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IMPROVED

COOLING TOWERFILTRATION

STORMWATER

SOLUTIONS

AT WORK

KEY FACTORS FOR

PROTECTOR SEALS

SEPTEMBER 2014PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

THE FUTURE OF

WATER REUSE

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CONTENTS SEPTEMBER 2014

4 INDUSTRY NEWS

10 TRADE SHOW PROFILE

C ASE STUDIES 12 Inventive Results Under Pressure

Ultra-high pressure waterjet technology provides powerful and safe downhole casing and pipe cutting solutions

16 Thinking Globally and Acting Locally to Preserve a Natural Wonder Septic tank replacement using a low pressure sewer system (LPS)

Part 1 in a 3-Part Series

W ATER & W ASTEWATER SOLUTIONS 20 A Material of the Future New innovations in FRP lightweight composit access covers

24 Recycling Earth's Rapidly Shrinking Resource A basic primer on how food and beverage plants can reuse water effectively and efficiently Part 2 in a 3-Part Series

28 A Holistic Approach to Process Control Providing process improvement and energy savings Part 2 in a 2-Part Series

M AINTENANCE SOLUTIONS 32 Improving Cooling Tower Filtration

The Southern Hemisphere's largest entertainment complex reduces maintenance and treatment costs Part 1 in a 2-Part Series

PUMP SOLUTIONS 34 How to Select Diaphragms for AODD Pumps

Asking the right questions and utilizing the best available tools will help AODD pump operators maximize diaphragm lifePart 2 in a 2-Part Series

DEWATERING SOLUTIONS

38 California Logistics Center Finds Stormwater Solution

MOTOR SOLUTIONS 40 The New Frontier of Self-Lubricating Solutions

A closer look at the benefits of carbon-graphite solutions across a range of applications

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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 anymeans, electronic or mechanical, including photocopy, recording, or any informationstorage-and-retrieval system without permission in writing from the publisher. Theviews expressed by those not on the staff of Modern Pumping Today , or who arenot specifically employed by Highlands Publications, Inc., are purely their own. AllIndustry News material has either been submitted by the subject company or pulleddirectly from their corporate website, which is assumed to be cleared forrelease. Comments and submissions are welcome, and can be submitted [email protected].

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

TIM GARMONPresident

LARRY DAUGHETY Vice President

DENNIS DAUGHETY Vice President

www.highlandspublications.com

312 Lorna Square | Birmingham, Alabama 35216T: 866.251.1777 | F: 205.824.9796

@ModPumpMag

RUSSELL HADDOCK COO/Publisher [email protected]

JEFF FLETCHER Associate [email protected]

RANDY ARMISTEAD Associate [email protected]

J. CAMPBELL [email protected]

DONNA CAMPBELL Editorial [email protected]

SCOTT GORDON Art [email protected]

CHRIS GARMON General [email protected]

LINDEY SCOTT Circulation [email protected]

JAMIE WILLETT Circulation Consultant

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

TONYA BROWNING Account Executive

RANDY MOON Account Executive

Terry BellDrives and Motion Solution Engineer

Baldor Electric Company

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

Process Machinery Consulting

Robert G. HavrinDirector of Technology,Centrisys Corporation

Michael ManciniConsultant and Trainer,

Mancini Consulting Services

John M. RoachEngineering Manager

for New Product Development,Trebor International, Inc.:

A Uni t of IDEX

Lisa RilesBusiness Development Manager,

Wastewater Pumps Xylem Inc.: Flygt

Greg TowsleyDirector of Regulatory andTechnical Affairs, Grundfos

Trey Walters, P.E.President, Applie d Flow Technolo gy

EDITORIAL ADVISORY BOARD

POWER GENERATION

SOLUTIONS 42

Polish Utilities Adopt Advanced Actuation Solutions SIPOS projects illustrate the capabilities of actuators

PROCESSING SOLUTIONS 46

Fouling and Cleaning Profiles of Filter Membranes A comparative analysis of four membrane cleaning profiles using Micro-90 Alkaline Cleaning Solution

and Micro A07 Citric Acid C leaner

V ALVES & CONTROLS

SOLUTIONS 50 Precise Gas Measurement for Mud Logging Operations

ST100 thermal mass flow meter provides solution for oil and gas upstream production operations

52

Gas and Flame Detectors Protect Portable LNG Vaporizers Remote drilling sites have a new option to monitor mobile equipment

SEALING SOLUTIONS 54

How to Cost-justify Bearing Housing Protector Seals Key factors for reliability-focused process pump users Part 1 in a 4-Part Series

58

MODERN PUMPING PRODUCTS Featured Product Release: FLUID METERING INC. CeramPump® QDX Hazardous Duty Metering Pump

PUMPING TRENDS 60

Flexible Manufacturing Means Sustainable Manufacturing The importance of Industrial and Systems Engineering for manufacturers

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4 | SEPTEMBER 2014 www.modernpumpingtoday.com

INDUSTRY news

ROTORKRECEIVESLETTER OFAPPRECIATIONFOR ANGOLA’SLATEST FPSOSTART-UP

The recent start-up of the CLOVFPSO (FloatingProduction,Storage andOfoading)vessel in Angola’sBlock 17 offshoreoileld hasbeen markedwith a letter ofappreciation toRotork from theleading Korean

engineeringcompany DSME (Daewoo Shipping and Marine Engineering).

DSME performed the design and construction of the CLOVFPSO on behalf of Total E and P Angola, with much of the workcarried out in Angola as a part of Total’s commitment to increaselocal content in its projects. Since 2011, Rotork Fluid Systemshas supplied more than 400 heavy duty CP and GP Rangepneumatic valve actuators on the project. Rotork’s professionalperformance throughout the duration of the contract and

contribution to the timely start-up has been recognised with theletter of appreciation.

A total of 34 subsea wells will be tied back to the CLOVFPSO, which has a processing capacity of 160,000 barrels ofoil a day and a storage capacity of nearly two million barrels.The Rotork actuators are installed in many areas of the vessel’sprocessing plant, including those parts designed to limit

environmental impact by eliminating aring under normaloperating conditions, recovering heat from turbine exhaust andrecovering vent gases.

The CLOV FPSO is one of a number of Rotork Fluid Systemscontract successes in Angola’s offshore oil industry. Theseinclude over 500 pneumatic actuators which were suppliedfor the Pazor FPSO in Block 17, following similar orders forthe Kizomba A and B FPSOs in Block 15. Rotork pneumaticand electro-hydraulic valve actuators are also used on Angola’sonshore LNG pipeline network, delivering gas from offshore tothe processing plant at Soyo.

ABB DELIVERS STRONG ORDER GROWTHAND CASH IN Q2

ABB today reported strong order growth, stable revenues anda signicant increase in cash from operations for the secondquarter of 2014. The lower operational EBITDA margin mainlyreects ongoing project-related challenges in the Power Systems(PS) division. Orders of $10.6 billion were 14 percent higher (13percent on a like-for-like basis) compared with the same quarterin 2013. Base orders accelerated and large orders grew morethan 70 percent. The positive growth momentum was supportedacross all regions.

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INDUSTRY news

“Last October we said that we will drive organic growththrough penetration, innovation and expansion and now weare delivering results,” says ABB chief executive ofcer UlrichSpiesshofer. “Our focused actions are paying off and supportoverall increased order momentum. In the second quarter wesaw encouraging growth in our two largest markets, the US andChina.”

The strong order intake resulted in a positive book-to-bill ratioof 1.04x. ABB delivered steady revenues of $10.2 billion despitethe lower opening order backlog. Group operational EBITDA wasimpacted by a loss in the PS division related to ongoing projectcharges in large engineering, procurement and construction(EPC) projects for offshore wind and solar power generation. Newmanagement has taken strict actions to de-risk the PS portfolioand adjust capacity. In addition to the exit from the solar EPCbusiness, ABB is implementing a new business model for offshorewind EPC. “As said previously, PS is likely to weigh on earningsin the coming quarters," Spiesshofer says. “We are driving the PSturnaround as a top priority and made good progress in loweringthe exposure.”

Operational EBITDA margin was stable to higher for the

remaining divisions, excluding the expected dilutive impact ofthe Power-One acquisition in Discrete Automation and Motion.Cash from operations improved by more than 60 percent to $888million in the quarter.

ABB successfully executed on its announced strategic portfoliopruning of businesses that have limited synergies with the rest ofthe portfolio. “Since October last year, we have moved quicklyon our commitment to optimize the portfolio in a value-creatingway and to strengthen the focus on the core,” Spiesshofer says.

“For the second half of the year we will continue to pushhard on our organic growth initiatives in a mixed marketenvironment,” he says. “We will drive our relentless executionon cash and further step up the momentum on cost savings. Weare condent that our balanced growth and execution initiativeswill yield positive results for our shareholders.”

THE BILCO COMPANY

RELEASES NEW

COLT NATURAL

VENTILATION

PRODUCTS CATALOG

The Bilco Company, amanufacturer of specialtyaccess products, hasreleased its new 2014Colt Natural VentilationProducts Catalog,detailing Colt’s line ofnatural ventilation and smoke and re control products for thecommercial markets. The catalog is available free of charge

by calling 800.366.6530, emailing [email protected] ordownloading it at www.bilco-colt.com .

Bilco partnered with Colt, a United Kingdom-basedmanufacturer of smoke and natural ventilation products, earlierthis year and now serves as the company’s distributor of naturalventilation and smoke control products in North America. TheNatural Ventilation Products Catalog features a user-friendlylayout, complete with information on the benets of and theproducts and options available.

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INDUSTRY news

Natural ventilation is becoming an increasingly importantdesign strategy for commercial buildings, particularly in GREENbuilding design. With careful design, buildings can be cheaperto maintain and operate and the addition of fresh air andnatural daylight creates a more pleasant and productive workingenvironment for building occupants. Colt’s products provide aninnovative and attractive solution for design professionals and

building owners.

PROCO CELEBRATES THIRTY YEARSProco Products, Inc. is proudly celebratingour thirtieth anniversary this year. Since1984, Proco Products has been dedicatedto providing quality products coupledwith superior customer service. Proco is amanufacturer of rubber, metal and PTFE expansion joints as wellas the ProFlex® Series rubber duckbill check valves. To learn moreabout Proco Products, Inc., visit www.procoproducts.com.

PCM GRAPHIC GUIDELINES EVOLVETO ACCOMPANY GROWTH

For fteen years, PCM has evolved in many different areas:technically, with a lot of innovations proposed to the customers(the new HyCare™ and EcoMoineau™ C pumps are availablein the market since 2012); humanely, PCM has known a largeincrease of staff the past few years; and geographically due tothe international expansion. Indeed, PCM is now divided intofour clusters and has more than twenty branches and subsidiariesworldwide, gathering about 600 employees from 35 differentnationalities (more than 50 employees have been recruited in

2013). PCM continues to evolve to be closer to its customers:PCM Group Australia Pty Ltd. has opened in April 2013, LLPPCM Kazahkstan in July 2013 and recently PCM Chile Spa inApril 2014. Also, PCM has decided to change the logo and thegraphic guidelines of the company to accompany the growth ofthe Group, continuing to express its dynamism and its innovationmind.

NEW HARTZELL AIR MOVEMENT SALESREPRESENTATIVE OFFICE IN ARIZONAAND NEW MEXICOHartzell Air Movement announces that Climatec EngineeredHVAC Solutions is now their new manufacturer’s sales rep ofcein Arizona, New Mexico, and El Paso, Texas. Climatec EngineeredHVAC Solutions has been in business since 1975. Selling Hartzellindustrial fans will be a smooth transition for the rep rm, whoalready sells other complementary products such as dampers,louvers, and air handling equipment.

Senior airside application engineer at Climatec EngineeredHVAC Solutions, Mark Addler states, “We are thrilled to joinforces with Hartzell, an established industry leader with a well-

engineered, heavy duty group of products.” The main marketsin the rep rm’s territory consists of semiconductor production,mining, agriculture, and wastewater treatment.

Chuck Abramson, director of sales at Hartzell Air Movementexplains, “Climatec is a perfect t for Arizona and New Mexico.They already have great relationships with several key customersthrough their other product lines, and now with the additionof Hartzell industrial fans, they will be able to provide theircustomers with a complete solution.” ■

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WEFTEC, the Water Environment Federation’s Annual TechnicalExhibition and Conference, is the largest conference of itskind in North America and offers water quality professionals

from around the world with the best water quality education and trainingavailable today.

Also recognized as the largest annual water quality exhibition in theworld, the expansive show floor provides unparalleled access to the mostcutting-edge technologies in the field; serves as a forum for domestic andinternational business opportunities; and promotes invaluable peer-to-peernetworking between its more than 22,000 attendees.

WEFTEC has shown continual growth for both the technical program andexhibition. WEFTEC 2013, which was held in Chicago, set new registrationand exhibit floor space records. WEFTEC 2014 is expected to be an equally

successful event.

EXPANDED EXHIBIT FLOOR

WEFTEC 2014 features an improved and expanded exhibitor floor that isresponsive to the requests of WEF members and past attendees. This year’sexhibition will be the first to feature a wide range of dynamic learning andnetworking opportunities as well as a reimagining of past event favorites.

Stormwater Pavilion: Specially dedicated area on the exhibit floor toshowcase stormwater treatment products and services including a theaterfor programming.

Innovation Pavilion: Specially dedicated area on the exhibit floor toshowcase innovative water treatment technologies and programming.

Technical Sessions on the Floor: Access up to 20 technical sessionson the exhibit floor to stay informed on the latest practices from industryleading speakers.

Public Official Tours on the Floor: Selected groups of public officialstour the exhibit floor to learn more about the water and wastewaterindustry and how to best represent their constituencies.

Mobile Sessions on the Exhibit Floor: Technical presentations will takeplace in several different booths containing related equipment to allow youto hear details from the experts. Move from booth to booth as a group andget your questions answered in an educational format. For example, mobilesessions this year will include topics such as UV disinfection, phosphorusremoval, and decentralized treatment.

WORKSHOPS AND FACILITY TOURS

WEFTEC workshops and facility tours enhance the attendees’ educational

experience. With more than twenty workshops over two days, attendeesare offered hands-on, interactive courses with subjects covering topicsfrom wastewater microbiology to management development. Facility toursoffer attendees a “technology in practice” experience, with the opportunityto visit active projects, construction, and/or operations at sites within thelocal host community.

OPERATIONS CHALLENGE

Operations Challenge is the water quality industry’s premier professionalskills competition. Recognizing excellence in wastewater operations, thefive events demonstrate the range of talents possessed by contemporarywater quality practitioners. Operations Challenge exposes participantsto emerging practices and products in a competitive, educational, andsocial atmosphere. Participating teams must be endorsed by their MemberAssociation. ■

WEFTEC 2014The world’s largest annual water quality exhibition continues to grow


TRADE SHOW prof ile

TECHNICAL CONFERENCE

The technical conference,workshops, and facility toursaremust-attend educationalopportunities. The technicalconference includes thefollowing tracks:

• Industrial Issues andTreatment Technology

• Municipal Wastewater

Treatment Process andDesign

• Residuals and BiosolidsManagement

• Collection Systems• Stormwater Management• Watershed Resources

Management andSustainability

• Water Reclamation andReuse

And many more.

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SEPTEMBER 2014 | 11www.modernpumpingtoday.com

ADEDGE TECHNOLOGIES678.835.0052www.adedgetechnologies.comBooth # 2058

A.W. CHESTERTON CO.978.469.6945www.chesterton.comBooth # 4363

CORNELL PUMP COMPANY503.653.0330www.cornellpump.comBooth # 5737

ENVIRONMENT ONE CORPORATION518.346.6161www.eone.comBooth # 5117

FLOWWORKS, INC.888.400.3288www.flowworks.comBooth # 2252

FRANKLIN ELECTRIC717.504.2625www.franklinwater.comBooth # 7945

GORMAN-RUPP CO.419.755.1011www.grpumps.comBooth # 2528

GRUNDFOS513.405.4866

www.grundfos.usBooth # 3429

THE HILLIARD CORPORATION607.733.7121www.hilliardcorp.comBooth # 5159

KSB804.222.1818www.ksbusa.comBooth # 4761

LAKESIDE EQUIPMENT CORPORATION630.837.5640www.lakeside-equipment.comBooth # 4228

PIONEER PUMP503.266.4115www.pioneerpump.comBooth # 2801

PULSAFEEDER, INC.585.292.8000www.pulsa.comBooth # 6329

QUARTZ LAMPS, INC.484.301.9233

www.qlistore.comBooth # 7247

SEE WATER, INC.888.733.9283www.seewaterinc.comBooth # 2641

SINGER VALVE604.594.5404www.singervalve.comBooth # 7313

TECHTOP INDUSTRIES678.436.5540www.techtopind.comBooth # 7347

VAF FILTRATION SYSTEMS303.425.4242www.vafusa.comBooth # 2557

Don’t Miss The Top Exhibitors This Year!

Make Your Plans Now and Schedulean Appointment TODAY!

87th Annual Water Environment Technical Exhibition and ConferenceSeptember 29—October 1, 2014 • New Orleans Morial Convention Center

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CASE Studies

Centura Oil Inc., a Minnesota-based waterjet service

contractor to the oil, gas, and mining industries,has developed a unique downhole casing and pipe

cutting system that can fit inside pipes as small as 2 inch(51 millimeter) diameter and cut multiple layers of groutedcasing in a single pass with a 55,000 PSI (3800 bar) abrasivewaterjet.

A DISTINCTIVE CHALLENGE

Operable in hazardous environments, Centura Oil’s CenJet90® casing and pipe cutting system is designed especially

for oil, gas and mining applications, including plug and

abandon operations. Its cutting process does not exceed140 degrees Fahrenheit (60 degrees Celsius), minimizing thechance of ignition.

A POWERFUL PAIRING

The CenJet 90 is powered by a 55,000 PSI, 200 horsepower Jet Edge waterje t intensifier pump and features a modified Jet Edge Permalign abrasivejet cutt ing head that is coupledto coiled steel tubing or conventional threaded rods. Thesystem, which is capable of cutting 16 inch (406 millimeter)

Nancy Lauseng is the marketing manager for Jet Edge. For more information about Jet Edge, visit www.jetedge.com or call800.JET.EDGE (538.3343) or 763.497.8700. For more information about Centura Oil, visit www.centuraoil.com or call

952.545.6431.

About The Author

By Nancy Lauseng, Jet Edge

Four layers of casing were jet cut six inches below thesurface casing at 30.5 feet (9.3 meters). After removingthis section the overcoring bit can be reduced, resultingin a successful retrieval of the entire string.

Very small casing sever and slot cut, 300 feet (91 meters)deep.

The hydraulic cylinders on the drill supporting the cuttinghead bled down while cutting causing this spiral effect.

U l t r a - h i g h p r e s s u r e w a t e r j e t t e c h n o l o g y

p r o v i d e s p o w e r f u l a n d s a f e d o w n h o l e c a s i n g

a n d p i p e c u t t i n g s o l u t i o n s

All pho tos courtesy Centura Oil Inc.

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thick steel, is deployed into the pipeor casing and cuts from the inside. Itcan perform cuts up to 300 feet (91meters) from the surface and can cut atany angle, horizontal, vertical and evenoverhead.

The CenJet 90 uses only 4 gallons(15 liters) of water and 1 pound (0.45

kilograms) of garnet abrasive per minute.Garnet is a natural stone that cannormally be disposed of in a landfill . Theeffluent created by the waterjet cuttingprocess is circulated to the surface usingformation water, treated water in strataprone to swelling, or nitrogen for anexplosion-proof environment. The returns

Left: Various used cutting heads, 4 inch (102 millimeter) OD to lessthan 2 inch (51 millimeter) OD.

Above: Jet Edge pump 2000 feet (609.6 meters) below surface ina mine.

We knew

immediately that

we had a new

product and service

to take back to the

oilfelds. We can

now cut at any

angle and ft inside

extremely narrow

pipes. And it’s

waterjet, so we can

work in hazardousenvironments.

—Michael Uthe, Centura Oil

president

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CASE Studies

and cuttings are handled in accordancewith industry standards.

A FLEXIBLE SOLUTION

Centura Oil originally developedthe CenJet 90 as an environmentallyfriendly downhole waterjet cuttingsystem for stimulating oil and gas well

production at depths of over 4000feet (1219 meters). It modified thesystem for casing and pipe cuttingfor a recently completed project ata uranium mine. During this 2.5 year project, CenturaOil staff worked 2100 feet (640 meters) underground andsuccessfully cut hundreds of pipes and grouted casings atdistances up to 300 feet (91 meters), many at a 70-degreeangle.

Centura Oil’s worldwide services include waterjetwell recompletion and production enhancement, wellplug and abandonment, and mobile waterjet cutting. Thecompany also sells its CenJet 90 systems under a licensingagreement. ■

CenJet 90 systemfits inside 2-inch (51millimeter) diameterpipe and cuts multiple

layers of grouted casingin single pass

Jet cutting using polymer enhanced circulat ion aid s incarrying returns to the surface.

Three layers of casing cut at 300 feet (91 meters) deeprecovered after overcoring.

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CASE Studies

The Town of Jerusalem, NewYork, is a picturesque se ttlement

blessed with year-roundrecreational activities, award-winningwineries, a portfolio of properties listedon the National Register of HistoricPlaces and desirable real estate on theshores of the glacier-formed KeukaLake.

Beneath the surface, however, theturn of the millennia found failingseptic systems were threatening theregion's scenic landscape. The KeukaWatershed Improvement Cooperative(KWIC) verified that deterioratingseptic systems mixed randomly witha few primitive holding tanks werecompromising the lake's water quality.

The town had required homes tobe scrutinized every five years. Ifan existing septic system flunkedinspection, corrections were requiredwhich often included the installationof a new tank and drain field at a costof $20,000 to $30,000 per residence.In many instances there was notenough room to put in an up-to-datereplacement.

A PRIME LOCATIONOne of the primary reasons whylakefront homes are sought after in

Jerusalem is the pristine shoreline helddear by 4500 residents and thousandsof visitors. However, eutrophicationgenerated by septic seepage and othersources of nutrient loading frequently

lead to poor water quality resulting inblooms of aquatic vegetation, algae and

a potential change in the ecologicalbalance of aquatic habitat.

The town recognized a solutionwas needed but its particular situationpresented some challenging siteconditions.

The Y-shaped Keuka Lake is oneof the eleven Finger Lakes, so calledbecause of their north-south axis inthe west-central region of upstate NewYork. Its 11,730-acre surface areastretches about 20 miles (32 kilometers)long but from east to west it spans anarrow half-mile to two miles wide.Most of Jerusalem's waterways flowinto the lake where Keuka College andKeuka Lake State Park also reside.

Hundreds of vacation homes(seasonal occupancy is onlyapproximately 20-percent full-timeresidents) are located very close to thelake, often on small building lots withvery little room for septic leach fields.A high water table and ineffectivesubsurface drainage means the drainfields have poor percolation to beginwith, so decline is rapid and inevitable.

The region's geography is gashed byseveral gullies and deep ravines thatrun down to Keuka Lake; valleys androlling hills used primarily as farm land;and, steep slopes on the waterfront.

It was precisely the natural beautyand rocky terrain the region prizesthat would make it laborious,

environmentally disruptive and almostcertainly cost-prohibitive to excavate

for conventional gravity sewering.

BUILDING A PLAN

Gravity sewer systems are the originalcentral sewers with origins in theRoman aqueducts and are almost as oldas the biblical city of Jerusalem itself.The bulky systems might require rockblasting and digging trenches 20 to 30feet (6.1 to 9.1 meters) deep to installlarge mains and lift stations.

When planning began in late 1999,the town calculated the probableconstruction cost for a conventional-type system was six million dollars,almost 50-percent more than a $3.2million low-pressure sewer system (LPS)also being considered. A decade later,a top-level summary of project costscalculated a final tab of $4,080,000including administrative ($190,000),technical services ($600,000),construction ($2,920,000) andcontingency ($370,000).

Community leaders in Jerusalem wereaware of several successful regionaland local LPS installations. The project

team, consisting of representatives fromthe Town of Jerusalem; Clough, Harbour& Associates LLP (CHA); SiewertEquipment Company; and EnvironmentOne Corporation, investigated theseprojects and learned from them.

Over a period of several years theproject team researched the type of

Wayne Ackart, P.E. is town engineer for the Town of Jerusalem. Clark A. Henry is director of engineering at Environment One.He can be reached at [email protected]. Michael Crowley is LPS system designer at Environment One. For more information

on Environment One Corporation’s full line of grinder pumps and LPS solutions, visit www.eone.com or call 518.346.6161.

About The Authors

By Wayne Ackart, Town of Jerusalem (New York),

and Clark A. Henry and Michael Crowley, Environment One

Thinking Globally and Acting Locally

to

Preserve

a

Natural

WonderPart 1 of 3

Septic tank replacement using a low pressure sewer system (LPS)

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sewer system that would best serveresidents. Because of topographicalconstraints, the Town determinedthat the most economically andenvironmentally favorable solutionwas to construct a low-pressure sewersystem.

LOW-PRESSURE SEWER SYSTEMS

LPS technology is a simple, effectiveand inexpensive solution which hasbeen effectively used for more thanforty-five years to collect and conveywastewater. The technology wasinitially adopted in the United Statesand Scandinavia and is increas inglyutilized throughout the developedworld. Published case studies of wellimplemented and smoothly operatingsystems are widely available.

Low-pressure sewer systems begin at

a grinder pump station installed at eachresidence, which accepts wastewater,grinds its contents into fine slurry andtransports it through small-diameter, 2-to 4-inch (51 to 102 millimeters) PVCpipes buried just beneath the frost lineto roadside force mains or treatmentfacility.

The proposed LPS for the Town of Jerusalem eliminated the need for 12lift stations with a total cost savingsof $900,000. Nor did it require a rockexcavation outlay pegged at $775,000.

Unlike conventional gravity centralsewers, which use up to 24-inch (610millimeter) pipe and require deepexcavation, an LPS system is notdestructive to the landscape's naturalor built features and requires lessmaintenance.

THE ROLE OF GRINDER PUMPS

The grinder pump manufactured byE/One is a self-contained unit barelybigger than a washing machine witha one horsepower motor, controlsand level-sensing built into a single

unit. It is activated automatically andruns for very short periods. Electricalconsumption of the grinder pump islow—a household that uses 250 gallons(946 liters) of water per day shouldconsume less than 10 kilowatt-hoursper month to run the pump.

E/One has assembled morethan 500,000 grinder pumps at itsNiskayuna, New York, headquarters. Itspumps comprise the largest installedbase of pressure sewers in the worldand E/One alone provides LPS serviceto more than one million peopleworldwide.

The town chose E/One becauseit has a proven record of successfulinstallations around lakes withconditions similar to the Town of

Jerusalem's proposed project. OtherE/One waterfront LPS jobs includeMartha's Vineyard, Baja California

(Mexico), Hawaii, and many lakefrontcommunities around the United States.

A CLOSER LOOK AT BLUFF POINT

In order for the town's LPS to maximizeits impact, planners chose to site theproject at Bluff Point, which givesKeuka its distinct Y shape and is one ofthe more dramatic lakeside hills in theFinger Lakes. It provides scenic vistas

from many of its roadways and cottagesalong the shore.

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CASE Studies

Most of the residences are locatedlakeside on East Bluff Drive and arebelow the road elevation. The lakeshoreelevation of 715 feet (218 meters) ison average 25 feet (7.6 meters) belowthe centerline of the road. Toward thenorth end of the district, the road is 50

feet (15.2 meters) or more above thelakeshore elevation. Most residentswould be required to have a sewagepump to pump up to a gravity sewerlocated under the road.

A gravity system to service these far-flung residences distributed on rollercoaster elevations was not feas ible. WithLPS, the wastewater discharged from thegrinder pumps can be propelled uphillfrom the homes, through diverse groundchallenges and even around contours.It is effective for distances at morethan a mile from force mains or water

treatment facility.E/One, the town determined, was the

only manufacturer offering a provensemi-positive displacement type grinderpump able to perform under higherhead conditions present in this project.

Unlike centrifugal pumps, the E/Onegrinder pump produces a nearlyconstant discharge rate over a widerange of head conditions, includingnegative head.

The project plan plotted a 5.5-mile (8.9 kilometers) long LPS thatdischarged into a manhole and flowedto an existing treatment facility in theneighboring Village of Penn Yan. Anagreement was reached between thetwo municipalities that the Town of

Jerusalem would pay Penn Yan basedon the anticipated flows the new LPSsystem would be discharging into thetreatment plant.

The town decided it would ownand operate the new system. Thehomeowner’s only responsibilitywould be to provide electricalpower (estimated at $24 annually) to

operate the grinder pumps. The Townutilized blanket property easementsso it possessed the flexibility to locatethe grinder pump stations wherevernecessary on the small rocky buildingplots.

ENVIRONMENTALLY-FRIENDLY

INSTALLATION

As with thousands of other installations,E/One's grinder pumps were set inthe footprint of the property’s septictank or just adjacent to it making theinstallations far less environmentallydisruptive to private landscapes.

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The equipment included thefollowing:

• 29,000 LF of force main pipe• 30,000 LF of pressurized lateral

pipe• 265 E/One Series 2000 grinder

pump stations and alarm panels• 265 check valves and curb (shutoff) valves

• 25 concrete vaults for flushingconnections and air relief valves

• 25 flushing connections• 5 air release valve stations• 1 bioxide feed odor control

system

Because of the seasonal occupancyof most town residents, threeinformational community meetingswere held on Memorial Day, the

Fourth of July and Labor Day of 2000.A referendum regarding the projectwas voted on during a meetingheld on Memorial Day of 2001. Thereferendum passed by a three-to-onemargin.

A LOOK AHEAD

A decade after the installation wascomplete, the Town of Jerusalemand E/One decided to revisit theproject. Parts Two and Three of thisarticle provide a ten-year (2003-2013) review of Operation andMaintenance (O&M) data and ahydraulic performance analysiscomparing expected design flowsto quantitatively measured flows forthe 265-unit septic tank replacementproject. ■

REFERENCES

1. Goncz, Daniel J., “Pressure Sewer SystemDesign, Construction and OperationHistory at Lake Latonka,” Mercer County,Pennsylvania, June 2010.

2. Albro, Henry S., “Ownership of Pressure

Sewer Systems,” with key contributionsfrom the towns of Chelmsford and Marion,Massachusetts.

3. EPA – R2-72-091 November 1972, “APressure Sewer System Demonstration.”

4. Wastewater Collection System Modeling& Design , Fir st Ed ition, Haestad, Walsk i,Barnard, Harold, Merritt, Walker &Whitman, 2004.

5. Water Environment Federation (WEF)“Alternative Sewer Systems,” SecondEdition, Manual of Practice FD-12, 2008.

6. Submersible Sewage Pumping Systems(SWPA) Handbook, Fourth Edition, SWPA2012.

@ModPumpMag

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WATER & WASTEWATER solutions

Todaycompositematerials

are used in windenergy, marine,construction,

aerospace,military anddefense,automotive, pipes,access covers,tanks and manymore applications.Composites offerseveral advantagesover traditionalmaterials: highertensile strength,lighter weight,greater corrosionresistance, nore-sale value (sowon’t be stolen),better surfacefinish and easierprocessing.

US-basedmanufacturerFibrelite has seena tremendousincrease ininquiries fortheir lightweight

composite access covers from industries keen to move awayfrom the traditionally used metal and concrete and changespecifications to composites (a future material).

CORROSION RESISTANCE

According to a study by the National Association ofCorrosion Engineers (NACE), the direct cost of infrastructurecorrosion was over $22 billion in 2002 in the United Statesalone. Adjusted for inflation, the direct cost of corrosion

in 2013 wasestimated to beover $42 billionon an annualbasis. It has beenestimated that

at least 25 to 30percent of annualcorrosion costscould be saved ifoptimal corrosionmanagementpractices wereemployed.

Fiber reinforcedplastic (FRP)products are nowbeing widely usedfor applicationswhere corrosioncan destroyundergroundinfrastructure.Perhaps the primereason for usingFRP productsis because oftheir inherentcorrosionresistance.

The corrosionresistance of FRPis a function of

both the molding technology and the specific resin usedin the laminate. Today, various resin systems are availablewhich can provide long-term resistance to almost everychemical and temperature environment.

One application in which FRP is being widely adoptedworldwide and changing specifications away from metalis with manhole access and service trench covers. Byhelping to reduce the costs of corrosion, composite coverscan allow utilities and other operators of underground

Jo Stott is the marketing director for Fibrelite. Technical experts from Fibrelite will be on hand at this year’s WEFTEC to

demonstrate new product innovations at Stand 7913, Hall 11. For more information, visitwww.fibrelite.com

.

About The Author

By Jo Stott, Fibrelite

A Material of the New innovationsin FRPlightweight

compositeaccess covers

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infrastructure to improve the financialstrength of their enterprises.

TRIED AND TRUSTED

Founded on a tradition of quality andinnovation, Fibrelite has been at theforefront of composite technologysince 1980. The first ever compositemanhole cover was designed byFibrelite for gas stations, to eliminate

health and safety issues associatedwith traditional metal covers. Today,Fibrelite is established as a leadingworld player in its specialist field,with a global reputation for highquality products.

ERGONOMIC DESIGN:

HEALTH AND SAFETY FRIENDLY

With recent statistics attributing overhalf of injuries (resulting in absencefrom work) to manual handling it’salready known that reducing hazardsin this area is a priority on a globalscale. Because of legislation restrictingacceptable manual handling weights,we are seeing a global t rend towardslighter weight FRP composite manholeand access covers, which also havethe benefits of ease of handling.

Lightweight composite coversthat provide safe and easy accesseliminating unsafe manual handlingissues are replacing aging concreteand heavy cast iron access coversall over the world. By using lightermaterials, operational injuries are

prevented, work sites are madesafer and ease of installation andmaintenance is made available toutility workers and contractors.

The design of these lightweightcovers incorporates up to two liftingpoints for specially designed liftinghandles. These allow the operator toremove the cover without trappingfingers or bending over thusmaximizing the safety of the liftingtechnique. The weight is kept close tothe body preventing back injury; oneof the main causes of absence fromwork and personal injury claims.

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CUSTOMIZED,COLORED COVERS FORIDENTIFICATIONIn response to customerdemand, Fibrelite nowoffers company logos andother brand markings onits covers. Any style logoor other marking can bepermanently molded intothe upper surface of the

cover in single or multiplecolors. For additional brandor product identification,or to blend in with thecolor or layout of a facility,Fibrelite can mold itscomposite covers in nearlyany color or combination ofcolors.

By introducing thepigment directly into theresin system during themolding process, Fibreliteensures that the color isnot merely applied onthe surface of the cover.Instead, the coloring isevenly and completelyinfused throughout thecomposite cover and will

not fade or wear over time.Customers have utilized

Fibrelite’s molded markingand coloring process toidentify undergroundsystems in a unique andhighly visible way. Colorcan also be used as a quickand reliable method of

identifying undergroundsystems, therebyproviding maintenanceor emergency personnelwith more accurateinformation about anyhazards or specialconditions relatedto the undergroundinfrastructure.

NO METAL, NO THEFTThe metal theft epidemicis not going away. Thereare few industries thatcan hide from the thievesand the water industryis still being severelyaffected. Cast iron andsteel manhole covers and

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drainage grates are routinelystolen for the scrap value ofthe metal cover or grate.

And while the financialcost of replacement is quitehigh, the thefts also leadto open manholes which

create significant hazards.Composite covers can solvethis problem as the fiberglassmaterial used has noinherent scrap value. Withthe inability to melt downcomposite covers into quickcash at the junk yard; thereis no incentive for thieves tosteal the covers in the firstplace.

NO MORE WET, WORNAND SLIPPERY METAL COVERS

FRP composite manhole covers are ideal for problem areas,particularly those prone to skid related accidents. Traditionalcast iron covers quickly become polished and thereforeprovide a poor level of grip which can lead to seriousaccidents through increased risk of skidding and slipping,even more so when wet.

“Fibrelite’s covers incorporate a molded anti-slip treadpattern equivalent to a modern high grade road surface. Infact, Fibrelite’s anti-slip/skid surface is guaranteed for the

life of the cover providinga Polished Skid ResistanceValue PSRV60> whenwet which exceeds therequirements of HA 104/09,part 5, for potentially highrisk sites,” says David

Holmes, technical directorand head of productinnovation.

HIGHLY ENGINEERED

Fibrelite's access coversare lightweight, durableand very strong. They aremanufactured using high-technology Resin TransferMolding (RTM) productionmethods to create a highlyengineered, monolithic

composite product. This offers the best strength to weight

ratio in the industry, allowing for maximum load bearingstrength and durability while remaining lightweight andeasy to handle. Fibrelite’s standard manhole covers alsooffer watertight solutions in a wide range of sizes andshapes.

Fibrelite’s comprehensive range of FRP composite trenchcovers are perfect for covering large areas, gullies, trenchesand ducts where occasional or frequent access may berequired. In fact, custom sizes are also available. ■

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SBR Versus MBR Cost-Benet Analysis

Category Sequencing Batch Reactor (SBR) Membrane Bio Reactor (MBR)

Footprint Large Medium to small

Installation Costs Higher Lower

Operating Costs Lower operation and maintenance costs Higher operation and maintenance cost

Other Requires pre-treatment forreuse applicationsCan be customized depending on

wastewater composition

In the first part of this series,we examined some of thebenefits of reusing wastewater,

especially as it relates to food andbeverage processing, as well asguidelines for identifying the righttreatment options for a specificneed. We’ll continue that focus inthis installment. When a facilityis looking to apply an advanced

treatment process, they can bebroken down into two categories:biological and disinfection.

BIOLOGICAL TREATMENTUnder biological treatment thereare two subcategories: SequencingBatch Reactor (SBR) and MembraneBio Reactor (MBR). Generally, SBRwill have lower capital requirements

than MBR, but MBR systems willcost less to operate. They combinebiological treatment with membranefiltration to provide a high qualityeffluent, meet stringent nutrient limitsfor phosphorus and nitrogen, andhave a smaller footprint compared toSBR technology. For a more detailedcomparison of SBR to MBR, refer toTable 2.

Nate Maguire is the Americas business unit director, industry, and agriculture for Xylem's applied water systems businessunit; Greg Claffey is Xylem’s director of treatment sales, North America; and Keel Robinson is Xylem’s North Americareuse marketing and business development manager. Xylem’s well-known global brands provide world-class products,comprehensive solutions, and unmatched applications expertise in more than 150 countries. To implement a water reuse

system in your facility, visit www.xyleminc.com/food .

About The Authors

By Nate Maguire, Greg Claffey, and Keel Robinson, Xylem

A basic primer on how food and beverage plants

can reuse water effectively and efciently

PART 2 IN A 3-PART SERIES

Recycling Earth’s

Rapidly Shrinking

Resource

Table 2: SBR versus MBR cost-benefit analysis

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Disinfection Technologies Cost-Benet Analysis

Category Chlorine UV Ozone

Footprint Large Small Medium

Installation Costs Low Medium High

Operating Costs Low to medium Average to high Average to high

Other Requires the intensive use ofchemicalsEnergy intensive but no

chemicalRequires additional mixing

processes

DISINFECTION

Under disinfection treatment there arethree categories: chlorine, ultraviolet(UV), and ozone. The most basicform is chlorine disinfection. In thistreatment type, water is filtered withhypochlorite to generate chlorine

residual that inactivates pathogenssuch as bacteria.

UV technologies are chemical-free and require less contact timethan chlorine disinfection. In thesesystems, water is channeled througha reactor that emits UV light atlow wavelengths to destroy theDNA structures of microorganisms,

including bacteria, viruses, yeastsand molds. Virtually any liquid canbe used with this technology, so it isoften found in beverage-processingplants; however, UV is sensitiveto the clarity of the water. Higherclarity water requires less energy to

treat, and, as a result, pretreatmentof wastewater is common in systemswhere UV disinfection is used.

Ozone and Advanced OxidationProcesses (AOP) are powerfuloxidation treatment technologiesthat generate hydroxyl radicals,the strongest oxidant used inwater treatment. AOP is an ideal

disinfection approach to treatrecalcitrant contaminants that areotherwise not removed by othertechnologies. AOP and ozonetechnologies are commonly coupledwith other filtration technologies.Table 3 outlines a cost-benefit

analysis of common disinfectiontechnologies.

In addition to the biological anddisinfection techniques presentedabove, there are other advancedtreatment technologies that canbe used either separately or inconjunction to fulfill wastewaterdischarge requirements.

Table 3: Disinfection technologies cost-benefit analysis

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MEMBRANES

Membrane filtration, using technologies such asmicrofiltration and ultrafiltration, provides suspended solidsremoval found in the processing of foods and beverages.These technologies can remove some pathogens, virusesand bacteria. See Table 4 for a breakdown of filtrationtypes.

REVERSE OSMOSIS (RO)

In reverse osmosis, salts and many dissolved organicsare removed through a semi-permeable membrane.RO is used when the highest quality reuse wateris needed, such as high-pressure boiler feedwateror any use where low salt and contaminant levelsare required. RO can be expensive and generatea concentrated brine waste stream that must bemanaged via proper disposal.

A LOOK AHEAD: PUMPING SYSTEMS

Treating water is only the first step to ensuringwastewater is recycled and reused efficientlyand effectively within a plant. It is important fororganizations to also consider the transportation andstorage of water reuse. Pumps serve two purposes ina reuse system: transporting and pressure boosting. Inthe conclusion to this series, we’ll address the keysfor selecting the right pump, implementing a waterreuse system, and ensuring standards for sustainabilityand safety. ■

REFERENCES

1. Shiklomanov, Igor. “World Fresh Water Resources.” Water inCrisis: A Guide to the World’s Fresh Water Resources .Ed. PeterH. Gleick. 1993. Print.

2. The Water Resources Group. Background, Impact and the WayForward. Rep. 26 Jan. 2012. 16. Web.

3. EMD Millipore. “Filtration Basics.” Millipore Membranes andFiltration. Web.

4. United States. Environmental Protection Agency. 2012Guidelines for Water Reuse. Sept. 2012. Web.

5. The Coca-Cola Company. 2012/2013 GRI Report “WaterStewardship.” Rep. Web.

Types of Filtration

0.0001 0.001 0.01 0.1 1 10 100

Na Insulin NSA

lgG

Hepatitis C

HIV

B. dininuta

Smallestvisibleparticle

Ions Proteins Viruses Bacteria Pollens

Fibrous Media

Membranes

RO/NF UF MF P/F

Particle Size ( m)h

UF MF P/FRO/NF = Reverse Osmosis = Ultrafiltration = Microfiltration = Particle Filtration

Table 4: Types of filtration

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In part one of this two part series, we introduced theCity of Lebanon (PA) Authority Wastewater TreatmentPlant (WWTP) and described the objectives and the

challenges associated with integrating the controls ofa complex biological nutrient removal system. We alsodescribed the core elements of the control system that wasinstalled: the BACS aeration control system and the BIOSnitrogen controller. In part two we will describe the start-upand operation of the holistic controls and show how theycontribute to the overall success of the plant.

EXAMINING THE RESULTS

In the first phase of the system start-up the BACS aerationcontrol portion of the control system was tuned while theBIOS process control remained switched off.

Good control of the blowers is critical to controllingaeration, and this was achieved in close cooperation withthe blower manufacturer. Blowers are typically controlledto maintain a constant pressure rather than a specified flowrate, so the master controls of the single-stage centrifugalblowers used at the Lebanon plant had to be reprogrammedfor this application. In the end, the blowers could reliablyand repeatably achieve flow rates within 1 percent or 25scfm of the set point. The transition phase when blowers areswitched on or off to meet changing demands was also wellmanaged by the blower master controls.

The aeration control was tuned to limit set point changesto a pace that the blowers can match, to ensure fastestpossible system response to loading changes withoutinstability.

The aeration control logic also opens and closes air flowvalves (in this case butterfly valves with modulating dutyactuators, as is common in WWTPs) to distribute the air

to the control zones according to the calculated needs ofthe respective zones. It uses a dynamic most-open-valve(MOV) logic so that the blowers always operate at the lowestpossible system pressure, which minimizes aeration energy.In the case of Lebanon, this means whenever the swingzones are aerated, the MOV is on one of the swing zones,because these zones, with fine bubble diffusion, will havea higher restriction than the IFAS zones with their coarsebubble diffusers. When the swing zones are not aerated,their valves will close and the MOV will move to one ofthe IFAS zones. At the same time, the system pressure willdrop from about 7.55 psi with aerated swing zones to about6.75 psi when only the IFAS zones are aerated. This requiresthat the transition conditions be well managed to preventpressure oscillations and resulting instability. The interactionbetween the blower master control and the aeration controlwas tuned to achieve this without disturbances.

DISSOLVED OXYGEN COMPARISONS

Figure 6 shows the dissolved oxygen (DO) set points andactual DO in the swing zones and IFAS zones through acomplete on-off-on cycle of aerating the swing zones, witha corresponding reduction and increase in the DO set pointsof the IFS zones. You can see that the DO set points slowlyramp down to ensure stable operation, and the actual DOtracks well with only minimal lag. The header pressure also

stabilizes quickly at the respective system pressure.

Using the fan law for constant diameter impeller fans:

Q1/Q2 = (RPM1/RPM2);

P1/P2 = (RPM1/RPM2)2;

PWR1/PWR2 = (RPM1/RPM2)3

Tilo Stahl, PhD is a systems engineer at BioChem Technology, Inc., and Frank DiScuillo Jr. is the superintendent of the Lebanon(Pennsylvania) Authority Wastewater Treatment Facility. BioChem Technology specializes in the monitoring, optimization, andcontrol of wastewater treatment processes. For more information, visit www.biochemtech.com. The consulting engineer and

process designer on the project was K. Friedrich Updegraff, vice president at Gannett Fleming, Camp Hill, Pennsylvania.

About The Authors

By Tilo Stahl, BioChem Technology, Inc., and Frank DiScuillo Jr.,

City of Lebanon Authority Wastewater Treatment Plant

A Holistic Approach

to Process ControlProviding Process Improvementand Energy Savings

Part 2 of 2

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at equal flow Q1 = Q2, youfind that at P1 = 7.55 psi and P2= 6.75 psi

PWR2/PWR1 = (6.75/7.55)3/2

=

0.845

Therefore, at the lower pressurethe blowers are drawing 15.5percent less power. This adds upto a significant cost and energysavings over the life of the p lant.

THE FUNCTION OF THE BIOS

The BIOS process control part ofthe integrated controls conceptwas started up after the aerationcontrols were tuned and proved tobe stable.

The function of the BIOS is to:

1. determine the precise amountof aeration required toachieve the process goals,which includes calculatingthe optimal DO set pointsin all aeration zones andaerating the swing zoneswhenever the aerobiccapacity is needed

2. control the internal recyclerate to maximize denitrification in the first anoxic zonewithout overloading the system

3. control the trickling filter bypass to add carbon to thefirst anoxic zone whenever it is carbon deficient.

Figure 7 shows the performance of the integrated BIOSand BACS over a 36 hour period. It shows how the BIOSreacts to the changing load, as represented by the influentammonium concentration, by adjusting the DO set poin ts ofthe IFAS zones and switching the swing zones between a DOof 0.0 (off) under low loading conditions and 3.0 (on) whenthe ammonia levels are higher. Since the BIOS calculatesthe reaction rates (ammonia removal rates) as a function oftemperature, biomass, hydraulic retention time, residual DOlevels and other factors, the switch point for the swing zonesis variable. It is not sufficient to simply select an ammoniumlevel at which to switch the swing zones between aerated

and anoxic.Over the described period the swing zones are aerated for

75 percent of the time, so the aeration savings based on themost-open-valve logic alone add up to about 4 percent. TheDO set point control adds about another 15 percent savings,for a total of 19 percent aeration energy savings. Since theaeration blowers are by far the largest energy consumers inany wastewater treatment plant, typically making up 50 to 70percent of total energy usage, this is a significant contributionto both the sustainability and the cost structure of the plant.

The BIOS also controls the mixed liquor recycle flow(IMLR) and the trickling filter bypass flow to improvedenitrification performance and total nitrogen removal.Figure 8 shows the response of the BIOS to changing nitratelevels in the effluent flow.

Figure 6: Dissolved oxygen (DO) set po ints and actual DO in swing zones and IFAS zones

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The goal is to load the anoxic zonewith the highest possible level ofnitrates that can be processed underthe given conditions, and introducethe precise amount of carbon via thetrickling filter bypass that is neededto process the nitrates. It can be seen

in the graph that as the nitrates dropbelow a set point of 2.5 mg/l theIMLR increases to increase the nitrateloading, and the bypass increases toadd additional carbon. As soon as theeffluent nitrate exceeds the target theIMLR decreases. At the same time thebypass flow drops when the nitratereadings drop below the set point andincrease when the nitrates start toclimb, but the bypass flow continuesto add carbon to treat the increasednitrate levels even after the IMLRdrops. The bypass flow decreases

whenever the nitrate levels dropbelow the set point.

With these control systems, theplant is consistently meeting itsprocess goals.

SUMMARY

The City of Lebanon AuthorityWastewater Treatment Plant wastasked with achieving stricternutrient removal limits withoutphysically expanding the plant. Anadditional objective was to improvethe sustainability of the plant byminimizing energy consumption.To support this goal it introduceda holistic process control systemto optimize the operation of thesecondary treatment, which consistsof an IFAS system with anoxic swingzones.

The control system integrates thecontrol of the blowers, the airflowvalves, the mixed liquor recyclerate and a trickling filter bypass. Thecontroller demonstrated that it canconsistently and reliably meet the

process goals and provides aerationenergy savings of about 19 percentover static control systems. ■

Figure 7: Performance of the integrated BIOS and BACS

Figure 8

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MAINTENANCE solutions

Improving Cooling Tower FiltrationThe Southern Hemisphere’s largest entertainment complex reduces maintenance and treatment costs

Part 1 of 2

Keeping an open recirculationcooling water system cleanaccomplished three crucial

operational goals and a fourthoverriding goal for sustainability:

1. Assists in maintaining heat transferefficiency—0.025 millimetersof fouling equates to 10 percent

reduction in cooling efficiencies(see reference 1),

2. Reduces maintenance costs, and3. Enhances the effectiveness of the

water treatment program, which4. All contribute to reduced costs

and increased cooling towersystem life.

Open systems are prone to foulingfrom airborne contaminants, waterborne contaminants and contaminantsassociated with a process. Air containsdust, dirt, organic matter, insects,microbiological organisms and gasses.Make-up water can contain a varietyof dissolved salts, suspended solidsand microbiological organisms.Systems can also produce suspendedsolids from within due to corrosion,scale and microbiological growth.

Filtration is commonly employedto remove these contaminants fromthe water and improve the circulatingwater quality. Centrifugal sandseparators (which are not consideredfilters), deep bed media filters, and

automatic screen filters all offervarying effectiveness in the way eachtechnology actually removes materialfrom the circulating water. Each ofthese technologies also differs in theirrespective benefits and associatedcosts. Filtration, separation and

other water cleaning systems canbe either in-line or side stream, andbasin cleaning systems can enhancecontaminant removal. Understandingthese technologies and theirdifferences are necessary for propertechnology selection.

CASE STUDY

The following case study describes oneend-user’s experience with multiplefiltration technologies and theirinherent advantages and disadvantagesin their cooling tower systems. Inpart 1, we’ll examine deep bed andsand media systems. In next month’s

conclusion, we’ll take a closer lookat centrifugal sand separators, pistonoperated self-cleaning screen filters,and finally—what is becoming thetechnology of choice for cooling towerfiltration applications—automatic self-cleaning screen filters.

A patented self-cleaning screenfiltration technology was supplied by

VAF Filtration Systems from the USAand was installed and commissionedby Hydrochem of Australia in 2013at a major entertainment complex inAustralia. VAF's V-Series filters weresupplied to replace three other typesof filtration technologies serving ten

Glenn Dobbs is president of VAF Filtration Systems, Arvada, Colorado, and has developed the company into providing state-of-the-art self-cleaning screen filtration products worldwide removing suspended solids down to 10 micron. Roy McDougallis senior projects manager for Hydrochem of Australia and has provided cooling tower treatment services including filtration

for more than thirty years. For more information, visit www.vafusa.com.

About The Authors

By Glenn Dobbs, VAF Filtration Systems, and Roy McDougall,Hydrochem Water Treatment Systems

Figure 1: The deep bed sand media installation

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individual cooling tower systems.The older filtration technologies werenot meeting the end-user’s strict KeyPerformance Indicators for cleanliness,and subsequently the cooling systemsrequired an unacceptably highfrequency of manual cleaning. So theend-user chose to install a newer filtertechnology to minimize problemsassociated with the older technologies.The replaced technologies includeddeep bed media, centrifugal separatorsand piston operated self-cleaningscreen filters. The following describeseach installation, the technologiesinstalled and the end-user'sexperiences with each.

DEEP BED MEDIA FILTRATION

One hotel building in the complexhas a cooling plant consisting of fourcommon cooling towers with 7925gallons (30,000 liters) total systemvolume. These were originally fittedwith six deep bed media filter unitsthat operated for approximately twoyears. In that time the deep bed mediasystems maintained the cooling towersin a clean state; however, they werefound to require very large amounts ofwater for backflushing which causedthe cooling tower system to lose themajority of chemical treatment everytime the f ilters were backflushed. The

media filters were then reconfiguredto utilize two filters per week on arotating basis to minimize the waterlosses.

However excessive water lossthrough backflushing was still found tobe a problem. In addition to the waterloss, a number of the media vessels’control valves failed and allowed largevolumes of media into the coolingsystem damaging the chiller system'sVSD's (variable speed drives) andfouling the condensers. Also, therequired periodic replacement ofmedia was very expensive.

The media filters were replacedwith two VAF V-250 filters which areoperating well maintaining the coolingtower basins in a clean state while

removing the residual media from thesystem.

Deep bed or sand media filterstypically require a relatively largevolume of water to backflush themedia of contaminant trappedwithin. With a sand media systemthat requires 1,200 liters of waste tobackflush, the equivalent size of VAF'sself-cleaning screen filter uses only 30liters to backflush. Backflushing sandmedia takes full flow for at least threeto five minutes, and the tank beingflushed must be completely off lineduring the backflush process.

SAND MEDIA

Sand media can remove mostparticulate that are 10 micron andlarger; however, it is difficult tobackflush heavy particles (such asdirt, sand or calcium carbonate)collected from the tower withoutlosing some of the media during eachflush. Therefore, expensive periodicreplacement of the media is required.Sand media is excellent for removingorganic particulate including algaeand sediment from the water andretaining those particles in the media.It has been shown by the EPA that sandmedia filtration on cooling towersand hot tubs provides an excellenthabitat for bacteria such as Legionellasince the organics combined with the

sedimentation held within the mediaare the major source of nutrients forLegionella (see reference 2). ■

REFERENCES

1. Systems and Equipment Handbook (2000), ASHRAE.

2. “Legionella: Human Health CriteriaDocument” (1999), Office of Science andTechnology / Office of Water, United StatesEnvironmental Protection Agency.

Opened Opened

OpenedOpened

Filtering Mode Flushing Mode

Closed Closed

ClosedClosed

Figure 2: Typical sand media configuration

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PUMP solutions

I

n the first part of this article, wediscussed some of the materials thathave been tested extensively for use

in diaphragms in AODD pumps—rubber,TPE (thermoplastic elastomer) and PTFE(Polytetrafluoroethylene or Teflon®)—with special attention given to rubberdiaphragms. In this month’s installment,we will examine TPE and PTFEdiaphragms and conclude by rating andcomparing all three diaphragm materialsfor the properties and attributes thatmake them suitable for differentapplications.

THERMOPLASTIC ELASTOMER(TPE) DIAPHRAGMS

TPE diaphragms are manufacturedby injection molding. As a result oftheir dimensional stability and tensilestrength, TPE diaphragms do not needfabric reinforcement. Following are theavailable types of TPE diaphragms:

• Polyurethane is an outstandinggeneral-purpose diaphragmfor nonaggressive chemical

applications such as water,wastewater and seawater. Itprovides excellent flex life, abrasionresistance and durability at aneconomical price.

• Wil-Flex™ provides a low-costalternative to PTFE with a cos tcomparable to neoprene. Madeof Santoprene™, Wil-Flex is idealfor use with acidic and causticfluids such as sodium hydroxide,sulfuric acid or hydrochloric acid.Exhibiting excellent flex life,abrasion resistance, temperaturerange and durability, it is widelyused in the chemical process, food,pharmaceutical and wastewaterindustries. Versions of Wil-Flex areavailable that comply with FDA 21CFR 177 standards for food andbeverage applications.

• Saniflex™ is an excellent materialfor food processing applications.Made of Hytrel®, it exhibits goodflex life and excellent abrasion

resistance. Hytrel also offerssuperior sealing or seal energizingdue to its low compression setcharacteristics. Saniflex versions areavailable that comply with FDA 21CFR 177 standards.

• Geolast® exhibits enhancedoil-resistance and low oil swellmaking it ideal for petroleum

industry applications. Equivalent tonitrile (Buna-N), Geolast providesmoderate flex life and goodabrasion resistance over a widetemperature range at a lower costthan fabric-reinforced Buna-N.

POLYTETRAFLUOROETHYLENE(PTFE) DIAPHRAGMS

Because it is one of the most chemicallyinert compounds available, PTFE can beused with an extremely wide range offluids. Also known as Teflon®, PTFE is

excellent for highly aggressive fluids suchas aromatic or chlorinated hydrocarbons,acids, caustics, ketones and acetates.Its properties provide excellent flexlife and moderate abrasion resistance.In addition, PTFE complies with FDA

Rob Jack is a development engineer IV for Wilden ® and Pump Solutions Group (PSG®). Wilden is a leading manufacturer ofair-operated double-diaphragm (AODD) pumps. He can be reached at 909.422.1784 or [email protected]. For moreinformation, visit www.wildenpump.com. Wilden is an operating company within Dover Corporation’s Pump Solutions Group(PSG®), which is comprised of several leading pump companies, including Abaque ®, Almatec®, Blackmer®, Ebsray®, Finder,

Griswold™, Maag, Mouvex®, Neptune™, Quattroflow™, and Wilden®. Find more information at www.psgdover.com.

About The Author

By Rob Jack, Wilden® and Pump Solutions Group (PSG®)

HOW TO SELECT DIAPHRAGMS

FOR AODD PUMPSAsking the right questions and utilizing the best available tools from Wilden® will help AODD pump operators maximize diaphragm life

PART 2 OF 2

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21 CFR 177 and USP Class VIstandards for food, beverage andpharmaceutical applications.Because PTFE is non-elastic, abackup diaphragm of a differentmaterial must be used to provideflexibility and memory. Materialoptions for backup diaphragmsare Neoprene, Saniflex and hightemperature Buna-N.

RATING AND COMPARING

DIAPHRAGM MATERIALS

Using extensive material testingand field data, Wilden® compileda Diaphragm Selection Guidethat compares and rates the flexlife, abrasion resistance, chemicalresistance, temperature limitsand relative cost of each materialtype. It is important to note thatthis chart should be used only asa guideline and in conjunctionwith thorough additional researchand expert advice to determinethe suitability of diaphragm

materials for individualapplications because one factorcan affect another.

When using the chart, alwaysstrive for an “A” or “B” rating andkeep the application’s maximumfluid temperature as close to thecenter of the “Operating Temperature Limits” as possible. Theselection of “C” -rated materials is generally not recommendedbut may be necessary in rare exceptions where fluids are highlyspecialized or processed under extreme conditions. For someapplications, two different materials may be suitable with costbeing the final deciding factor.

Other factors to consider in selecting the right diaphragminclude the hardware configuration of the pump, type and

frequency of cleaning fluids,pump operation (intermittentor continuous), and how oftendiaphragms are being replaced.On average, diaphragms thatneed to be replaced more oftenthan every three months warrantfurther evaluation as to the rightfit for the application.

CONCLUSION

Whether pumping water,aggressive acids, food productsor solid-laden slurries, there isa Wilden diaphragm for everyapplication. The challengecan often be selection of theoptimum diaphragm that willassure safe, efficient, costeffective and trouble-freeoperations. Determining thecorrect diaphragm requirescarefully identifying andfactoring all process andapplication parameters into theanalysis. A valuable resource to

assist with diaphragm selectionis the network of Wildendistributors, who have extensivetraining in AODD pumptechnology and applications.Because one selection factorcan offset another, expert advice

should be obtained in determining compatibility based on allfactors. ■

NOTES

Hytrel®, Viton® and Teflon® are registered trademarks of DuPont™Company.Geolast® and Santoprene® are registered trademarks of ExxonMobil.

Saniflex™ and Wil-Flex™ are registered trademarks of Wilden®.

Correct diaphragm material selection for each application is critical to assuresafe and efficient AODD pump operations.

Wilden® offers the widest selection of diaphragms for nearly everyapplication. From aggressive chemicals to highly abrasive materials toextreme operating temperatures, Wilden has the right diaphragm for superiordurability, higher performance and significant labor savings.

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DEWATERING solutions

California Logistics CenterFinds Stormwater Solution

The Rialto, Calififornia-basedI-210 Logistics Center is partof a proposed master-planned

project located on and around the RialtoMunicipal Airport. The 1445 acre site i s apremier West Rialto location, with high-profile corporate neighbors includingTarget, Under Armour, Black & Decker,Solo Cup and Kuehne + Nagel. The718,000 square-foot (66,704.4 square

meter) industrial distribution warehousewill house products until they are readyto be shipped to their final destinationsacross the country.

Upon completion,the Logistics Center willfeature a cross-dockfacility with 32 feet(9.75 meters) minimumwarehouse clearance,185 to 344 feet (56.39 to104.85 meters) concretetruck courts, 112 dockloading doors, each 9by 10 feet (2.74 by 3.05meters) high, and 249trailer parking spaceseach measuring 10 by53 feet (3.05 by 16.15meters). Approximately 3380 square-feet(314.01 square meters) of the buildingwill be dedicated to the office space.

THE CHALLENGE OF A DUAL-

SYSTEM DESIGN

In addition to designing the facility,engineers from SB&O Inc. collaborated

with EW Harmon Contracting, Inc. todesign and install a stormwater detentionand retention system to comply withwater quality requirements as well asprovide stormwater pre-treatment to thesite.

Engineers determined that the mosteconomically effective method of

stormwater management would be tocombine an underground network ofchambers with a separate above-groundsystem consisting of retention/detentionbasins—a relatively new practice. Achallenging aspect of the dual-systemdesign was determining how the twosystems would interact with each other,

and how to keep siltation out of theunderground system, into which waterfrom the above-ground system migrates.

To mitigate water quality concerns,engineers chose to raise the inlets inthe above-ground detention basins sothat the silts had a chance to settleprior to flowing into the underground

chamber system consisting of 726 units.Two CULTEC StormFilter® 330 unitsfilter runoff before it enters a CULTECSeparator Row™. The StormFilter 330 isa chamber-shaped secondary filter whichcontains two removable pass-thru filters.Water passes thru the filter baffles and iscaptured or settles to the bottom of theunit. For maintenance, the StormFilterhousing can be vacuumed out and thefilter bags may be replaced or cleanedand reused.

THE SEPARATOR ROW:

A CLOSER LOOK

The Separator Row, comprised of aselect row of underground chambers, isenveloped with No. 410™ filter fabricand sits on top of two layers of wovengeotextile fabric. The Separator Rowpre-treats runoff by capturing silts andfine particles in a row of chambers priorto runoff overflowing into the rest of the

CULTEC’s technical staff offers free design assistance including preliminary calculations and job-specific CAD details.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 technical staff

California Logistics CenterFinds Stormwater Solution

Engineers determined that a combination of undergroundchambers and above-ground retention/detention basinswould be the most economically effective method.

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infiltration basin. To help maintain thestormwater system, debris can be easilyvacuumed out using a water jet, whichpushes water toward the catch basinand sump while removing waste.

The Recharger V8HD was selectedfor the Logistics Center because it

both maximizes storage in a smallfootprint and satisfies the other designrequirements of the site. The internalmanifold feature available on thestormwater chamber allows for a morecost-effective and condensed bed sizesince a costly and time consumingcustom pipe and fitting externalmanifold fabrication is not required.Smaller chamber-like “feed connectors”are inserted into side portals locatedon the sidewalls of the stormwaterchambers to create the internalmanifold. Installation is quick and

efficient.

MEETING REGULATORYREQUIREMENTSRegulatory bodies called for astormwater solution that would mitigatethe proposed flows to be equal to orless than the existing flows on site—particularly for higher-flow floodconditions. Moreover, to meet waterquality regulations, a certain volumehad to be retained onsite and infilt ratedinto the ground to accommodate lower-flow water quality requirements.

“Water flows into the above-grounddetention/retention basins and fillsabout a foot deep before overflowinginto the CULTEC chambers locatedunderground,” says Don Brooks,engineer with SB&O Inc. “The twosystems combined provide the detentionand retention volumes required tomeet the regulatory requirements of thecounty.”

Each Recharger V8HD chambermeasures 32 inches (812.8 millimeters)high and 60 inches (1524 millimeters)

wide and has a bare chamber capacityof 8.68 cubic feet (0.25 cubic meters)per linear foot. The bed of chambersprovides the site with a total of 72,857cubic feet (2063.08 cubic meters) ofstorage. In addition, the V8HD modelis able to withstand traffic loadingwith minimal cover—a major siterequirement since the chambers willlargely be covered with parking areas.Further, there is no underground stormdrain system to tie into, so the runoffoutlets are located to the street surface.For this reason, the engineers wereeager to keep the storage elevation as

CULTEC introduced its Contactor® andRecharger® HDPE septic and stormwaterchambers in 1986, which helped begina revolution toward the use of plasticconstruction products. Since then, severalproduct developments and strategicalliances have seen the chambers used as

subsurface retention or detention systemsand as replacements for ponds, concretestructures or pipe and stone installations. ■

high as possible to direct the flow to thestreet.

A WINNING TEAM“This was our first time working withCULTEC, and we look forward to teamingup with them again in the future,” recalls

Brooks. “Their team was very responsiveand helped us get the job done quicklyand efficiently.”

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MOTOR solutions

Metallized Carbon Corporation,a global leader in themanufacture of oil-free,

self-lubricating, carbon-graphite

materials for severe service lubricationapplications, is committed to expandingthe benefits these products can offer to arange of applications.

For example, today’s rotary vanepump users can now benefit fromcustom vanes, rotors, and end platesfor use in pumping both liquidsand gases. The carbon-graphitecomponents provide superiorlubrication in most environments,and are ideal for pumping liquidswith poor lubricating qualities, strongchemicals that attack metals, and topump air, vacuum, combustion productsand gasoline vapors. Also, aviationengineers are discovering the benefitsof carbon- graphite bushings for use inaircraft engine gear pumps tha t pumpfuel.

CUSTOM VANES, ROTORS, ANDEND PLATES FOR ROTARY PUMPSMetallized Carbon’s carbon-graphitevanes, rotors, and end plates a reused in such dry running applicationsas automotive anti-smog pumps

and gasoline vapor pick up pumps,breathable air pumps and vacuumpumps. In-liquid applications includevending machine beverage pumps,fuel and liquid chemical pumps, andmedical liquid pumps.

Metallized Carbon supplies thecarbon-graphite vanes, rotor, and end

plates to rotary pumpand compressor manufacture andrebuilders. The materials are chemicallyresistant and are compatible with FDAfood and beverage regulations. Theyhave a low wear rate running in both

gas atmospheres and low viscosityliquids.

IDEAL FOR BOTHLIQUIDS AND GASESCarbon graphite vanes can withstandthe rubbing of the vane tip against thehousing bore and the rubbing of the

side of the vane against the slots inthe rotor. Lightweight carbon graphiterotors save energy and withstand therubbing against the vane and the endplates. Carbon graphite end plates are

pressure tight and dimensionally stableso that they can make a close clearanceseal with the rotor and vanes. They alsowithstand the rubbing of both the vanesand rotor.

These materials work best in severeservice applications With dimensionallystability and high strength-to-weight

Matthew Brennan is president and CEO of Metallized Carbon, an ISO certified and producer of the Metcar brand of solid,oil-free, self-lubricating materials. For additional information about the company and its services, visit www.metcar.com or

call 914.941.3738.

About The Author

By Matthew Brennan, Metallized Carbon Corporation

The New Frontier OF SELF-LUBRICATING SOLUTIONS

A closer look at the benefits of carbon-graphite solutions across a range of applications

Pressure tight anddimensionally stablecarbon graphite end platesoffer the benefit of a closeclearance seal with therotor and vanes.

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UNIQUE MATERIAL WITHNUMEROUS ADVANTAGESA second major advantage ofcarbon-graphite bushings is thatthey are self-lubricating—theycan run dry for short periods oftime without catastrophic pump

failure or signif icant wear.In addition, carbon-graphitebushings are dimensionallystable, which permits theclose bushing to shaft runningclearances that are required ingear pump applications.

Finally, these carbon-graphitebushings have a relatively lowelastic modulus. While elasticenough that they can be press-fit into the metallic gear pumphousing with no diff iculty,after being properly press-fit,

the carbon-graphite bushingsare pre-stressed in compression.Therefore, they exhibit nearly the samecoefficient of thermal expansion as themetallic gear pump housing material.This assures that the running clearancebetween the shafts and the bushings willremain the same throughout the entireoperating temperature range of thepump. ■

ratio, the components areavailable in several gradesof Metcar’s proprietarycarbon/graphite material.Metcar engineersassist in selecting theoptimum grade based on

application, environment,housing materials,revolutions per minute,and other parameters.The components can besupplied to meet customprints and specifications.

CARBON-GRAPHITEBUSHINGS FORAIRCRAFT ENGINEFUEL PUMPSA more unique severeservice lubrication

application for carbon-graphite bushings is in use in gearpumps that pump aviation fuel foraircraft engines. Here, the carbon-graphite bushings are used to suppor tboth the drive gear shaft and theidler gear shaft. Metcar carbon-graphite bushings are preferred forthis application because they can useaviation fuel as the bushing lubricant.

Since carbon-graphite material possesses no atomic attraction to a metallic shaft, eventhe thin fuel film provided by aviation fuel is sufficient to lubricate metallic shafts runningin the carbon-graphite bushings.

Aviation fuel is a low viscosity liquidthat produces only an extremely thinhydrodynamic film, too thin to provideadequate lubrication for traditional metallicbushings. But since carbon-graphitematerial—in contrast—has no atomicattraction to a metallic shaft, the thin fuelfilm is sufficient to lubricate metallic shaftsrunning in the carbon-

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Modern Pumping - 092014