gorman-Rupp Company, 2015

Gorman-Rupp Pumps USA is an ISO 9001:2008 and an ISO 14001:2004 Registered Company

Circle 111 on card or visit psfreeinfo.com.

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