Pumps & Systems Sep2010

The Magazine for Pump Users Worldwide September 2010

pump-zone.com

The Magazine for Pump Users Worldwide

pump-zone.com

September 2010

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2 SEPTEMBER 2010 www.pump-zone.com PUMPS & SYSTEMS

Letter from the Editor

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Pumps & Systems, a member of the Cahaba Media Group, 1900 28th Avenue So., Suite 110, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and additional mailing offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. Annual sub-scriptions: 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) 482-3050 inside or outside the U.S. POSTMASTER: send change of address to Pumps & Systems, PO BOX 9, Batavia, IL 60510-0009. ©2010 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.

is a member of the following organizations:

It’s September, and as the mother of two extremely active children (ages 12 and 15), I am continually asked if I’m ready for “back

to school.” Is it just me…or am I the only mom in America who embraces September as an opportunity to focus on wastewater treatment?

Yes, it’s probably just me.h is is the time of year that we prepare for

WEFTEC, our biggest tradeshow of the year. h is generally means it is also our biggest issue. So while I am helping my daughter with her Civil War essay and my son is cramming all his summer reading into about two days, I’m learn-ing about wastewater treatment. Surprisingly, they do not teach this stuff in the Alabama public school system.

I have learned that it was not until the 19th century that large cities began to realize the necessity of reducing the amount of pollutants used in the water that was discharged into the environment. Many outbreaks of life-threat-ening diseases were traced to bacteria found in polluted water. Since then, many impactful technological advancements have been made to perfect wastewater collection and treatment.

Several million gallons of wastewater fl ow through a typical wastewater treatment plant daily. Some statistics show this can amount to 50 to 100 gallons for every person using the system.

In this issue of Pumps & Systems, which is “All About Water,” we explore technologies

that contribute to the importance of wastewa-ter treatment, and Dr. Lev Nelik takes a look at the future of wastewater treatment (page 24). In this issue, we also cover everything from sealing technologies, the importance of fl ow meters and eff ective remote communication used in water applications to reverse osmosis and metering and submersible pump technologies. Even the island of Alcatraz cannot escape from the need for wastewater treatment (page 80).

Please visit the Pumps & Systems team at our WEFTEC Booth (#2959 in F Hall) in New Orleans, La., Oct. 2 – 6. We will also be attending and co-sponsoring the Submersible Wastewater Pump Association’s 5th Annual Advanced Controls Training Seminar in con-junction with its 9th Annual Pumping Systems Training Seminar. For more information on this event, please contact SWPA Executive Director Adam Stolberg at [email protected].

In the meantime, please let us know about any advancements in wastewater treatment technologies that you are using.

Best Regards,

Michelle [email protected]

PUBLISHER

Walter B. Evans, Jr.

ASSOCIATE PUBLISHER

VP-SALES

George [email protected]

205-345-0477

EDITOR

VP-EDITORIAL

Michelle [email protected]

205-314-8279

MANAGING EDITOR

Lori K. [email protected]

205-314-8269

MANAGING EDITOR—

ELECTRONIC MEDIA

Julie [email protected]

205-314-8265

CONTRIBUTING EDITORS

Laurel DonohoJoe Evans, PhD

Dr. Lev Nelik, PE, APICS

SENIOR ART DIRECTOR

Greg Ragsdale

PRODUCTION MANAGER

Lisa [email protected]

205-212-9402

CIRCULATION

Tom [email protected]

630-482-3050

ACCOUNT EXECUTIVES

Charli K. [email protected]

205-345-2992

Derrell [email protected]

205-345-0784

Mary-Kathryn [email protected]

205-345-6036

Mark [email protected]

205-345-6414

ADMINISTRATIVE ASSISTANT

Ashley [email protected]

205-561-2600

A Publication of

P.O. Box 530067Birmingham, AL 35253

Editorial & Production1900 28th Avenue South, Suite 110

Birmingham, AL 35209Phone: 205-212-9402

Advertising Sales2126 McFarland Blvd. East,. Suite A

Tuscaloosa, AL 35404Phone: 205-345-0477 or 205-561-2600

Editorial Advisory Board

William V. Adams, Director, New Business Development/Corp. Mktg., Flowserve Corporation

Thomas L. Angle, PE, Vice President, Product Engineering, Weir Specialty Pumps

Robert K. Asdal, Executive Director, Hydraulic Institute

Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co.

Kerry Baskins, Vice President, Grundfos Pumps Corporation

R. Thomas Brown III, President, Advanced Sealing International (ASI)

John Carter, President, Warren Rupp, Inc.

David A. Doty, North American Sales Manager, Moyno Industrial Pumps

Ralph P. Gabriel, Director of Product Development,

John Crane

William E. Neis, PE, President, NorthEast Industrial Sales

Dr. Lev Nelik, PE, Apics, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pumps & Equipment/Smith-Koch, Inc.

Mike Pemberton, Manager, ITT Performance Services

Earl Rogalski, Sr. Product Manager, KLOZURE®, Garlock Sealing Technologies

Focus on what you

can control. Everything.

Think about ITT.

www.flygtus.com

The new Flygt Station Control Panel System delivers:

Introducing the Flygt Standard Control Panel.

Experience the launch of the Flygt Standard Control Panel at Booth 5025

at WEFTEC 2010, October 4–6 in New Orleans, LA.



ALL ABOUT WATER

p Predictable Pump Motor Maintenance at a Cranberry Bog

Chris Rayburn, Fluke CorporationDue to the delicate nature of the cranberry, pump failure is not an option.

p Cellular Communications for SCADA ApplicationsIra Sharp, Phoenix Contact

Effective and secure cellular communications for remote data acquisition.

p Technology Saves Valuable EquipmentBrad Clarke & Kari Oksanen, Singer Valve

Airdrie, Canada, prevents cavitation damage by using an anti-cavitation trim.

p Considerations for Choosing a Flow MeterMarcus P. Davis, McCrometer

Find the right fl ow meter for your process and plant.

p Clean Water for Florida CommunityHenia Yacubowicz, Koch Membrane Systems

An RO system solved the problem of purifying brackish water.

p The Balancing Act of DP Flow Meter SelectionKitty Elshot & Emily Vinella, Emerson Rosemount Measurement

Choosing the right differential pressure fl ow meter for an application can be challenging. This article outlines the considerations and trade-offs in selecting the optimal technology.

p WEFTEC PreviewLearn what to expect at North America’s largest water quality event.

SEALING TECHNOLOGIES

p Reliable Flange SealingPamela Dauphinais, A.W. Chesterton Company

Improve sealing reliability in bolted fl ange connections.

p Unique Sealing Solution Solves Sulfur Leakage Problem

Alton R. Smith, EagleBurgmannSulfur leakage, causing housekeeping and environmental issues in a refi nery, was stopped with an innovative seal confi guration.

METERING & SUBMERSIBLE PUMPS

SPECIAL SECTION

p Non-Metallic Mag Drive Pumps—Great Equipment for Abrasive Fluids

Travis Lee, Pulsafeeder, Inc.Non-metallic magnetic driven gear pump technology improves equipment life and maintenance costs for metering and transfer applications.

p Peristaltic Pump FactsTodd Loudin, Larox Flowsys

The peristaltic pump explained—from advancements to maintenance.

p Escape to AlcatrazBill Nestor

A low-pressure wastewater disposal alternative offers a cost-saving installation solution for wastewater and raw sewage disposal.

Table of Contents

29

32

38

40

46

50

58

60

66

70

78

82

PRACTICE & OPERATIONS

p Reclaiming the GoldMike Dwyer, Quadna

Investment in mine expands production capabilities.

p When Maintenance Becomes EmergencyDonald Spencer, P.E., HydroAire, Inc.

In this case study, routine maintenance of a condensate pump at a nuclear power plant becomes an emergency situation.

DEPARTMENTS

Readers Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P&S News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pump Ed 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Joe Evans, Ph.D.AC Power (Part Four): Transformers

Pumping Prescriptions . . . . . . . . . . . . . . . . . . . . . . . 24Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLCChris Staud, Engineering, Wastewater Group, Atlanta, Ga.Wastewater Treatment Industry: Present Challenges and Future Horizons

Business of the Business . . . . . . . . . . . . . . . . . . . . . 26Jen Yao, Frost & SullivanElectric Motors: Driving to Higher Effi ciency

Maintenance Minders. . . . . . . . . . . . . . . . . . . . . . . . . 86Preston Walker, Jr., Caliber Pump RepairUnderstanding the Basics of Pump Repair

Efficiency Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Greg KriebelPrimer on Polymer Handling

HI Pump FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Centrifugal pumps: how do they handle slurries, and what is their maximum allowable working pressure?

FSA Sealing Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . 96What is the Sealing System Energy Footprint for Controlling Process or Barrier Fluid Temperature?

Product Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Index of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . 107

P&S Stats and Interesting Facts . . . . . . . . . . . . . . . .112

September 2010

Volume 18 • Number 9

The Magazine for Pump Users Worldwide September 2010

pump-zone.com

The Magazine for Pump Users Worldwide

pump-zone.com

September 2010

100

102

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Readers Respond

Energy Savings with the Correct Duty

Point, June 2010Your recent article “Energy Savings with the Correct

Duty Point” presented some interesting details about VSX-Vogel analysis software tools.

Since I am not familiar with EN 12056/DIN 1986, Formula 3 (the domestic-wastewater-drainage) and Formula 4 (storm-water-outfl ow) were new to me.

In Formulas 2 and 6, the “p” symbol appears to be used as mass density: i.e., rho. In Formula 5, if “p” is used without a “g,” the resulting units would be weight per unit volume for friction loss. Is “g” a missing factor in the numerator of Formula 5?

I am accustomed to seeing “Hv” as a symbol for velocity head. In Formula 6, if the (Va2 x Ve2)/2g term should have been (Va2 - Ve2)/2g, then this term would be the velocity head, and Hv(Q) would, therefore, be the friction head loss. Under Formula 6, Va and Ve are defi ned as pipe length. I assume this was a typo.

h anks for the commentaries and fi gures.Lee RuizOceanside, CA

Jens-Uwe Vogel responds: h ank you for your feedback. I need to agree with you.

Unfortunately, some mistakes arose during the whole docu-ment process.

You stated that in Formulas 2 and 6, the “p” symbol appears to be used as mass density: i.e., rho. You are right; it should be the Greek letter ρ (rho).

P1 = Q • H • ρ • g

ηtotP1 = Power inputρ = Density of the mediumg = Gravitational accelerationηtot = Total effi ciency of the unit

Formula 2. Power requirement of a centrifugal pump

Also, in Formula 5, if “p” is used without a “g,” the result-ing units would be weight per unit volume for friction loss, and you wondered if “g” were a missing factor in the numerator of Formula 5. h e friction loss here is given as pressure p. Anyway, even here a mistake came in. Below, you will fi nd the correct formula, where I have added the metric units in brackets (see Formula 5 below).

You are absolutely right regarding Formula 6. h e correct formula is of course:

Htot = pa - pe

ρ • g + (za - ze) + Hv(Q) +

va2 - ve

2

2gpa - pe = Pressure diff erence between suction and discharge tankza - ze = Hgeo = geodetic heightHv(Q) = Pressure loss in dependancy of fl ow rateva, ve = Pipe length

Formula 6. Head of the plant

I am somewhat surprised that so many mistakes came into our article. It says to me that we have to improve our quality management for such documents throughout the whole pro-cess. Finally, I want to apologize for any trouble that may have been caused by this incorrectness.

Once again, thank you for your feedback.

pv [Pa = N

m2 =

kg m

s2 m2 =

kg

s2 m ] =

U [m] • L [m]

4A [m2] •

ρ[ kg

m3] • = v2[(m

s )2 =

m2

s2 ]2

• λ [–]

pv = Friction lossA = Passed cross section areaU = Circumference related to AL = Pipe lengthρ = Density of fl uidv = Average fl ow velocityλ = Friction factor

Formula 5. Friction loss in straight pipes

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Readers Respond

Suction-Side System Design, March 2010h e “Relative Resistance of Materials to Cavitation

Damage” chart shows two aluminum alloys. Can these be defi ned?

Excellent magazine.Alexander Kargilis, PEALKAR Engineering Company

Terry Henshaw responds: Stepanoff (Note 1 from the article) places “aluminum”

between bronze and steel. Yedidiah (Note 5) places “aluminum and certain alloys” below plastics. I don’t know which is correct or why the apparent discrepancy. I would put more faith in the Stepanoff report.

Vertical Turbine Pump

Reliability, March 2010I read your interesting VT Pump

Reliability article in the March P&S.I am curious if Item 13 in Figure 2

could possibly be a lan-tern ring. If so, maybe there was a fl ush con-nection at the box that wasn’t being used.

Lee RuizOceanside, CA

Lev Nelik resonds: Very observant and true. h e fl ush

indeed was disconnected. Otherwise, it would (at least) provide an expan-sion outlet for the vapors being formed (water boiling) to expand and not create a pressure cooker eff ect.

Responding to other

readers, April 2010My eye was caught by the graphic

accompanying Jim Elsey’s letter in the “Readers Respond” section, April 2010. His point was in reference to the posi-tioning of an eccentric reducer at the suction inlet of a pump. His conten-tion is that the fl at side of the eccentric

Lee Ruiz

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PUMPS & SYSTEMS www.pump-zone.com SEPTEMBER 2010 9

reducer should be on top only if the suction source is below the pump and that the fl at side should be on the bottom if the suc-tion source is above the pump.

Mr. Elsey is absolutely correct if the pump in question is a horizontal, end suction design, and if we ignore the fact that the elbow should be 5 to 10 diameters away from the pump suction in any well-designed piping system.

However, when you relate his state-ment to the diagram accompanying the letter and the fact that it identifi es a double suction pump, the positioning of the eccentric reducer has very little eff ect on the fl ow pattern to the impeller eye in the pump. h e fl ow patterns within the casing design in such a pump can accommodate any disruption that may be caused by either arrangement.

A more frequent and expen-sive problem of pump suction piping arrangements with a double suction design occurs when the elbow approach-ing the pump suction is on a parallel plane with the pump shaft. When the pump is horizontal and the suction piping leading to the pump is also in a horizontal plane and turns through a horizontal elbow into the pump suction, then the trouble starts. Under such con-ditions, seal or bearing failure will occur with alarming regularity owing to the

hydraulic imbalance created within the pump.Ross MackayConsultant in Pump ReliabilityAuthor of “h e Practical Pumping

Handbook”Creator of h e Mackay Pump School

P&S Ross Mackay

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P&S News

PEOPLE

CRANE PUMPS & SYSTEMS (PIQUA,

OHIO) adds key sales personnel to support growth in the plumbing, pressure sewer, HVAC and municipal markets. Graham Hackett is the new regional sales manager for the Western Region, Plumbing. He will develope and manage wholesale repre-sentatives and distribution channels in the plumbing market. Nathan Kimball is the new regional sales manager for the West-ern Region, HVAC and Industrial. Nathan will be growing Crane Pumps & Systems’ presence in the region. John Lazinski is the new regional sales manager for the South-east Region, Municipal and Pressure Sewer. He will be growing municipal sales and supporting pressure sewer projects in the region.

Crane Pumps & Systems is a manu-facturer of pumps, accessories and services, providing solutions for pressure sewer, municipal, plumbing, HVAC, industrial, military and dewatering markets. www.cranepumps.com

ITT WATER & WASTEWATER U.S.A.

(CHARLOTTE, N.C.) announces that Chris Ambrose has joined the company as the new director of marketing and business develop-ment. Ambrose was most recently the vice president of sales and marketing for John Zinc Company managing the sales and mar-keting of engineered combustion products throughout the Americas. Ambrose received his Bachelor of Science Chemistry degree from Florida Atlantic University.

ITT is an engineering and manufacturing company in water and fl uids management, global defenses, and motion and fl ow control. www.itt.com

HINES INDUSTRIES (ANN ARBOR, MICH.)

names Matthew Pohl as general manager of sales and marketing. Pohl will be respon-sible for all sales and marketing initiatives, expanding the industrial, high-perfor-mance, and aftermarket business units in North America and abroad.

Hines Industries provides balancing solutions to pump manufacturers, pump rebuilders and rotat-ing equipment professionals through a wide variety of standard machines and custom equipment. www.hinesindustries.com

COLFAX CORPORATION (RICHMOND, VA.) announces that William E. Roller has been promoted to executive vice president of Colfax Americas. He was most recently senior

vice president and general manager of Colfax Americas. In his expanded role, he is responsible for the company’s operations in the Americas, as well as its global oil & gas and Colfax Defense Solutions organi-zations. His duties also include expanding the two-screw pump business and driving global sourcing.

Colfax Corporation produces fl uid-handling products and technologies. h rough its subsidiaries, Colfax manufac-tures positive displacement industrial pumps and valves used in oil & gas, power generation, commercial marine, defense and general industrial markets. www.colfaxcorp.com

DANFOSS (NORDBORG, DENMARK) announces that its VLT division has appointed Frank Taaning-Grundholm as Global Pump OEM business manager.

In this position, Taaning-Grundholm will be responsible for sales to all interna-tional and major regional pump original equipment manufacturers (OEMs), includ-ing business development, marketing, prod-uct portfolio and application support.

Danfoss is a manufacturer of electronic and mechani-cal components and controls for air-conditioning, heating, refrigeration and motion systems. www.danfoss.us

AROUND THE INDUSTRY

KSB GROUP (FRANKENTHAL, GERMANY) acquired Stan-dard Alloys Inc., based in Port Arthur, Texas, on July 29, 2010. Standard Alloys Inc. specializes in spare parts man-agement for pumps and compressors. Standard Alloys brings experience in Rapid Cast Technology (RCT) and engineer-ing expertise in pump hydraulics to KSB Group. KSB will use this experience and applied technology to bring a greater level of service and satisfaction to its customers.

Standard Alloys has two locations with a total employ-ment of 90 people. h e main facility located in Port Arthur, Texas, houses engineering, administration and foundry activities. Component machining, pump repair, and assembly take place in the Vidor, Texas, location.

KSB is a manufacturer of pumps, valves and related systems for industrial applications and building services, for water and wastewater management and for the energy and mining sectors. www.ksb.com

Graham Hackett

William E. Roller

Frank Taaning-

Grundholm

Chris Ambrose

Matthew Pohl

John Lazinski

Nathan Kimball

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P&S News

PUMPTECH, INC., (BELLEVUE, WASH.) has been appointed the Grundfos Master Distributor for its Grundfos/Aldos line of chemical dosing pumps in the Pacifi c Northwest. h e prod-uct line includes the DDI and DME digital dosing pumps as well as the DM and DMH series of diaphragm dosing pumps. PumpTech has invested $100,000 in inventory to service the states of Washington and Oregon.

PumpTech is a distributor and manufacturer of packaged pumping systems for the municipal and industrial sectors. www.pumptechnw.com

TENCARVA MACHINERY COMPANY (GREENSBORO, N.C.) announces the acquisition of the assets and operations of Greensboro-based Electric Service and Sales Company Inc. (ESSCO), a division of Enerphase Industrial Solutions Inc., as of May 28, 2010.

ESSCO is a distributor for Toshiba motors and drives, Marathon motors, and ABB drives and controls. h e assets of ESSCO were acquired from Enerphase Industrial Solutions, Inc., of which ESSCO was a division.

Tencarva Machinery Company is a distributor specializ-ing in liquid process, compressed air, vacuum equipment and custom-designed systems for the industrial and municipal mar-ketplace. www.tencarva.com.

GRAPHITE METALLIZING CORP. (YONKERS, N.Y.) announced that NSF® International—an independent, not-for-profi t/non-governmental organization that provides mate-rials evaluation, standards testing and product certifi cation services involving public health and safety issues—has just certifi ed two grades of GRAPHALLOY® material for use in municipal well pumps and water treatment plant applica-tions. h e two newly certifi ed GRAPHALLOY® Grades are certifi ed to NSF/ANSI Standard 6—“Drinking Water System Components—Health Eff ects” and approved in the category for Multiple Water Contact Materials (MLTPL) up to 180 deg F. h ese newly certifi ed grades are used in the manufacture of pump bushings and bearings for both vertical and horizontal pumps.

Graphite Metallizing Corporation produces GRAPHALLOY®, a graphite/metal alloy bearing material used in the manufacture of self-lubricat-ing bearings and components for pumps, machin-ery and process systems. www.graphalloy.com

VARNA PRODUCTS (CAMERON PARK, CALIF.) announced the release of Calculating the Value of Prelube spreadsheet & ANDROID phone application. h is application can be used to

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P&S News

calculate the savings and value of prelube for your industrial/marine application.

VARNA produces solutions for prelube, soakback, transfer and many other applications in industrial/marine oil & fuel pumps & turnkey control.

VARNA Products is the production arm of Transportation Research Corporation specializing in custom fl uid control solu-tions for diesel engine systems. www.varnaproducts.com

EAGLEBURGMANN (HOUSTON, TEXAS) has become one of four Fraunhofer institutes and seven other partners to receive the Stifterverband Award. h e award, one of German industry’s joint initiatives for supporting research and higher education, was presented to EagleBurgmann as one of the partners in the alliance that developed DiaCer®, a new diamond-ceramic com-posite material for applications under extreme conditions in industrial environments.

EagleBurgmann manufactures mechanical seals, systems, packing and expansion joints. www.eagleburgmann.com

JWC ENVIRONMENTAL (COSTA MESA, CALIF.) announced that Big Fish Environmental is using its products in a unique and effi cient septage receiving and treatment plant design. h e products being used are the Honey Monster® septage receiving system, the Muffi n Monster® grinder and the Auger Monster®

screen. Part of Big Fish’s development process is achieving EPA Environmental Technology Verifi cation (ETV) which is now in the fi nal approval stages. Biosolids produced at some plants are approved by the State of Michigan as EQ Class A reusable biosolids and are being distributed over agricultural fi elds.

JWC Environmental produces a family of wastewater, stormwater and sewage treatment products. JWC Environmental distributes its products through a global network of indepen-dent representatives and distributors. www.jwce.com

IDEX CORPORATION (NORTHBROOK, ILL.) announced the acquisition of OBL, S.r.l. A provider of mechanical and hydraulic diaphragm pumps, OBL provides polymer blending systems and related accessories for a diverse range of industries, including water, wastewater, oil and gas, petrochemical and power generation markets. Headquartered in Milan, Italy, with annual revenues of approximately €8.5 million, OBL will oper-ate within IDEX’s Fluid and Metering Technologies segment as part of the water and waste water group of companies.

IDEX Corporation is an applied solutions company spe-cializing in fl uid and metering technologies; health and science technologies; dispensing equipment; and fi re, safety and other diversifi ed products built to its customers’ specifi cations. www.idexcorp.com.



P&S News

UPCOMING EVENTS

PUMPTEC

September 20 – 21Holiday Inn Select / Norcross, Ga.Presented by Pumping Machinery, LLC770-310-0866 / www.pumpingmachinery.com

SPE ANNUAL TECH CONFERENCE

September 20 – 22 Fortezza da Basso / Florence, ItalyPresented by Society of Petroleum Engineers+39-055-33611 / www.spe.org/atce/2010

CADWORX UNIVERSITY

September 27 – 29Woodlands Waterway Marriott Hotel / Houston, TexasPresented by COADEwww.cadworxuniversity.com

WEFTEC

October 2 – 6Ernest N. Morial Convention Center / New Orleans, La.Presented by the Water Environment Federation 877-933-4734 / www.weftec.org

TURBOMACHINERY SYMPOSIUM

October 5 – 7George R. Brown Convention Center / Houston, TexasPresented by the Texas A&M Turbomachinery Lab979-845-7417 / turbolab.tamu.edu

SMRP CONFERENCE

October 18 – 21Midwest Airlines Center / Milwaukee, Wisc.Presented by the Society for Maintenance and Reliability Professionals703-245-8011 / www.smrp.org

FSA FALL MEETING

October 19 – 21Austin, TexasPresented by the Fluid Sealing Association 610-971-4850 / www.fl uidsealing.com

CERTIFIED OPC PROFESSIONAL

TRAINING

Level 1: OPC & DCOM Diagnostics – October 19 – 20 Level 2: OPC Security – October 21 – 22Level 3: OPC Unifi ed Architecture – October 25 – 26Level 4: OPC Integration Projects – October 27 – 28ExecuTrain Houston / Houston, Texas780-784-4444 / www.opcti.com

PACK EXPO

October 31 – November 3McCormick Place / Chicago, Ill.Presented by the Packaging Manufacturers Machinery Institute703-243-8555 / www.packexpo.com

INFRAMATION

November 8 – 12Bally’s Hotel / Las Vegas, Nev.Presented by FLIR Systems, Inc. 866-872-4647 / www.inframation.org

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Pump Ed 101

Last month, we studied the properties and eff ects of resistive, inductive and capacitive loads in an AC cir-cuit. h is month, we will take self induction a step

further and apply it to that simple machine that is at the heart of AC power—the transformer.

As I mentioned in Part One, (Pumps & Systems, June 2010) a unique quality of AC power is that its voltage can be changed easily and in either direction—up or down. h is allows us to generate power at some voltage and step it up to a higher voltage for long distance transmission. h is decreases losses due to heat and signifi cantly reduces the wire size. Once it reaches its point of use, voltage can be reduced to a useable intensity. h e key element in this process is the transformer, and the key to its operation is a phenomenon known as mutual induction.

Mutual InductionIf two coils of wire are placed near each other (see Figure 1), an alternating current fl owing in one will create a magnetic fi eld that induces a voltage and current in the one nearby, even though they are not in direct contact. h is occurs because the lines of fl ux associated with the magnetic fi eld extend well beyond the coil that created them. h is property is called mutual inductance or mutual induction, and it is the

basis of the transformer. h e transformer gets its name from the process of transforming electrical energy into magnetic energy and then back to electrical energy. h e coil that pro-duces the magnetic fi eld is called the primary (input) and the coil that intercepts that fi eld is called the secondary (output).

Although some transformers consist of coils separated by an air gap, most use insulated wire wound about a laminated iron core (see Figure 2). h e iron core increases transformer effi ciency by directing nearly all the fl ux produced by the primary through the secondary coil. h e laminations reduce eddy current losses that would be much higher in a solid core design. Depending on the design and capacity, trans-former effi ciency can range from 20 to 99 percent. Larger ones—for example those designed for power distribution

Joe Evans, Ph.D.

AC Power (Part Four): Transformers

Figure 2 Figure 3

Figure 1

Last of four parts


applications—operate at 98 percent or better. Another impor-tant property of the transformer is electrical isolation. Since the primary and secondary coils are not in contact, the power source is isolated from the point of use.

Voltage, Current and the Turns RatioAccording to Faraday’s law, voltage produced in the secondary of a transformer depends on the voltage in the primary and the number of turns (loops) in the primary and secondary coils. h is may sound a little compli-cated, but this relationship can be simply stated with something called the turns to voltage ratio. h e equation below—where V is voltage, N is the number of turns, p is the primary and s is the sec-ondary—explains this relationship:

Vs = (Ns / Np) x Vp

Secondary voltage is directly pro-portional to the product of the turns ratio and primary voltage. If Ns is greater than Np, then the voltage in the second-ary coil is greater than that of the pri-mary coil, and the transformer is called a step-up transformer. If the opposite is true, we have a step-down transformer. For example, suppose a transformer has a primary with 1,000 turns and a sec-ondary with 100 turns. Based on the equation above, the turns ratio is 1/10 or 0.1. If the voltage feeding the primary is 1,200 V then the secondary voltage will be 120 V.

However, what about current? How do we calculate its change? h e trans-former is an intelligent machine because it automatically adjusts the current to keep power (in watts) constant. A slight modifi cation of the original equation explains this relationship:

Is = (Np / Ns) x Ip

In the equation above, current (I) replaces voltage and the turns ratio is reversed. When fewer turns are in the secondary, a transformer steps down voltage, but it increases current and, therefore, keeps power constant. In the case of our step-down transformer example above, if the primary is fed by 1,200 V at 1 A, then the secondary

would provide 120 V at 10 A. Both volt/amp combinations provide 1,200 W of power.

Winding Confi gurationsTransformers allow an extremely fl exible secondary output and are not limited to a single secondary winding. Figure 3 shows

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an example of a typical power supply transformer. h e primary is fed by 110 V and induces three individual secondary coils providing 5 V, 6.3 V and 700 V. h e 700-V coil shows another feature of the trans-former. A “tap” placed at the center of the coil provides two 350-V outputs in addition to its full voltage output. Multiple taps may also be placed within a single coil.

Three Phase Transformers

Transformers used in three-phase appli-cations can consist of three, single-phase transformers or a single transformer wound in a manner that accommo-dates all three phases. h e primary and secondary windings of the three-phase transformer are confi gured in two basic patterns—Delta and Wye. h e primary and secondary can be any combination of the two (such as Wye/Delta, Delta/Wye, Delta/Delta and Wye/Wye). h is article will examine the Delta and Wye secondary characteristics only. Additional resources are provided at the end of the article if you are interested in pursuing the eff ect of a particular pri-mary on a secondary.

Figure 4 is the schematic of a Delta secondary that produces three individ-ual-phase voltages of 120 V. h e Delta gets its name from the Greek letter that has a similar appearance. You might think that such a confi guration would short circuit since they are connected in series. However, note the angle associ-ated with each phase starting at the top and proceeding counter clockwise. If you refer to the three-phase power curve in Figure 3 of Part Two (Pumps & Systems, July 2010), you will see that the volt-ages cancel one another and no current fl ows through the circuit. If, however, a load is connected across any two of the three “lines,” a current will fl ow and the line-to-line voltage will be the sum of the phase voltages, which equals 240 V.

Figure 5 is the schematic of a WYE secondary that also produces three indi-vidual-phase voltages of 120 V. It gets its name from its resemblance to the letter Y and is sometimes called a “star.” At the junction of the three phases, a separate connection, known as a “neutral” is usu-ally supplied. A load connected between the “neutral” and any of the three “lines”

Pump Ed 101

Figure 4

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Pump Ed 101

will see a voltage of 120 V. When a load is connected across any two of the three “lines,” the voltage will not be the sum of the two phases. Instead, it will be approximately 208 V. h e reason this occurs is due to the phase angle and the way the coils are connected. Although we will not show one here, a phasor diagram would illustrate that the voltage vector created by any two WYE phases produces a voltage that is only 1.732 of the phase voltage. If you are interested in viewing WYE and

Delta phasors, check out “h e Changing Voltage Puzzler” on my website.

Based on the line-to-line voltage, it would appear that the WYE transformer is less effi cient than the Delta. However, an interesting event occurs within the Delta confi guration. A phasor diagram would show that the line-to-line cur-rent is only 1.732 of the phase current. h erefore, the relationship below will hold true for any circuit regardless of whether it is Delta and WYE connected:

Power (watts) =

volts x amps x 1.732 x power factor

I hope that this brief introduction to AC power has been useful. A lot more is involved, so below are several websites that you can visit for more information. In the future, I plan to write a similar series on AC motors.

P&S

Resources

All About Circuits: www.allaboutcircuits.com/

vol_2/index.html

Integrated Publishing – EE Training Series:

www.tpub.com/content/neets/

Electronics – Tutorials:

www.electronics-tutorials.ws/index.html

Siemens:

www3.sea.siemens.com/step/templates/lesson.

mason?bep:2:1:1

Electrician’s Toolbox: www.elec-toolbox.com

RLC Circuits – Java Applet:

www.walter-fendt.de/ph14e/accircuit.htm

Joe Evans is responsible for cus-tomer and employee education at PumpTech, Inc., a pumps and packaged systems manufacturer and distributor with branches through-out the Pacifi c Northwest. He can be reached via his website www.PumpEd101.com. If there are topics that you would like to see discussed in future columns, drop him an email.

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These days, the importance of a fresh water supply and safely-treated wastewater returned to the river cannot be overemphasized. No matter how hard we try, we

are still a long way from the most effi cient, economic and reliable ways to ensure that our cities are properly equipped and ready for the clean water challenge.

As a civilization, we have achieved isolated instances of superb effi ciency in water treatment and reuse, such as space shuttles and stations that rely on the almost perfect use and transformation of the precious water cycle, as there is no alternative other than that in space. But on the ground, the quantity of issues are grander and not as technically advanced. Yet this is where are our world is and what we have to work with—a world in which we must be in tune with nature and our environment as we look toward more innovative ways to maintain a fresh water supply and safely treat wastewater.

Chemical vs

Biological Treatment MethodsIs wastewater about to be treated in other more innovative ways? Currently, most plants use a combination of biologi-cal and chemical waste stabilization. Increasingly, the EPA is presenting the idea of making wastewater effl uents cleaner in terms of nutrients. h is forces more plants to add large quantities of chemicals to polish their effl uents.

h e other unintended eff ect is that multiple systems now need more maintenance. Wastewater plant operators have trouble maintaining complicated systems while keep-ing costs low. Eventually, chemical stabilization methods will displace some of the biological stabilization techniques.

For instance, one big problem area is biological phos-phorus removal followed by anaerobic digestion. h e unfor-tunate consequence of this procedure is the release of phos-phorus back into the plant, whereas chemical phosphorus removal permanently ties up the phosphorus until it leaves the system. Complex systems are not only hard to run, they are expensive to maintain.

Pump ProtectionProtecting treatment pumps (primary, secondary and ter-tiary) from grit that accompanies the incoming water is an

important component of extending equipment life. h e ways that water is pumped have undergone changes, as well. h e traditional end suction pumps have steadily been replaced by wet submersible units and now even by dry submersibles, which are mounted into a dry pit and connected to a wet pit allowing easy access to the pumps for repair or maintenance.

Combined SewersCombined sewers present challenges, and separating the water streams is expensive. In practice, the more readily acces-sible piping is handled fi rst, and the more diffi cult accesses are put on hold until later. With the complexities involved in sewer separations and the disruptions to business, many communities are turning to tunnel collection systems when upgrading (due to capacity issues or government regula-tion) is required. Increasingly, deep drop shafts have become common in many urban areas. h e drainage of storm water will be benefi ted by the implementation of drop shafts.

Simplifi ed Repairs and New MaterialsRepairs must become simpler and faster. Presently, main-tenance departments conduct simple repairs in house, and large and more sophisticated equipment is repaired by out-side contractors. Systems are more complex, and more com-puters are used to control them.

Computer specialists, who have good technical under-standing of the systems, are more common at wastewater treatment plants, but they may lack the knowledge of work-ing on the equipment. Likewise, maintenance personnel may be experienced with the equipment, but may lack the technical knowledge of the systems. A disconnect between the equipment handling and the systems that operate and control the handling can occur. More training is required to bridge this gap. In addition, more interaction between the departments and groups is essential.

New materials are available today that were novel or nonexistent years ago. For example, duplex stainless steel per-forms better in high-G centrifuge applications. Composites are becoming more common, bringing with them the advan-tages of light weight, cavitation resistance and corrosion resistance.

Dr. Lev Nelik, P.E., APICS, President, Pumping Machinery, LLCChris Staud, Engineering, Wastewater Group, Atlanta, Ga.

Wastewater Treatment Industry: Present Challenges and Future Horizons

Pumping Prescriptions


The Future

How will our plants look 20 years from now? Hopefully, higher effi ciencies and eff ectiveness of systems will mean less waste and a better recycling of resources. We may see technologies applied and new trends. Perhaps water and waste treatment plants will combine, and less wastewater will be discharged into rivers, with more of it contained in a closed cycle, making our rivers safer and more environmen-tally friendly.

Plant space (or green areas), par-ticularly in cities, will have to be used better, and some communities will likely apply new methods—such as closed-cycle water systems—to be more self-sustaining and less pollut-ing. Remember the experiment with biosphere conducted in Arizona years ago? h is type process can work in a small-scale situation. h e challenge is to implement it on a wider scale.

h e benefi ts of closed-water sys-tems would be impressive. Less water discharged to rivers would mean less piping, less repairs and less ground-work disruptions, and an easier-to-pre-serve infrastructure. Problems that are common today—such as cracked pipes, infi ltration and plugging—would be eliminated.

Solar energy could be better used, with solar panels and special bacteria growing methods that may advance us even further, making us less energy dependent and more effi cient.

Perhaps one day, present issues with our water supply will be reversed with more innovative water treatment and delivery systems. h e public is increas-ingly concerned about whether we actu-ally remove all the harmful pathogens in drinking water in urban areas.

It is diffi cult to tell, how the world will look in 20 years. However, if we do not try to imagine it today, we may fi nd ourselves unprepared in the future. Perhaps the time to plan or at least talk about it, is now. We would like to hear input from our readers, and we wel-come any additional ideas, challenges or thoughts that you may have.

P&S

Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery, LLC, an Atlanta-based fi rm specializing in pump consulting, training, equipment troubleshooting and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He can be contacted at www.PumpingMachinery.com.

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Business of the Business

The freefall in electric motor sales is a direct eff ect of the worldwide eco-nomic downturn, which has severely

depressed industrial and commercial produc-tions. Despite the 20 to 30 percent drop in motor sales in 2009, manufacturers remain optimistic about the future market landscape, as the economic recovery, the need to improve energy effi ciency and the demand in high-growth sectors will create need for high-per-formance motors.

When selecting a new motor today, a buyer has two choices for electric motor effi -ciency: EPAct (Energy Policy Act of 1992) effi ciency or NEMA (National Electrical Manufacturers Association) Premium effi ciency, which has a higher effi ciency requirement and costs 10 to 15 percent more than motors that just meet the EPAct standard. With the passage of the Energy Independence and Security Act of 2007 (EISA), all general purpose motors of at least 1 hp and less than 200 hp will have to meet or exceed NEMA Premium motor effi ciency levels beginning on December 19, 2010.

As a result of this legislation, motor selection is likely to be consolidated, and NEMA Premium is expected to become the new industry motor effi ciency standard. h e inclusion of the NEMA motor effi ciency standards into U.S. law and the recognition of NEMA standards by environmental

groups, such as the American Council for an Energy Effi cient Economy (ACEEE), has resulted of a resurgence in a mature electric motors market.

Despite the high, premium costs associated with high effi ciency motors and concerns with making new capital investments amidst an uncertain economic environment, the trend toward higher energy effi ciency has been gaining momentum in North America. To adhere to EISA, end users are replacing less effi cient motors with NEMA Premium effi -ciency motors.

h e U.S. Congress and President Obama passed the American Recovery and Reinvestment Act, or “h e Stimulus Plan,” which provides funding for the federal government,

states and cities to improve energy effi ciency in buildings and schools. ARRA also provides enhanced incentives for consumers to upgrade existing heating and cooling equipment and allows consumers to purchase energy effi cient HVAC systems, energy effi cient motors and energy effi cient water heaters. h ese incentives include receiving a tax credit of up to 30 per-cent of the cost for energy effi cient products. h e stimulus encouraged consumers to make their homes more energy effi cient, and also drives the sales of high effi ciency motors.

To off set the price factor associated with

Electric Motors: Driving to Higher Effi ciencyJen Yao, Frost & Sullivan

Figure 1

Figure 2


NEMA Premium motors and encourage faster adoption, the U.S. Senate’s Energy and Natural Resources Committee voted in favor of adopting the NEMA advocated premium energy-effi cient motor rebate program, known as “crush for credit.” Once the $700 million motor rebate bill is passed, it will pro-vide a $25 per horsepower rebate for the purchase of NEMA Premium energy effi cient motors, and a $5 per horsepower rebate for the disposal of the old, non-NEMA Premium motor.

With all the emphasis on energy independence, other opportunities for electric motors exist. Wind power is gaining acceptance and becoming an increasingly cost-eff ective and clean alternative to conventional energy sources. Electric AC motors and servo motors are used in yaw drives, pitch controls and other control systems. h e North American wind power market has experienced tremendous growth during the last three years, growing at an average annual rate of 37 percent from 2006 to 2009 and reached a capacity of 34,000 MW and $13.5 billion in rev-enue in 2009. Increasing government concerns about energy security and independence, government incentives on renewable energy and other factors such as rising energy prices and volatil-ity of fuel costs have contributed to the accelerated market growth.

Looking forward, wind power con-tinues to be a strong growth sector; it is expected to reach a capacity of 127,000 MW and $37.1 billion in revenue by 2015, with an average annual growth rate of 24 percent. Since electrical and control systems (including yaw systems, pitch systems, brake systems, power converters and transformers) account for 13.8 percent of the capital cost of a wind turbine generator system, electric motors used in wind energy are pro-jected to experience strong growth to meet the strong demand.

Manufacturers moved quickly to make changes to their product off erings to ensure NEMA Premium compliance and began moving more inventory to the new levels to ensure availability and a smooth transition to high-performance

motors. Furthermore, manufacturers are seeking opportunities within the high-growth sectors, such as wind energy, to stay competitive. With the economic recovery, the requirement to meet energy effi ciency standards and demand from high-growth sectors, the electric motors market is expected to see a fast recovery.

P&S

Jen Yao is a research analyst with Frost & Sullivan.

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All About Water

SPECIAL SECTION CONTENTS

Predictable Pump Motor Maintenance at a Cranberry Bog . . . . . . 29

Cellular Communications for SCADA Applications. . . . . . . . . . . . . 32

Technology Saves Valuable Equipment. . . . . . . . . . . . . . . . . . . . . . 38

Considerations for Choosing a Flow Meter . . . . . . . . . . . . . . . . . . 40

Clean Water for Florida Community . . . . . . . . . . . . . . . . . . . . . . . . 46

The Balancing Act of DP Flow Meter Selection . . . . . . . . . . . . . . . 50

WEFTEC Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58


When a pump or motor fails at Sea Wind Cranberry Farm in Langlois, Ore., farm manager Knute Andersson’s business is at stake. An equipment

malfunction could allow the farm’s cranberry fi elds to cool just a couple degrees, and on a cold night, that can mean losing part of the crop. For modern cranberry farmers, properly function-ing pumps, motors and sprinklers help ensure that their berry yield will be high. Without them, the berries are at the mercy of hostile climates that can cause crop-killing frost or destruc-tive heat.

Because of the fragile nature of the cranberry crop, Andersson needs an on-call electrician who can provide emer-gency repair service eff ectively and effi ciently enough to save the berries, sometimes in the middle of the night. Even more important, Andersson needs an electrician who can ensure through eff ective predictive maintenance that many of these emergencies do not happen at all. Andersson’s electrician is Joe Buchanan, project lead man and safety chairman at Kyle Electric, North Bend, Ore. Buchanan has been in the electric business 33 years; “since I was a pup,” he says. h roughout that career, he has made safety and customer satisfaction his per-sonal mantra.

Buchanan helps keep his customers happy by maintain-ing and repairing their equipment before it fails. Buchanan has worked with Andersson on the maintenance of the cranberry farm’s pump system for about six years.

Berry ParticularAndersson has 11 pump houses, each with between two and fi ve pumps and just as many motors for those pumps. h e motors range from 10 to 100 hp. All the fi elds have temperature sen-sors that relay back to the pump houses. If the temperature goes up or down too far, the pumps come on to start the sprinklers, which then use water to adjust the air temperature in the bogs.

h e equipment maintains the proper temperature of the fi elds 24 hours a day, 10 months each year. h e cranberry vines must stay within two or three deg of their ideal temperature, otherwise the crop is damaged and the yield is reduced.

“If they get frosted, they freeze. h at’s a throw away,” Andersson says. “If it gets too hot, it will cook them, and they will rot on the vine. Yield is all about temperature control.”

While high temperatures are less common in temperate, coastal Oregon, often the air and water on early spring nights can dip dangerously low. If a motor fails then, when the ambi-ent temperature is too high or low, Andersson could lose part or all of an entire fi eld before the pump is up and working again.

Since he started managing the farm in 1991, Andersson

Predictable Pump Motor Maintenance at a Cranberry BogChris Rayburn, Fluke Corporation

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has worked on his pump and motor system to maintain the nec-essary temperature for the berries in his fi elds. Buchanan began helping him six years ago when he installed the farm’s most recent pump house and its four 100-hp motors and pumps at a price of more than $100,000. Each pump can move as much as 1,500 gal of water per min to provide frost protection, irriga-tion, weed control and fl ooding of the bogs at harvest time or when otherwise necessary.

Water, Water, EverywhereMother Nature not only provides haz-ards for the berries, it can also cause abuse to the equipment. Buchanan must be mindful of those hazards during maintenance of the farm’s 27 motors. h e salt air eats through insulation, and the constant presence of water slowly corrodes the motors and relays. “Windings fail faster. h ere is corro-sion and insulation degradation ahead of schedule,” Buchanan says. However, equipment failure is not an option.

Buchanan has worked to eliminate failure by implementing a predictive maintenance plan. Each winter, he visits the farm for an annual inspection of motors, controls and pumps and checks for loosened terminals and connections and any damage from moisture or age.

On each predictive call, Buchanan looks for changes in readings, and he checks the insulation and lining around each motor. “We want to prevent criti-cal shut down,” he says. To do this, he compares all his readings against those he measured at the same time the pre-vious year. He also tests for any power dips, looks for any damage to the insu-lation or the lining of the motor, and ensures that no feedback or deteriora-tion is present.

“We’ve gone through it all, and it is now pretty much trouble free,” Andersson says. If a problem occurs in any of his pump houses, most com-monly, starters burn up or a relay fails.

The Bottom LineSafety is Buchanan’s top priority, and he says that the right tools can make a dif-ference. “Use quality tools and be a good craftsman.” h ese tips not only ensure safety but keep customers coming back, Buchanan says.

P&S

Marketing Manager for clamp meter, earth ground, and insulation test products, Chris Rayburn has an extensive background in aerospace with a masters of science in aero-nautics and astronautics from the University of Washington and an MBA from the same school. Prior to Fluke, Chris worked for Aerojet, Accenture and GE. You can contact him at christopher.rayburn@fl uke.com.



All About Water

Managers of water/wastewater facilities need to collect accurate information from remote assets

such as pumps, tanks and booster stations. Traditionally, this information is collected manually by collecting the chart record-ings. h is might be done monthly, weekly or daily, depending on available staffi ng.

While manual collection of this data is the norm, plants want to move to an automated process using a central station for all monitoring and control, which can reduce or eliminate the need for manual data collection. h is type of system is called a SCADA (Supervisory Control and Data Acquisition) system. h ese advanced networking SCADA systems can provide all the information from remote assets at a single location, improving the accuracy and timeliness of the operation.

A SCADA system requires a network with a secure communication path. Many diff erent technolo-gies—including dial-up, DSL, leased line and private radio—can provide this communications link. In water applications, networks must often reach areas where phone lines or tradi-tional wiring does not exist. Conduits can be trenched and wire can be laid, but this is often cost-prohibitive. Radio can provide access to these remote locations without the need for wires. When it comes to radio, there are a variety of options available. h is article examines the use of cellular technology in SCADA applications, how it can be implemented, the diff erent networking options available and security.

Cellular Network OptionsIn the world of cellular communications, two network options, voice and data, are available. Each has diff erent capabilities for SCADA applications. In this article, we will focus on the Global System for Mobile Communication (GSM) network

for voice communications and General Packet Radio Service/Enhanced Data Rates for GSM Evolution (GPRS/EDGE) for data communications, but the same principles exist for other cellular technology segments.

h e general diff erence between these types of networks is that the GSM network addresses all devices on the network by a phone number. On the GPRS/EDGE network, all devices are addressable via an IP address, making data communications easy.

Simple Control with the GSM Network for

SCADA applicationsh e GSM network connects with the Public Standard Telephone Network (PSTN), allowing communications from cellular devices to land-based modems using a phone number. h is is used for voice communication and Short Message Service (SMS), also known as text messaging.

Cellular Communications for SCADA ApplicationsIra Sharp, Phoenix Contact

Effective and secure cellular communications for remote data acquisition.

Cellular modem-to-modem text message communications can be used for autonomous

tank-level control


However, in the U.S., dial-up networking, where one modem calls another using the PSTN, is not permitted over the cellular infrastructure. h is limits the use of the GSM network for SCADA applications in the U.S. to SMS-only. Despite this limitation, the GSM network can be useful for simple control applications in a SCADA system.

For these simple control applications, modems can use a text message to take an event—such as a door alarm, high- or low-level tank alarm, or change in pump status—and report it to a control room or another modem for autonomous system opera-tion. In modem-to-modem commu-nications, when the second modem receives a command, it provides some action or status update. h e modems create an autonomous system that can control some part of an event-based process.

For example, Modem A receives a low-level alarm message from the tank. h is modem then sends a text mes-sage to Modem B, which turns on the pump and fi lls the tank. Once the water reaches an adequate level, Modem A sends another message to Modem B, requesting that the pump be turned off . While this process occurs, the modems also send the text message to a second number for the control room. h is pro-vides real-time updates to the control room SCADA system about the actions occurring on site.

If an autonomous system is not nec-essary, the facility can still use text mes-saging. h e modem can send informa-tion about the processes to the control room SCADA master, which will pro-vide the needed logic for control. It can also send a text message directly to the technicians who are responsible for the system. h e technicians can then make the necessary changes to the system. Text messaging can be an eff ective way to monitor and control simple processes.

Advanced Networking

with GPRS/EDGE for

SCADA ApplicationsFor applications that demand more than simple, event-based monitoring and control, the GPRS and EDGE networks off er additional capabilities. h e GPRS and EDGE networks can connect to a

private network or to the Internet using standard networking protocols. Since this allows for more information exchange from the remote assets, greater fl exibility is available for moni-toring, controlling, or even programming over the cellular infrastructure than the GSM network allows. When using the GPRS or EDGE network for data communications, you must decide if you will leverage a private network or use the standard

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public network. Private networks off er a great deal of fl exibility. Just about

any network architecture can be realized, including host-ini-tiated communication, and all communications do not need to fl ow over the Internet. However, to create a private cellu-lar network, you must work with a carrier—such as AT&T, T-Mobile, Verizon, etc.—to defi ne how your network should

be constructed. h ese private networks typically charge a one-time setup fee to create the network. h is fee can range from hundreds to more than $2,500, depending on the type of net-work being constructed.

With this type network, you will also need to do some network management to ensure proper network use. Private networking can be ideal for larger cellular networks, but smaller

systems usually fi nd the public network more suitable.

h e public network does not require any special confi gurations. Service plans are easily accessible, and generally, no setup fees are required. However, all data communications will fl ow over the Internet, which heightens the chance of network security threats.

In addition, typical poll-response networks used in SCADA systems will not work over the public network with-out proper preparation. h e public net-work is designed for mobile-originated communications. In other words, the remote device talks, and the host receives the information. In most SCADA sys-tems, however, the host initiates the communication to the remote device. A VPN (virtual private network) can over-come both the security concerns and the remotely initiated communication issues.

Security with VPN

TunnelingA VPN tunnel is one simple way to ensure the security of the Ethernet traf-fi c over the Internet. To use a VPN tunnel, the modem must support VPN networks. A router that supports VPN networking must also be at the control room.

Leveraging the VPN tunnel to secure the communicated information also solves other cellular issues. As men-tioned earlier, cellular networks typically require that the remote modem initiate all data communications. Many indus-trial protocols, such as MODBUS and EtherNet/IP, however, are designed for poll response. h e SCADA master at the control room must initiate the commu-nications, not the remote modem.

By creating a VPN tunnel between the remote modem and the SCADA system, the modem will be available on demand. h is allows the SCADA master

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All About Water

to do the polling. h e modem will initiate communications at startup and will keep the tunnel up, making access of the con-nected devices easy.

Using this type of network in a water application means that a SCADA master located in a control room can poll a remote PLC, which monitors various aspects of a process, for information on demand, such as pump status. h is provides a

real-time look at the water process without the need for manual interaction. In addition, changing variables or programming is possible in the remotely located PLC over the cellular network, eliminating the need to visit each location for a system update.

Whether the application involves simple data collection, non-critical control, or remote programming capabilities, the cellular network provides the network access necessary. I/O modems with text message capabilities provide alarm notifi -cations based on a condition or control another device. Data modems provide data communications to remote assets. When used with a VPN, modem technology allows users to collect information, program controllers and access other critical information, all through a single secure wireless link.

P&S

Ira Sharp is Lead Product Marketing Specialist for Phoenix Contact’s wireless products. Ira has a Bachelor of Science in Electrical Engineering from Pennsylvania State University. He has worked for Phoenix Contact with a concentration on wireless technology, industrial automation and process control for fi ve years. His active professional memberships include: the Instrumentation, Systems, and Automation Society (ISA); Wireless Systems for Automation (ISA100); and Institute of Electrical and Electronic Engineers (IEEE). He can be reached at 1-800-888-7388, x3777, or [email protected].

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All About Water

Set in the foothills of Canada’s Rocky Mountains is the city of Airdrie. Without a water supply, Airdrie purchases its water from neighboring Calgary. Every night, Calgary

pumps enough water to fi ll two reservoirs in Airdrie (a total of four million gallons). h en Airdrie pumps water into its distri-bution system so the city’s 38,000 people have water through-out the day. Calgary supplies water at 5,300 gpm (335 l/s) at 60 psi (4.1 bar) to the inlet of the reservoir fi ll valve. Outlet pressure of the fi ll valve is at or close to atmospheric pressure.

Pressure Drop Is a ProblemAnytime there is a high-pressure drop ratio across a valve, (typi-cally a three to one ratio or more in absolute pressure) cavitation can be an issue. h is is a common occurrence with reservoir feed valves as well as relief valves when they are designed to continuously relieve higher, upstream pressure to atmospheric pressure. People have tried to resolve this problem by using two valves in series: the fi rst reducing the pressure partly, and the second valve reduc-ing the pressure to the required outlet pressure, which eliminates the three to one pressure drop within one valve. h is approach can work. However, it requires extra space, extra piping compo-nents and two valves. So, this is often not the best solution due to cost and space constraints.

Cavitation is a serious problem when a valve reduces pres-sure with a ratio of three to one (or greater) of the absolute inlet pressure. From 60 psi (4.1 bar) to atmospheric pressure may not sound overly dramatic, but it is deep in the cavitation

zone. Typically, if the inlet pressure into a reservoir fi ll valve is 20 psi (1.3 bar) or less, cavitation should not be an issue; however, when pressure at the valve inlet exceeds 20 psi (1.3 bar), some form of cavitation control should be considered. Kelly McKague, Airdrie’s facility operator discovered this the hard way.

“We inspected the reservoir fi ll valve every year for damage due to cavitation,” says McKague. “h e valve was completely eaten away, so we had to replace it every 18 months because of cavitation damage.”

The Cause of CavitationCavitation is the formation of vapor bubbles that are created

anywhere there is a local pres-sure low enough to allow the water to vaporize. h ese bubbles migrate to the downstream side of the valve and/or the down-stream pipe where the velocity of the water slows down and the resultant pressure increase allows these vapor bubbles to implode with incredible destructive force. It sounds similar to small rocks rolling around within a valve. h ese imploding vapor bubbles will erode any coatings on the valve and the cast or ductile iron, creating a porous, pock-marked

surface. h is occurs most frequently around the seat area and on the downstream bridge of the valve.

The SolutionMcKague attended a trade show where he was fascinated to learn about an anti-cavitation trim. “On display was the exact

Technology Saves Valuable EquipmentBrad Clarke & Kari Oksanen, Singer Valve

Airdrie, Canada, prevents cavitation damage by using an anti-cavitation trim.


valve we had in the reservoir,” says McKague. “h at caught our attention; so, the conversation led to the anti-cavitation trim technology.” After further consultation, the City of Airdrie decided to purchase this new technology. h e valve was then customized to specifi c to Airdrie’s application.

In customization, the specifi c application must be consid-ered, as well as the capacity of the valve to prevent the supply side from being reduced to unacceptable levels. Airdrie pro-vided the company with the actual fl ow ranges as well as the inlet pressure ranges and the required outlet pressure. With this information, the company’s engineering team modeled that performance and selected a drilling pattern for the mul-tiple orifi ces specifi c to Airdrie’s application. h e trick was to supply orifi ces that could manage maximum fl ow while creat-ing enough backpressure within the cage to prevent the micro-scopic vapor bubbles from escaping.

h e anti-cavitation cage is not a sacrifi cial lamb and does not cavitate, as all the destructive forces are kept in the middle of the cage and the opposing vapor bubbles collide and implode against each other, not against a metal surface. Newer entries to the anti-cavitation market tend to use elongated grooves and take a position that one size fi ts all. h e problem with this is that when the pressure drop is extreme, not enough back pres-sure is created, and orifi ce plates may be required as extra insur-ance, which complicates the entire installation and does create a sacrifi cial lamb.

h e challenge in designing this kind of anti-cavitation trim is to control the pressure inside the anti-cavitation cage so that through the full stroke, the pressure remains low enough to prevent cavitation when fl owing out of the cage, and yet high enough to assure that the valve opens. h e main valve used by Airdrie was diff erent from the traditional main valves to ensure a smooth constant fl ow around the entire diameter of the anti-cavitation cage.

h is solution was by no means a simple task and was the result of fi ve years of R&D from the company’s engineering team. For guaranteed results in solving a cavitation problem, you need to have an engineered solution as each application is diff erent and requires some customization. A one size fi ts all approach is not the best approach.

After Airdrie’s anti-cavitation trim had been operating for six months, McKague was curious to check the valves perfor-mance. “We could have boxed the valve and resold it,” says McKague. “h ere was absolutely no sign of cavitation damage, not even on the coating. We couldn’t believe it.”

h e trim allowed for smooth control and protection from cavitation damage. h e double sliding cages of heavy stainless steel construction directed and contained the cavitation recov-ery, allowing it to dissipate harmlessly. h e cage was engineered to meet the fl ow/pressure diff erential of this specifi c applica-tion. “h e anti-cav trim did not eliminate cavitation,” says Summit Valve’s Harry Rehmann. “Instead, it contained the cavitation and caused the vapor bubbles to collapse away from any metal surface.”

One year after installa-tion, McKague inspected the valve again and still no damage. “We were used to seeing exten-sive damage,” says McKague. “Singer’s anti-cavita-tion trim has saved us a lot of grief. h e valve is working perfectly, and we won’t inspect it again for another few years.”

Rehmann was on site when the valve was opened and inspected. “When I saw the valve after it had been operating for several months,” he says, “there were no marks on it. Not one. It was phenomenal. I estimate that the anti-cavitation trim prolongs the life of the valve by about 10 times. h at’s how eff ective it is.”

Another benefi t of the anti-cavitation trim is noise reduc-tion. “Cavitation is really noisy,” says Rehmann. “It is like gravel going through the valve. With the anti-cav trim, the valve is amazingly quiet.” Noise can be an issue when these valves are located in a residential area with domestic housing nearby. Also from a worker safety perspective, any reduction in noise is a real benefi t.

Pleased with the overall performance of the anti-cavitation trim, Airdrie offi cials ordered another valve with the anti-cavi-tation trim for its newest reservoir.

h ese are long-lasting, dependable valves that handle high pressure drops without causing damage while minimiz-ing noise. “We didn’t have to think twice about that decision,” says McKague. “h is anti-cavitation valve is defi nitely the right valve for the job.”

P&S

Brad Clarke is the VP of sales and marketing for Singer Valve Inc., a global designer and manufacturer of auto-matic control valves. He can be reached at [email protected].

Kari Oksanen, Singer Valve’s general manager, has over 30 years of extensive knowledge and experience in the auto-matic control valve industry. He can be reached at [email protected].


All About Water

Selecting a liquid fl ow meter to measure volumetric fl ow rate or totalized fl ow can be a complex process. Many fac-tors must be considered, including the fl uid type; appli-

cation environment; operating parameters, like temperature; pressure and fl ow rate; fl ow meter technology; accuracy and repeatability requirements; reliability; installation constraints; maintenance requirements; and instrument life cycle.

For example, many types of fl ow meters measure liquid, and some are better suited to clean water than wastewater treat-ment environments. Some are more accurate and repeatable than others. Some require less frequent or more complex main-tenance, and some last longer than others.

In choosing a liquid fl ow meter, all the selection criteria must be considered rather than focusing on one aspect alone, such as price. Low purchase price alone can often be a mislead-ing indicator considering required performance, maintenance costs and life cycles. A better consideration would be total cost of ownership, which takes into account not only purchase price but also the cost of installation, maintenance, calibration and meter replacement.

On the other hand, sometimes an inexpensive fl ow meter with simple features does the job adequately. When the appli-cation is simple, performance may be less critical, and there might be no compelling reason to consider a more sophisti-cated solution.

Selection ConsiderationsDeveloping an application-specifi c comparative fl ow meter evaluation tool is a good place to start. Table 1 is an example of a fl ow meter selection matrix, in worksheet format, that will help in comparing fl ow meters to specifi c fl ow meter criteria. Time invested upfront in thoroughly understanding the fl uid to be measured and the process or plant environment where the fl ow meter must operate will ultimately pay dividends.

Fluid Media TypeSelecting a fl ow meter begins with understanding the process

media fl uid. Do you need to measure liquid, steam or gas? For the purpose of this article, we are focusing on liquid for volu-metric measurement (fl ow rate or totalized fl ow). h e question then becomes what kind of a liquid?

For example, the fl ow meter you choose to measure drink-ing water may not be the appropriate choice for wastewater treatment. Not all liquid fl ow meter technologies are appro-priate to measure dirty fl uids, particulate laden slurries, high-density, viscous fl uids or sanitary liquids for food/beverage or pharmaceutical applications. h e conductivity of a liquid and the presence of bubbles in a liquid are additional factors to consider.

h e chemical properties of the liquid are important, too. Corrosive and caustic liquids may require specialty materials to prevent damage to the meter. Excessive maintenance or costly replacements can result when the chemical properties of the liquid are not fully considered in advance.

Operating Temperature and PressureFull knowledge of the liquid to be measured is only part of understanding the overall application. Some fl ow meter technologies are aff ected by fl uid temperature and operating pressure. If a fl ow meter’s sensing accuracy is aff ected by tem-perature, then you may either need a fl ow meter with built-in temperature compensation or you will likely need to add a temperature sensor. Some fl ow meters also rely on moving parts not designed to withstand high-pressure operation. While some meters work exceptionally well at a regular fl ow rate, others will easily outperform in high turndown applications such as those that start and stop frequently.

Flow RangeKnowing the fl ow range and pipeline diameter are both critical factors to consider. Will the fl ow rate be continuous or will it be variable? In some plants, such as municipal water treatment, the plants are often designed specifi cally so the fl ow rate has pre-dicted fl uctuations because there are daily or seasonal high- and

Considerations for Choosing a Flow MeterMarcus P. Davis, McCrometer

Find the right fl ow meter for your process and plant.


low-fl ow periods based on consumer demand. In other opera-tions there may be a year-round continuous fl ow or stable fl ow that exists when the process runs. Not all fl ow meters respond well to a sudden decrease or increase in the rate of fl ow. Some fl ow meters operate well over a wide turndown rate.

Likewise, not all fl ow meters are designed for all pipe diameters. When outfi tting or retrofi tting a plant, it is a good idea to use fl ow meter technology that meets the needs of all fl ow measure-ments throughout a plant. It greatly sim-plifi es purchasing, installation, training and maintenance.

Sensor Typeh e complexity of fl uid fl ow measure-ment has resulted in the development of numerous fl ow sensing and measure-ment technologies. Once you start ana-lyzing the liquid to be measured, the accuracy desired and the process and plant requirements, however, you will usually fi nd two or three options for your application. h e major fl ow sens-ing technologies are:Coriolis—Liquid fl owing through a

U-shaped tube results in the tube twisting, and the twisting motion or vibration is used to calculate the fl ow rate.

Cone—A cone is placed in the pipe, and the diff erence between the upstream and downstream fl ows is calculated with diff erential pressure technology to indicate fl ow rate.

Electromagnetic—A conductive liquid moving through a magnetic fi eld generated in a pipe creates an electric charge, which is measured to determine the fl ow rate.

Orifi ce Plate—Diff erential pressure technology is used to measure fl ow by determining the diff erence in pressure from the upstream to the downstream side of the obstructed pipe.

Propeller/Turbine—Liquid fl owing in a pipe spins a propeller or a turbine, and the rate of spin is measured to determine the fl ow rate.

Venturi—A fl ow element forces liquid into a smaller diameter area of the pipe and the diff erence between the restricted and unrestricted fl ows is calculated with diff erential pressure

technology.Vortex—An obstructive device is placed in a pipe to create

vortices downstream. h e vortices are measured with tem-perature or pressure sensors to determine the fl ow rate.

Ultrasonic—Ultrasonic transducers are placed in a pipe to measure the velocity of a passing liquid. Flow rate is deter-mined based on the velocity measurement.

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All About Water

AccuracyHow accurate does your measurement really need to be? While highly precise fl ow meter technologies can measure within ±0.01 percent of full scale, there is a price to be paid for this type of performance. If you are measuring chemical additive injections into pharmaceutical, biotech or food/beverage prod-ucts, then this type of accuracy is essential. On the other hand,

many other processes are less critical, and “good” rather than “precise” accuracy is all that is needed to get the job done.

RepeatabilityWhen you consider accuracy, do not forget to ask your fl ow meter manufacturer about repeatability. h e term repeatability in fl ow instrumentation is equivalent to consistency of accurate

Evaluation Criteria Requirement/Goals Manufacturer 1 Manufacturer 2

Application Process Infl uent

Fluid Type Raw Water

Fluid Temperature 40 - 50 deg F

Fluid Pressure 20 – 40 psi

Flow Range 100 – 1000 gpm

Pipe Diameter 12 Inch

Flow meter Technology Cone, Mag or Propeller

Accuracy +/- 2% of Rate

Repeatability +/- 0.5%

Installation Considerations Retrofi t with pump and valve in close proximity

Maintenance Schedule Inspect/Repair Verify Calibration

Table 1. Flow meter selection worksheet



measurement. Because fl ow meters are typically calibrated to pipes fl owing at a specifi ed rate, then the accuracy of measure-ment can drop too. h e manufacturer’s repeatability specifi ca-tion will help in comparing accuracy specifi cations among dif-ferent devices.

Installationh e requirements for fl ow meter installation vary by the type of fl ow meter technology. h e three basic types of installation in

order of complexity from most diffi cult to simplest are: inline, insertion and clamp-on. An inline meter requires cutting the pipe; in contrast, insertion and clamp-on types can be installed under fl owing conditions.

Nearly all major fl ow meter technologies require a man-ufacturer’s specifi ed pipe diameter straight run upstream and downstream from the meter to ensure a stable fl ow profi le. Failure to comply with the manufacturer’s straight pipe run installation requirements often leads to either poor accuracy or

Evaluation Criteria Requirement/Goals Manufacturer 1 Manufacturer 2

Expected Installation Life > 25 Years

Budget $7,500

Meter Purchase Price $3,500

Installation Cost $1,000

Annual Maintenance & Calibration Costs $500

Meter Life Expectancy 10 Years

Replacement Cost $5,000

1 Year Cost of Ownership $5,000



Table 1. Flow meter selection worksheet (cont.)

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inconsistent performance (repeatability problems). When fl ow meters are placed too close to pumps, valves

and other equipment, unstable or irregular fl ows can impact performance and eventually result in maintenance problems. If you fi nd yourself in a tight spot in terms of a plant retrofi t or limited space in a complex pipe gallery, a limited number of fl ow meter technologies, such as electromagnetic devices or self-conditioning diff erential pressure meters, will off er the appro-priate solution. Either meter type requires virtually no straight run due to the sensing technology, or they feature built-in fl ow conditioning technology that removes swirl and other fl ow dis-tortions without the need for straight pipe conditioning.

MaintenanceAsk the manufacturer about the required maintenance of any fl ow meter under consideration. h ese requirements can range from periodic inspection and cleaning with devices such as ori-fi ce plates to replacing moving parts that wear to calibration checks to maintain accuracy. Increasingly, environmental and safety regulations at the federal, state and local levels specify maintenance procedures for all types of plant instrumentation including fl ow meters.

Life CycleWhat is the expected life of your fl ow meter? In some applica-tions such as subsea oil/gas production, your fl ow meter must have a life expectancy of 25 years or more with no possibil-ity for maintenance. In other applications, a simple disposable device with a one- to two- year lifespan is perfectly acceptable. Your application probably falls somewhere in between. As you compare diff erent fl ow meter technologies, be sure to calculate the cost of installation and maintenance and also amortize the cost of the fl ow meter over its lifespan. h ese cost comparisons can be revealing.

ConclusionWhile choosing a fl ow meter can be a complex task, simplify the task by using a comparison table, such as Table 1. Do not hesitate to ask your fl ow meter manufacturer for product infor-mation, demonstrations and training. Flow meter manufactur-ers are happy to help you fi nd the best fl ow meter solution for your process and plant.

P&S

Marcus P. Davis is a product manager for McCrometer, 3255 West Stetson Ave, Hemet, CA 92545, Phone: 951-652-6811, Fax: 951-652-3078, www.mccrometer.com.

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All About Water

Roy Fallon, chief operator of the wastewater treatment plant in the Village of Tequesta in Palm Beach County, Fla., said that after the company installed two reverse

osmosis systems in 2000, more than eight years passed before the membranes needed to be cleaned. Naturally, after using a reverse osmosis (RO) system for eight years to desalinate a water supply—and never cleaning it even once—one might assume that the buildup of dirt and slime would be more than even a hazmat team could stomach. But that is not the case at Tequesta.

“We have recently passed eight years since we installed the reverse osmosis systems, and we have not had to clean them once,” said Fallon, who is responsible for managing all phases of water treatment at the plant, including maintenance, water quality control and laboratory safety. “From my experience, even with a relatively clean water source, when you hit six or seven years with one of these systems, you have typically gone through multiple cleanings and you are even thinking about replacing the membranes.

“Yet it was eight years before we reached the point when the membranes underwent their fi rst cleaning. It was pretty remarkable.”

Located at the northern end of Palm Beach County, the water treatment plant serves 5,000 water customers, including residents of Tequesta, Jupiter Village and Jupiter Island, as well as a number of residents from unincorporated areas of Palm Beach and Martin Counties. Based on the performance of the RO systems, which have increased the capacity of the plant to more than 5 million gallons per day (mgd) of potable water, Tequesta now enjoys complete water supply autonomy.

Village of Tequesta Challenges:

How It All Began In the early 1980s, the local water management district discov-ered a signifi cant amount of salt water intrusion occurring in the surfi cial aquifer from which the Tequesta water treatment plant was extracting its water supply. h is salt water intrusion subsequently entered the village’s wells.

Due to the unwanted movement of the salt water/freshwa-ter interface, and to prevent more intrusion, the water manage-ment district implemented restrictions on the amount of water the plant could extract from the upper aquifer. Consequently, Tequesta offi cials developed a plan to draw water from a much deeper aquifer (the wells are down 2,000 ft; in the upper aqui-fer they descend a mere 100 ft). Because no restrictions existed on the deeper water supply—a far more abundant supply—the amount of water the plant needed to take from the upper aquifer was greatly reduced, alleviating the salt-water intrusion dilemma.

Unfortunately, this seemingly perfect solution had a down-side: the water in the deeper aquifer was far more brackish, with a much higher salt content. While the aquifer would not be subject to salt water intrusion, it would clearly require desalina-tion before it was suitable for consumer use. Water from the upper aquifer had been treated using a standard aeration fi ltra-tion system to remove iron and was then chlorinated. However, since the water from the upper aquifer was much purer, it did not require the treatment level of deeper water. h erefore, the

Clean Water for Florida CommunityHenia Yacubowicz, Koch Membrane Systems

An RO system solved the problem of purifying brackish water.

The Wellington project showed the scope of what the company could

do, not only with the membranes that it manufactured but with the

company’s overall expertise in water treatment and desalination.


existing system had not been designed to provide the desalina-tion that the deeper aquifer demanded.

RO Membranes Help Solve ProblemEager to identify a suitable solution, Tequesta offi cials solicited bids from a variety of engineering fi rms. Arcadis Engineering (Denver, Colo.) ultimately submitted the winning bid, and the fi rm was contracted to design a new plant and recommend all requisite equipment.

“We were certainly aware of the kinds of processes available for a project of this type, such as electrodialysis rever-sal and ion exchange,” said William D. Reese, now vice president of Arcadis. “But we did not try to go against the grain in terms of where the industry was headed. We were confi dent that a membrane-type process, specifi cally reverse osmosis, would be the optimal approach.”

In late 1997, design of the facil-ity that would include the RO systems commenced. A concrete block structure was conceived that would blend in with the architectural landscape of the vil-lage. Since a fair amount of noise was associated with the pumps that feed the membrane process, they were housed in a diff erent room, creating a far more comfortable operating environment when maintenance on the membranes was required.

A Process That Worksh e facility was built to house a maxi-mum of three 1.2 mgd RO trains, for a total capacity of 3.6 mgd. Currently, there are two installed trains; the second one was commissioned in 2007. After the water is pumped from the newer, deeper water source, booster pumps increase the pressure to provide the proper operating pressure for pre-treat-ment with sulphuric acid to keep the pH low; the lower pH helps keep the hydrogen sulfi de gas in the well water throughout the process. An anti-scalant is then added to prevent the formation of carbonates, after which the water travels through a pre-fi lter (one micron), before going to the high pressure pump, which increases the pressure to the RO membranes.

Once at high pressure, about 276 psi, the water is forced through the semi-permeable membranes to separate the impu-rities; the fi ltered water or permeate passes through the mem-brane and the concentrate is sent to waste and discharged. h e permeate from the RO is pumped to the clear well, or fi nished water tank, where it is mixed with the 2.74 mgd of water drawn from the upper aquifer and goes through fi ltered systems; the



All About Water

entire mix is then treated via the older fi ltration process, then goes into a clear well.

h e entire water treatment system is fully treated with chlorine and computer-driven; any out-of-range conditions are immediately communicated to plant operators for remediation or shutdown. h is RO permeate is a high-quality water, more like a distilled water, which makes it an excellent complement to the older water source.

“Combining the two water sources produces a perfect blend,” says Reese. “h e older source comes out with a couple hundred parts per million of calcium hardness, which helps improve the taste. By blending it with the newer source, we still have enough calcium for taste concerns, but overall it is a purer end product. With over 5.1 mgd of total capacity, we are more than satisfying the needs of our customers, even in times of peak demand.”

RO System Exceeds ExpectationsFallon says that the performance of the RO system has been exceptional. “h ere are a lot of factors that enter into how the system performs, not the least of which is the design of the wells and all the ancillary equipment,” he explained. “But there is no doubt that the RO system has done everything we had hoped it would. h ey have been almost maintenance free, which has

saved us substantial dollars in labor costs. And, of course, we are now producing a higher-quality product than we were before the system was built.”

How about the fact that the membranes remained so clean for so long? “It is time to clean membranes when either the feed pressure increases 10 percent or more from its original set point, or if when you hold the pressure constant, the pro-duction drops by 10 percent,” said Reese. “After eight years, we were just hitting the point where the feed pressures were bouncing slightly above 10 percent higher than they were at the original start of the plant. Maintaining your production within 10 percent for this long is not what I have experienced at other facilities.”

In the fi nal analysis, the RO systems used by the Village of Tequesta have performed almost fl awlessly, requiring little maintenance and needing no cleaning until they passed their eighth birthday.

P&S

Henia Yacubowicz is domestic director process engineer with Koch Membrane Systems, Inc., 850 Main Street, Wilmington, MA 01887-3388, 888-677-5624, Fax: 978-657-5208, www.kochmembrane.com.



All About Water

Selecting the right diff erential pressure fl ow meter is a balancing act—one that involves defi ning the purpose of

the measurement, specifying the applica-tion parameters, understanding the envi-ronmental and safety needs, and prioritiz-ing the selection criteria to determine the optimal fl ow technology.

Purpose of MeasurementUnderstanding the purpose of the mea-surement is the fi rst step in the selection process. What will be done with the fl ow information? How critical is the measure-ment? What decisions will the user make with the information? In general, fl ow information is used for either the control-ling or monitoring of processes. h ere are many reasons to measure fl ow, some more critical than others. h ey can range from batching, continuous blending, custody transfer and mass balance, to inventory control, governmental regulation compli-ance and safety.

Flow ApplicationOf the many fl ow meters available for mea-suring fl uid fl ow, the type of fl ow meter used often depends on the phase of the fl uid—liquid, gas or steam—and the con-ditions under which the fl uid is measured. h ese conditions include line size, fl ow rate, process pressure and temperature, ambient pressure and temperature, and chemical properties. For example, insertion fl ow meters are more frequently used in steam, large line sizes and situations in which process shutdown is not a possibility.

Wet gas applications, where the presence of liquid in a gas

stream can pose signifi cant challenges, are another example. Technologies like conditioning orifi ce plates eliminate dam-ming and provide predictable and correctable results when the moisture content is known. Inline metering technologies are the best practice for small line sizes as the possibility of errors caused by installation are reduced.

The Balancing Act of DP Flow Meter SelectionKitty Elshot and Emily Vinella, Emerson Rosemount Measurement

Choosing the right differential pressure fl ow meter for an application

can be challenging. This article outlines the considerations and

trade-offs in selecting the optimal technology.

Figure 2. Differential pressure fl ow meter technologies for comparison

Figure 1. Flow data for application example


h e fl ow application example ref-erenced in the remainder of the article is detailed in Figure 1 and compares four dif-ferent fl ow meter technologies, as shown in Figure 2.

Flow Meter Capabilityh e next step in the selection process is to determine how well the fl ow meter meets the given application. Flow meter capa-bility is, among other things, dependent on the following parameters: installed performance, transmitter performance, permanent pressure loss and straight pipe requirements. h ese performance param-eters should be prioritized based on the measurement purpose.

Installed PerformanceWhen considering installed performance, be sure to understand the performance of the fl ow meter over the entire fl ow range. It is important to note that the installed per-formance is not equal to reference accuracy because it takes into account environmen-tal eff ects, including line pressure variabil-ity, temperature fl uctuation and drift/sta-bility. Additionally, transmitters specifi ed as a percent reading perform better at low fl ow ranges. When a fl ow meter is speci-fi ed as percent of span the error at low fl ow rates gets magnifi ed.

For example, if the transmitter is spanned for 0 to 100 inH2O, a reference accuracy of ±1 percent of span refl ects a 1 inH2O error across the full fl ow range. If the transmitter is reading 5 inH2O, this represents a 20 percent error. Alternately, a transmitter specifi ed to be 1 percent of reading would have a 0.05 inH20 of error if it were reading 5 inH2O.

Another key consideration is that coeffi cients, such as the discharge coef-fi cient of the primary element, the gas expansion factor of the liquid source and the thermal expansion of the construction material, vary with fl ow. If accuracy is sized at a specifi c fl ow point, then there is a risk that errors will occur away from that sizing point. It is therefore recommended that accuracy is sized over the full range of fl ow to dynamically correct for these variables. Other factors may also contribute to mea-surement variation.

Errors in fl ow measurements are also circle 169 on card or go to psfreeinfo.com


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All About Water

attributed to errors in density measurement. For uncompensated velocity—a volu-metric measurement that does not take into account the fl uid’s density properties, such as a turbine meter—the percent error in fl ow is optimal. While an uncompen-sated diff erential pressure measurement results in reduced percent error, it is still

Figure 3. Total system performance of differential pressure fl ow meter installations

Figure 4. Permanent pressure loss for DP fl ow meters

Figure 5. Upstream straight run piping requirements by technology

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not optimal. A multivariable measuring device compensates for both pressure and temperature variation, and consequently produces the lowest fl ow error at <0.1 per-cent. Figure 3 compares the total system performance of the various fl ow meter technologies. It is evident that (B) and (C) rate higher in accuracy through a wider fl ow range.

Permanent Pressure Loss (PPL)Whenever a piece of equipment is added to a fl ow system, pressure is lost. h is pres-sure loss makes the pump or compressor work harder to generate the same fl ows in the system. In the case of fl ow meters, a loss is incurred because a piece of straight pipe would not have as much loss as the fl ow meter. h is pressure loss varies by DP fl ow meter. Starting with the orifi ce plates (highest PPL) and sorted in descending order of permanent pressure loss are ori-fi ce/nozzle, wedge, V-cone, venturi and averaging pitot tube.

A properly sized orifi ce plate with a beta ratio of 0.6 will typically lose 40 per-cent of the sensed DP to permanent pres-sure loss, whereas an averaging pitot tube has a blockage range between 15 and 20 percent. Lowering permanent pressure loss will reduce pumping or compressing costs, increase capacity and minimize the size requirements for the compressor, pump or boiler. For this article’s example, the per-manent pressure loss for each fl ow meter is shown in Figure 4.

Straight Pipe Run Requirements Traditional orifi ce plate fl ow meters require long straight pipe lengths to meet specifi -cations. Minimizing piping requirements improve performance and lower installed cost. h is presents a challenge as most plants are not designed with suffi cient straight pipe, making it diffi cult to engineer and add fl ow measurements. Technologies are available that require shorter straight run, eliminating the need for costly piping modifi cations. Figure 5 plots the piping requirements of the options available in the market.

Using technology designed for short straight run can enhance performance. In a 2-in. line size with a 0.4β and 2D straight run with an induced swirl,




All About Water

selecting a conditioning orifi ce plate, which only requires two pipe diameters upstream and two pipe diameters downstream, improves the fl ow measurement accuracy to 0.5 percent compared to a standard orifi ce. h e piping requirements of the fl ow meters in the original example are in Figure 6.

Another benefi t is that these technolo-gies allow mounting at grade, allowing for easier access and increased operator safety. h e lower installed costs are realized from the savings in labor, procurement, design and engineering, and materials.

Environmental and Safety NeedsMinimizing leak potential is critical in mitigating negative emissions and hazardous waste eff ects. Traditional installa-tions require impulse lines. h e impulse lines create numerous potential leak points, and have a tendency to plug, leading to inconsistencies in measurement. h e potential for leak points is signifi cantly reduced in a best practice installation, where the pressure transmitter is directly mounted to the primary element, eliminating the need for impulse lines and ultimately improving the measurement’s reliability. h is equates to cost and time savings—less process fl uid lost, energy wasted and

maintenance necessary in repairing leaks—and improves over-all personnel safety. A three-year user study found that replac-ing impulse line with direct-mount technologies resulted in a 90 percent reduction in work orders, and 46 percent reduction in total maintenance cost.

Economic FactorsIn a traditional installation, the materials costs, namely the price of the components, accounts for only 65 percent of the total installed costs. h e remaining 35 percent is comprised of engineering (sizing technology and creating specifi cation sheets and drawings), procurement (generating purchase order and

managing delivery dates) and labor costs (preparing piping, installing and com-missioning). Selecting the right DP fl ow meter can generate substantial savings in the total installed cost. For instance, choosing a directly mounted fl ow meter over a traditional orifi ce meter can trans-late to a total installed cost savings rang-ing from 20 to 30 percent, depending on the line size.

In general, no fl ow meter meets every application need. Every applica-tion should be considered individually. Start with the end in mind by consid-ering the purpose of the measurement. Make sure the application requirements are understood and met. Eliminate any technology that cannot handle the appli-cation. Finally, prioritize, rank and opti-mize fl ow meter capabilities to guarantee a customized recipe for success.

P&S

Kitty Elshot is the marketing manager and Emily Vinella is the marketing engineer for Rosemount Measurement, 8200 Market Boulevard, Chanhassen, MN 55317, 800-999-9307, www.rosemount.com.

Figure 6. Straight pipe requirements for fl ow meter combinations


IF THEY WORK IN WATER, THEY WILL BE AT

If you can only attend one event during the year, make it WEFTEC, the largest water quality exhibition in North America.

83rd Annual Water Environment Federation Technical Exhibition and Conference

New Orleans Morial Convention Center | New Orleans, Louisiana USA

Conference: October 2–6, 2010 | Exhibition: October 4–6, 2010

www.WEFTEC.org

Activated Carbon

Advanced Water and Wastewater Treatment

Aeration Systems

Aerobic and Anaerobic Treatment

Biological Nutrient Removal

Biosolids and Sludge

Chemicals and Chemical Handling

Collection Systems

Contractor Services

Consultant Services

Contaminant Removal

Corrosion Protection

Computer Software

Data Monitoring and Analysis

Dewatering

Digesters

Disinfection

Environmental Filters

Hydrogen Sulfi de Control

Infi ltration/Infl ow Control

Instrumentation

Laboratories

Leak Detection

Membrane Technologies

Motors and Motor Controls

Odor Controls

Ozone

Pipes

Pumps

Rehabilitation

SCADA Systems

Security

Stormwater

Tanks

Valves

Water Recycling/Reuse

...and so much more.

Take advantage of the opportunity to meet one-on-one with more than 900 exhibiting companies, the most knowledge-

able manufacturers, consultants, and contractors in the water and wastewater industry. Capitalize on unique educational

opportunities and form quality business relationships for your organization.

WEFTEC Exhibitors represent the most comprehensive array of products and services including:

Preview the technical program and exhibitor list at www.WEFTEC.org/announcement



All About Water

Water…used in nearly every application involving pumps and other rotating equipment. h e Water Federation’s Technical Exhibition and Conference

(WEFTEC), will highlight many of the applications in which water is a key component, just as it did last year when 17,744 people and 995 companies attended in Chicago.

h is year, 112 technical sessions and 35 workshops will focus on the following topics:• Collection systems• Membrane technologies• Plant operations, treatment and management• Regulations and research• Residuals and biosolids• Water recycling

We hope that you will come see what WEFTEC has to off er and visit us at Booth 2959 in F Hall. We look forward to seeing you there!

Learn what to expect at North America’s largest water quality event

WEFTEC 2009 by the Numbers

Total Attendance — 17,744

Exhibitors — 995

Net Square Feet of Exhibits — 264,400

preview

Show and Conference Hours

Saturday, October 2

Workshops 8:30 a.m. – 5:00 p.m.

Sunday, October 3

Workshops 8:30 a.m. – 5:00 p.m.

Monday, October 4

Exhibition 9:00 a.m. – 5:00 p.m.

Technical Sessions 10:30 a.m. – 12:00 p.m. &

1:30 p.m. – 5:00 p.m.

Tuesday, October 5



1:30 p.m. – 5:00 p.m.

Wednesday, October 6



1:30 p.m. – 5:00 p.m.

Company Name Booth Number

ABB Discrete Automation & Control 3115

ABS USA 2127

ATC Diversii ed Electronics 6120

Baldor Electric Company 2543

Benshaw 2872

BLACOH Fluid Controls, Inc. 3733

Blue-White® Industries 1957

Boerger, LLC 3243

Cole-Parmer 1644

Crane Pumps & Systems 3417

Danfoss Drives 2017

Environment One Corporation 3017

Fairbanks Morse 1035

Fluke Corporation 810

Fuji Electric 3629

Global Pump 6647

Griffco Valve, Inc. 7605

Hyundai Heavy Industries Co. Ltd. 6113

ITT Corporation 5025

Iwaki America 6657

KSB, Inc. 2351

Larox Flowsys, Inc. 7857

LobePro Rotary Lobe Pumps 5757

Lutz-JESCO America 5414

Meltric Corporation 1843

Mercoid Division, Dwyer Instruments Inc. 6531

Moyno, Inc. 5739

MTH Pumps 4750

Company Name Booth Number

Myers 1035

National Pump Company 2951

Neptune PSG 2538

Orival, Inc. 7017

PeriFlo, Inc. 6555

Proco Products 5939

ProMinent Fluid Controls 5531

Racine Federated Inc. 1634

Revere Control Systems 2401

Rockwell Automation 2409

Salem Republic Rubber Company 7227

seepex 3043

Shanley Pump 2963

ShinMaywa® 1245

SJE Rhombus 5119

Swaby Manufacturing Co. 5421

SWPA 5353

TECO-Westinghouse 2571

Valve & Filter Corp 1654

Vaughan Company, Inc. 2613

Verder GPM 5428

VibrAlign, Inc. 2582

WAGO 1638

Weir SP 4828

WILO USA LLC 1015

Yaskawa America, Inc. 7125

Zoeller Company 2041

Perferred Booths


Sealing Technologies

Typical operating environments create unique chal-lenges for plant maintenance personnel when meeting their goals of reliably sealing bolted fl ange

connections.Many factors can prove detrimental to the performance

of a gasket used to seal fl anges—including fl ange alignment and fl ange imperfections, vibration, pressure and tempera-ture surges, chemical attack, gasket creep, changes in clamp-ing force and improper gasket loading. An understanding of bolted fl ange connections is critical to ensure optimum gasket performance and improve fl ange sealing reliability.

Bolted Flange ConnectionsA fl ange is a method of connecting pipes, valves, pumps and other equipment to form a system. A bolted fl anged con-nection versus a welded connection provides easy access for cleaning, inspection and modifi cation of a piping system. Flange joints are made by bolting two fl anges together with a gasket between them to form a seal.

Many types of bolted fl ange connections have been designed for diff erent equipment—including ANSI/DIN pipe fl anges, valve bonnets, site gages, manways, handholes and heat exchangers. An ideal fl anged joint would consist of two, mirror-fi nish, perfectly fl at and parallel surfaces bolted directly together to create a leak-free seal. However, manu-facturing processes do not allow for perfect sealing surfaces. Most fl ange faces have surface irregularities that cannot be sealed without the use of some type of compressible, resil-ient material or a combination of materials between them to seal the fl uid being transferred. h erefore, a gasket is used between these surfaces to compensate for real world conditions.

h e fl ange faces are the eff ective sealing areas of the fl ange. A gasket is placed between the fl ange faces, and they are mated together when the fl ange is bolted and the gasket is compressed between them.

Bolted fl ange joint leaks have been a cause for concern across all industries—including chemical, hydrocarbon pro-cessing, power and pulp and paper. While advancements

have been made—such as gasket design, materials and bolt-ing—the high-temperature, high-pressure applications con-tinue to create a sealing challenge.

Flange leakage can be gradual, sudden or drastic. Visible fl ange leakage is recognizable and leads to costs associated with loss of fl uid. In addition, fl uid leakage can result in environmental and safety concerns. Even though individual fl ange leaks may not be considered to have large leakages, so many fl anges are used throughout a plant that they do con-tribute to overall leakage. An average plant may have from 3,000 to 30,000 fl anged components to be monitored, and large facilities may have more than 100,000 components, with diff erent standards applied for monitoring and compli-ance with environmental regulations.

In some industries, non-visible leakage can also be a concern such as fugitive emissions from Volatile Organic Compounds (VOCs) and Volatile Hazardous Air Pollutants (VHAPS). Leak Detection and Repair (LDAR) is a program implemented to comply with environmental regulations for reducing the leakage of targeted fl uids into the environment. Process components subject to LDAR are often monitored to detect VOC and VHAP leaks, which are required to be repaired within a predefi ned time period. Enforcement Consent Decrees and LDAR monitoring programs can result in signifi cant fi nes for non-compliance.

Proper Selection and TechniquesSome important items to consider in fl ange sealing are selecting the right gasket and applying the correct load.

Selecting the Proper GasketTo ensure that an application is sealed properly, the fi rst step is to choose the right gasket.

When selecting a gasket there are many factors to con-sider including:• Chemical compatibility • Temperature resistance• Pressure capability• Compressibility• Recovery

Reliable Flange SealingPamela Dauphinais, A.W. Chesterton Company

Improve sealing reliability in bolted fl ange connections.

• h ickness• Temperature cycling• Flange condition• Flange vibration

Larox Flowsys has been providing innovative fl ow solutions to the process industry for the past 30+ years.

High Performance PVE valves are constructed in

a manner to create the longest sleeve lifetime in a

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h ese factors are all related. Many times, a change in one parameter can aff ect, another so all need to be considered to determine the best gasket for the application.

Proper Bolting TechniquesProper bolting practices ensure that the gasket gets the proper sealing stress. h e primary factors aff ecting gasket loading from

bolting are:h read Friction—lubrication of bolts is necessary to reduce

excess thread friction and maintain a consistent coeffi cient of friction during assembly. Proper lubrication of all thread con-tact areas, nut faces and washers with an anti-seize lubricant will help ensure that the torque applied to the fl ange bolts yields as accurate and consistent a gasket stress as possible.

Bolting Sequence—proper bolting sequences must be followed to ensure even loading of the gasket.

Tightening Method—the installation and torquing procedures are important to the reliability and operational safety of fl anges. Assuring that a correct seal-ing force is applied and maintained will help avoid problems with fl anges. Use of a torque wrench, hydraulic tensioning equipment or stretch control to apply the recommended sealing force is critical to establish bolt loads and gasket seating stress above the minimum required to maintain a seal.

Often selecting the right gasket and using proper bolting techniques will be enough to ensure fl ange reliability. However, some fl anges such as criti-cal and problematic fl anges can benefi t from an engineering analysis.

Engineered Flange Sealing

SystemOptimizing Gasket Sealing StressImproving fl ange reliability requires an understanding of why the bolted con-nection failed. Critical and diffi cult fl ange applications at a plant often need a more detailed understanding and anal-ysis of the fl anged joint. Heat exchang-ers are often critical problematic appli-cations due to thermal variations and hydrostatic pressures. See Figure 1. An engineered fl ange sealing system takes into consideration proper gasket sealing stress and optimized bolt loading.

Improper gasket load is a leading reason for gasket failures in plants. h e ASME Boiler & Pressure Vessel Code establishes code for fl ange design and discusses m & y factors. h e gasket must conform to the fl ange surface and must be compressed enough to seal any voids and prevent leaks. h is stress referred to as the minimum gasket seating stress (psi, MPa) is the Yield “y” value. h e “m” maintenance value is used to determine

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the compressive load on the gasket to maintain a seal when the vessel is pressurized. However, these m and y values have limi-tations and can not be used solely to ensure a leak-free fl anged joint. A complete analysis of the entire assembly needs to be completed to ensure fl anged joint reliability.

Too little applied stress results in excessive leakage; too much applied stress can result in gasket creep and irrevers-ible damage to the gasket and excessive fl ange and/or bolting deformation. See Figure 2.

Optimized Bolt LoadingGaskets perform the sealing in fl anges, but the fl ange bolts provide the gasket stress necessary to achieve an eff ective seal. A bolt is an elastic element. When it is tightened, it will stretch. When the

bolt is stretched in its elastic region it will retain its memory. As a result, when the bolt is stretched it will exert a force on the fl ange and the gasket as it tries to get back to its original length. h e more you stretch it in its elastic region, the higher the bolt force transferred to the fl ange. h e stretch of the bolt is limited by the yield strength. It is important that the bolt stress is within its elastic limits. If the bolt is stressed beyond its yield

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point, it will no longer provide the required elasticity for the fl anged joint to seal reliably. See Figure 3.

A correct and constant bolt load is essential to reach and maintain the proper compression of a gasket throughout its service life.

h e seal is aff ected by the action of force on the gasket surface. Suffi cient stress/load must remain on the gasket surface to prevent leakage. Hydrostatic end thrust works to open the fl ange joint and reduces gasket seating stress. See Figure 4. h e bolt load force must be greater than the force created by system pressure to maintain the seating stress on the gasket above the minimum required to maintain a seal.

Many problem fl anges are subject to thermal expansion and contraction, pressure surges and vibration. h ese factors can either decrease or increase the bolt load and gasket stress from the initial installed values, which can lead to prema-ture leakage and failure of bolted assemblies. Flanges can be a dynamic component and often require a dynamic sealing solu-tion to be properly sealed.

Maintaining Gasket Sealing StressAn engineered fl ange sealing system provides a complete engi-neered solution focused on fl uid compatibility, pressure and temperature and maintaining the proper seating stress of bolted

joints through temperature cycling and mechanical distortion due to vibration. All these dynamics are considered to recom-mend the best fl ange sealing solution, and where applicable will incorporate fl ange live loading engineered specifi cally for the fl ange. Upon engineering analysis Flange Live Loading often provides the necessary increased margin of safety and reliability for these applications when used in conjunction with the opti-mal gasket and bolt loading.

Flange live loading uses specially designed fl ange discs to

Figure 3. Typical Elastic Curve for a Bolt.

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replace washers under the bolt nuts and increases the original bolt stretch. h e typical engineered live loading system will pro-vide approximately six to eight times the stored energy through the use of fl ange discs to maintain a load on the sealing system when compared to standard bolting. h e live loading system allows stored energy to automatically adjust to system fl uctua-tions and maintain enhanced pressure on the gasket.

h e use of fl ange live loading can help maintain proper gasket stress through thermal cycling by storing elastic energy.

Stored elastic energy minimizes the loss of bolt stress resulting in a longer life.

For diffi cult fl ange sealing applications, an engineered fl ange sealing system will:• Maintain a uniform clamping force, improving bolted joint

sealing reliability• Compensate for thermal expansion and contraction• Absorb vibration shock• Dampen the eff ects of pressure surges, preventing gasket

blowouts• Provide a cost eff ective solution for expensive leakage and

maintenance on critical equipment

Plant personnel working together with a supplier who has the engineering expertise, tools and resources to evaluate fl ange sealing needs can properly implement an engineered fl ange sealing reliability program designed to improve MTBR, lower leakage and reduce total maintenance and operating costs.

P&S

Pamela Dauphinais is the marketing analyst, Mechanical Packing and Gaskets, for A.W. Chesterton Company, 860 Salem Road, Groveland, MA 01834, 978-469-6448 Fax: 781-481-7030, www.chesterton.com.

Figure 4. Hydrostatic End Thrust.


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No other industry has come under such intense scru-tiny as the oil refi ning industry. Still, no one can deny that processing crude oil into useful petroleum prod-

ucts such as gasoline, diesel fuel and heating oil is an impor-tant part of the global economy. h e oil refi ning industry has strived to become more environmentally friendly both in its product line and process facilities.

Liquid molten sulfur is a by-product of clean fuel produc-tion. As environmental legislation mandates stricter controls on refi ned products, oil refi neries must remove more sulfur from refi ned products, such as diesel fuel. h e recovered sulfur is sold to other industrial companies for use in other prod-ucts—such as fungicides, black gunpowder, detergents and phosphate fertilizers—and for rubber vulcanization.

Leaking Liquid SulfurFor one major U.S. refi nery, the sulfur recovery process created problems in its process line. Sulfur has a high melting tempera-ture of 250 deg F and must be constantly heated at or above this temperature to maintain a liquid state for pipeline trans-portation. However, molten sulfur also has an upper tempera-ture limit of 300 deg F, at which point the viscosity increases, and it begins to re-solidify. Trying to control this narrow tem-perature range and maintain the molten liquid state can be diffi cult. As a result, the refi nery experienced reliability issues with its pumps and mechanical seals.

Immediately after installation and start-up, the pump’s mechanical seal would begin to leak. Within weeks, a large pile of hardened sulfur formed around the pump base causing

huge housekeeping issues along with environmental disposal problems. h e plant would operate the pump for an extended period of time, while the hardened sulfur formed around the pump. When an opportunity arose, they would replace the seal and clean up the sulfur. h is bad-actor pump and seal confi gu-ration was a never-ending problem for the refi nery. Not only did the plant have to contend with continually cleaning up the leaking sulfur, it also had to make sure that the sulfur was disposed of in an environmentally safe manner.

In searching for a solution to its problem, the refi nery tried several diff erent sealing confi gurations, but the leaking still occurred. Since the standard seal designs were not provid-ing a solution, the refi nery looked for customized help from a mechanical seal manufacturer. After assessing the situation, the manufacturer’s team realized that the typical seal confi gu-ration would not work for this application and a new approach was needed.

The Sealing Situationh e engineers at the refi nery gave all the details of the applica-tion and process conditions to the seal company. h e existing seal was a typical rotating bellows design with a carbon bush-ing outboard of the seal faces and a steam jacket around the bushing. However, no steam quench was being used between the bushing and seal faces. Although a traditional steam 5-psig quench had been employed in the past to prevent the sulfur from accumulating and solidifying around the seal faces, the quench line would become plugged with sulfur and tended to accelerate the formation of solid sulfur around the pump.

Unique Sealing Solution Solves Sulfur Leakage ProblemAlton R. Smith, EagleBurgmann

Sulfur leakage, causing housekeeping and environmental issues

in a refi nery, was stopped with an innovative seal confi guration.


h erefore, it was eliminated. Because of the barrier fl uid sulfur contamination, a double seal was not a viable option.

h e sulfur temperature in the pump was at 280 deg F, and the pump speed was 3,600 rpm. h e refi nery engineers and incumbent seal manufacturer theorized that the heat gen-eration in the seal gap was signifi cant enough that the sulfur migrating across the seal faces was reaching its upper solidi-fi cation temperature (300 deg F). A steam quench on the atmospheric side of the seal faces was keeping the sulfur at this upper temperature. Without the quench, the solidifi cation still occurred but at a much lower rate.

“In either case, the result was a domino eff ect,” said Jeff Batinick, a rep-resentative of the seal company. “Sulfur leaking past the faces was accumulating and solidifying around the atmospheric side of the faces, causing them to hang up, and ultimately leading to additional and accelerated sulfur leakage.”

A Non-Traditional

ApproachAfter examining the situation at the refi nery, the seal company engineering department was asked to fi nd the best solution. h e engineers recommended a pusher seal instead of a metal bel-lows seal to eliminate the sulfur build-up. “We looked at the application and, although a bellows seal is the tra-ditional approach, we knew that what was required here was ‘out-of-the-box’ thinking,” Batinick said.

h is non-traditional approach looked beyond standard product off er-ings. “Ocassionally, in mature indus-tries such as refi ning, the industry gets hooked into canned solutions to problems,” commented Batinick. “We looked at it diff erently.”

h e pusher seal is a slurry seal design. It features a stiff , single-coil, stationary spring that loads up the faces to resist hang-up. It also has a dynamic O-ring on the OD of the spring-loaded, stationary face with the spring on the atmospheric side, and it uses faces with large clearances between their ID and the sleeve OD to resist hang-up if sulfur begins to accumulate on the atmo-spheric side. h e other unique feature is

a segmented carbon (Espey-type) bushing on the atmospheric side of the faces that can be used for a high-pressure (30- to 40-psig) steam quench.

Steam at 35 psig has a saturation temperature of 260 deg F, which is near the lower solidifi cation temperature for sulfur. h erefore, introducing a steam quench between the faces and the segmented carbon bushing at this pressure and temperature

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and controlling it with a needle valve on the fl ange drain line would:• Equalize the temperature around the faces to create a better

environment for the sulfur in the seal gap, resulting in a more even transfer of the seal-generated heat away from the faces to keep the temperature in the gap below the upper solidifi cation temperature

• Improve the heat transfer capability of the seal, since steam conducts heat better than air, which is an insulator

• Prevent the sulfur from reaching the lower solidifi cation temperature as it leaks across the faces

• Move the sulfur leakage away from the ID of the faces to prevent it from accumulating, solidifying and hanging up the faces

Sealing the DealTo install this solution, the refi nery had to make a few design modifi cations to its process line. Engineers from the refi nery and the seal company teamed up to minimize equipment modifi cations. h e seal company’s engineers made recommen-dations both for the equipment design and for implementing environmental controls.

“Teamwork made this a successful outcome,” said Batinick. “We were present for the seal installation and start-up, and we

provided training and support. h ere should be no issues with the seal based on operators following the revised recommen-dations and procedures from plant engineering and the seal manufacturer.”

Within two weeks after the pump start-up—the time when sulfur would have started to accumulate around the pump—no sulfur leakage was detected. Housekeeping is now a non-issue for the refi nery and although it has had other pump issues, none were related to the seal. h e refi nery is pleased with this solution and is currently in the process of modifying a second pump to accommodate the pusher seal and is consid-ering retrofi tting several other pumps within the facility.

P&S

Alton R. Smith is the senior regional sales manager for EagleBurgmann. He can be reached at [email protected].

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Metering & Submersible Pumps Special Section

Finding an effi cient and economically feasible way to transfer and meter aggressive chemicals is a constant challenge in many industries ranging from chemical pro-

cessing to food and beverage production to municipal water treatment. Limited maintenance resources and critical service demands put a premium on equipment uptime and extending MTBF (mean time between failures).

In metering applications, choices have traditionally included: controlled volume reciprocating diaphragm metering pumps; peristaltic hose pumps; and, for certain applications, even progressive cavity-type pumps. Critical factors for deter-mining which technology to use for a given application include:• Material selection/chemical compatibility• Accuracy and repeatability requirements• Total cost of ownership (TCO)• Mean time between failures (MTBF)• Ease of maintenance• Initial capital cost• Installation considerations (footprint, compatibility with

existing control schemes, etc.)

With the continued focus on lean operating principles in many industries, the importance of MTBF, ease of main-tenance, and TCO continue to play a greater role in the deci-sion of which process technology to use for a given application. A relatively new entrant into the fi eld provides a solution for many applications and meets the expectations of users regard-ing these key categories. Non-metallic magnetically driven gear pumps are becoming a frequent choice due to their simple

operation and maintenance, long-term reliability and ability to meet performance requirements.

Non-Metallic Magnetically Driven

Gear PumpsWhile positive displacement rotary gear pumps have been around for years, the designs featured metallic construc-tions, which required the use of high-grade alloys (Alloy 20, Hastelloy C, etc.) for aggressive chemical applications. h ese material requirements required larger capital investments than other technologies chosen for these applications. h is has lim-ited the application of rotary gear pumps in chemical metering and transfer applications. However, a completely non-metallic magnetically driven (mag drive) gear pump has been developed that solves many of the critical issues faced in chemical transfer and metering.

Non-metallic mag drive pumps include all wetted parts in non-metallic construction including ETFE housings, PTFE

Non-Metallic Mag Drive Pumps—Great Equipment for Abrasive FluidsTravis Lee, Pulsafeeder, Inc.

Non-metallic magnetic driven gear pump technology improves equipment

life and maintenance costs for metering and transfer applications.

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gears, and alumina ceramic shafts. h e non-metallic construc-tion extends to the containment can portion of the mag drive. h is is critical not only for chemical resistance in harsh environ-ments, but also to eliminate energy loss and heat increase that can be caused by eddy current losses in metallic gear pumps. Bearings are also off ered in both carbon graphite and silicon car-bide constructions. h ese material off erings allow the pumps to

accommodate almost all the hazardous and classifi ed chemical applications that a plant operator or engineer would encounter. h ey are also cost eff ective. A non-metallic mag drive pump can cost up to 30 percent less than a comparable alloy pump and 60 percent less than Hastelloy C.

In addition to material compatibility, the pumps off er sealless mag drive technology. h is eliminates the need for a

mechanical seal, the potential for leaks and the need for frequent maintenance. h is also ensures that no emission issues arise when regulated chemicals are involved.

A Good Choice for Many

ApplicationsReducing the TCO for process equip-ment is a priority for most users, and several features of the non-metallic mag drive gear pump assist with this goal. One of the most important consider-ations for equipment users is MTBF. h e overall cost of equipment failures in chemical applications goes far beyond the expense to repair the equipment. It also includes the downtime costs; labor hours required for the repairs; and the potential product loss and safety consid-erations, especially in aggressive chemi-cal applications. h e non-metallic mag drive gear pump allows for extended MTBF in chemical metering applica-tions when compared to other choices.

Peristaltic technology relies upon unpredictable hose/tube life, which may result in frequent replacement. h e potential risk of product loss due to “catastrophic failure” of a hose/tube is also eliminated with non-metallic gear pumps. In addition, the sealless mag drive technology eliminates the need for seal maintenance when compared to non-mag drive gear pumps. h ese sav-ings manifest themselves throughout the life of the equipment.

Another consideration when attempting to reduce TCO is the ease and cost of maintenance. While reduc-ing MTBF is important, so is repair cost reduction when repairs are necessary. In this regard, the non-metallic gear pump provides a unique solution. h ese pumps contain only 16 wetted compo-nents (comparable metallic gear pumps contain 46 components), allowing for quick repair and servicing. All wetted circle 148 on card or go to psfreeinfo.com

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components are easily accessible from the front-pullout design (see Figure 1). h is allows the pump to be repaired without disconnecting process piping or removing the pump from its installation location. h is saves time and expense.

h e simplicity and intuitiveness also allows for quicker training of operations and maintenance personnel. h e com-bination of extended MTBF, low-cost maintenance and simple

operation ensures a low resource requirement piece of equip-ment for maintenance and operations departments that are continually asked to operate with fewer resources.

Many users operate multiple chemical dosing and transfer applications on-site and may have to maintain a wide range of spare parts to fi t diff erent technologies and varying chemi-cal compatibility requirements. With the non-metallic mag

drive gear pump, the basic confi guration handles the majority of chemical feed applications. h is allows the end user to maintain a minimum inventory of spare parts to service chemical feed systems.

Perhaps even more important than the economic factors are the application benefi ts. h ese pumps can handle a wide range of process conditions including:• Diff erential pressures to 150 deg F

psig• Working pressures to 200 deg F psig• Temperature range to 200 deg F

(with de-rated pressures; 150 deg F at full pressure)

• Flow ranges from 0.1 gpm to 33 gpm• Viscosities to 10,000 cps

In addition to standard chemical applications, these pumps are an ideal fi t for high viscosity applications, such as polymer blending, as the gear pump effi ciency improves with higher viscosity fl uids.

Metering Applicationsh e non-metallic mag drive gear pump can be an excellent fi t for metering appli-cations. h ese pumps provide a pulse-less fl ow which eliminates the need for pulsation dampeners in the system. A metering application with a vector type variable frequency drive for the pump, a fl ow meter for fl ow measurement and a PID controller provides a high level of accuracy (less than one percent variation for properly sized fl ow meter and drive) and performance in metering applica-tions. h is type of system also allows for fl ow verifi cation due to the fl ow meter, which is not typically available in most other metering applications in which reciprocating or pulsating fl ows are used. h is provides a high level of accuracy and a high level of turndown capacity with fl ow rate proportional to the rpm of the motor.

h is compact metering pump circle 153 on card or go to psfreeinfo.com



system contains all the functionality required for most systems.

Transfer ApplicationsWith fl ow rates available up to 33 gpm, this tech-nology can be a good fi t for small to mid-sized transfer applications as well as metering applica-tions. Th e pulse-free fl ow and ability to handle a wide range of chemical applications with a single confi guration makes this type of technology an excellent fi t for chemical transfer applications. Th e pulse-free fl ow eliminates the need for com-plicated piping confi gurations, such as pulsation dampeners, while the transfer application may not require the fl ow meter and verifi cation required in metering pump systems, which results in a simple and eff ective transfer system with a low TCO due to MTBF, ease and reduced maintenance costs.

Recommended Applications:• Sodium hypochlorite• Hydrofl uorosilicic acid (fl uoride)• Polymers• Ferric chloride• Ammonia P&S

Travis Lee is the western regional sales manager for Pulsafeeder, Inc., Rochester, N.Y. Pulsafeeder is a manufacturer of chemical metering pumps and electronic control systems for a variety of chemical dispensing and control applications. He may be reached at 800-292-8000 or at [email protected].

Pulsafeeder is an IDEX water and wastewater company.

The Pumps & Systems News You Can Use

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The earliest peristaltic pumps have been in existence since the 1930s. h rough the years, the designs have

been continuously refi ned for improved performance and enhanced lifetime. During the early developmental years, the greatest peristaltic pump improvements have been advancements in rubber tech-nology. h e average consumer of automo-biles has also experienced this improved rubber technology with automobile tires, wiper blades, hoses, and tubes. In earlier years, these automobile components were not durable and often required repairs.

As rubber technology advanced, the need for replacements became seldom. Peristaltic pump technology has advanced similarly, but the quality and prevalence of rubber gets overlooked. If average con-sumers take the time to consider the reli-able performance of their automobile tires, they may realize that rubber is a durable material that is used globally in millions of products that we rely on daily to make our lives easier and more effi cient.

To further establish the signifi cance of superior rubber technology in pumping systems, we must examine progressive cavity, centrifugal and diaphragm pumping technologies and also larger diameter peristaltic pumps. h ese all rely on rubber as one of the most important wear components of their pumps. h e rubber hose is the main wear element and, in most per-istaltic pump designs, is the only repair part that is replaced periodically.

Sliding Shoe vs. Roller DesignsEarly designs and even some current designs of peristaltic pumps have high friction from fi xed shoes that slide against the hose and limits a pump’s capabilities. h e sliding shoes generate friction and heat, and enormous amounts of glycerin are required to transfer the heat to the casing to help dissipate the heat generated. Many sliding shoe peristaltic pump users understand that the large quantity of glycerin used is a costly

nuisance when the pump needs to be repaired. One gallon of peristaltic pump glycerin costs approximately $85 per gal. A typical 3–in. sliding shoe peristaltic pump uses about 10 gal of glycerin. h erefore, every hose failure is a loss of $850 in glycerin, not including the 10 gal of contaminated glycerin that must be disposed.

Sliding shoe design peristaltic pumps also cannot be con-tinuously run at a high rpm. For instance, a 3–in. shoe design peristaltic pump may have a limit of 40 rpm to maintain con-tinuous service. For a larger shoe design pump to be run at higher rpms, it must be run for two hours and then turned off and allowed to cool for one hour. Obviously, this downtime is not possible or ideal with many processes. Some require two pumps for continuous process running.

Newer and more advanced peristaltic designs use either single or double rollers, which can eliminate 80 percent of the friction caused by sliding shoe peristaltic pump designs, allow-ing peristaltic pumps to run at higher rpms. Roller designs require only a fraction of the glycerin used in shoe designs and have hose lives that are signifi cantly longer. In the larger diameter peristaltic pumps, the motor size required is smaller in roller designs than in sliding shoe designs. A 3-in. roller design

Peristaltic Pump FactsTodd Loudin, Larox Flowsys

The peristaltic pump explained—from advancements to maintenance.


peristaltic pump only requires 2.2 gal of glycerin, instead of 10 gal for a sliding shoe design. At $85 per gallon, the savings on each hose change for the rolling design pump is $663 in glycerin alone.

Roller design pumps can run at higher rpms and still pro-duce a longer hose lifetime than shoe design peristaltic pumps. In many cases the work or fl ow rate that a 3-in. shoe design pump produces can be accomplished by a 2.5-in. roller design peristaltic pump.

In peristaltic pumps the number one determining factor of pump hose life is the number of times the hose is com-pressed. h e medium being pumped can have an impact, but the number of hose compressions is the most impor-tant factor. Sliding shoe designs generate signifi cant heat which also factors into how quickly the hose breaks down. A majority of peristaltic pumps compress the hose two times per revolution. So in almost all cases, the hose lifetime of a single roller design pump is two times longer than a shoe design or multiple-roller peristaltic pump.

For example, the costs of running a peristaltic pump on abrasive slurry for a one-year timeframe are more economi-cal than other pumping technology. For instance, if a 3-in. progressive cavity pump was used in the above application, the cost of rotor and stator replacement during that same year may be as much as $50,000. Regardless of the peristal-tic pump type chosen, it may produce signifi cant cost savings versus other pumps. Also, peristaltic pumps can run dry, which is often the cause of rotor and stator failure in progressive cavity pumps.

Peristaltic Pump MaintenanceMaintenance of all peristaltic pumps is relatively simple. It con-sists of removing a broken or damaged hose, cleaning the inte-rior casing of the pump of contaminants and then installing a new hose with the manufacturer-required amount of glycerin. In some designs, this can be accomplished by one man in 15 to

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20 minutes. In other designs, the maintenance may require two or three people, but it is still a fairly easy and uncomplicated procedure.

Also with peristaltic pumps, you do not need to remove the pump from the pipeline or take it to a repair shop. h e repair work can be done at the pump installation location. With centrifugal or progressive cavity pump re-builds, the pump is almost always removed from its mounting and piping and taken to a repair shop. In general, the rebuild time with other pumps is an eight-hour shift if all the parts are in stock. With peristaltic pumps, the only required parts are a new hose and the necessary glycerin.

Peristaltic pumps do produce pulsations. Many applica-tions require a high-quality pulsation dampener. Since peristal-tic pumps are positive displacement devices, it is recommended to install a programmable pressure transmitter on the pump outlet that can shut the pump down if the pressure increases to higher-than-desired levels. Another option is to have a rupture disc installed downstream of the pump to prevent any undesir-able pressure escalations if the pipeline becomes blocked.

The Varied Uses of Peristaltic PumpsPeristaltic pumps are used in many applications—such as print-ing inks and colorings, mining slurries, wastewater slurries,

bleach, food, beverages, titanium dioxide, sodium bromide and lime slurry pumping to name a few. Peristaltic pumps are also excellent for abrasive slurries and suction lift applications.

As with all technologies, peristaltic pumps have evolved and improved. h e early designs of peristaltic pumps were limited by the shoe design or the inferior rubber technology. Today, peristaltic pumps have come a long way and provide signifi cant reliability.

P&S

Todd Loudin is the president of Larox Flowsys Inc. in Linthicum, M.D. Larox Flowsys is headquartered in Lappeenranta Finland and also manufactures in Linthicum.

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Alcatraz Island is probably best known as the place where an “inescapable” federal penitentiary housed some of the most notorious convicts–including Al Capone;

George “Machine Gun” Kelly; and Robert Franklin Stroud, the “Birdman” of Alcatraz. In 1963, U.S. Attorney General Robert F. Kennedy decided to close the penal complex on Alcatraz Island, and in 1976, Alcatraz was listed on the National Registry of Historic Places.

h e plan was to open the island for tours and educational opportunities. In 1972, the Clean Water Act became the prin-cipal federal law in the United States governing water pollu-tion and discharges to navigable waters. Alcatraz prison had no sewer system, and during the time it was open, wastewater and raw sewage were directly released into San Francisco Bay. How could the Park Service open the island, off er tours, actively welcome thousands of visitors and meet the Clean Water Act’s wastewater guidelines?

h e answer came with the installation of a low-pressure wastewater disposal alternative that off ered a cost-saving instal-lation resolving the problem with minimal disturbance to the natural or manmade environment and requiring zero rock blasting.

A manufacturer of grinder pumps for pressure sewer sys-tems used a low-pressure system to solve the problem. “It con-sists of a network of pipes and grinder pumps installed at sani-tary stations on the island,” said Environment One President George Earle. “h e grinder pumps collect and pulverize sewage and push the resulting slurry to a holding tank through unob-trusive small-diameter (1 ¼ in.) pipes that conform to the natu-ral topography.

“Unlike conventional gravity-central sewers, which can use up to 24-in. pipe and require deep excavation, the E/One Sewer system provides minimal disruption to the environment or built features.” h e low-pressure system employs technology that is known for its minimal maintenance; low, upfront costs; reduced operating expenses; and ability to be installed at any site, regardless of landscape challenges.

“h ere are two duplex grinder pump stations and one sim-plex station installed on Alcatraz. E/One’s system grinds the solids, uses small diameter pipe to transfer sewage to a holding

tank for transport off the island, incorporates durable pump components that are compatible with saltwater fl ushing and is easy to service,” said Don Reppond of Correct Equipment, E/One’s local distributor.

Two of the three grinder pumps positioned on the island are above ground and one is below. Pump One sits atop the prison cell building. It pumps ground-up waste into a slurry which fl ows through a 1-¼-in. pipe to ground level and then

Escape to AlcatrazBill Nestor

A low-pressure wastewater disposal alternative offers a cost-saving

installation solution for wastewater and raw sewage disposal.


Alcatraz, from Prison to Educational Tourist Spot

Alcatraz was considered ines-

capable. From 1934 to 1963,

most, if not all, of the prisoners

incarcerated at the maximum-

security prison wanted to get off

“The Rock,” as it was known.

Today, about 5,000 people

escape to the island each day

for special programs and guided

tours. Alcatraz Cruises, LLC,

transports 1.4 million people

annually from its dock at Pier 33. The private company has the exclusive concession agreement with the

National Park Service to take people to and from the island. The cruise boats run year round, 10 times daily

during the winter and 14 times during the summer.

The National Park Service’s “Alcatraz Development Concept and Environmental Assessment” plan,

approved in 1980 and made public in 1993, doubled the amount of the island that was accessible for public

visitors to enjoy its scenery, observe nature, appreciate the gardens and explore the island’s rich history.

Alcatraz has also taken its place as a seabird nesting island and sanctuary. Portions of the island are set

aside to protect habitat and breeding grounds for black-crowned night herons, western gulls, cormorants,

pigeon guillemots, snowy egrets, slender salamanders and deer mice.

“Education of guests is paramount to the mission of the Park and Alcatraz Cruises. Not only is teach-

ing about the island’s history, nature and gardens paramount, but so too is an emphasis on learning about

sustainability of an island ecosystem along with our planet. Incorporating thoughts and ideas with visitors

that can be implemented into their own daily lives and homes is increasingly important,” said Cameron Clark,

Director of Environmental Service at Alcatraz Cruises. People come to Alcatraz in style and comfort to be part

of a living sustainability lab.

Alcatraz Island is off the power grid and currently uses 52,000 gal of diesel fuel annually to supply energy

needs. The Park Service’s goal is to continue to install alternatives and implement sustainable systems to

reduce the consumption of fossil fuels. The ferry used to transport tourists to and from the island is part of the

service’s plan. Alcatraz cruises uses a combination of solar, wind, grid electric, and diesel generator energy to

power its 64-foot long, 150-passenger boat, Hornblower. The Hornblower, the fi rst hybrid ferry in operation in

the U.S., began service in December 2008.

Two of the three engines on board are used for propulsion and the third creates energy for appliances.

The onboard wind turbine system produces 5 kW, and the photovoltaic panels add another 15 kW; both are

used to operate audio, video, lights and refrigeration.

“Photovoltaic panels mounted on top of the vessel absorb sunlight to create solar electric energy that is

combined with energy generated by the wind turbines. The power produced from these sources charge 380 V

DC batteries. The diesel generator provides additional power. The vessel can operate on propulsion batteries

alone for over an hour of silent cruising,” Clark added.

A non-hybrid 500-passenger vessel is also part of the San Francisco Bay fl eet. It has been retrofi tted by

Alcatraz Cruises with mechanical engine features including a catalytic converter and scrubbers. The increased

energy effi ciency has resulted in reducing diesel fuel consumption by 230,000 gal during the fi rst year.

For more information, visit:

Golden Gate National Recreation Area (www.nps.gov/goga)

Alcatraz Cruises (www.alcatrazcruises.com)

Environment One Corporation (www.eone.com)

Correct Equipment (www.correctequipment.com)


another 200 ft along the surface to a dock-side collection tank. Pump Two, which is above ground and housed in an open-air stainless steel container, sends slurry via a 1-¼-in. line for 500 ft to the dockside holding tank. Pump h ree, underground, pumps the slurry 1,500 ft to the same tank.

Alcatraz Cruises, the company that brings tourists to the island, has a service agreement to bring fresh water, fuel and supplies to the island and dispose of trash and wastewater. Using a specially equipped Mechanized Landing Craft (LCM 8), Alcatraz Cruises pumps sewage and waste-water from the on-island storage tank to a built-in container on the LCM 8. h e LCM 8 is also used to carry water, fuel and supplies from the mainland to Alcatraz.

Upon arrival in San Francisco, the waste is pumped from the onboard tank directly into the city’s sewer line, where it fl ows through four-in. pipes to the main before arriving at the sewage treatment plant for processing. h e procedure trans-fers 6,000 gal each day and 2.19 million gal/1,095 tons of waste annually.

“h e pumps run and the process moves waste to the collection tank regu-larly throughout the day. h ere is minimal but continuous service and maintenance done to ensure uninterrupted functioning of system. h is is particularly important given the 1.4 million island visitors, the use of salt water for fl ushing and harsh salt air environmental conditions on Alcatraz Island,” said Cameron Clark, Director of Environmental Service at Alcatraz Cruises.

h e Golden Gate National Recreation Area is one of the largest urban national parks. It occupies miles of California’s coastline and includes a large area of San Francisco and Alcatraz Island. h e evolu-tion of Alcatraz from a harsh, inhospitable place of discomfort to a popular tourist attraction is a tribute to the far-reaching thinking of the Park Service to preserve and share a valuable part of American history.

P&S

Bill Nestor writes about travel, lifestyle, nature and sustainable development from his home in Vermont. He can be reached via email, [email protected].



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Maintenance Minders

Technical manuals with specii cations such as tolerance and pressures are important tools for troubleshooting hard-to-i x problems.

General shop tools and a range of wrenches, sockets and screwdrivers are also helpful. Packing pullers, grease guns and the proper lubricants save time and money.

In addition to these physical tools, most pumps require that the user have a certain depth of knowl-edge when inspecting or servicing. Problems with pumps normally have an underlying cause of failure, which ot en extends beyond the failed item. h e maintenance methods described below form some of the basic knowledge needed for servicing.

Packing When checking the packing gland, look for exces-sive leakage and repack if needed. When leakage is excessive, the maintenance operator should tighten the packing gland. Keep in mind the leakage should not be completely stopped because water serves as the coolant for the packing in the stui ng box.

Packing around the shat should be tightened just enough to allow about 20 drops per minute. If the follower cannot be properly adjusted anymore, the pump needs to be repacked with the proper packing.

When selecting packing, keep in mind the pump’s pres-sure and shat speed.

Repacking a PumpWhen repacking a pump, ensure that the driver and pump have been safely isolated and that all safety precautions are followed.

New packing should never be added on top of old pack-ing. Start by removing all existing packing and the lantern ring. Once you have removed the old packing, clean out the stui ng box and inspect the shat sleeve for unusual wear. Proper tools should be used—never use a screwdriver. Using the wrong tools may damage the stui ng box or shat sleeve.

New packing should i t around the shat with no gaps at the joints. Place the joint of the second piece of packing 90

deg away from the joint of the i rst piece of packing. Stagger each joint 90 deg from the last one, and ensure that the lantern ring aligns with the coolant port attachment. h is method of staggering the joints prevents water from escaping through the joints. Follow this process until the stui ng box is full.

h e packing gland should be placed on top of the packing. Tighten down the followers. Adjust the followers one l at or ¾ of a turn every 30 minutes or until the leakage is controlled. Feel the packing gland (be careful of the rotating shat ) to see if the packing gland is too hot or uneven, which will result in damage to the pump shat .

BearingsOverheated bearings are caused by friction, which can result from a lack of lubrication. When inspecting a bearing, all i t-tings and grease cups should be cleaned before greasing to remove any dirt. Dirt particles can cause bearing contamina-tion and premature bearing failure.

Lubrication of a bearing should follow the manufacturer’s

Understanding the Basics of Pump RepairPreston Walker, Jr., Caliber Pump Repair

General troubleshooting tips can simplify preventive maintenance.

Improperly adjusted packing gland with no leak off.


recommendations. Additional grease above the recommended amount may cause the bearings to overheat.

When you start greasing a bearing, remove all relief plugs. Removing the plugs allows the old grease to pump out as the new grease is pumped into the housing. Conduct an inspection of the old grease and look for metal particles or metal shaving. Any particles found in the old grease indicate wear, which needs to be addressed.

Couplings Like bearings, couplings require lubrication. When performing maintenance on cou-plings, ensure that safety procedures are followed.

When preventive maintenance is performed, remove the coupling guard to expose the l exible grid. Remove the grid, and inspect it for wear. Whenever metal particles are found, check for misalignment. Immediately inspect the grease for any metal particles.

Once it is determined that the coupling can be reused or if a new one is needed, clean all parts to ensure that no dirt or grit is on the grid or coupling halves. To reas-semble, the grid goes on the drive end of the motor and the driven end of the pump. Put the couplings bolt in place and remove the relief plug. New grease should be pumped into the grease i tting until it is expelled from the relief port. Take care not to over-grease the coupling since it will damage the rubber seal on the coupling halves.

InspectionInspections play a vital role in a preventive maintenance program. Inspections are con-ducted to determine the operation condition of pumps and associated equipment and to help predict what corrective or preventive maintenance will be needed to avoid seri-ous problems.

Inspections, cannot be overlooked or falsii ed. h ey should be routine—daily or even weekly.

During a visual inspection, the operator should look for clogged drain lines, excessive leaking from packing glands, overheated bearings or bearings operating at higher than normal temperatures.

Listen for any unusual noise or vibration or anything uncommon when con-ducting a visual inspection. Vibration is associated with pump operation and must be addressed immediately before serious problems occur and the pump ultimately fails. Noisy bearings can be caused by vibration from loose bearings on the shat or a failed shat coupling.

Excessive leaking at packing gland.

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Maintenance Minders

An inspection checklist is a great way to ensure that nothing is overlooked. I highly recommend that main-tenance operators carry a copy of past inspection data to compare with new i ndings. h is will allow them to detect any new problems and identify trends among the normal operations.

Operation conditions may not be ideal to start and stop equipment. However, an inspection must be con-ducted before the next inspection cycle.

At er inspections, maintenance operators must sit down with supervisors to discuss any problems that were found. Supervisors must be able to prioritize concerns and schedule preventive and corrective maintenance.

Although problems vary, corrective maintenance can be minimized with proper operation and preventive main-tenance procedures.

Basics Checklist

1. Packing glands must not be allowed to leak excessively and should be corrected.

2. Bearings must have the proper amount of grease and i t clean to prevent premature failure.

3. Vibration must be addressed, or serious pump failure will result.

4. Maintenance operators must document all i nds and express

their concerns so the proper corrective or preventive mainte-nance action occurs.

P&S

Preston Walker, Jr., is a plant maintenance senior and pump repairer. He can be reached at 678-698-5366.

Improperly adjusted packing gland with no leak off.


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Introduction

A major concern at water and wastewater treatment facilities is identifying the most eff ective and effi cient way to deal with and

dispose of solid particles and materials that are found in the liquid stream. h ese unwanted con-taminants can have an adverse aff ect on the plant’s operation if they are not contained properly. h e best way to eliminate these solid particles is to have them clumped together into a sludge that can be swept out of the water-treatment stream.

h e most eff ective means of achieving this sludge-creating process is through the use of poly-electrolytes, or polymers, that consist of long-chain organic molecules. h ese polymers have the ability to attract and absorb suspended solid particles, making them easier to remove from the water that is being treated. Activated polymer molecules can perform this crucial task because they have charged sites that attract suspended solids of opposite charge.

Although their higher molecular weight makes them eff ective for this process, polymers can be diffi cult to mix and feed into the treat-ment process. While other typical water/waste-water chemicals such as alum, ferric chloride and sodium hypochlorite can be easily diluted or applied directly to the treatment process from a storage container, to be eff ective, polymers must be “activated.” A polymer is activated by being hydrated and extended prior to dilution and introduction into the process stream.

Polymers are used to remove colloidal sus-pensions from surface waters and to condition municipal wastewater sludges to enhance the

Primer on Polymer HandlingGreg Kriebel

There are many benefi ts of using liquid polymers in water-treatment

applications as long as the blending equipment is able to

accommodate their unique characteristics.

Effi ciency Matters

This system simplifies the polymer blending process because it has been

designed to effectively activate all types of liquid polymer.


dewatering process. While lower-cost, metallic salts like alum or ferric chloride can be used to initiate the coagulation process, high molecular weight polymers, or fl occulant aids, are fed into the process to form larger, neutralized particles—called fl ocs—that settle faster. Some potential, negative side eff ects of using metallic salts for coagulation include the chance that they can contribute to high levels of residual metal content in the treated water and in some cases an excessive amount of sludge, which will increase treatment costs. A more cost-eff ective approach to coagulation and fl occulation would be to use smaller doses of metallic salts for charge neutraliza-tion and to add polymer for bridging to create a large, settleable fl oc.

The ChallengeWhen a polymer makes initial contact with water, the outer surface of the poly-mer particles becomes sticky. If the particles are not properly dispersed prior to and during the initial wetting phase, agglomerations, or fi sh-eyes, will be formed. Agglomerations make it more diffi cult for water to penetrate and successfully hydrate and activate the bound-up polymer. h erefore, pumping neat (concen-trated) polymer into a tank of water and using a high-speed mixer may properly disperse the polymer and prevent clumping, or the formation of agglomerations. Once activated, however, polymers are fragile. In their concentrated form, polymers are like a coiled spring. However when the molecules are uncoiled and extended, the polymer molecules become fragile and are susceptible to fracture by any high-shear device. High-speed mixers that are used to keep the sticky polymer particles separated will fracture the activated polymer strands and render them less eff ective in forming settleable fl ocs.

To compensate for any reduced eff ectiveness, plant operators often feed more polymer than necessary into the stream, which leads to increased chemical costs. One option that is used to eliminate fractured polymer molecules is low-speed, low-shear mixing. Unfortunately, this method requires excessively large tanks that allow for the slow dissolution of the inevitable agglomerations that are formed. Such a system also requires the batching of polymer to begin hours before the diluted polymer solution is needed, which greatly increases the capital costs of equipment and facilities.

The SolutionA better option to large and expensive tank systems is a liquid polymer blending and feed unit. An ideal polymer feed system should include a means of introducing the neat (meaning as delivered) polymer to the water to avoid the formation of agglom-erations while incorporating a two-stage or tapered mixing system in its design. h e fi rst stage supplies the high-shear and high-energy needed to disperse and wet the polymer molecules, a process often referred to as inversion.

To meet these criteria, polymer feeder manufacturers have developed various ways of introducing polymer to the dilution water to prevent the formation of agglomerations. One such method is to draw the polymer out in a ribbon-like thin sheet and introduce it to a high-energy water stream. Research has shown that when polymer is introduced into the water in this fashion, it will be instantly and thor-oughly wetted into a useable solution. h ese wetted and extended polymer mol-ecules may be easily fractured if they remain in the high-energy zone for an extended period of time. h at necessitates a second low-shear zone or tapered mixing regime that will complete the blending of the polymer with dilution water while not dam-aging the activated and fragile polymer strands.

Polymers are available in a variety of forms and concentrations. Developing an understanding of the diff erent characteristics is essential when evaluating the process design that best suits your operation.

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Effi ciency Matters

• Dry Polymers. Shipped in a powder form that is similar to table salt or sugar, dry polymers are considered 100 percent active when calculating for process design. h e typical shelf life of dry polymers is several years, making them ideal for quan-tity purchase and storage.

• Emulsion Polymers. Available in an oil-based liquid form with a milky opaque appearance, emulsion polymers have vis-cosities that range from 100 to 2,000 cps, which is similar to motor oil. Emulsion polymers have an average content that is 40 percent active. h e typical shelf life of emulsion polymers is four to six months.

• Dispersion polymers. Also available in an oil-based liquid form with a viscosity that is similar to motor oil, dispersion polymers diff er from emulsion polymers in that their average content is 50 percent active when calculating process design. h eir shelf life is four to six months.

• Solution polymers. h ese are known as polyamines and are used for coagulation purposes only, primarily in water plants.

Solution polymers are a water-based liquid with viscosities that range from 2,000 to 10,000 cps, which is similar to honey. h e average content is 10 percent active, for the purpose of calculating pro-cess design.

• Mannich polymers. h is formaldehyde-based liquid has a clear-to-milky appear-ance with viscosities that range from 10,000 to 50,000 cps, which is similar to gelatin. Average content is 5 percent active for calculating process design. h e typical shelf life of this polymer is several weeks.

Choosing the best polymer to use depends on a number of variables, not the least of which is the type of clarifi er, fi lter or dewatering equipment that is being used in the water-treatment process. Equipment selection also must consider the water and wastewater characteristics, potential changes in the water or wastewater characteristics, bench test results and a comparison of sav-ings versus ease of use.

Conclusion

Today’s high molecular weight liquid polymers can represent a signifi cant part of a water or wastewater treatment plant’s chemical cost. Properly mixing and activating polymer can result in improved process performance and reduced chemical costs, making proper feeding of these chemicals of particular interest to plant operators.

P&S

Greg Kriebel is the national sales manager for Fluid Dynamics, a divi-sion of Neptune Chemical Pump Co., Lansdale, Pa. You can contact him directly at [email protected] or 215-699-8700. For more information on dynaBLEND, please go to www.dynablend.com. Neptune is an operating company within Dover’s Pump Solutions Group (PSG™), Downers Grove, Ill. PSG is comprised of six leading pump companies—Wilden®, Blackmer®, Griswold™, Neptune™, Almatec® and Mouvex®. You can fi nd more informa-tion on PSG at www.pumpsg.com.




It is illegal to duplicate this CD. Copyright © 1997-2010 Hydraulic Institu

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■ ANSI/HI 1.1-1.2 Centrifugal Pumps – Nomenclature & Definitions

■ ANSI/HI 9.6.4 Rotodynamic Pumps – Vibration Measurements & Allowable Values

■ ANSI/HI 9.6.5 Rotodynamic Pumps – Condition Monitoring

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Q. How do rotodynamic (centrifugal) pumps perform when handling slurries?

A. h e performance of a rotodynamic pump on slurries will diff er from its performance on water, which is the basis for most published curves. Head (H) and rate of fl ow (Q) will normally decrease as the solids, size and concentration increase. Power (P) will increase and starting torque will be higher.

In most circumstances, the net positive suction head required (NPSHR) by the pump, not to exceed 3 percent head drop, will increase. h e eff ects of solids on NPSHR are

dependent on the slurry type and the pump design and can be variable. For settling slurries of low to medium concentration, a modest increase in NPSHR can be expected. For a particu-lar application, a conservative estimate of this increase can be found by dividing the value of NPSHR on water by the head de-rating factor.

For viscous and non-settling slurries or slurries with entrained air, the eff ect on NPSHR can be greater. h e pump manufacturer should be consulted for guidance regarding slurry eff ects on NPSHR.

Diff erent approaches can be used for predicting the centrifugal pump performance change from water to slurry, depending on the slurry type. When the solids-fl uid mixture, as shown in Figure 12.17, is considered homogeneous and exhib-its Newtonian behavior that can be characterized by an appar-ent viscosity, the ANSI/HI method for pump performance vis-cosity correction can be applied. See ANSI/HI 9.6.7, Eff ects of Liquid Viscosity on Rotodynamic Pump Performance.

h e viscosity correction methods in HI 9.6.7 are empiri-cal methods based on the best test data available from sources throughout the world. Many factors for particular pump geom-etry and fl ow conditions are not taken into account. However, the methods provide for dependable approximations when lim-ited data on the application is available.

Pump users should consult with pump manufacturers for more accurate predictions of performance for a particular pump and particular slurry.

Q. What factors determine the maximum allowable working pressure of a centrifugal pump?

A. h e maximum allowable working pressure (MAWP) for centrifugal pumps is based on the minimum of any or all of the following:• h e maximum allowable stress level in the pump casing.

h e stress level is determined by the design methods estab-lished by the American Society of Mechanical Engineers (ASME) and considers the casing material, operating tem-perature and factor of safety.

• Finite element stress analysis methods are often used to calculate stress levels, but empirical methods are also used

PUMPFAQs®

Figure 12.17


based on existing designs and experience.• Allowance for casing wall corrosion and manufacturing

thickness is also added to the desired wall thickness. In this regard, manufacturers often provide minimum casing wall thickness for use in monitoring the service life of a pump casing.

• Pressure ratings for standard design fl anges used to connect pumps to the system are a major consideration, and many pump MAWP ratings are equal to the fl ange ratings. h e minimum casing wall thickness is then calculated to match the fl ange rating.

• Mechanical seal housing design and seal selection must also be capable of withstanding the MAWP.

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This is the second of a four-part “Sealing Sense” series that provides guidance on best practices to mini-mize the size of the sealing system energy footprint.

h e fi rst article discussed energy losses from the interaction between the seal faces of a mechanical seal. h is article will discuss the thermal energy needed to maintain a suitable temperature for the interfacial lubricating fl uid in high-tem-perature processes.

Process Fluid Flushh e reliability and emission performance of any mechanical seal depends on the ability to maintain a stable fl uid fi lm between the faces. h e three types of mating face lubrication regimes were discussed in the August 2010 “Sealing Sense.” For most applications, it suffi ces to provide a small amount of process fl uid fl ow as fl ush to remove the seal-face-gener-ated heat and lubricate the faces. h e minimum fl ush fl ow rate is based on a 10 deg C (18 deg F) maximum allowable process fl uid temperature rise.

h is fl ush-fl ow rate represents a small energy loss because the process fl uid used for the fl ush needs to be re-pumped from suction back to discharge. h ese systems do not rely on the cooling of the fl uid, so they consume an insignifi cant amount of energy compared with the total energy footprint of the pumping system. API Piping Plans 1,11,12,13, 14 and 31 are examples of sealing systems that use process fl uid without cooling as fl ush. h ey are applicable to single seals and the process side seal of a dual, unpressurized seal.

h e maximum recommended operating temperature of these piping plans will depend on the process fl uids’ lubri-cating qualities at operating conditions such as seal chamber pressure and pump speed. Other considerations include the temperature limits of the secondary seals and the potential consequences of normal and transient leakage rates, or a major leak (seal failure) to the surrounding environment and the safety of personnel.

External cooling h e small energy footprint for operating seals at high tem-perature has been recognized, but in some cases, cooling of the process fl uid is needed to achieve acceptable reliability, emission and safety targets. Historical data of seal OEMs show that an annual energy savings of approximately 2.3

What is the Sealing System Energy Footprint for

Controlling Process or Barrier Fluid Temperature?

Second of four parts

This month’s “Sealing Sense” was prepared by FSA member Eric Vanhie

Figure 1. API Piping Plans 21 and 23.

From the voice of the fl uid sealing industry

SEALING SENSE


kW per 25 mm (1 in.) of shaft size can be realized for every 38 deg C (100 deg F) of cooling requirements that can be removed from the seal cavity. Many high-temperature applications are found in refi neries, power plants and some chemical processes. h e most common sealing systems to incorporate cooling of the process fl uid are API Piping Plans 21 and 23.

API Piping Plans 21 and 23In these plans, an external heat exchanger reduces the process fl uid temperature considerably and provides a cool fl ush over the seal faces. h is may be needed to protect against vapor for-mation, meet temperature limits of secondary sealing elements, reduce coking or polymerizing of the leakage or improve the lubricating qualities of a process fl uid such as hot water.

h e primary benefi t of Plan 21 is a suffi cient pressure dif-ferential to achieve the high fl ow rates needed to cool the seal. h e drawback is that the cooler duty is high and the fl ush fl ow needs to be re-pumped to discharge, which may result in a sig-nifi cant energy foot print.

Plan 23 is the default for many hot water and hydrocarbon services in power plants and refi neries. h e cooler duty is much lower than that for Plan 21 because it only removes the seal face generated heat and a small amount of heat soak from the process. h e seal incorporates a pumping device that circulates the process fl uid to the cooler and back to the seal chamber. h e

process fl uid in the seal chamber is isolated from the hot process fl uid with a throat bushing in the impeller area to minimize the heat soak loss.

Heat soakHeat soak is a source of heat fl ow into or out of the fl uid that lubricates the seal faces. It is the result of the temperature diff er-ence between the seal chamber and the environment surround-ing the seal chamber. Calculating the heat soak loss is a complex matter because of the many variables involved. Mechanical seal standard API 682 provides a simplifi ed method for estimating this heat loss. h e cooling capacities of the heat exchangers that are used in Plan 23 are 6 and 36 kW, which cover the majority of all high-temperature applications. From an energy standpoint, Plan 23 has a smaller footprint than Plan 21, but the process fl uid cannot contain many solids or be too viscous, sticky or have polymerizing tendencies.

Dual sealsSealing systems for dual seals require an external cooler to con-trol the barrier fl uid temperature within a specifi ed range, with the maximum at 80 deg C (176 deg F) for many barrier fl uids. h e thermal loss due to heat soak may become signifi cant for process temperatures above 150 deg C (302 deg F). h e sources of energy consumption in these auxiliary systems include the


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FSA Sealing Sense

pumps and motors to create the fl ow and pressure in the sealing system, the heat removed by cooling water through heat exchangers and additional system heat removed above and beyond the seal chamber heat load because of system design.

Each service is somewhat diff erent and can best be esti-mated by your local seal manufacturer. h e maximum cooling capacity of systems for dual seals is 8 kW for Plans 52 and 53A and up to 36 kW for Plans 54 and 53B. Systems for gas-lubricated seals consume an insignifi cant amount of energy as described in the August Sealing Sense.

Air coolingh is is an eff ective method for reducing the energy footprint of sealing systems in general. h e elimination of cooling water reduces the cost to operate the seal and pump. h e drawbacks of air cooling include its limited capacity and typical restriction to outdoor installations. Another method for eliminating the cooling water is to use product cooling. In this case, the process fl uid is circulated through a coil in the barrier fl uid reservoir or heat exchanger to remove the heat from the seal. h is method is limited to process temperatures up to 50 deg C (122 deg F), and the fl uid must be free of solids. h e energy required to re-pump the process fl uid back to discharge must be considered as the fl ow rates may be fairly high in this scenario.

Conclusions1. h e energy footprint for controlling process or barrier

fl uid temperature can be estimated for any fl ush plan application. Meaningful comparisons can be made to determine the most energy-effi cient system.

2. Reliability, emissions and safety aspects of the seal must be considered during the evaluation and selection process.

3. For the majority of seal applications, the energy footprint for controlling process or barrier fl uid temperature is small compared with the overall footprint of the pump. Exceptions apply in services involving high temperatures and/or dirty fl uids.

4. For single seal and dual unpressurized seals in a high-temperature environment, the footprint for API Plan 23 is smaller than that for Plan 21. Plan 21 should be used only when Plan 23, for some reason, cannot be applied.

5. Heat soak losses can be reduced signifi cantly by having a close clearance bushing at the bottom of the seal chamber.

6. For dual seals in a high-temperature environment, API Plans 52 and 53 consume less energy than Plan 54.

7. Air cooling and product cooling may be eff ective methods for reducing the energy foot print in specifi c applications.

In next month’s article we will focus on the energy required to remove external fl uids or diluents from a process stream.

Next Month: What is the Sealing System Energy Footprint for removing diluents from the process stream?

We invite your questions on sealing issues and will provide best eff ort answers based on FSA publications. Please direct your ques-tions to: sealingsensequestions@fl uidsealing.com.

P&S

Figure 2. API plans 52, 53A and 54.

Sealing Sense is produced by the Fluid Sealing Association as part of our commitment to industry con-sensus technical education for pump users, contractors, distributors, OEMs and reps.

In the September 8, 2008 issueof the Wall Street Journal, anarticle appeared, headlined“New Nukes.” Reporter RebeccaSmith led the piece with thestatement:

“If there ever were a time thatseemed ripe for nuclear energy,it's now. For the first time indecades, popular opinion is onthe industry's side. A majority of Americans thinks nuclearpower, which emits virtually nocarbon dioxide, is a safe and effective way to battle climatechange, according to recentpolls. At the same time, legisla-tors are showing renewed interest in nuclear as they huntfor ways to slash greenhouse-gas emissions.”

CLYDEUNION Pumps could not agree more with these sentiments about the nuclear industry. In July of thisyear, CLYDEUNION Pumps formed the Nuclear ServicesGroup and appointed Timothy B. Frisbie, Sales Director,to develop this important and ever-growing business inthe Americas.

It was also in 2008, that Clyde Pumps (formerly WeirPumps–Glasgow) and Union Pump merged to form CLYDEUNION Pumps. This new company brought about the best of two worlds—it retained almost 300 years ofcombined proven experience and generated a youthful vitality to meet the challenges of today’s fast pace andever-increasing demands.

Tim Frisbie embodies CLYDEUNION Pumps persona of vitality and experience. He brings nearly thirty years ofexperience in the fluid-handling industry from oil refineries to desalination plants. Yet, one would neverguess his age when you first meet him.

CLYDEUNION Pumps is well positioned to serve the nuclearindustry with new and rebuilt OEM quality pumps and24/7 on-site service. The company is a world leader in thedesign and manufacture of pumping plant for the powergeneration industry and has been authorized since 1977by the American Society of Mechanical Engineers to markits products manufactured to ASME Sec III Classes 2 and3 with the ‘N’ and ‘NPT’’ stamps. We are currently seek-ing U.S. and Canadian accreditations for our BattleCreekMichigan and Burlington, (Toronto) Ontario facilities tosupport dedicated nuclear repairs and component supply.

Frisbie says, “I am excited to be part of our company’s nuclear aftermarket services group. It has been my visionfor a long time to be a leader in the Nuclear industry forthe supply of new pumping equipment, repairs of all manufacturers and to be the ‘go to’ company for field service. We never ran away from the nuclear market, butnever really did support it like it deserved. Now, with themerger of our two companies, it is finally coming tofruition. My years of working with engineers, machinistsand customers in the field taught me the importance ofmaking sure I stand behind everything I promise and deliver on those commitments without question and onschedule. This has become one of CLYDEUNION Pumps’ real competitive advantages.”

Tom Tesoriero, a former U.S. Navy nuclear professionalwith more than 25 years of commercial nuclear machinery experience, leads the group’s marketing efforts. Tesorierosays, “These are exciting times at CLYDEUNION Pumps aswe bring together expertise from both the European andUnited States nuclear pump machinery industries. Thisenables us to provide the best global solutions for the resurgence of the U.S. commercial nuclear power fleet.”

To find out what CLYDEUNION Pumps can do for you, talkto a CLYDEUNION Pumps representative today. Whetherit’s a new or rebuilt system or on-site service on existingequipment, you can count on CLYDEUNION Pumps. Please visit our web site www.clydeunion.com or call TimFrisbie directly at (269) 317-2892 for sales or service with24/7 on-site service support.

Tim Frisbie

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Practice & Operations

During the third quarter of 2009, a new grass roots gold mine opened in the state of Zacatacas, Mexico.

GoldCorp’s Minera Peñasquito mining proj-ect soon became the largest open pit mine in Mexico and a signifi cant contributor to its annual production and profi ts. h e huge proj-ect encompasses traditional mining, crushing, grinding and fl otation circuits of sulphide ores. Signifi cant by-products of silver, zinc, and lead add considerably to the viability and profi tability of this state-of-the-art mineral processing facility.

A need for multiple pumpsh e facility needed products and services for several of the process pump applications found in this massive mining endeavor. h e largest single order was for the reclaim water pumping system, which returns water from the tailings pond to the plant for use in multiple processes.

h e system consisted of eight barge-mounted vertical turbine pumps equipped with 900 hp motors. h e pumps and motors, located in the tailings pond and gravity fed to the processing plant, deliver 10,000 gal of water per min each, or a maximum of 80,000 gpm, to a secondary booster pump station that houses eight additional 1,000-hp, can-type vertical turbine pumps. In the mineral process-ing circuit of this plant, after the metals have been extracted from the ore, the waste material is sent by gravity fl ow to the tailings pond. h e excess water in the tailings is reclaimed and pumped back up to the processing circuit via this barge mounted pump station and a secondary booster station for reuse. h e system’s 100-plus million gal per day of total fl ow are reused continuously. Additional make-up water is added to the system, as needed, for use in the mineral process facility.

h e process required pumps that could not only handle the abrasive nature of the dirty mine water, but pumps that are also adaptable to the varying conditions expected over the 22-year estimated life of the mine. Multi-stage turbine pumps that could be de-staged at future intervals as the tail-ings pond levels rise and the pump system head requirements

Reclaiming the GoldMike Dwyer, Quadna

Investment in mine expands production capabilities.

The 900 hp vertical turbine pumps are situated on the Minera Penasquito mine’s

barge.


decrease over the life of the mine were chosen. In addition, special chrome oxide bearing and shaft surfaces that will greatly extend the wear life of the pump components were supplied for the project.

A Boost to Mexico’s Gold

Production

h e more than $2-billion-USD investment made by GoldCorp in the Peñasquito mine has been important to the domestic mining sector in Mexico and will position Mexico as one of the fi ve largest gold producers in the world. It will generate 2,500 direct jobs and 12,500 indirect jobs. On March 23, 2010, Goldcorp celebrated the mine with a visit from Felipe Calderón, the president of Mexico.

In the second quarter of 2010, a second sul-phide line, which further expanded production capabilities, was completed. h e annual production life of the mine will ramp up to approximately 500,000 ounces of gold, 30 million ounces of silver and more than 400 million pounds of zinc.

With gold and other commodity prices continuously on the rise, the possible profi tability of this mine is impressive.

P&S

Mike Dwyer, project manager for Mining Accounts, has 23 years’ experience with Quadna and 31 years total in the pumping industry. He can be contacted at 2803 E. Chambers Street, Phoenix, AZ 85040, 602-323-2370. Quadna, a DXP Company, engineers, fabricates and ser-vices mechanical systems that move fl uids and gases for industrial applications.

All pump systems are installed and the barge readied for operations in the mine’s

pond.


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When a nuclear power plant pulled its vertical IR32 APKDnine-stage condensate pump for routine

maintenance, an emergency situation was not expected. h e plant pulled the pump and installed a replacement from storage, but it failed catastrophically after only two days in service.

Requiring a solution for the emergency need, the plant accepted a workscope from a service center that promised a refurbished pump within nine days. h e plant shipped both pumps to the service center and sent a condensate system engineer to oversee the work and maintain an open line of communication between the organizations.

h is case study highlights the root cause of pump fail-ure for a nuclear power plant and the emergency response required to repair the pump. One key factor to handling this emergency pump failure was the teamwork between the plant’s management, an onsite plant engineer located at the repair facility and the personnel at the repair facility. A lesson learned for pump users in emergency situations is that close teamwork and having a customer engineer onsite is critical to facilitating a rapid response.

Root Cause of Failureh e pump failed as a result of having been previously incor-rectly repaired, coupled with contributing installation issues, ultimately causing the upper shaft to break. h is root cause became apparent during the disassembly process. h ese photos illustrate what the pump service center found.

Best practice is to maintain stringent alignment and concentricity between interfacing parts. h is ensures cor-rect concentricity and perpendicularity between shaft and

bearings and rotor to casing. h e service center discovered that the top bowl male fi t had been previously repaired by pad welding (see Figure 1), which is an improper practice due to the presence of a sealing O-ring. When a pad weld is performed on a pump that uses the O-ring design, fi ts and tolerances no longer meet acceptance criteria. It appeared that the previous repair provider coated the faces with sil-icone or another sealant in an attempt to re-establish the proper fi ts or control leakage (see Figure 2).

h e top of the discharge bowl did not fi t properly in the bottom of the discharge head (see Figure 3). Excessive force used to make these components fi t bent the shaft and created a condition ripe for fatigue failure. h e forced bend-ing of the shaft caused the impeller ring to contact the case (bowl) ring during operation (see Figures 5 and 6). h e motor had to produce more torque to drive the assembly due to frictional resistance from the heavy rub (see Figure 7). Furthermore, the suction bell was not properly seated in the alignment ring (see Figure 8).

h e misalignment and excessive bending load on the entire rotating element assembly caused the shaft to break at the snap ring groove, which resulted in catastrophic pump failure.

When Maintenance Becomes EmergencyDonald Spencer, P.E., HydroAire, Inc.

In this case study, routine maintenance of a condensate pump

at a nuclear power plant becomes an emergency situation.

Figure 1. Pad welded male fi t for the top bowl.


Figure 8. h e alignment ring at the bottom has a damaged edge, which is evidence that the suction bell was not properly seated in the alignment ring.

Emergency Response Required to Repair

the Condensate Pumph e agreed plan to repair the pump was to use in-spec parts from the fi rst pump and reusable parts from the failed pump to deliver one working pump. h e plant’s ability to supply condensate pump parts from its inven-tory helped decrease the turnaround time because fewer parts needed to be manufactured.

Bowls and BearingsBowls from the fi rst pump were used because the impeller case wear ring running clearances were acceptable; however, the shaft graphalloy bearing

Figure 2. Silicone coating appears to have been used in a previous repair after the

male fi ts were pad welded in an attempt to seal the proper fi t between the top

bowl and the discharge head.

Figure 4. The bolts between the can fl ange and the discharge head appear to have

been tightened with additional force as one section of the fl ange rose up about

¾ in. on one side after the discharge fl ange was unbolted from the base-plate.

Figure 5. Damaged case ring as a result of galling

contact.

Figure 6. Heavy grooving from running stage impeller

eye ring.

Figure 3. The male fi t of the top discharge bowl was

over size at 18.754 in. and the female fi t of the dis-

charge head was 18.7445 in., causing an interference

fi t (Exaggerated diagram, not to scale).



running clearances were not. Fortunately, the plant had new bowl/shaft bearings in their inventory and pro-vided them for use. After installing the bearings, bowl TIRs (wear ring and bearing bores) were checked. In the lower fi ve bowls, the wear rings had excessive run-out. h e plant had fi ve bowl wear rings in stock that could be used with the impellers and bowls.

Shafth e upper shaft from the original pump and the lower shaft from the failed pump were used because both had acceptable TIR readings of less than 0.003 in.

Impellersh e impellers from the original pump had to be used because the bowls were taken from that pump and the impeller wear ring diameters were sized to those bowl rings. Each impeller was balanced individually to 1 W/N, and then each rotor was balanced (upper with fi ve impellers and lower with four impellers).

Discharge HeadPlants often use a common discharge head in a given conden-sate pump position. Spare heads are not usually kept. Using the same discharge head with diff erent bowl assemblies can aff ect the geometric centerline between the rotor and the casing as well as the head-to-bowl assembly. After inspection, the discharge head was welded and machined at critical fi t locations to re-establish proper concentricity. h e completed pump was shipped back to the plant within the agreed nine-day turnaround time.

Lessons Learned

h ere is no doubt that the disassembly, inspection, analysis and complete repair would have required much more time in a typ-ical pump repair shop. h e service center, which was dedicated to nuclear pump aftermarket services, was able to determine the root cause of failure and provide a rebuilt pump within nine days because they had an in-house engineering team and customer partnership during the repair process. Working with a pump service facility that combines experienced individuals using proper repair and rebuilding practices for vertical pumps is important. Vertical pumps require precision manufactur-ing and attention to detail during the rebuild and installation process because of their multiple components, which when assembled, result in a tolerance stack-up that must be concen-tric within fairly narrow limits from top to bottom.

P&S

Donald Spencer, who has over 30 years’ experience in the nuclear pump industry, recently became HydroAire’s Manager of Nuclear Services. With a Bachelor’s of Science in Nuclear Engineering, Don’s career spans major OEMs, including Bingham-Willamette, Johnston Pump Co., and Sulzer. For details on this article or HydroAire’s Nuclear Services, contact Donald Spencer at [email protected] or by calling 312-738-3000.

Figure 7. The high amps reading at pump failure show motor torque.

Figure 8. The alignment ring at the bottom has a damaged edge,

which is evidence that the suction bell was not properly seated in

the alignment ring.


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Self-Priming Chopper PumpsVaughan Company intro-duces its line of self-priming chopper pumps, which are designed for lift stations, scum wells, portable cleanout or any retrofi ts of clogging pumps. Vaughan Company Inc. is the only manufacturer of a self-priming chopper pump. h e new, high-effi ciency chopper impeller design allows priming up to 24 ft. h ese pumps cover a wide range of applications with fl ows up to 6,000 gpm.Circle 204 or go to psfreeinfo.com

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conveying systems as well as gas and liquid applications. Tuf-Lok pipe couplings can be used on mild steel, stainless steel, aluminum and most other thick or thin wall pipe. Numerous gasket materials are available for diverse design conditions.Circle 218 or go to psfreeinfo.com

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potential h e MAGDOS LB is available in several sizes with a dosing capacity of up to 15 l/h or up to 16 bar. h e MAGDOS LB can be used in almost all process applications. h e compact, space saving design and footprint of the pump is suitable for integration into almost every metering system. Moreover, the pump can be installed in diverse positions. As part of the new “Plug&Play” con-cept, dosing pump confi gurations with a range of 110 to 240 VAC are available worldwide for immediate use. Circle 215 or go to psfreeinfo.com

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- Tube Compounds: Natural Rubber, EPDM, Nitrile (Buna-N), and

FDA Safe White & Tan Materials

- For Watson-Marlow™, Blackmer™, Verder™, Ponndorf™, Periflo™,

and Other Posiピve Displacement Pump Manufacturers

Peristaltic Pump Hose

Call us for a quote or visit our website for addiピonal informaピon.

ID

(mm)

OD

(mm)

Length

(mm)

ID

(in)

OD

(in)

Length

(in)

10 31.0 508.0 0.39 1.22 20.0

15 36.0 762.0 0.59 1.41 30.0

25 53.2 1006.4 0.98 2.09 39.6

32 61.0 1250.9 1.25 2.40 49.2

40 66.4 1489.0 1.57 2.61 58.6

50 80.0 1820.8 1.96 3.14 71.6

65 99.2 2336.8 2.55 3.90 92.0

80 122.0 2781.3 3.14 4.80 109.5

100 144.0 3276.6 3.93 5.66 129.0

Non-standard or custom built peristalピc hoses are also available.

TOLL FREE: 1-800-686-4199

www.salem-republic.com


Product Pipeline

ASI Model 550 Sealh e ASI Model 550 is suited for slurry applications, particu-larly those with harsh operat-ing parameters and diff ering product consistencies and those of a corrosive nature. It also seals many bleaching materials, including multiple forms of HTH paste, as well as higher concentration caustic products. In addition, the 550 (equipped with its “pumper” option) lends itself to hazardous waste applications, overcoming the large abrasives, varying chemicals and occasional dry-run scenarios typical to the service.Circle 222 or go to psfreeinfo.com

Vortex PumpsZoeller Engineered Products introduces their broad selection of 1 to 15 hp submersible, solids-handling pumps with vortex impellers. Vortex pumps, recognized for their superior solids handling capabilities, are being applied in challenging wastewater pumping applications.

Zoeller off ers these pumps in either 2.5 in. or 3 in. solids han-dling capacity. Discharge sizes are 3 in., 4 in. and 6 in. with standard or explosion proof motors. Circle 224 or go to psfreeinfo.com

KSB Dry-Pit SubmersibleKSB announces a new, dry-pit submersible series with NEMA MG1 premium effi ciency motors. h is versatile pump can be mounted in a ver-tical or horizontal position in areas that are prone to fl ooding. Modular construction incorporates motors up to 10 hp, using three diff erent impeller types and sixteen diff erent hydraulics, covering a wide range of fl ows and heads.Circle 223 or go to psfreeinfo.com

P&S


INDEX OF ADVERTISERS

ABB Discrete Automation & Control 129 31

ABS USA 102 71

ABZ, Inc. 188 108

AE Pumps, Inc. 194 109

All Prime Pumps 195 110

ATC Diversii ed Electronics 130 14

Baldor Electric Company 103 35

BaseTek, LLC 159 84

Benshaw 133 33

BLACOH Fluid Control, Inc. 134 20

Blue-White® Industries 135 8

Boerger, LLC 136 68

Boerger, LLC 196 111

Caliber Pumps 197 110

Chemicals Direct 198 109

CLYDEUNION Pumps 104 99

CLYDEUNION Pumps 199 109

Cole-Parmer 137 9

Coupling Corporation of America 171 107

Crane Pumps & Systems 138 19

Dan Bolen & Associates 300 109

Danfoss Drives 160 52

Dwyer Instruments, Inc. 105 17

Environment One Corporation 108 69

EagleBurgmann 106 13

Eccentric Pump 172 88

Electro Static Technology 139 25

Equipump 189 108

Fairbanks Morse 161 51

Flowserve 140 34

Fluke Corporation 110 45

Frost & Sullivan 173 93

Fuji Electric Corporation of America 111 49

Garlock Sealing Technologies® 112 5

Global Pump 117 73

Graphite Metallizing Corporation 174 95

Griffco Valve, Inc. 141 16

Heinrichs 175 64

Holland LobePro 142 67

Hydra Service, Inc. 107 75

Hydraulic Institute 176 93

Hydromatic® 131 62

Hyundai Heavy Industries Co. Ltd. 113 30

Inpro/Seal 114 11

International Products Corporation 163 84

ITT Goulds 162 87

ITT Water & Wastewater M & C 109 3

Junty Industries, Ltd. 301 110

KSB, Inc. 143 41

Larox Flowsys, Inc. 115 61

LEWA Inc. 144 27

Load Controls, Inc. 145 65

Load Controls, Inc. 190 108

Lutz-JESCO America Corp. 116 BC

MSE of Canda Ltd. 302 111

Macromatic Industial Controls 177 97

Megator 178 106

Meltric Coporation 179 97

Mid-West Instruments 180 106

Moyno, Inc. 118 21

MTH Pumps 181 101

Myers 132 79

National Pump Company 146 47

Neptune PSG 147 80

NOC 191 108

Orival, Inc. 164 53

PeriFlo, Inc. 148 72

Proco Products 165 92

ProMinent Fluid Controls 119 81

Pump Pro’s 166 54

Pump Solutions Group 167 91

Pumping Machinery 192 108

R + W America L.P. 149 63

Racine Federated Inc. 150 42

Rain for Rent 303 111

Revere Control Systems 182 95

Rockwell Automation 101 IFC

Ruhrpumpen 120 15

Salem Republic Rubber Co. 183 105

seepex 151 36

SEPCO 152 22

SEPCO 304 110

Shanley Pump 184 101

ShinMaywa® 185 88

Sims Pump 100 56-57

Sims Pump 100 110

SJE Rhombus 168 53

St. Marys Carbon Company 186 107

Summit Pump, Inc. 306 111

Swaby Manufacturing Co. 153 74

SWPA 154 93

Synchrony, Inc. 121 IBC

Tamer Industries 307 111

Tarby,® Inc. 169 51

TECO-Westinghouse 122 37

Trachte, USA 308 111

Trask Decrow Machinery 309 110

Tuf-Lok 310 111

Turbomachinery Symposium 128 89

Unitronics, Inc. 193 108

Valve & Filter Corp. 155 43

Vaughan Company, Inc. 123 23

Verder GPM 156 12

Vertil o Pump Co. 187 64

VescoPlastics Sales 311 109

VibrAlign, Inc. 170 76

WAGO 157 48

WEFTEC 124 55

Weir SP 158 44

WILO USA LLC 125 77

Yaskawa America, Inc. 126 7

Zoeller Company 127 85

Zoeller Company 312 109

* Ad index is furnished as a courtesy and no responsibility is assumed for incorrect information.

Advertiser Name R.S. # Page Advertiser Name R.S. # Page Advertiser Name R.S. # Page


BULLETIN BOARD

Pump Tec 2010EVERYTHING YOU EVER WANTED TO KNOW ABOUT PUMPS!

7th Pump TecPumps Hands-On Maintenance

and Reliability Conference

Atlanta, GA USA

September 20-21, 2010

For more information go to

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770-310-0866



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√√√√√√√√√√

Easy to Install...

For more information on the Progressing Cavity Grinder Retroit,

please visit www.zoeller.com

Model 6932A

NNIVERSAR

Y

SINCE 1939


“Serving the Pump & Rotating Equipment, Valve, and Industrial Equipment Industry since 1969”

Domestic & International

Specializing in placing:

• General Management • Engineering • Sales & Marketing • Manufacturing

DAN BOLEN • JASON SWANSON

CHRIS OSBORN • DAN MARSHALL

9741 North 90th Place, Suite 200Scottsdale, Arizona 85258-5065

(480) 767-9000 • Fax (480) 767-0100Email: [email protected]

www.danbolenassoc.com

EXECUTIVE SEARCH/RECRUITING


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For informaピ on:

(800) 803-0353

www.allprimepumps.com

All Prime self-priming centrifugal pumps are marketed in the

United States, Canada & Mexico exclusively by the All Prime

Division of Power & Pumps Inc., Jacksonville Florida. Based

on the design of Gorman-Rupp’s T SERIES® & U SERIES®,

these pumps are available as bare pumps, parts, base

mounted and assembled fi berglass lift station units.

Materials of construction available include Cast-Iron, CD4MCu,

316-SS, 304-SS, ADI, Hastelloy & High-Chrome.

T SERIES® & U SERIES® are trademarks and registered trademarks of The Gorman-Rupp Co. in the

US & other countries. All Prime is not sponsored by nor affi liated with The Gorman-Rupp Company.




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PRECISION MACHINED IMPELLERS, RINGS, SLEEVES & BEARINGS

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1-800-SIMS-303SIMS PUMP CO.Since 1919

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US Navy Approved100% Made in USA

www.simsite.com






Rotary Lobe PumpsMacerating Technology

The Multichopper, (Single Shaft Grinder)

for solids and debris

laden fl uids, macerates

and conditions stringent

material in homogenous

sludge.

The Multicrusher, (Twin Shaft Grinder)

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skins, etc.

Boerger, LLC | Minneapolis, MN | 877.726.3743 | www.boerger-pumps.com

innovat ion



Your Best Value in ANSI Centrifugal Pumps

Model 2196

Green Bay, WIwww.SUMMITPUMP.com

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P&S Stats and Interesting Facts


P&S Stats and Interesting Facts

1100

1200

1300

1400

1500

1600

1700

1800

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

-0.20%

-0.10%

0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10

Pump and Pumping Equipment Manufacturing

Air and Gas Compresor Manufacturing

Pump and Compressor Manufacturing

65.00%

70.00%

75.00%

80.00%

85.00%

90.00%

95.00%

Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10

Chemical

Food, Beverage and Tobacco

Petroleum and Coal Products

Mining

Paper

$1.50

$1.70

$1.90

$2.10

$2.30

$2.50

$2.70

$2.90

$3.10

$3.30

Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Jun-10 Jul-10

Average Price of Gasoline

Average Price of Diesel Fuel

Rig Count (U.S.): Jan. 7 – Aug. 13, 2010

Nu

mb

er

of

Rig

s R

un

nin

g

Week

Month-to-Month Percentage Price Change

in Pumps and Compressors

Plant Capacity Utilization by Industry

Average Fuel Prices (U.S.)

Source: Baker-Hughes Inc.

Source: Federal Reserve Statistical Release

Source: Energy Information Administration

h e Producer Price Index program of the U.S. Department of Labor measures the average change over time in the selling prices received by domestic producers for their output. h ese charts detail the month-to-month percentage change in selling prices. Source: U.S. Department of Labor

2009 R&D 100 Award Winner Synchrony Fusion

®

Magnetic Bearing


Pumps & Systems Sep2010

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Transcript of Pumps & Systems Sep2010