Modern Pumping - 042014

PUMP EfficiEncy

REVOLUTiOn

WhEn DO WaTER Main

BREaks OccUR?

ThE PERfEcT fLUiD sEnsOR

April 2014providing SolutionS for the WorldWide pump induStry

modernmodern

todAytodAy®

Products and services Guide2014

ContentS April 2014

12

16

30

4 industry news

10 trade Show prof ile

Case Studies 12 Clean Water Challenges feed entrepreneurial dreams

16 Subsurface Stormwater drainange Solutions maximize land use Increased storage with a small footprint revitalizes Fairfax Gardens housing development

Water & Wastewater Solutions 18 When do most Water main Breaks occur? Compression waves (water hammer), pipeline failures, and pumping stations

maintenance Solutions 22 Simplifying the Search for the perfect fluid Sensor Move from search to solution quicker and more successfully

pump Solutions 26 A revolution in pump eff icieny All-Flo's A200 pump reduces energy costs, improves performance Part 1 in a 4-Part Series

motor Solutions 30 Compact drives-and-Controls Solution leads to new performance levels Advanced PLC-controlled drive systems ideal for packed engine room of PSVs

processing Solutions 32 What not to Cool on Some process pumps Part 2 of a 2-Part Series

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

valves & Controls Solutions 36 dCS versus plC A user's guide to selecting the most effective control platform for your application Part 2 of a 2-Part Series

Sealing Solutions 40 Saving valuable Water for All Municipalities learn from homeowners' example

43 products and Services guide 2014

www.modernpumpingtoday.com P.O. Box 660197 | Birmingham, Alabama 35266

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff of Modern Pumping Today, or who are not specifically employed by Highlands Publications, Inc., are purely their own. All Industry News material has either been submitted by the subject company or pulled directly from their corporate website, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected].

For address changes, please contact Lindey Scott: [email protected]

TiM GaRMOnPresident

LaRRy DaUGhETyVice President

DEnnis DaUGhETyVice President

www.highlandspublications.com 312 Lorna Square | Birmingham, Alabama 35216

T: 866.251.1777 | F: 205.824.9796

@ModPumpMag

RUssELL haDDOck COO/Publisher [email protected]

JEff fLETchER Associate Publisher [email protected]

RanDy aRMisTEaD Associate Publisher [email protected]

J. caMPBELL Editor [email protected]

DOnna caMPBELL Editorial Director [email protected]

scOTT GORDOn Art Director [email protected]

JOEL DORninG Assistant Art Director [email protected]

chRis GaRMOn General Manager [email protected]

LinDEy scOTT Circulation Manager [email protected]

JaMiE WiLLETT Circulation Consultant [email protected]

inGRiD BERky Administrative Assistant

nancy MaLOnE National Sales Manager

RanDy MOOn Account Executive

kRisTi nEiL Account Executive

40

Terry BellDrives and Motion Solution Engineer

Baldor Electric Company

Heinz P. Bloch, P.E.Consulting Engineer,

Process Machinery Consulting

Robert G. Havrin Director of Technology, Centrisys Corporation

Michael ManciniConsultant and Trainer,

Mancini Consulting Services

John M. Roach Engineering Manager

for New Product Development,Trebor International, Inc.:

A Unit of IDEX

Lisa RoeBusiness Development Manager,

Wastewater PumpsXylem Inc.: Flygt

Greg TowsleyDirector of Regulatory and Technical Affairs, Grundfos

Trey Walters, P.E.President, Applied Flow Technology

editoriAl AdviSory BoArd

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

http://www.mpt.com

https://www.facebook.com/pages/Modern-Pumping-Today/262372740522483

https://twitter.com/ModPumpMag

4 | April 2014 www.modernpumpingtoday.com

INDUSTRy newsLEWA, BP FORM PARTNERSHIPLewa GmbH have been awarded a five-year global framework agreement with BP to supply chemical injection packages for BP's Global Projects Organisation.This framework agreement enables BP’s Global project teams (including their EPMS/EPC contractors) to access Lewa GmbH international resources to supply chemical injection packages. Lewa GmbH have demonstrated technical and commercial capabilities that increase product quality, reliability, and drive standardization within the process packaged equipment category.

DANFOSS SHOWCASES ENERGY- AND WATER-SAVING TECHNOLOGIES During Water Week 2014, Danfoss joined other manufacturers and solutions providers, industry associations, and non-profit organizations on Capitol Hill to discuss perspectives and solutions as well as challenges and opportunities in U.S. water and wastewater sectors.

“Water and wastewater treatment represents the third largest energy consumer in the United States,” explains Lisa Tryson, director of corporate communications and public relations at Danfoss. “Policy, regulation, and financing options are critical to get available, proven energy-efficient technologies deployed. Through public and private sector engagement, we can make progress on the water-energy nexus.”

Specifically, on April 9, Danfoss showcased its high efficiency, readily-available variable frequency drive technology as a viable solution for energy-intensive water and wastewater treatment processes. The one-day Water Infrastructure & Innovation Expo was hosted by Water Environment Federation (WEF) as part of the National Water Policy Forum & Fly-in, Water Week’s anchor event hosted by The National Association of Clean Water Agencies (NACWA), WEF, and Water Environment Research Foundation (WERF).

Held in the Rayburn House Office Building, the Expo was attended by members of Congress and congressional staff, general managers and plant managers of waste and clean water facilities, water agencies, federal agency employees, and the public.

“This Expo was a great way to bring together various perspectives on the state of water in the United States, and continue to reinforce the availability and capability of high efficiency technologies that, with broader deployment, could help to solve urgent—and growing—energy challenges,” comments John Masters, vice president of sales/water, Danfoss. “There was very strong interest from attendees on the benefits of variable frequency drives and the ability to reduce


INDUSTRy newsenergy use in the water and wastewater treatment sector, and this interest is critical to advancing the deployment of these technologies.”

The National Water Policy Forum & Fly-in convened water and wastewater professionals from around the country and members of Congress and other federal regulators to share perspectives on federal clean water policy. The Fly-in set the stage for the Expo’s strategic and technical insights.

To learn more about Danfoss technologies for water and wastewater, visit www.envisioneering.danfoss.com/water.

MAAG AUTOMATIK PLASTICS MACHINERY WINS MAJOR CONTRACT

Maag Automatik (a Dover Corporation Member) announces

that M&G Finanziaria (Italy) has chosen the German manufacturer to supply the equipment needed for a complete PET pelletizing plant.

Not only will Automatik deliver a number of its production proven underwater SPHERO® pelletizing systems but also corresponding melt pumps, screen changers and the company's highly innovative direct crystallization CC-PET® process.

Located in Corpus Christi, Texas, the new operation is designed for a capacity of one million tons per year and as a consequence will be the largest PET production site ever built. Commissioning is expected to commence by the end of 2015.The M&G Group is among the world's three largest producers of PET resin for packaging applications, and the second largest in the Americas. The company expects that the project will both consolidate and strengthen its dominant position.

Maag Automatik is particularly pleased that the M&G group has decided to further cement the existing, successful relationship between the two market leaders and selected Automatik as partner for this challenging and pioneering project. This once in a decade order underlines once more the unrivalled leadership of Maag Automatik in the supply of PET pelletizing systems.

BLUFFTON ACQUIRES RAE CORPORATIONBluffton Motor Works announces that its affiliate, DC Products Group, has acquired RAE Corporation, a manufacturer of high-performance motion control motors, controllers and gearmotors for industrial and commercial applications. Headquartered in McHenry, Illinois, the RAE Corporation was founded in 1946 and has earned a reputation for flexible designs, application engineering support, quality assurance, customer service, on-time delivery and application-matched performance. Terms were not disclosed.

This acquisition complements the Bluffton line of industrial and commercial grade AC motors, gearmotors and speed reducers. By being a part of the Bluffton organization, this


INDUSTRy newsacquisition will strengthen RAE's position in the fractional DC motor and gearmotor markets by enhancing Lean Manufacturing practices, utilizing Six Sigma tools and introducing manufacturing flow improvements. It enables a wider array of services, increased depth and more resources to bring to the company's customer base.

According to Bluffton Motors Works' president, David Nussear, "We are excited by having the RAE team in the Bluffton family. They provide excellent engineering, product designs, manufacturing, customer service and are a good fit with the Bluffton organization. This synergy between the companies will enable our mutual customers to benefit from a wide selection of value-added products from a single source."

Bluffton Motor Works is an American owned and operated manufacturer of custom designed AC fractional and integral horsepower motors and gearmotors. Formerly the Engineered Motor Products Division of Franklin Electric, Bluffton Motor Works has manufactured high quality motors and gearmotors at its corporate headquarters in Bluffton, Indiana since 1944.

Bluffton manufactures electric motors ranging from 1/20 to 5 horsepower in 56, 48, or 36 frame ratings with open, enclosed or explosion proof enclosures. It also offers a superior line of washdown duty motors, including the patented HydroDuty line of stainless steel motors and the HydroWash and Picker Plus epoxy washdown motors.

In 2012, Bluffton Motor Works expanded their product line through the acquisition of Toledo Gearmotor, which manufactures right-angle and parallel shaft gearmotors, as well as inline reducers and right angle cast iron worm gear reducers.

DEMATIC SPONSORS PROJECT MANAGEMENT INSTITUTE COMPETITIONDematic, a supplier of logistics systems for the factory, warehouse and distribution center, sponsored the Project Management Collegiate Competition on April 14, 2014, at Davenport College in Grand Rapids, Michigan. The organizer of the event, The West Michigan Chapter of the Project Management Institute, created the one day event to support the development of business leaders with partnering college students, community leaders and project management professionals to competitively tackle a commonly shared business challenge.

"It is an Inter-Collegiate Competition that highlights the Project Management skills that engineering companies like Dematic needs to be successful in today's complex technical environment" says Katie Wierengo, vice president of supply chain for Dematic. College students from ten colleges and universities in Michigan will compete in this year’s event. Dematic is the Event Sponsor.

For 2014, the Project Sponsor was Governor Rick Snyder, state of Michigan. The project scenario was Connect Michigan Military Veterans with their Federal Benefits. Each college team will present their proposal, a project plan and supporting documentation to a panel of West Michigan business leaders for judging. Teams were judged on their project management skills and ability to properly utilize project management techniques. The West Michigan business community will benefit from a wider understanding of the value project management can bring to their organization. A focused career fair occurred after the student presentations. ■


TRADE SHOW prof ile

With an abundance of technical forums, education sessions, highly regarded speakers, and networking opportunities,

the annual Electrical Apparatus Service Association (EASA) convention exemplifies the organization’s mission provide its members opportunities to stay current on materials, equipment, and the next generation of technology. Hosted in Boston, Massachusetts, the 2014 EASA Convention boasts a variety of viewpoints and venues for industry professionals to learn, connect, partner, and succeed.

THE BUSINESS OF EASA IS BUSINESSThe 2014 EASA Convention kicks off with an early-bird education session focused on improving attendees’ sales strategies and effectiveness. The session, “Improving Sales Call Success: Are You Asking the Right Questions?” by Jerry Peerbolte, prompts attendees to improve their sales call success by making better use of the time the customer or prospect provides. Most salespeople use this precious time asking questions to identify any unmet needs or opportunities—but are these the right questions?

Based on the popular SPIN® Selling model, this workshop will present an alternative to the classic sales approach. The SPIN method emphasizes the questioning techniques salespeople use when identifying customer needs. Research has clearly shown that when applied properly these techniques

2014 EASAConventionLearn, Connect, Partner, Succeed

April 2014 | 11 www.modernpumpingtoday.com

improve sales call success. Participants will learn these questioning techniques and the related research findings.

Other topics will include

• Setting realistic sales call objectives• Understanding the difference between implied and

explicit needs, and why that’s important• Determining the

customer’s value equation

• Explaining features, advantages and benefits. What does each mean?

• Recognizing key buying signals

• Preventing customer objections

EDUCATION SESSIONSA highlight of the annual convention, each education session features an expert in the field sharing his or her knowledge with attendees in a relaxed yet invigorating atmosphere. Of special interest this convention will be “Assessing Impeller Damage” by EASA Pump and Vibration Specialist Gene Vogel. The impeller is generally the most difficult pump component to repair and the most expensive to replace. This session will look at case histories of failed pumps and the steps to determine the cause of failure, including topic as erosion, corrosion, cavitation, or wear; how to diagnose an impeller and to spot the tell-tale signs of wear; and how to deduce the operational conditions that led to impeller damage.

Mike Howell, an EASA Technical Support Specialist, will be presenting another session of note, “AC Motor Redesign: Speed Changes,” which will focus on AC motor redesigns involving speed changes. Service centers encounter scenarios such as the procurement of a single-speed motor that must be redesigned for two speeds or redesign of an existing two-speed motor for use on an adjustable-speed drive.

Topics will include

• Single-speed, one-winding to two-speed, one-winding• Single-speed, one-winding to two-speed, two-winding• Two-speed, two-winding to single speed, one-winding• Two-speed, one-winding to single speed, one winding

The redesign examples will be performed using EASA’s AC Motor Verification and Redesign program, including use of the newly integrated Motor Winding Database for locating comparative data. Examples will include other changes such as voltage, frequency and horsepower.

NEW PRODUCT THEATERBack by popular demand, the New Product Theater provides attendees with an opportunity to see the latest products in the industry marketplace. All sessions are thirty minutes in length, allowing interested observers to quickly learn first-hand about new products. New Product Theater participants for 2014 include the following

• Marathon Motors, showcasing BCP: Bearing Current Protection.

• Siemens, offering Flexible Duty Motors FD.

• Rea Magnet Wire Co., Inc./ Elantas PDG, introducing Ultimate Protection for Inverter Duty Applications.

• Bradleys', Inc., presenting Large Horizontal and Vertical Motor Load Testing.

And many more.

MOTOR DECISIONS MATTERFor more than a decade, EASA has partnered with energy efficiency programs across North America to promote the adoption of motor management practices, including best practice repair, through the Motor Decisions Matter campaign. This session will update members on the expansion of the campaign to include motor systems management and describe how MDM’s resources and tools can help EASA members communicate with customers and

provide added value, reducing downtime, decreasing energy costs and improving productivity—e.g., campaign resources can help members educate customers about motor operating costs and assist them in developing motor inventories.

Managed by the Consortium for Energy Efficiency (CEE), Motor Decisions Matter is regularly presented and discussed at CEE member meetings and other industry events.

ALL WORK AND A LITTLE PLAYSunday evening, the 2014 EASA Convention lets its hair down with a networking event that provides nourishment for body and soul! This evening’s festivities begin with a reception followed by a delicious dinner (with a few playful side dishes thrown in). Then, after briefly but respectfully honoring the winner of this year’s Exceptional Achievement Service Award, the evening will quickly transition to the hilarious musical comedy of The Water Coolers. E! Entertainment TV has called them “the hottest ticket in town,” so prepare to “laugh out loud”! Their comedy is clean, funny, and smart–an authentic take on work and life based on things people share around the water coolers of everyday life. ■


CASE Studies

The rising demand for clean water worldwide has created huge opportunities for creative engineers, researchers and entrepreneurs with great ideas and

dreams of starting their own businesses. But what does it take to build an innovative global company?

In Ontario, more than 300 companies have developed innovative water technologies and several have blossomed into world leaders in niche markets. One of the best known of these companies is TrojanUV. TrojanUV is part of the Trojan Technologies group of businesses. This group includes

Michael Stewart is the senior economic officer for the Ontario Ministry of Economic Development, Trade, and Employment. For more information about the companies mentioned in this article, visit www.trojanuv.com and www.realtechwater.com. For more information about locating a business in Ontario or doing business with Ontario entrepreneurs, visit www.investinontario.com.

About the Author

By michael Stewart,ontario ministry of economic development, trade, and employment

Clean Water Challenges Feed Entrepreneurial Dreams

One of Ontario's water filtration entrepreneurs shows off his facility. For more information on the water filtration sector in Ontario, visit www.investinontario.com.


seven businesses: Aquafine, OpenCEL, Salsnes Filter, Trojan Marinex, TrojanUV, US Peroxide, and VIQUA.

SUPPORTING INNOVATIONBased in London, Ontario, TrojanUV develops and manufactures UV disinfection and UV-oxidation systems for municipal water and wastewater treatment. Over the past thirty-seven years, the company has grown to become a global leader in UV technology. It has the largest installed base of UV water treatment facilities in the world, a list that

includes over 8500 municipal systems in 102 countries, treating 50 billion gallons (189.3 billion liters) of water per day.

Today, the company has 750 employees worldwide, with manufacturing facilities in London and Guelph, Ontario, California and Germany. It’s a remarkable transformation for a company that, in 1976, was a small metalworking shop whose main business was making toolboxes.

“What sets TrojanUV apart from most companies in our industry is our commitment to R&D,” says Trojan


CASE StudiesTechnologies president Marv DeVries. “We invest about 5 percent of our top line in R&D and that’s allowed us to expand into markets. We now have more than 250 patents granted or pending.”

Some of TrojanUV’s research is done in-house and some has been in partnership with local universities.

Ontario is internationally recognized as a centre for water research, with more than twenty-one institutes dedicated to water-related research across the province. To further encourage R&D by companies, Ontario offers one of the most generous R&D tax incentive programs in the G7.

“Government support for R&D has been very important for us,” says DeVries.

REWARDING SUCCESSThat’s a sentiment echoed by Jodi Glover, co-founder and CEO of Real Tech Inc., a Whitby-based a start-up. Real Tech is a four time recipient of the Deloitte Technology Green fifteen awards for their remarkable success in developing affordable and reliable water quality monitoring technology.

In many ways, Real Tech is a classic story of an entrepreneurial family business with a high-tech twist.

“I grew up in the water business,” says Glover, explaining how her dad, Ron Hallett worked in the water treatment sector for years before starting UV Pure, a company that develops water purification technologies using ultraviolet radiation.

Recognizing a need in the water industry for a small portable unit that could quickly test for organic contaminants, Jodi and her husband Andrew, an engineer, started Real Tech.

“We knew that there was a real market opportunity since traditional water quality testing can take days to complete in a central laboratory using delicate and very expensive equipment.”

Andrew began researching approaches that could overcome many of the challenges faced by such analytical instrumentation. The result was Real Tech’s breakthrough product, a portable, reliable and affordable water analyzer that was rugged enough to be tossed into the back of a truck. With a few minutes training, a technician could take one of the units out in the field, draw a water sample, test it and see the results on-the-spot.


Real Tech has since expanded its technology platform and product line to include real-time online quality monitoring for large treatment systems. They have also racked up sales in 40

countries to customers including the Ontario Ministry of Health, the U.S. Environmental Protection Agency, NASA, Coca Cola and almost every major water company, including TrojanUV.

“We wouldn’t be here without the support we received from the Ontario government,” says Glover. “The support for R&D, marketing, labour costs—it’s amazing.”

ENTICING TALENTEqually vital for growing companies is the ability to attract and retain top talent, says TrojanUV’s Marv DeVries. Often that comes down to quality of life and, for TrojanUV, London Ontario has what it takes.

“London offers a person a great balance of living,” he says. “Housing costs are relatively low, and there are education and recreation opportunities that are important for the young people with families that we are looking to hire.”

Ontario offers water technology companies research expertise, an exceptional talent pool and a range of government supports to bolster their chances of building global market leadership. Will the next generation tackled the emerging water challenges and find success? If the Ontario industry track record is any indicator, the answer is a resounding yes. ■

http://www.gusher.com

http://www.naglepumps.com

http://www.greatsouthernpump.com


CASE Studies

Built in 1951, Fairfax Gardens is a 150-unit public housing development in the middle of a low-density, single-family neighborhood in Taunton, Massachusetts.

The development’s infrastructure, utilities, and many building components are original to the site, making them outdated and in need of complete replacement. The current distressed conditions at Fairfax Gardens not only negatively impact the residents’ health and quality of life, but they have also caused a decline in the property value of nearby homes. In light of these issues, the United States Department of Housing and Urban Development selected Fairfax Gardens as one of eight nationwide recipients of the HOPE VI Grant, which will fund major re-habitation, new construction and other community and support service programs for residents.

BUILDING A NEW COMMUNITYIn July 2012, demolition of the existing 150-units was completed and plans for the new Fairfax Gardens development and Parcel 6A, an additional, offsite complex, were underway. The original site will include 88 “green,” mixed-income, townhome units. The existing community center will be

replaced, new streets and bike and pedestrian paths will be built and each unit will feature a front and backyard. Parcel 6A, which is approximately one mile away on a lot that is currently vacant, will feature seventy-two energy-efficient, mixed-income units.

The site is located across from the Greater Attleboro Taunton Regional Transit Authority (GATRA), which allows for residents to live in a denser, more urban environment and support the city’s ongoing revitalization of its downtown area into a vibrant, mixed-use, walkable environment for employees, shoppers, and new residents.

AN EYE TOWARD EFFICIENT SOLUTIONSIn order to support the new development at Parcel 6A, engineers from Kelly Engineering Group, Inc. based in Braintree, Massachusetts, coordinated with general contractor CWC Builders Inc. and subcontractor J. Derenzo Co. to develop an efficient subsurface stormwater management system. In doing so, the team was faced with a number of challenges onsite.

Being located directly across from GATRA and adjacent to railroad tracks, they found pockets of lead- and petroleum-

For more information about Cultec stormwater management chambers and other products, call 203.775.4416 or visit www.cultec.com.

for more information

By Cultec

Subsurface Stormwater Drainage Solutions Maximize Land Use

Subsurface Stormwater Drainage Solutions Maximize Land Use

Increased storage with a small footprint revitalizes Fairfax Gardens housing development


contaminated soil which had to be removed. A portion of this soil was shipped out immediately and treated at a facility in Maine, while the remaining soil was first treated in place and then shipped to a facility in New Hampshire. During this time, workers dug out the rest of the site and tested the sides to be sure all contaminants had been removed, prior to refilling it.

The site also had a high groundwater level, requiring engineers to provide the maximum volume at the lowest possible depth so that the site did not require too much fill.

SELECTING THE RIGHT CHAMBER“One concern we had was that systems one and two were very close together,” says Brandon Li, project engineer at Kelly Engineering Group. “I called CULTEC to be sure these systems would function properly without having to install a drain, and their representative assured me that, much like a bathtub, they would simply flow over once full. They were able to get me an answer right away without having to hold up the project. It was very helpful.”

Engineers selected CULTEC’s Recharger 330XLHD®, an efficient chamber which has a lower volume in the early stages of a storm. HD Supply, one of the industrial distributors in North America, distributed a total of 353 chambers which

were installed twenty-four rows to make up the separate subsurface stormwater system.

“Luckily CULTEC’s chambers are shallow, because we were working within a very tight area. The chambers sit right above the water table and the minimum one-foot of cover just fits above them, with sixty parking spots right on top,” says Bradd Biagini, project manager for J. Derenzo Co.

The Recharger 330XLHD has a capacity of over 400 gallons (1514.16 liters), making it one of the largest CULTEC chambers available. The unit itself is 52 inches wide by 30.5 inches high (1320.8

millimeters by 774.7 millimeters) and has an installed length of 7.5 feet long with a bare chamber capacity of 7.5 cubic feet (0.21 cubic meters) per linear foot. In all, the CULTEC system provided 29,609 cubic feet (838.43 cubic meters) of storage, which maximized storage capacity within a small footprint to best satisfy the requirements of the Parcel 6A site. ■


WATER & WASTEWATER solutions

On March 11, 2014, in the LinkedIn blog “American Water Works Association,” Riley Vittitoe, the general manager for the water utility of Topeka, Kansas,

posted a curious question: “When do most water main breaks occur?” One of the most interesting comments posted on the blog was that one respondent noticed that water main breaks in his system disappeared after he installed variable frequency drives on his system pumps. Although this answer was one item of many mentioned, it was interesting. Other causes listed in the blog indicated that improper bedding conditions, swelling or shrinking of the soils, and seasonal factors contributed to the frequency of breaks. Other commenters suggested that large changes in demand also contributed to the frequency of breaks.

Changes in demand, and the starting and stopping of system pumps, can create pressure waves in all types of pipes. This article will look at some of the effects of pressure waves and how they can damage a piping system.

THE BIRTH OF A PRESSURE WAVEFirst, when we change the flow in a pipe, it creates a pressure wave in that pipe. Depending upon the diameter of the pipe, and the length of the pipeline, the pressure wave can, by itself, cause pipe ruptures, and can generate very large forces.

The basic equation of motion from Newton’s First Law reminds us that force is equal to mass times acceleration. Acceleration is the change in velocity, and the mass is the amount of liquid in the pipe. For long pipes, this can be a very great force because of the length of the pipe. A quick example follows:

Given a cast iron transmission main 12,000 feet (3650 meters) long 16-inch (406.4 millimeter) nominal Schedule 150 pipe (actual dimensions from the Mueller catalog are diameter of 16.32 inches [414.528 millimeters] and wall

thickness is 0.54 inches [13.716 millimeters]) diameter pipeline full of water, carrying 6500 gallons (24 cubic meters) per minute moving at 10.4 feet (3.171 meters) per second.Compute the pressure rise from valve closure or pump failure.

The force exerted is the sum of the density times the quantity times the change in velocity. Note that this is simply the weight of the liquid in the section divided by the force of gravity. Written as an equation:

ΣF= ρQ (ΔV )

Where F is the force, and ρ is the density of the liquid, Q isthequantity,andΔVisthechangeinvelocity.Lookingatsome terms are re-arranging and making some substitutions,

we get:

Where –p’ is the pressure force, w is the weight of the fluid, A is the area of the pipe, and c is the velocity (celerity) of the pressure wave. The pressure wave reduces the velocity in the pipe to zero as it passes each section. This is much in the same way as a freight train slows down: The engine leads, and as it slows the resistance force is transmitted through each coupling until the entire train is slowed.

If the pipe is rigid, the velocity or celerity of the pressure wave can be calculated by some additional manipulation (not shown) to be

David L. Russell, PE, is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., a specialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projects ranging from environmental process designs and hazardous wastes to water systems and wastewater treatment. He can be reached at 770.923.4408 or by visiting www.globalenvironmental.biz.

About the Author

By david l. russell,global environmental operations, inc.

Compression waves (water hammer),

pipeline failures, and pumping stations

When Do Most

Water Main Breaks Occur?

-p' A=w*(A*c)

*(0-V) g


Where Ef is the bulk modulus of elasticity of the liquid (compressibility of the liquid), and ρ is the density. For water, the bulk modulus of elasticity is approximately 313,000 psf, and the calculation, which assumes a totally rigid pipe wall is c= (313000*144/1.94) = 4820 feet (1469.5 meters) per second at 60 degrees Fahrenheit (15.56 degrees Celsius).

MATERIAL CONSIDERATIONSBut if the pipe is non-rigid, cast iron, steel, or plastic, some of the energy is dissipated by pushing on the walls of the pipe and stretching it a bit. In steel and cast iron materials, this is small to negligible, but in PVC it can be significant. This stretching action also slows down the pressure wave.

The accurate formula for the velocity of a pressure wave in a non-rigid pipe including steel, cast iron, and plastic is shown below.

Where Ef is the bulk modulus of the liquid, Ep is the bulk modulus of the pipe, d is the diameter and t is the thickness. The density of the fluid is ρ. If we apply the actual values to our example above, the speed of the pressure wave becomes: 3342 feet (1019 meters) per second. The pressure wave will travel the length of our 12,000 feet (3657.6 meters) of pipe in 3.59 seconds. Any valve closure or pump failure which has a

time less than 3.59 seconds will generate a pressure wave or water hammer in the pipe.

If a pipe has a length of L , the water hammer will reflect off of a reservoir or another closed valve, and the travel time for the return wave will be twice the length of the pipeline divided by the speed of the wave, or in this case 6.34 seconds. It is important to note that the return wave will be negative, and it will be reflected from the closed valve as a positive wave of slightly lesser magnitude, and travel back and forth as a positive and negative waveform until it finally dissipates.

For our pipeline example from above the increase in pressure will be given by

h=cV/g

and the resulting numbers are h=3342*10.4/32.18=1080 feet of head or (449.6 PSI or 3100 kpa).

If we calculate the stress on the piping using the accepted hoop stress formula, the 469 psi increase will generate a stress (over and above the stress due to the existing pressure) in the pipe wall, of

Stress = pressure * radius/thickness

The additional stress is equal to 469.6*8.18/0.54 = 9655 psi increase in tension on the pipe wall. The yield strength of cast iron, depending upon the type is between 25,000 psi and 50,000 psi. If the wall has been corroded and is thinner, the pressure at that point could exceed the tensile strength of the cast iron, resulting in a dramatic release.


WATER & WASTEWATER solutionsBULK MODULUS OF LIQUIDS AND SOLIDS Below are some values for the bulk modulus of liquids and solids used in piping systems.

A QUESTION AND SOME ANSWERSThe sudden stopping of a fluid in a pipeline can cause high pressure waves. OK, so how do we prevent water hammer?

Increase the valve closing times will help. An initial calculation suggested above where the valve closing time is greater than twice the length of the pipe divided by the celerity of the wave will greatly reduce the incidence of water hammer. Similarly, providing pumping stations with variable speed drives and standby generators to reduce sudden starts and stops of the fluid will also help prevent water hammer.

For long pipelines, a surge tank is recommended to help reduce water hammer. Even in some houses, this can be as simple as a tee and a pipe stub filled with air near the faucet or valve subject to sudden closure. The stub should be vertical, and may or may not contain an air valve to allow it to be filled with air from an external pressure tank. Similarly, a pressure tank which is filled with air in small water systems

MaterialBulk Modulus

(106 psi) (GPa)

Aluminum, Various Alloys 9.9 -10.2 1.05

Brass, 70-30 1.91 132

Brass, Cast 1.54 1.06

Copper 1.9 1.3

Iron, Cast 6.31 4.35

Iron, malleable 2.6 1.8

Magnesium alloy 1.9 1.3

Monel metal 41.4 28.5

Phosphor bronze 2.41 1.66

Stainless Steels 18-8 1.55 - 2.16 1.07-1.49

Steel, cast 4.4 3

Steel, cold rolled 2.2 1.5

Steel, various 3.39 2.34

Table 2: Bulk modulus of common solids Source: www.engineeringtoolbox.com/bulk-modulus-metals-d_1351.html

COMMERCIAL SOFTWAREKYPipe www.KYPipe.com

KYPipe is an advanced variant of the SWMM model. The program was developed by Drs. Don J. Wood, and Sria Lingireddy. The description indicates that it can handle stedy state, surges, gas, steam and it will work with SWMM as well. The systems do perform water hammer and transient and surge analyses, and will perform steam and gas distribution and collection system analyses, and can be used to help design sprinkler systems as well. The program is commercially available.

MIKE Urban (from DHI Software)www.mikebydhi.com

MIKE is a software suite which includes water distribution systems, water collection (sewer) systems, and wastewater treatment modeling systems. The software will perform transient and water hammer analyses. The software is commercially available and is widely used outside the US. It is an integrated suite where water supply, sewer collection, stormwater, and wastewater treatment systems all work together on a single platform.

Water CAD and HAMMER (from Bentley systems)www.bentley.com/en-US/Products/Water+and+Wastewater+Network+Analysis+and+Design/

These are a series of programs which were formerly marketed under the name Haestad, and the Water Cad program is significantly easier to use than EPANET, but provides much of the same information. The Hammer program has been successfully used by a number of municipal systems to analyze water hammer in pipelines.

table 2

Bulk Modulus - EImperial Units

- BG(105 psi, lbƒ/in²)

SI Units(109 Pa, N/m²)

Acetone 1.34 0.92

Benzene 1.5 1.05

Carbon Tetrachloride 1.91 132

Ethyl Alcohol 1.54 1.06

Gasoline 1.9 1.3

Glycerin 6.31 4.35

ISO 32 mineral oil 2.6 1.8

Kerosene 1.9 1.3

Mercury 41.4 28.5

Paraffin Oil 2.41 1.66

Petrol 1.55 - 2.16 1.07-1.49

Phosphate ester 4.4 3

SAE 30 Oil 2.2 1.5

Seawater 3.39 2.34

Sulfuric Acid 4.3 3

Water 3.12 2.15

Water - glycol 5 3.4

Water in oil emulsion 3.3 2.3

Table 1: Bulk modulus for some common fluids Source: www.engineeringtoolbox.com/bulk-modulus-elasticity-d_585.html

table 1


FREEWAREEPANET (from the USEPA)www.epa.gov/nrmrl/wswrd/dw/epanet.html

The program will handle a wide variety of conditions in water systems, and an unlimited number of pipes, reservoirs and pumps. The program is flexible, but it is difficult to use. It comes with a complete manual, and a reasonably good demo for learning it’s use. Data input into the system is often difficult, but once input, the program is quite powerful and can track contaminants and age of water as well as chemical contamination. The program will not compute water hammer.

SWMM (from the USEPA)www.epa.gov/athens/wwqtsc/html/swmm.html

It is a stormwater management model. The program has been around in various generations since 1971, and contains a number of models and routines which allow GIS Data, water quality data, and even one dimensional river modeling. It is a complete package, and allows good graphical outputs with postprocessing of the data. The latest version was developed by CDM, Inc., and the system runs under Windows.

ITM (Illinois Transient Model)web.engr.oregonstate.edu/~leon/ITM.htm

The program is a finite volume model which is designed to analyze transient flows in closed conduit systems over a wide range of conditions, including flows with free surfaces as well as flows under pressure. The ITM model uses the SWMM EPANET interface, so it is not the easiest to use, and for a condition such as that mentioned above, for a single pipe, hand calculations are faster.

located immediately following a pump can easily reduce water hammer from the starting and stopping of the pump while it maintains overall system pressure. But it won’t reduce water hammer occurring on the system pipes leading from the tank to distribution points.

ANALYTICAL SOLUTIONS ABOUNDThere are a number of computer programs which model piping systems and can model water hammer and help one to figure out how to reduce it. Some of these programs will work together, others are commercially available, and some are freeware. ■


MAINTENANCE solutions

A search on Google for “sensors” delivers 38,600,000 results. Even the more specific search for “liquid level sensors” dumps 4,520,000 results in your lap. Whether you call it

information overload or the “Tyranny of Choice,” it adds up to a daunting task as an engineer to source the ideal sensor component for a particular application.

One way to simplify the search is to start with a company that has application expertise and the willingness to share it, combined with a broad portfolio of sensor product types and technologies. A conversation with a sensor application specialist can rapidly introduce the options available for a given project and, more importantly, provide clarity on the pros and cons of a specific sensor in the context of your application.

Taking this route can save time over the hit and miss results of typical internet searches. A frictionless translation of “engineering needs” to “sensor solution” is the goal of any time-constrained engineering project.

EMBRACE TECHNOLOGY ALTERNATIVESA typical aggravation for a sourcing engineer is the single-technology manufacturer. For instance, if you consult with a company that makes only ultrasonic sensors, they will most likely recommend an ultrasonic sensor for your application, even though there may be alternatives that can do the job better in a variety of ways—size, price, accuracy, etc. It’s natural for them to recommend the technology they are most familiar with, and of course they want to sell their product. But it is not necessarily the best fit for your product or company’s success.

Gems Sensors & Control is a leading global manufacturer of liquid level, flow, and pressure sensors; solid-state relays and barriers; liquid and pneumatic miniature solenoid valves; and pre-assembled fluidic systems with facilities in North America, Europe, and Asia. For more information, call 800.378.1600 or visit www.gemssensors.com.

for more information

By gems Sensors & ControlsSimplifyingthe Searchfor the PerfectFluid Sensor Move from search to solution

quicker and more successfully


As an engineer it is beneficial to devote precious time resources to a source that can evaluate the pluses and minuses of multiple technology paths, in order to deliver the best possible solution. Plus there is a level of confidence afforded when a recommendation is made by a company without a vested interest in one particular technology. Beware of those pounding round pegs into square holes.

FIND A VENDOR WHO PROVIDES CHOICESelecting a sensor, even from a reputable source, is never easy if choices are slim. Easing your task of finding the right sensor will be expedited by starting with a source that can show you the pros and cons of different technology options as they apply to your application.

Many engineers like to begin with a company’s website, and that can be a good way to familiarize yourself with the options they offer. With a broad range of fluid sensing technologies and lots of information to download on each product, however, it can quickly become overwhelming.

That’s when it’s time to get in touch with someone who can point you in the right direction, whether you prefer to submit a contact form or pick up the phone.

For example, within each of Gems’ primary sensing categories—level, flow, and pressure—there are dozens of product series and hundreds of unique sensors. A Gems representative can make the difference in pinpointing the specific sensors and customizations that make sense for a particular application.


MAINTENANCE solutions

KNOW MANUFACTURING CAPABILITIESKnowing about a potential sensor vendor’s manufacturing credentials can avoid the quality control and fulfillment problems that can cause disasters downstream. Sensor malfunctions can damage expensive equipment when coolant runs dry, or lead to hazardous spills if a high level alarm fails. Selecting from a source with the right certifications and internal process controls goes a long way to ensure that your sensor choice will be the reliable one.

PRIORITIZE A GLOBAL REACHUnderstanding how and where the sensor will be used in various applications is an important consideration. Is the sensor being sourced going into a product that will be deployed internationally? Do the components need electrical safety certifications from multiple agencies? Will attributes such as port thread types or electrical termination vary depending on the country into which it will be sold? Will your product be manufactured in various plants around the world?

If the answer to any of these questions is “yes,” you should narrow your sensor selection search to companies that have global capabilities and reach.

TAKING A BROAD APPROACHWith these above considerations in mind, Gems Sensors & Controls takes a broader approach to sensor technology, designing and

manufacturing sensors around a wide range of the most effective technologies, with the recognition that each has strengths and limitations. Gems holds stringent ISO 9001 and ISO 13485 quality registrations, and additionally implements strict design controls and management processes throughout all aspects of its business. These include• Design control and

documentation• Risk management• Process yield / defect analysis• Statistical process control (SPC)• Formal corrective / preventive

action• Training and certification

programs• Material traceability systemsAnd, as necessary, sensors from

Gems carry important agency

approvals including CSA or UL-recognition and CE Marking.

KEEP IT SIMPLEWith representatives, distributors and customer service around the globe, Gems speaks your language, too. This global reach simplifies logistics and after sales service. Although it may not specifically change the process by which you select a sensor, it certainly impacts with whom you should select a sensor.

Simplifying the search for the perfect fluid sensor has been a sixty-year mission at Gems Sensors & Controls. By keeping the end-user’s selection process at the forefront of design and manufacture, Gems is the easiest and most successful path to a solution, an ideal starting point of your next sensor search. ■


PUMP solutions

As you’re traveling at a speed of 500 miles per hour, at an altitude of 30,000 feet, you are probably

very aware of the large amount of energy used during one flight and the fact that it is energy that drives our modern economy. It can be argued that today’s access to abundant and low-cost energy is a key ingredient to a thriving economy.

Over the last decade, the cost of energy has risen dramatically. According to the Bureau of Labor Statistics, the average consumer pays 47 percent more

for electricity than they did ten years ago. Many producers and consumers are aware of this increase in energy costs and most have come to accept it as a necessary cost to do business in today’s economy.

In a modern manufacturing environment, energy is used in many forms including electrical, liquid fuels, hydraulics and pneumatics. For this discussion, we will examine air usage, particularly when used in air operated double diaphragm pumps (AODDP). AODDP are used in a variety

of applications, but the most frequent usage is for a basic transfer application, a process that transfers fluid from point A to point B via positive displacement. During this process, AODDP consume energy in the form of compressed air and convert that energy into positive displacement, resulting in liquid transfer.

Before going any further into our discussion, we should agree on some assumptions. Though electrical rates vary widely across the globe, we will use the price of $0.07 per kilowatt-hour

Paul McGarry is the All-Flo sales and marketing manager for North America. To learn more, visit www.all-flo.com, and www.aoddpumpefficiency.com.

About The Author

By paul McGarry, All-Flo pump Co.

All-Flo’s A200 pump reduces energy costs, improves performance

A Revolution in Pumping Efficiency

Part 1 in a 4-Part series

Discharge Flow - Liters/Min.

Pres

sure

Inl

et/O

utle

t PS

IG (

Bar

s)Total H

ead in Feet (Meters)

Discharge Flow - U.S. Gals./Min.

Figure 1: All-Flo’s Legacy Product Performance Curve, an illustration of a performance curve for a typical 2-inch (50.8 millimeter) AODDP.


for all calculations throughout this article. Also, we will assume that, in an oversimplified manner, a 1 horsepower compressor can generate 4 SCFM of compressed air.

READING AN AODD PUMP PERFORMANCE CURVEKnowing how to properly read an AODDP performance curve is essential to determining operating costs for AODDP. For a given operating condition, the pump performance curve is meant to convey two key pieces of information:

1. The flow rate (GPM)2. The air flow rate (SCFM)

Each manufacturer’s performance curves look similar; the vertical axis represents pressure and the horizontal axis represents flow rate. Figure 1 shows the standard performance curve for a 2-inch (50.8 millimeter) AODDP, based on All-Flo’s legacy product design prior to making drastic improvements in the AODDP’s overall air consumption.

Identifying the operating conditions (the input pressure and liquid discharge pressure of the pump) is a necessary first step to reading a pump performance curve.

Typically, an AODDP sees no more than 20PSI liquid discharge pressure in a basic transfer application. An air input pressure of 80PSIG is common when

using AODDP, though conditions vary. For this example, we will assume that a standard AODDP operates at 80PSIG air inlet pressure and the pump operates against 20PSIG liquid discharge pressure.

To read the curve featured in figure 1, start on the right side of the vertical axis at the 80PSIG air inlet line. If we follow the line until it intersects with the 20PSIG horizontal line, we find the operating point of the pump, 125 GPM at a cost of 118 SCFM.

CALCULATING OPERATING COSTWith this information, we can derive the total cost for operating the pump during an eight-hour day, using the standard air compressor yield and cost of electricity.

Based on these calculations and the assumed operating conditions, we can see that our pump costs $1.54 per hour of operation and assuming that the pump operates eight hours per day, five days a week, the pump costs $3203 to operate each year.

An operating cost of $3200 per year is typically more than the initial purchase

price of a basic 2-inch (50.8 millimeter) AODDP. When you consider that some installations can operate more than 100 pumps, you then realize that the cost to operate these pumps can cost more than $300,000 each year. This substantial cost can, in some cases, represent more than the initial purchase price of the pumps.

A LOOK AHEADEnergy is the engine behind all of our economic activity, but when confronted with rising energy costs, customers are left with few choices—raise prices or accept a lower profit in order to remain competitive. However, with AODDP, consumers have a third option, improving manufacturing techniques and equipment with a new All-Flo A200.

The performance curve featured in figure 2 is the standard performance for All-Flo's new A200 pump model—we will be taking a closer look at the curve in part 2 of this series, revealing how the A200's more-efficient use of space leads to better performance than traditional AODDP models. Also, in subsequent articles, we will evaluate air consumption of the new A200 model compared to typical other AODDP as well as highlight some real world applications where improvements in overall air-efficiency yield better bottom lines for those involved. ■

EXAMPLE: Total Operating Cost

118 SCFM x 1 hp / 4 SCFM = 29. 5hp

29.5hp x 0.746kW/1 hp = 22.0 kw

22.0 kw x $0.07/1 kwhr = $1.54/hr

Discharge Flow - Liters/Min.

Pres

sure

Inl

et/O

utle

t PS

IG (

Bar

s)Total H

ead in Feet (Meters)

Discharge Flow - U.S. Gals./Min.

Figure 2: All-Flo's new A200 performance curve.


MOTOR solutions

Modular liquid-cooled drives and PLCs from ABB

have been included in VARD Electro’s innovative, application-specific propulsion and thruster power solutions for offshore supply vessels. The electric motor propulsion technology designed by VARD Electro is used on a series of six platform-supply vessels (PSVs), the first two of which currently are being built in Japan.

A COMPETITIVE EDGETwenty years ago, in response to growing global competition and demands for ever-more sophisticated propulsion performance, the innovative shipbuilding group VARD decided to bring their systems integration function in-house by establishing a fully owned daughter company, VARD Electro, which specializes in system integration

and development and providing tailor-made marine electronics solutions for offshore specialized vessels world-wide.

VARD Electro looked for a drives and control supplier that could provide a highly configurable drives platform, and chose drives from ABB's ACS800 range, with control provided

by ABB's AC500 PLCs. The high degree of modularity of both the controller and drives, the availability of sophisticated PLC development tools in the form of ABB's Automation Builder engineering software suite—together with valuable local programming and HMI capabilities of the drives themselves—provided the economy and versatility of platform that the shipbuilder was looking for.

These system components also provided a number of tangible performance

advantages for this particular motor control application. They include fast real-time control updates and low harmonics power conversion of the drives, and compactness that comes from liquid cooling - an extremely valuable feature for the packed OSV engine rooms housing the main engines and thrusters.

Christopher Stamas is the product manager for servo motion and PLCs at ABB Inc.—a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. For more information about ABB’s PLC offerings, visit www.abb.com/plc.

About the Author

By ChristopherStamas,ABB inc.

Compact Drives-and-Controls Solution Leads toNew PerformanceLevels

Advanced PLC-controlled drive systems ideal for

packed engine rooms of PSVs

PLC-Drive-Motor package from ABB used in PSVs.


For each vessel of the six PSVs which are being built in Japan, ABB is supplying five PLC-controlled variable-speed drives to control a total of over 6 megawatts of power: two 2-megawatt drive systems for the main engines, two 730-kilowatt drives for bow thrusters, and one 730-kilowatt drive for a dual-fed bow thruster that is able to survive the failure of either of the vessel's two power generators.

THE SPEED ADVANTAGEThe ABB drives and controller system are now part of VARD Electro's new SeaQ Power intelligent power systems range, which was created during the past year. To support the development process for the new propulsion power offering, ABB initially supplied the company with a small-scale version of the PLC-drive-motor package, plus development tools. Supplying the complete control and drive package ensured that there were no integration problems. ABB's AC500 is also one of the fastest PLCs on the market, and VARD Electro also chose a version of the PLC with one of the fastest

processor options—the PM590-ETH—to ensure very good real-time control performance. The PLC is connected to the drive using Profibus DP fieldbus communications.

VARD Electro's control logic for the propulsion system includes all of the standard control features, as well as numerous variations to optimize performance in a number of situations, including a “ride through” specification to overcome power supply glitches smoothly, seamless switchovers for dual-fed supply arrangements, and rich local status, alarms/diagnostics and control possibilities on each of the drives - provided via the addition of a touch-screen HMI located on each cabinet's front panel. For this latter task, they chose to install large CP660 HMI panels from ABB's state-of-the-art CP600 series, which meet DNV standards—to display information to operators in very clear and detailed forms.

COMPLETE INTEGRATIONThe integration of all these components was simplified by the

use of ABB's integrated Automation Builder software, which provides a common development tool for the spectrum of automation components used in this application: PLCs, drives, HMIs, fieldbus, networks and web services.

Before the new electric power propulsion control system was delivered, detailed testing was performed on the PLC and drive combinations at a test facility in Søvik, Norway. These trials were also witnessed by the customer, a Japanese shipyard. The integrated control system passed all of its tests and VARD Electro now has shipped the propulsion systems for the first two vessels. The very first vessel with this technology will be launched in mid-2014, and will be destined for use in platform supply applications.

"By combining ABB’s high quality drives and PLCs with VARD Electro’s specialist system integration know-how, we have been able to deliver a propulsion solution offering state-of-the-art performance," says Tommy Damm, a drives specialist with ABB Norway. ■

What Not to Cool on SomeProcess Pumps

PArT 2 OF A 2-PArT SErIES


PROCESSING solutions

Heinz P. Bloch, P.E., is one of the world’s most recognized experts in machine reliability and has served as a founding member of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME, in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at [email protected].

About the Author

By heinz p. Bloch, process machinery Consulting

In part 1 of this article, we began our explanation of cooling water-related experience at true Best-of-

Class (BOC) companies. Now, in the second half, let us turn our attention to some of these best practices in order to better preserve water while also reducing maintenance expenditures. As we’ll see, the pump cooling provisions that can still be found in process pumps provided by many

manufacturers do not always coincide with necessary cooling practices.

OIL REPLACEMENT MORE FREQUENT WITH COOLING AND RISKY ISOLATORS? One experienced refinery changes oil only every three years. It should be noted that pumps at this refinery are equipped with soundly engineered constant level lubricators (see

reference 3) and intelligently designed bearing housing protector seals (also known as bearing isolators; see the lower half of figure 4).

The refinery uses premium quality synthetic lubricants (ISO VG 32 or 68, depending on mode of application). In sharp contrast, another refinery has not yet broken with old traditions. This refinery’s insistence on cooling and its lack of properly designed bearing

Figure 4: Comparison of conventional lip seal (top half) and advanced bearing housing protector seal (lower half) (source: AESSEAL Inc., Rotherham, UK, and Rockford, TN). Figure 5: O-ring degradation due to contact with a sharp-edged groove.

Groove inshaft fromLip seals

LabTectaTM

rotary sealposition

Debris in theO-ring groove


protector seals prompted them to replace oil in their process pumps as often as four times per year. Needless to say, to use cooling water on pumps that really do not benefit from the practice would be wasteful. Likewise, it may be false economy to use anything but best available bearing protector seals.

Bearing protector seals designed with rotating dynamic O-rings that come in contact with sharp-edged non-rotating O-ring grooves could lead to O-ring damage and debris formation. This potential vulnerability does not exist in designs where O-ring contours match a large surface and avoid excessive frictional contact (see figure 4). The point: Find elusive sources of lube contamination, such as slivers of O-ring material (figure 5).

SUPERIOR MAINTENANCE REQUIRES UPGRADINGSuppose there was a design flaw, or some other hidden, elusive issue that is responsible for causing repeat failures, short run lengths of a pump, or whatever else. More than traditional

maintenance effort may be needed, which gets us to the subject of superior maintenance. Superior maintenance is a reliability improvement task. The best-performing or Best-of-Class companies are not repair-focused; they are reliability-focused. These are

Figure 6: The “cooling fan” on left is quite ineffective. A reasonably effective (but unnecessary) fan is shown on right. However, the fan covers can serve as personnel protection guards.

The all new...

• Achieves up to a 60% savings in air consumption over competitive AODD pump technologies

• Easily reduce your carbon footprint (higher productivity withreduced energy)

• Easy to maintain (fewest ADS partsof any AODD pump competitor)

22069 Van Buren StreetGrand Terrace, CA 92313-5607 USA

T: +1 (909) 422-1730 • F: +1 (909) 783-3440www.wildenpump.com

See the proof atprofl oshift.com/proof

The world’s most energy e� cient pump in its class. Period.

See Us At IFAT 2014: Booth #A6.214

14-WILD-0811 - Modern Pumping Today Ad.indd 1 3/14/14 7:15 PM


PROCESSING solutionscompanies that have given some of their personnel the task of determining if upgrading to a better component is feasible.

If an upgrade is feasible, the contributor is asked to calculate its cost. A best-performing company would then ask what this upgrade effort will be worth, perhaps in a simple benefit-to-cost or payback estimate.

A good example involving upgrade issues would be figure 6. The “cooling fan” in the left illustration is simply too small to be of any value. The well-dimensioned fan shown on the right will probably be very effective. Recall, however, that there are serious risks in applying cooling only to bearing outer rings. The hot inner rings may thermally expand and cause bearing preload

increases that will then reduce bearing life (see references 3 and 4).

Suppose an effective fan was used. In that case, the entire design must be reviewed for pressure differences surrounding the bearings. These differences might affect lube oil flow or oil level conditions in the adjacent bearing set. Therefore, the interior (!) of some bearing housings must be upgraded to reduce failure risk. There might even be pumps where the best course of action would be to discard either of the two fans in figure 6. Also, it would be prudent to implement means of pressure equalization across the thrust bearing set. Note how this was effectively done by a series of pressure equalization holes drilled around the bearings in figure 2.

PUMP PEDESTALS SHOULD NOT BE WATER-COOLEDFinally, do not allow pedestal cooling of centrifugal pumps, regardless of process fluid or pumping temperature. Pedestal cooling is inefficient and corrosion starting from the inside of pedestals has caused massive support failures on more than one occasion (see reference 2). On pumps with water-cooled pedestals, calculate and accommodate thermal growth by appropriate cold alignment offset. Then, consider using hot alignment verification measurements (see references 6 and 7).

SUMMARYWith regard to bearing cooling issues in general, this is what our article attempted to convey and summarize:

• Do not allow jacketed cooling water application on bearing housings equipped with rolling element bearings. Note that water surrounding only the bearing outer ring will sometimes cause bearing-internal clearances to vanish, leading to excessive temperatures, lube distress, and premature bearing failure.

• Forced-air cooled “finned” bearing housings are acceptable because the bearing outer ring has sufficient clearance in the housing bore so as not to be excessively preloaded by the cooling effect of the air. However, even such maintenance-free air-flow cooling may simply not be necessary if superior synthetic lube oil formulations are used.


• Understand and accept the well-documented fact that, on pump bearing housings equipped with rolling element bearings, it is possible to delete cooling of any kind (see reference 4). For cost and reliability-optimized results, simply change over to the correct synthetic lube type and lube formulation. For best results, the lubricant will have to contain proprietary additives.

• Use a suitably formulated synthetic lubricant which, at operating temperature, exhibits viscosity characteristics needed for the oil application method utilized in that particular bearing housing.

• Recognize that cooling water coils immersed in the oil sump may cool not only the oil, but also the air floating above the oil level. The resulting moisture condensation can cause serious oil degradation. This is one of several reasons for avoiding water cooling of pump bearing housings.

• Recognize that stuffing box cooling is generally ineffective. If mechanical seals need cooling, investigate alternative seal flush injection and external cooling methods. In the 1960s it was proven that with stuffing box cooling the face temperature of mechanical seals is decreased by only about 2 degrees Fahrenheit, i.e., little more than 1 degree Celsius.

• Cooling water may still be needed for effective temperature control in sleeve bearing applications. On sleeve bearings, close temperature control is far more important than on rolling element bearings but here, too, excessively cold cooling water will often cause moisture condensation. Even trace amounts of water may greatly lower the ability of lubricants to adequately protect the bearing.

• Do not use water-cooled pump pedestals. ■

REFERENCES1. SKF USA, Kulpsville, PA; Catalog 4000 US

(1991).

2. Bloch, H. P. "Machinery Reliability Improvement," Gulf Publishing Co.,

Houston, TX, April 1982. Also, revised 2nd & 3rd Ed. (ISBN 0-88415-663-3).

3. Bloch, H.P. Pump Wisdom: Problem Solving for Operators and Specialists, (2011), John Wiley & Sons, Hoboken, NJ (ISBN 978-1-118-04123-9).

4. Bloch, H.P., and Budris, A.R. Pump User’s Handbook—Life Extension, (2012) 4th Ed., Fairmont Press, Lilburn, GA (lSBN 0-88173-720-8).

5. Bloch, H. P., and Geitner, F.K. Machinery Failure Analysis and Troubleshooting, (2012) 4th Ed. (ISBN 978-0-12-386045-3).

6. Bloch, H. P. "Use Laser-Optics for Machinery Alignment," Hydrocarbon Processing, October 1987.

7. Bloch, H. P. "Laser-Optisches Maschinenausrichten," Antriebstechnik, Volume 29, Nr. 1, June 1990.


VALVES & CONTROLS solutions

As process automation advances, so too does the need for guidance

on how to apply each technology effectively. In part 1 of this article, we discussed distributed control systems (DCSs) and programmable logic controllers (PLCs)—both their histories and their differences. In this section, we’ll examine some of the key considerations when choosing a control system platform and some of the more common application guidelines.

THE RISE OF HYBRID CONTROL SYSTEMSGiven the complexity of today’s control applications, the choice of controller technology isn’t limited to DCS or PLC. On the contrary, advances in process automation and controller technology make it possible for PLC and DCS to coexist in a networked environment—in hybrid control systems.

Hybrid controller integration offers plants more options to cost effectively optimize existing systems,

whether the goal is to add capabilities, streamline processes, increase capacity, or improve operational efficiency. Consider the following application criteria:

Speed Controller speed is vital to safety and quality, particularly in processes involving interlocking and motion control, where controllers operate at millisecond speeds. PLCs historically perform more cost-effectively than their DCS counterparts when it comes to processing high-speed discrete data such as in assembly lines and equipment sequencing. However, DCSs have been more cost effective at crunching analog signals in more complex operations involving more than single-loop control strategies. One typically selects a PLC to allow flexibility and different methods of performing similar operations. DCSs are configured to trade customization for repeatable and dependable performance.

Jim Hazelwood is a project engineer at Revere Control. He has spent the past thirty years helping manufacturing companies improve plant throughput and reduce operational costs through the design of robust automation systems. Bill Butler is a business development manager at Revere Control Systems. He is a forty-five-year veteran of the manufacturing automation controls industry and has helped manufacturers optimize their assets by designing integrated control systems.

About the Authors

By Jim hazelwood and Bill Butler, revere Control

DCS Versus PLCPart 2 in a 2-part series

A user’s guide to selecting the most effective control platform for your application


Criticality Risk relative to safety, cost, and regulatory compliance drives redundancy decisions. Consider the probability of a controller failure and the potential outcomes that may result. Processes where failures could result in loss of life, equipment, or expensive materials often include redundancy and triple modular redundancy. DCS technology typically has been the preferred choice for high-risk unit process applications where redundancy is necessary for product integrity. However, for safety interlocking and SIL rating per IEC 61511 and 61508, the PLC is the most often used and cost-effective solution. Also, given the cost of redundant DCSs, a hybrid approach is becoming a more popular and economical alternative to a single controller technology. For example, PLCs are used in high-risk machine-level process phases and for safety interlocking, while the DCS is used in high-risk plant-level process phases.

InteroperabilityThis is a key consideration relative to legacy systems in terms of understanding whether the network environment is open or closed to third party and non-native devices and protocols. Despite the standardization of programming languages and network protocols, both DCS and PLC maintain mostly proprietary architecture. Many applications today involve retrofitting to an existing network; therefore, it is important to know the devices’ interfacing capabilities and protocols.

Training Assessing the skill levels of technicians, operators, and plant engineers is needed to determine the learning curve.

If personnel already know PLC ladder logic control, moving from one PLC platform to another will be easily accomplished. DCSs, however, are more complex, requiring a longer learning curve and more extensive skill sets to properly configure a system. The learning curve affects day-to-day operation, which factors into the cost to deploy and maintain the system.

COMMON APPLICATIONS AND GUIDELINES Following are some common controller applications and general guidelines for selecting the most effective controller technology for each:

OEM Controller UnitsThese represent a smaller part of a larger system, such as skid mounted equipment. In the water industry, common applications for skid-mounted PLC usage include grit removal equipment, aeration systems, pumps, filters, centrifuges and filter presses. OEM controller units tend to be cost-sensitive applications that do not require extensive reprogramming, which make them more conducive to PLC technology for its lower installation costs, easier maintenance, and attractive total cost of ownership (TCO).

Applications with Large Complex Processes These processes (for example, chemical, power, and pulp and paper) tend to include highly complex control loop interactions and batch control, and require high redundancy for process uptime, making DCS technology a preferred choice given its robust capabilities. Today, PLCs often manage many of the areas within these large industrial sites and communicate to the DCS for operational control.


VALVES & CONTROLS solutionsApplications with Motionand Interlocking Processes This application category—examples of which are conveying systems and machine and motor control—includes numerous discrete control devices such as proximity switches and motion detectors. PLC technology tends to be more compatible with such operations, particularly since many may undergo ongoing lineup changes.

KEY CONSIDERATIONS WHEN SELECTING A CONTROL PLATFORMThe table provides general guidance for narrowing down the selection of controller platforms and is not intended to replace a consultation by a trained knowledgeable professional.

TRENDS TO WATCH IN CONTROLLER TECHNOLOGYIn part 1 of this article, we examined two examples of poorly managed complexity and poorly managed technology for DCS and PLC use-case scenarios. Now, let’s look ahead to some trends in controller technology.

The paradigm of specifying PLCs only for discrete control applications and DCS for proportional-integral-derivative (PID) loop control no longer applies. Driven by advancements in microprocessors and COTS, technologies have converged, and in some cases, the differences between the two are barely discernible. As a result, it is imperative to fully understand the process application to ascertain the best control strategy for the end user. Each technology and each vendor has a sweet spot. This is what needs to be fleshed out and matched with the operational requirements.

Today we are beginning to see secure cloud computing technologies, virtualization, and mesh networks migrating from the IT world to the realm of process control. The convergence of PLC and DCS will continue, and many of the functions that have been the domain of control systems will be pushed to intelligent field devices, including the use of more bus and wireless I/O.

These trends will continue slowly. Production facilities are wary of leading edge technologies; they will maintain a conservative viewpoint and continue to demand their control systems are proven technologies.

CRITERIA PLC DCS NOTES

Product Value: We know a pound of gold is worth more than a pound of coal, so if you lose a batch of product, will it be bad or catastrophic?

Good Better

Is the added cost of redundancy, hardware, and engineering worth the benefit? The DCS has redundancy capabilities from the processor down to the individual I/O point.

Production Startup: Does your process start with the push of a button and return to speed quickly, or do you have to stage and/or charge production units over a lengthy period of time?

Better choice on fast startups

Better choice on slow startups

PLCs are fast; they run an input-process-output cycle in milliseconds. Slower processes typically require coordination across various production units, which matches the capabilities of the DCS.

Data Analysis: Enterprise-wide data historization and manufacturing execution system (MES)

Good Better

PLCs have begun to close the gap with SPC (statistical process control), historian, and data storage capabilities; however, these functions are typically integrated tightly within the DCS platform.

Discrete I/O: Motor controls, fans, interlocks, and other on/off equipment

Better Good

This is where PLCs first gained experience, and they remain very effective in this environment with fast scans and low cost. DCS providers can offer micro-DCS to compete in this arena.

Analog I/O: Pressure controls, flow rates, and PID control loops

Good Better

PLCs are fine for simple PID loops; however, DCSs have the built-in infrastructure to perform advanced regulatory control on a plant-wide scale.

Exception Notification: Alarming based upon defined limits; limited operator interaction

Better GoodMany PLC applications can run for days or weeks with little, if any, operator interaction.

Centralized Control: Operations continuously monitor process conditions and change setpoints based upon condition changes.

Good BetterDCSs provide a system-wide database and can handle large loop counts in a multitasking mode.

Maintainability: Engineering and technician capabilities Better Good

PLCs utilize symbology common to electrical technicians, which typically requires less training. Many technicians are already familiar with common PLC ladder logic programming. Along with the added capabilities of the DCS comes the need for highly trained personnel. DCSs typically require more specialized training involving IT-related networking and database functions.

table of Key Considerations when Selecting a Control platform


ConvergenceConvergence of the two technologies precipitates the need to consider application and customer requirements. Often the customer’s needs and wants go beyond the application itself and involve a business requirement such as lower TCO or flexibility to meet changing market demands. A hybrid system can often address manufacturing requirements and business needs. For example, apply DCS technology where process material risk and cost of downtime are high, and PLC technology where changes in output or product variation require flexibility.

Both technologies continue to trend away from proprietary systems toward open standards. PLC technology, for example, uses IEC 61131-3, which standardizes programming languages. Standardization contributes to cost and time savings by making PLCs more interoperable. DCS technology, too, has adopted PC architecture and open networking standards such as Ethernet and Fieldbus. Taken a step further, it’s possible to interface with today’s DCSs or PLC systems from a laptop or iPad.

Collaborative EffortsAs industrial control systems become more distributed, interconnected, and reliant on the Internet, they become targets for cyberattacks. Many may recall the Stuxnet worm that infected SCADA systems. The process control system can no longer be considered an isolated island of automation. It is an integral part of the business unit and must meet the same rigors of an enterprise’s risk management and IT security/ business continuity and disaster recovery plan. The lines become blurred between the IT department and operations, each with unique risk requirements relative to safety, availability, and fault tolerance.

It is not always the faceless hacker attempting to create chaos as a political statement or for bragging rights. Harm can originate from disgruntled employees as well as the unintentional introduction of malware. These scenarios must become part of an organization’s business continuity and disaster recovery plan.

CONCLUSION AND SUMMARYWhen designing, specifying, and sourcing controller technology, keep

in mind that it’s no longer necessary to choose one or the other. On the contrary, for many applications, a hybrid approach can optimize cost, efficiency, and performance without compromising safety, security, or regulatory compliance.

Trends including advances in microprocessor technology, open

standards for interoperability, and web-based applications are driving the need for new and different approaches to applying existing controller technologies. The result can be a more cost-effective control system from an initial cost and overall operating cost perspective, as well as from improved efficiencies. ■


SEALING solutions

American Leak Detection has found over seven million leaks since 1974 establishing the franchise system as a leader in the world of saving water. According to the

Environmental Protection Agency (EPA), “Household leaks can waste more than 1 trillion gallons annually nationwide,” and homeowners who fix easily corrected household water leaks can save themselves about 10 percent on their water bills. Whether the leak is in hidden plumbing, a pool, a slab foundation, sewer, commercial or municipal lines, American Leak Detection finds leaks without damaging property.

LEARNING FROM THE GRASSROOTSHomeowners are American Leak Detection’s primary customers, but municipalities often seek out the professional “Leak Specialists” to administer water system surveys. Between January 8, 2013, and February 20, 2013, American Leak Detection of East Tennessee completed a leak detection survey for the town of Oliver Springs Water Department which maintains and distributes water to over 2200 customers. The water distribution system has approximately 70 miles (112.7 kilometers) of water mains, ranging in size from two inches to ten inches (50.8 millimeters to 254 millimeters). For the leak survey, 30 miles (48.3 kilometers) of the water distribution system were selected as the focus.

The entire survey was conducted using leak detection survey devices such as American Leak Detection’s proprietary “XLT99 Leak Surveyor” and a Sewerin correlator. The system’s leaks were detected utilizing highly sensitive sonic leak detection equipment where a special microphone (accelerometer) is coupled to valves, fire hydrants, meter curb stops and any available appurtenances in the water distribution system to detect leaks. A total of sixty-nine leaks were detected and, as of

American Leak Detection’s last day on the job, the Water Department repair crews had repaired fifteen of the leaks.

Upon completing the survey American Leak Detection of East Tennessee’s owner, Jeff Deel, concludes, “A conservative water loss estimate for the 69 leaks detected during the survey would equal 2,980,000 gallons [11,280,527 liters] per month.”

THE IMPORTANCE OF LEAK SURVEYSLeak surveys have been popular in the Pacific Northwest as well. During the month of February, American Leak Detection of Oregon and Southwest Washington completed a five day survey for a small water district in Sheridan, Oregon. They covered 35 miles (56.3 kilometers) of pipe and found leaks totaling 23 gallons (87 liters) per minute.

Shari Botermans, franchise owner, estimated once the leaks found are repaired, they could save up to one million gallons

Jennifer Nachtweih is the PR and social media specialist for American Leak Detection, the world leader in accurate, non-destructive detection of hidden water, sewer and gas leaks in residential, commercial and municipal buildings. To schedule an appointment with a leak detection specialist, call 866.570.LEAK, or for more information, visit www.americanleakdetection.com.

About the Author

By Jennifer nachtweih, American leak detection

Saving Valuable Water for AllMunicipalities learn from homeowners’ example


(3,785,411 liters) of water per month. “The district water operator was very impressed with the expertise and efficiency of our Salem technician, Dan Schaffner,” says Botermans. “He was extremely thankful for our assistance and said ‘it was the best money the District ever spent.’”

American Leak Detection of Oregon and Southwest Washington’s municipal client list includes 121 different cities, water districts and associations. The office averages at least one five day survey per month and performs a multitude of one day or site specific jobs for public utilities every week. During March’s “Fix A Leak Week,” they worked for the city of Banks doing a three-day survey, and this month they will be in the city of The Dalles.

SPREADING THE NEWS, SEALING LEAKSAlso in the Pacific Northwest, American Leak Detection of Spokane and Tri-Cities’ owner, Patti Godwin, says they are currently working on their third municipal survey in the past year. The city of Lewiston in Lewiston, Idaho, which is known for their steadfastness in maintaining their water system, had a 25 mile (40.3 kilometer) survey completed during which three issues were discovered. Also a part of the Spokane territory, the city of Walla Walla had its system checked for leaks this past October unearthing 37 leaks in the 45 miles (72.4 kilometers) of lines surveyed. The city is fervently making strides to save water as it has already fixed all 37 leaks, and 50 more miles (80.5 kilometers) will be surveyed by Godwin’s team. ■

The average household's leaks can account for more than 10,000 gallons (37,854 liters) of water wasted every year. American Leak Detection Leak Specialists point to a number of ways to identify leaks:

SIGNS OF A SLAB LEAK• The sound of running water when all water is turned off.• A hot spot on the floor could indicate a hot water line leak.• If you observe cracks in walls or floors, it could be damage

from a slab leak.• Mildew or excessive moisture under carpets could indicate

your slab is cracked and the pipes are leaking water.• High water bills could also indicate a slab leak. Although a

high water bill could indicate a water leak behind the wall, or in your pool, plumbing under the slab is also suspect.

SIGNS OF A POOL LEAK• Air bubbles in the water return lines.• Visible cracks in the liner and/or bottom.• Pool deck is sinking or lifting.• Soggy spots on the ground around the pool.• Pool loses more than regular evaporation (1/4 inch [6.35

millimeter] per day).

SIGNS OF A SEWER LATERAL LEAK• Foul sewer odor.• Backed-up sewer line.• Overgrown patch of grass in the yard.

Products and services Guide2014


products and services GUIDE

EXOnE

For years, the pump industry has relied on traditional processes to create the molds for pumps and parts, which, because of the necessary man-hours, often result in work

stoppages and slowdowns. But now the industry is in the midst of an overhaul as additive manufacturing—3D printing for the industrial sector—led by ExOne offers the promise of a fast and cost-effective way to build the sand molds for castings.

ExOne, a publicly traded leader in the additive manufacturing space, provides 3D printing machines, 3D printed products and related services to industrial customers in several segments, including pumps, automotive, aerospace, medical, and energy. The ExOne process gives traditional manufacturers an opportunity to reduce costs, lower the risk of trial and error and create opportunities for design innovation.

ExOne delivers functional parts—primarily in stainless steel and foundry silica sand—which can be used for both prototyping and real-world production applications. Headquartered in North Huntingdon, Pennsylvania, ExOne has U.S. production service centers in Texas, Michigan, Washington, and Nevada as well as in Germany and Japan, which helps localize the process for key industrial bases around the globe.

Manufacturers that use ExOne’s additive manufacturing process see significant, strategic advantages over traditional methods. The ability to expand creativity and flexibility with virtually unlimited design complexity, without the need for draft angles, enables product designs previously unattainable. Additionally, the opportunity for rapid production of castings and prototypes in turn reduces lead times significantly, and gets new products to the market faster.

In the pump industry, ExOne has dramatically improved hydraulic balancing of impeller castings and produced quick turnaround times for one-off castings. Concurrent iterations can be achieved in a matter of weeks. Additive manufacturing is also the ideal application for reverse engineering of legacy pump components and reduces the need for physical warehouse space for patterns, since data files can be stored on a hard drive.

The ExOne process helps customers in the pumping industry produce castings for prototyping, replacement impellers, volute shapes and rotating parts, by printing entire mold packages or as part of a “hybrid” approach to print just the cores. By creating these types of molds and cores through an additive process, ExOne significantly reduces the time and cost required to rapidly produce castings. When compared to traditional

pattern manufacturing process, delivery of mold packages to the foundry is measured in days versus months. In addition, customers have experienced parts that have shown to yield additional benefits, such as improved impeller core accuracy, superior blade registration, better hydraulic performance, and

ease of dynamic balance.Several leading pumps manufacturers

around the world, including Flowserve and Hydro Parts Solutions Inc., have seen significant value in working with ExOne to integrate multi-piece assemblies and enhance product functionality. ExOne’s work with Standard Alloys began with a challenge to create a 57-inch impeller casting within critical lead time requirements. Using digital part materialization and 3D sand printing technology, ExOne produced Standard Alloys’ largest RCT core to date—from concept to completion in less than eight weeks.

Andritz Ritz also sought out ExOne’s process to fast-track complex prototype and spare part production to meet tight production schedules while driving down costs. ExOne’s successful solution was to print several cores and shells for a complete mold package as well as using a hybrid approach with traditional methods to create prototype step pump housings and impellers.

It’s no secret that additive manufacturing/3D printing continues to explode, with major companies like Ford, Apple, Samsung, and GE publicly announcing the integration of the technology into their production processes. In fact, a report recently published by Research and Markets claims the 3D printing/additive manufacturing industry will be worth four billion dollars by 2025. To meet the unique needs of specific customers, ExOne has made significant

investments in its material qualification research and testing with the opening of a new material characterization and testing facility in St. Clairsville, Ohio, in April 2013.

ExOne has firmly positioned itself as the leader in the industrial market, and over the past year has made significant strides to further solidify that position. The company continues to develop machines that increase print speeds and reduce lead time in an effort to continually lower the cost curve for industrial customers. ExOne’s S-Max 3Dsand printer creates complex sand casting cores and molds directly from CAD data, in about 24 to 30 hours—without hard tooling, which significantly reduces lead time, increases design freedom, and improves the entire casting process chain. ■

the new Standard for PumP manufaCturing

Standard Alloys’ 3D printed core

Standard Alloys’ finished casting

Andritz Ritz CAD rendering



GLOBaL EnViROnMEnTaL OPERaTiOns, inc.

Global Environmental Operations, Inc. has adopted a unique philosophy that is committed to customer satisfaction. Our work guarantee is that it's either

right and acceptable, or there is no charge for our work. We believe in our ability to deliver on our promises: quality work done quickly, on time and on budget.

WHO WE AREGEO, Inc. is a small consulting and engineering firm with over 35 years of experience in all phases of environmental work in both municipalities and industry—including the chemical industry. Some of GEO, Inc.’s strengths include remediation; environmental restoration; underground storage tank removal; environmental assessments; hazardous waste incineration and disposal; air permitting and modeling; wastewater consulting; modeling; system design; trouble-shooting; industrial and commercial water supply; liquid, solid and hazardous waste disposal; and development and consulting on environmental technologies and their development.

TRULY GLOBALAt Global Environmental Operations, Inc., we offer solutions to problems wherever you may be. GEO, Inc. has a proven track record of international clients and partnerships.

• Environmental studies on two Hungarian Petroleum Refineries.

• LPG Gas Cylinder Demand Study for Ghana for US Trade and Development Agency (UST&DA).

• Review of Chernobyl Soil Cleanup Business Plan for UST&DA.

• Consulting to Georgian National Academy of Sciences in Tiblisi, Georgia.

• Joint paper on wastewater treatment in a Hungarian petroleum refinery.

• Multiple studies on Venezuelan oil industry in Maracaibo, Venezuela, and the chemical industry for development of projects in the petrochemical industry.

• Marketing study for development of a new industrial process and business area in Romania.

• Water Environment Federation / US Asian Environmental Partnership selected lecturer for India on hazardous wastes (June 2001).

no nonSenSe ConSuLting and exCeLLent CoSt ControL

Global Environmental Operations770.923.4408

4642 Warrior Trail SW • Lilburn • GA • 30047www.globalenvironmental.biz

A RANGE OF SOLUTIONSAlthough we are a small firm, we offer a range of specialists to meet your needs. GEO, Inc.’s technical staff includes Environmental Engineers, Chemical Engineers, Geotechnical Engineers, Safety Professionals, Health Professionals, Geologists, and Chemists. Our history of success includes• Process consultant for Proprietary Waste Disposal Processes

using molten aluminum as a reactant in a thermo-chemical destruction process.

• Design of municipal and industrial wastewater treatment facilities, for treating various types of wastes including nitroparrafins, electroplating, and metal finishing.

• Environmental assessments for industrial, public schools, and financial clients.

• Environmental Compliance Assessments for chemical and industrial clients, including ISO 14000 Gap analyses and formal environmental.

• Instructor for HAZWOPER and RCRA Training classes.• Development of Hazardous Waste Landfill Technology

Master Plan.• Consultant on hazardous waste cleanups and incineration

projects.• Consultant to the State of New York on site cleanup of the

Enviro-Chem facility in Tonawonda, New York.• Expert testimony to US Justice Department in Chemdyne

Inc., Hamilton, Ohio.• Consultant to the City of Atlanta on remediation lawsuit.• Design and development of Cable Manufacturing air, water,

and odor treatment system.• Development of a unique system for management of

biosolids from municipalities by composting.• Design and development of water and wastewater treatment

systems.• Ten years environmental control experience in US chemical

Industry.• Wastewater treatment systems for explosives manufacturing.• Design of industrial building for Grayling Industries, Inc.,

Alpharetta, Georgia.• Risk and Evaluation Studies for insurance companies.• Preparation of Air Pollution Title V permit applications.• Water and wastewater sampling and process design and

modeling.• Risk assessment and hazard assessment, including

HazOps. ■



GREEnE, TWEED

Greene, Tweed is a global manufacturer of high-performance materials and engineered solutions. Leveraging its portfolio of elastomers, thermoplastics,

and thermoplastic composites, the company provides custom-engineered solutions for critical applications.

With a long history in the petrochemical and power industries, Greene, Tweed components are found at all stages of refining and power generation. By equipment type, the company has designed solutions for centrifugal pumps, mechanical seals, valves and compressors. The following highlights a few of these, each designed with the aim of reducing maintenance and ensuring safe, reliable performance in challenging conditions.

PUMPSWR® and AR® abrasion-resistant thermoplastic composite wear rings, bearings and bushings extend MTBF (mean time between failures) in centrifugal pumps. Their non-galling, non-seizing properties enable them to withstand process upsets like dry-run, reducing downtime over traditional metallic materials. In addition, WR and AR components run 50 percent tighter clearances for boosted efficiency.

The Xycomp® thermoplastic composite containment shell eliminates eddy-current loss in large sealless magnetic drive pumps. It maintains sealing integrity at higher pressures (40 bar) and temperatures (250 degrees Fahrenheit, 120 degrees Celsius) than past non-metallic shells could attain. With exceptional chemical and impact resistance, it expands the application of sealless pumps to include challenging processes such as caustics handling and refrigeration.

VALVES & MECHANICAL SEALSChemraz® perfluoroelastomer seals feature broad chemical resistance; they are ideal for handling acids, ethers, aromatics and other corrosive media. Service temperature ranges from -40 to 600 degrees Fahrenheit (-40 to 315 degrees Celsius), and exceptional compression set provides a wide operating band. As O-rings or in assemblies, Chemraz seals deliver high performance and long life across applications.

Arlon® and Avalon® engineering thermoplastics feature low wear, thermal stability and high impact and chemical resistance. These versatile materials are suitable for a range of applications, and virgin and filled grades afford a high degree of design flexibility. Ensuring long life and reliable performance, they may be used as valve seats, backup rings, in seal assemblies and more.

CENTRIFUGAL COMPRESSORSFKM 944 is the newest in a range of elastomers developed specifically for RGD (rapid gas decompression). It has passed ISO 23936-2 with zero damage at 390 degrees Fahrenheit (200 degrees Celsius) with a decompression rate of 2,175 psi (150 bar) per minute. Combining high tensile strength and high elongation, it enhances safety and reliability in centrifugal compressors, mechanical seals and valves.

The Arlon 4020 labyrinth seal uses a flexible tooth profile to deliver tighter running clearances for increased efficiency. Reduced tooth contact loading eliminates deformation for extended seal life,

and reduced mass flow rate enhances sealing performance. The Arlon 4020 material provides excellent corrosion and erosion resistance, making it ideal for high mercury and other severe applications.

PARTNERSHIPAt Greene, Tweed, combining partnership and technical expertise is critical to success. The company’s engineers and material scientists regularly collaborate with customers to analyze problems and develop solutions. Capabilities such as rapid prototyping, a Quick Response Center, and state-of-the-art laboratories enable new solutions to be designed with accuracy and speed. Advanced manufacturing expands the limits of production, and embedded Lean Six Sigma maintains quality throughout. The result is a comprehensive process that ensures every solution brought to market enhances efficiency, improves reliability, and delivers the most value possible. ■

Greene, Tweed1910 Rankin Road • Houston, TX 77073

281.765.4500 • Fax: [email protected] • www.gtweed.com

advanCing the future of ChemiCaL ProCeSSing, refining, and Power generation

150TH ANNIVERSARYGreene, Tweed celebrated its 150th anniversary in 2013. For over a century-and-a-half, the company has gained deep industry knowledge through working with customers to identify and solve critical challenges. Building on this experience, it continues to partner with industry stakeholders today, expanding its capabilities and advancing the future of chemical processing, refining, and power generation.



yaskaWa

Yaskawa’s P1000 variable frequency drive provides simple, reliable, cost-effective control

for variable-torque loads through 1000 horsepower. Specific application features, energy savings, and network connectivity make the P1000 a great choice for industrial fans and pumps.

Exceptional quality is the hallmark of Yaskawa products. Yaskawa drives have demonstrated extremely high reliability with an average MTBF (mean time between failure) of twenty-eight years or more. Yaskawa’s 1000 series drive products take reliability to the next level with a calculated design life that is twice as long as previous generations.

User-friendly configuration tools, including a multi-language LCD display with a real-time clock, parameter storage, fan and pump application presets, and a portable USB copy unit make programming and configuration simple. DriveWizard® computer software delivers configuration, monitoring, and trending functions enhanced by direct connectivity through the P1000’s standard USB port.

A significant quantity of control points are included as standard. For applications requiring more functionality, the P1000 offers three expansion ports for additional I/O, feedback, and network communications, including DeviceNet, EtherNet/IP, Modbus TCP/IP, Profibus-DP, PROFINET, BACnet, and Lonworks.

Energy efficiency is maximized with variable speed control, and the P1000’s integrated 12-pulse version reduces harmonic demand from the power system, contributing to a cleaner environment. Additionally, all materials used in the P1000 comply with the directive for Restriction of Hazardous Substances (RoHS).

P1000 drives are also available in Bypass and Configured packages. The P1000 Configured package provides a P1000 in a NEMA 1, NEMA 12, or NEMA 3R enclosure, with space for several commonly used options, such as reactors, RFI filters, circuit breakers, etc. The P1000 bypass package provides a P1000 Drive in a NEMA 1, 12, or 3R (UL Type) enclosure, with a 3-contactor style bypass, allowing motor operation from either the drive or across the line. These packages have been designed for flexibility in providing commonly requested features and options

to provide a customized drive solution.The P1000 drive is available in 200-240VAC Three Phase

50/60 Hz (up to 175 horsepower), 380-480VAC Three Phase 50/60 Hz (up to 1000 horsepower), and 500-600VAC Three Phase 50/60Hz (up to 250 horsepower) ratings. All ratings are available in a Flange configuration that allows for mounting the drive with its heatsink out the back of any Type 12 enclosure. In addition, the P1000 is designed for use around the world, and carries agency certifications for all major geographical regions. ■

P1000 drive: the fLexibLe, intuitive SoLution for fan and PumP aPPLiCationS

The P1000 Drive from Yaskawa is the solution for fan and pump applications

P1000 Bypass Package P1000 Configured Package P1000 Flange Version



BOERGER, LLc

In 1975, Alois Börger founded the company in his parent’s barn. Since then the company has continued

to flourish. Today, there are more than

240 employees and representations across fifty countries. Boerger has become the market leader for elastomer-coated rotary lobe pumps,

unbeatable product maintenance and customized solution systems. Boerger’s innovative technologies have transferred to other products including macerators.

Boerger’s core product, the Rotary Lobe Pump, is a self-priming, valveless, positive displacement pump available in twenty different models delivering flow rates up to 5000 gallons per minute. Boerger offers three product lines (Classic, Select, and Protect) with different shaft seals and a variety of optional equipment for a standard pump chamber. The classic product line has a wide selection of size and rotor models. It is equipped with the well-proven, single-acting mechanical seal. The Select pumps have a pressurized single-acting mechanical seal for each shaft. The intermediate chamber between the pump chamber and gear unit ensures a high degree of safety. The protect product line is equipped with a double-acting mechanical seal. The pump has now successfully been on the market for several years under the DPL type design.

Boerger offers a choice of three different macerating units; the Multicrusher, the Multichopper, or the Rotorrake. The choice depends on the solids in the application. The Multicrusher is a twin-shaft grinder for coarse materials with capacities up to 1400 gallons per minute. The Multichopper is a single-shaft chopper with a central perforated disk. The Multichopper is available in two models with optional debris collector. The Rotorrake is a non-clogging single-shaft coarse chopper (capacities up to 3500 gallons per minute) in an in-line version for use in liquid containing solids with optional debris collector.

All Boerger equipment is constructed using the proprietary MIP (Maintenance In Place) which allows for an almost limitless operational lifetime. The Quick Release Cover provides quick access to the internal parts, thereby reducing the costs of maintenance and downtime. All wetted parts can be maintained or replaced by your own staff—without the removal of pipe or drive systems. ■


chEck-aLL VaLVE MfG. cO.

Since 1958, Check-All Valve Mfg. Co. has manufactured a complete line of in-line spring-loaded piston-type check valves. With worldwide service, Check-All Valve

serves a wide range of industries including the chemical, petrochemical, pharmaceutical, food and beverage, water treatment, OEM, MRO, and many others. Lightweight, efficient, and rugged, every Check-All valve is designed and built to perform to exact needs and specifications. The company is ISO 9001-2008 certified and manufactures product lines compliant with CE/PED requirements, Canadian Registration Number guidelines, 3A Sanitary Standards, and others.

Check-All valves are engineered for silent operation. They close quickly and smoothly to eliminate hammer noise. They are designed to function equally well in either a vertical or horizontal position, with proper spring selection. They are also designed to reduce installation costs. The insert series check valves easily fit into existing line components

which reduces initial cost and installation time. The seating surfaces are parallel to each other thereby eliminating the excessive wear occurring in plug, cone and ball seats. Check-All valves can also be used as low pressure relief valves and vacuum breakers.

With many styles available, Check-All Valve provides check valves for practically every service application. Valves are offered with metal-to-metal or soft seats in sizes ranging from 1/8 inch NPT to 20 inch flanged connections. Pressure ratings are available from full vacuum to 10,000 PSI. Standard or exotic materials are available and you can choose from a wide variety of spring settings and seat materials for any valve. Most options are available with fast delivery. Specially designed valves are another option that Check-All Valve performs on a regular basis.

Check-All Valve Mfg. Co. is staffed to supply you with a quality product as well as personal technical services. Contact us for a complete catalog. ■

Get me a Check-All!

S I N C E 1 9 5 8

Our spring loaded check valves are assembled to your exact needs, ensuring absolute precision and reliability. They work like they should. Plus, most lead times are less than one week. That’s what makes Check-All the only choice.

IT’S A CHECK-ALLIt’s more than a check valve...

Manufactured in West Des Moines, Iowa, USA • 515-224-2301 • www.checkall.com

Check-All_Ads2014_V2.indd 2 3/12/14 4:16 PM

Check-All Valve Mfg. Co. 515.224.2301 • [email protected] • www.checkall.com



DREisiLkER ELEcTRic MOTORs

Improving reliability, increasing uptime, and saving energy are ways to counteract downtime costs. How? With smart management of critical electric motors.

MANAGING YOUR ELECTRIC MOTORSMaintaining your critical motors assures that your operation will run efficiently and without costly downtime. At Dreisilker Electric Motors, our mission is to guide your organization through this process and provide the services needed to help you increase uptime, improve reliability, and save energy.

Through smart motor management including Infrared Inspection, Dynamic Balancing, Laser Alignment and other diagnostic tools we can work with your maintenance team to optimize the performance of your electric motors. And when repair is needed our Exclusive Motor Safe Repair method is the key to returning your motors to service quickly and with optimal efficiency.

WHY WE’RE DIFFERENTWith our Motor Safe Repair process we’re able to maintain the integrity of the stator, laminations, and windings—something that shops using the “burn-out” method can not

do. Having the ability to do a forensic analysis of your motor can help determine the root cause of the failure. Knowing why is the first step in preventing future issues.

In addition to this ability to dive into the causes of your motor’s issues, motors repaired with Dreisilker’s Motor Safe method: • Are turned around in less time than other repair methods • Last twice as long as motors repaired with other

methods • Experience no damage due to the repair process.

(warping, uneven amperage draw, higher operating temperatures, core loss and increased energy costs)

• Do not negatively affect the environment and cause potential health concerns with toxic emissions.

You don’t have time for downtime. Register for our FREE Motor Repair White Paper Series and learn about Motor Safe Repair and how to bring your electric motors back to OEM specifications. Plus they’ll last twice as long as they would if repaired by other methods.

Dreisilker can be contacted at 800.922.1882, via email at [email protected], or by visiting www.motorsaferepairs.com/mp. ■

eLeCtriC motor downtime CoStS $10,000 an hour


GODWin PUMPs

Godwin’s diesel-driven Dri-Prime® pumps include the Godwin PrimeGuard

automatic level controller, standard on all electronic diesel engines and available for mechanical diesel engines. The Godwin PrimeGuard is a fully programmable microprocessor engine control system that allows for inputs from flow meters, level transducers, pressure transducers or standard floats. Using any of these systems, your Godwin Dri-Prime pump can start and stop automatically with no operator intervention required.

These features are now enhanced with the added functionality of our new Field Smart Technology (FST). Diesel pumps can be monitored and controlled from anywhere in the world with an internet connected computer, phone, or tablet. Engine and pump data can be collected in one-minute intervals and transmitted to a password-protected website for viewing and data logging.

FST communicates through both cellular and satellite connections to provide remote users the same information that is shown locally on the PrimeGuard panel. The dual connection means that FST works even without a cell signal, such as on remote jobsites or deep in quarries. FST also provides the ability to start and stop the pump remotely through the website, allowing better use of labor and resources. Using FST can eliminate or significantly reduce the need for on-site pump watch.

FEATURES AND BENEFITS• Monitor engine and motor

parameters• Monitor pump operation

parameters• Start and stop remotely• Cellular and satellite

communication• Log data• Alarm• Locate the unit via GPS

Many of Godwin's Dri-Prime pumps are already equipped with

FST, and available for sales or rental. Xylem offers proven 24/7 service and support, backed by a strong

application engineering team. For more information, call 800.24.PUMP4 or visit www.godwinpumps.com. ■

Primeguardtm ControLLer with fieLd Smart teChnoLogy

godwinpumps.com

Your Task. Our Force.

Xylem brings you dewatering solutions backed by our industry-leading rental fleet of Godwin and Flygt pumps, world-class application engineering, and proven 24/7 service and support.

We pride ourselves on our response and reliability. We have the experience you need to get the job done efficiently, the products and service to meet your needs whenever and wherever they occur, and the emergency response culture that understands the urgency of your projects.

Let us put our great pumps and great people to work for you.

For more information, call 1-800-24PUMP4.



haiGhT PUMPsHaight® Pumps is

recognized as a leading manufacturer

of high quality rotary gear, positive displacement pumps for use in a broad variety of applications. As a member of the Baker Manufacturing Co., LLC family, Haight Pumps’ customers benefit from in house services such as:

• Metallurgical expertise• On site foundry• Premier research and

development capabilities• Extensive technical

knowledge of pump applications

Today’s complex processing environments demand greater integration of equipment and application. Now more than ever, we can offer you a customized approach to both your operational needs and cost requirements. Haight’s heavy-duty, positive displacement rotary gear

pumps are truly “pumps that perform.” All of our engineering, manufacturing, and application skills are focused on the development and production of dependable, versatile, and quiet products designed to meet the needs of our customers.

The most reliable of today’s rotary gear pumps are built on the “gear within a gear” principle that Haight Pumps pioneered nearly seventy years ago. The benefits for the end user are substantial. The smaller, inner drive gear (pinion) and shaft assembly are supported by bearings on both sides of the pinion to resist movement, unlike other designs. The larger gear (rotor)

is hydraulically balanced within the pump housing, finding its optimal position naturally. Our current products include internal and external gear pumps, customer gear pumps, centrifugal pumps, and bed plate assemblies. ■

Pipe plug inserts provide access for mounting optional gauges and tank return feature.

Bolt on reversible relief valve.

Top quality ductile iron bodies with iron bearings.

Patented Haight gear and rotor for more efficientpositivedisplacement pumping.

Three-Tooth contact for smoother discharge. Extra deep gear mesh greatly reduces noise, avoids trapping.


MiLTOn ROy

Milton Roy is the world's largest manufacturer of controlled volume metering pumps and

equipment and a brand of Accudyne Industries. Our pumps set the industry standard for performance, accuracy and durability in the most challenging and demanding applications. Since 1936, Milton Roy has concentrated its scientific, engineering, and production resources on the development and manufacture of equipment that accurately controls fluids ranging from water to high viscosity polymers, corrosive or abrasive chemicals, toxic substances, and other difficult pumping media.

Milton Roy’s complete product offering includes specialty pumps, analytical instrumentation and metering pump system components. These products range from low-pressure water treatment applications to demanding installations with pressures up to 30,000 psi (2070 bar), and can withstand high temperature fluids such as molten sulfur. Milton Roy’s designs include packed plunger pumps and liquid end diaphragm technology, which stand up to the most demanding applications with superior life performance. Pump capacities range from 0.0003 gallons per hour (12 milliliters per hour) to some of the highest in the industry.

Available with single or multiple drive designs and a wide range of liquid end configurations and materials, Milton Roy pumps can best meet the requirements for any application.

Milton Roy provides local support to customers with direct sales offices and a wide network of well-trained representatives around the globe. Regional authorized service centers with factory trained technicians assure high quality local product support and parts availability.

Recognized by our customers for superior performance and value, Milton Roy’s knowledgeable team of engineers and product developers can satisfy routine and custom designs to fit every application. The company also provides high-level application

engineering, customer training, and system support to assure successful installations. Depend on the strength

of Milton Roy’s extensive range of products and knowledgeable team for your most demanding requirements. ■

reCogniZed for SuPerior PerformanCe and vaLue



scaLEWaTchERDeveloped and patented in the

Netherlands by Mr. Jan P. de Baat Doelman, Scalewatcher

technology was introduced to the European market in the 1980s. With immediate market success, Mr.

Doelman brought the technology to the United States and applied and received a patent in 1991. From that moment on, Scalewatcher North America has been on the forefront of environmentally-sensitive water treatment. Located in

Oxford, Pennsylvania, Scalewatcher North America continues to lead the industry in descaling products that do no harm to the environment.

Scalewatcher North America focuses on the elimination of scale and the problems associated with scale build up. Industries know the costs involved in keeping their capital investments running smooth. Scalewatcher is there to help. Scaled cooling towers, chillers, and associated equipment can negatively impact a company’s bottom line, and not just in cash. The caustic chemicals used to remove scale only create more problems with the environment. Your company can “GO GREEN” and stay within your budget.

If our product does not work for your application, we will buy it back! With our “Performance Guarantee,” you never have to worry about losing cash on a product that does not work.

Scalewatcher North America Inc. manufactures its products in Oxford, Pennsylvania, so you know its MADE IN THE USA! We can treat pipe sizes from ½ inch up to and including 120 inches. Cooling towers, chillers, evaporative condensers and boilers can all benefit from Scalewatcher water treatment. If it scales up, we can break that scale bond and show you cost savings on maintenance. No plumbing required!

Why keep adding chemicals when Scalewatcher can reduce your chemical dependency?

Break the cycle now and save on energy, water, and maintenance costs with Scalewatcher products!

For more information, call 800.504.8577 and visit www.scalewatcher.com. ■


VULcan PUMPsVulcan Pumps is a supplier of

submersible pumps designed for pumping abrasive and corrosive

liquids. Our designs offer the flexibility to provide a product that perfectly matches our customers’ individual requirements. Not all industrial operations are the same, so why should your pump be? We give our customers a choice when it comes to the right pump for the job, including materials of construction, broad performance ranges, and optional features that ensure you get the best product for your specific application—all at competitive pricing. SUBMERSIBLE SLURRY PUMPSThe Volt series submersible slurry pump is a complete pump and motor package designed for uses in all types of submersible applications. The pump set has many advantages, including construction from high-quality specialized materials, state-of-the-art structure, wide flow channel, and high capacity for sewage/solids. It is suitable for delivery of liquid mediums containing sand, coal slurry, mine solids, and much more. It is widely used in mining, metallurgy, thermal power stations, and more. It is an ideal alternative for traditional slurry pumps that aren’t designed to perform under rigorous conditions.

HEAVY DUTY SUBMERSIBLE SLURRY PUMPSThe HDS Series is Vulcan's line of heavy duty, Hard Metal slurry pumps. With a robust motor and wet end, these pumps are designed to deliver quality performance in extreme conditions. For corrosive slurry applications, the HDS is available with a CD4MCu liquid end and 316 stainless motor. These pumps are suitable for use in a wide range of applications, including those in the mining, steel, sand & gravel, food processing, power generation, pulp & paper, and many more industries. The HDS Series offers serious performance at competitive cost.

CUSTOMER-ORIENTED PUMPING SOLUTIONSVulcan Pumps, LLC. is a Brownlee-Morrow Enterprises company. Our focus is on submersible pump sales

and support for industrial applications. It is our mission to provide customer-oriented pumping solutions through efficient performance, highly flexible design, and superior cost effectiveness. ■

Vulcan Pumps www.vulcanpumps.com

800.624.7069



ZOELLER cOMPany

Zoeller Company has been selling its innovative reversible grinder pumps for

over twenty years. Often referred to as being bi-directional, the star cutter operates in a shearing fashion, rotating in the opposite direction from that of its previous cycle. Before Zoeller incorporated this feature into its design, this method of cutting was thought to be superior to any other being used.

When the 2 horsepower model was introduced in 1993, the benefit of the reversible cutting action was immediately noted as the roping effect that clogged other grinder pumps was not found in systems where the reversing grinder pumps were being used. A few years later it was discovered that the cutter’s design, with it shearing type cutting

action, had a longer than expected service life as it was able to utilize both sides of the cutter blades.

Later, with thousands of units in service, customers wanted larger reversible grinder pumps for use in their commercial and municipal lift stations so 3, 5, and 7.5 horsepower models were introduced. Then, to meet customer requirements, they were designed for hazardous locations with a third-party Class I Division 1 Group C & D rating. Users throughout the United States and Canada have benefited from this product with its efficient cutting action and dependable service.

For more information on this or any of our fine products contact Zoeller Company at 800.928.7867 or www.zoeller.com. ■

the reverSing grinder PumP


cOnTinEnTaL PUMP cO.

Continental progressive cavity pumps have been time tested with proven unique characteristics that excels in performance unlike other types of pumps. They are built

of various materials in many sizes with capacities from less than 1 to over 500 gallons per minute and pressures to 450 psi.

Our pumps can also be purchased separate or built into complete units mounted on welded steel bases with specified Couplings or Belt Guards and driven by: (a) Flexible Couplings, (b) V Belts, (c) Gearbox Reducers, (d) Hydraulic Motor Adapters, or (e) Variable Speed Drive units by (a) Electric Motors, (b) Gasoline/Diesel Engines, (c) Air Motors.

Progressive cavity pumps are most commonly used in the following industries: gas and oil, mining, and industrial wastes with byproducts. However, they are also very versatile and are the perfect pumps for abrasives, transferring, circulating, metering, pastes, slurries, sludge, wastewater, sewage, and more.

With a variety of models to choose from Continental progressive cavity pumps are the solutions to handling many types of fluids. We now offer vertical suction housings for our cost-effective CP Line pumps for tightfitting areas.

Between our pumps and our additional features Continental Pump Co. can make a pump specifically for your needs. Visit us at www.continentalultrapumps.com. ■

BJM PUMPs

Long-lasting energy efficient pumps suited

specifically for hot, corrosive or non-corrosive, clear or solids laden liquids up to 200 degrees Fahrenheit (93.3 degrees Celsius). This is a higher temperature than other pumps like it, making it particularly beneficial for a host of applications in a variety of industries where variations in temperature are critical to safety, product quality and efficiency. Standard or high head, side-discharge sump pumps. Available configurations include shredder pumps, slurry pumps with agitator, dewatering pumps, vortex solids handling pumps. Most series available in either cast iron or 316 SS. Dual mechanical seals with the lower seal constructed of highly wear-resistant silicon carbide against silicon carbide for longer life. Used in beverage/bottling plants, dairy product processing, poultry/meat processing and chemical/pharmaceuticals. For more information, please visit www.bjmpumps.com or call 860.399.5937 ■

fahrenheit™ SubmerSibLe PumPS



GRaPhiTE METaLiZinG cORPORaTiOnGRAPHALLOY®, a graphite/metal alloy, is the solution for

tough bearing problems. GRAPHALLOY bushings and wear rings enable pumps to handle low lubricity fluids,

survive upsets, and run dry or flash without damage. Non-galling GRAPHALLOY can be designed with tighter clearances than metal and plastics to reduce vibration and improve seal life.

Used in the manufacture of bushings, bearings and other components for machinery and process equipment, GRAPHALLOY materials are self-lubricating, impervious to temperature extremes from -400 to 750 degrees Fahrenheit (-240 to 399 degrees Celsius) and thrive in harsh environments where other bearings fail. Special grades provide reliable service up to 1000 degrees Fahrenheit (538 degrees Celsius) and higher in non-oxidizing atmospheres.

FDA accepted grades of GRAPHALLOY are available for food service equipment. NSF® International has certified two grades of GRAPHALLOY material for use in municipal well pumps and water treatment plant applications.

Graphite Metallizing Corporation is ISO certified. For more information, visit us at www.graphalloy.com or call 914.968.8400. ■

GREyLinE insTRUMEnTs inc.

Greyline is a worldwide leader in ultrasonic instrumentation for industrial and environmental markets. We develop, manufacture,70 and market

industrial flow and level monitoring instruments including ultrasonic level transmitters, flow meters, and open channel flow meters.

Greyline’s primary market is environmental—especially water and wastewater treatment systems. Customers include industry and municipalities. Modern research facilities at Greyline include closed pipe and open channel flow systems.

With years of steady growth, Greyline products are sold and supported worldwide. ■

Greyline Instruments Inc.

[email protected]


PROcOPRODUcTs, inc.

Proco’s ProFlex® Series 700 check valve offers a unique “zero” maintenance valve which requires no man power to clean out the discharge, free jammed flap gates,

remove and replace worn out hinges or pins. Our ProFlex® 700 check valves never fail to close in the event of slurry

or tailings settling on the discharge side!

The simple design allows effluent to force the two opposing rubber lips apart permitting flow, yet quickly closes preventing return of tailings or slurries with as little as 1 to 2 inches of back pressure. Even at low head pressures or maximum flood conditions, the ProFlex® 700 valve will continue to provide

full port flow while standing ready for the first chance of back pressure or return flow. The installation and maintenance of a ProFlex® 700 valve is trouble-free and can be installed without need for heavy equipment or electrical services.

Visit www.procoproducts.com for more information. ■

sT. MaRys caRBOn

St. Marys Carbon serves a broad range of markets and industries. We produce high quality parts and products from carbon graphite, metal graphite, and

electrographite, as well as resin-bonded products. With seventy-five years of diversified experience, we have become a global leader in the electro-mechanical carbon market. Some of the industries that we serve include• Mining• Automotive• Oil & Gas• Aerospace• Hot Glass Handling• Military• Nuclear• High Temperature• Transportation • Fluid Handling

St. Marys Carbon’s quick delivery times, total customer service, employee craftsmanship, and technology sets us apart from our competition. SMC is a custom provider, so no matter what industry, contact us for your application needs—we have a material to meet your specific application. ■



WORLD chEMicaL

The YD-25A6GWN (the newest of World Chemical’s GWN series) is a unique submersible pump. It

is a magnetic drive submersible pump, which means no seals or lubrication oils to contaminate the area of operation. In addition, its Carbon Fiber Reinforced Polypropylene (CFR-PP) construction allows the pump to resist even the most corrosive acids and alkalis. The pump’s lowest suction point of only 0.4 inches (10 millimeters) makes it possible to transfer the most from each tank, saving costs on expensive liquids.

The YD-25A6GWN can be used in a wide variety of applications, from foamy chemicals, pumping liquids up from breakwater / broiler rooms, and even environments where the surface layers may be frozen. Its lightweight (30 pounds) and simple (can be used anywhere with an available power source) design makes this pump an ideal choice for emergency situations, where the time to transport and install equipment is critical. ■

Documents

Modern Pumping - 042014