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CALCULATING

PIPING LOSSES

FOR PUMPING

OPTIMAL

LIFT STATION

PUMPING

SOLUTIONS

DESIGNING

FORMEDDIAPHRAGMS

FOR PEAK

PERFORMANCE

JULY 2014PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

IMPROVING

EFFICIENCY

IN CITY-WIDE

SYSTEMS

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CONTENTS JULY 2014

4 Industry News

10 Trade Show Prof ile Case Studies 12 Water Quality Insights Through

Real Time Data The LiquIDTM improves efficiency in poultry processing

16 Improving Eff iciency and Effectiveness

Across the Board Schneider Electric completes energy retrofits to city facilities in Kirksville, Missouri

Water & WastewaterSolutions 20 Electronic Water Treatment Reduces

Fouling in Reverse Osmosis

24 CIP Guidelines for Filter Membrane

System Cleaning

Maintenance Solutions 28 Know Your Pump Base Plate

Installation Options Part 3 of a 3-Part Series

Pump Solutions 30 A Revolution in Pumping Eff icieny

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

Part 4 in a 4-Part Series

34 Calculating Piping Losses and Their

Effect on Pumping

Dewatering Solutions 38 Optimal Pumping for the Pleasure Pier

Lift Station BJM submersible shredder pumps provide a reliable solution for the "Coney Island of the South"

Motor Solutions 40 Fish Friendly Pumps Go Direct Drive

Cam Pumping Station replaces diesel for improved efficiency

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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]

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JOEL DORNING Assistant Art Director

[email protected] GARMON General Manager

[email protected]

LINDEY SCOTT Circulation [email protected]

JAMIE WILLETT Circulation [email protected]

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

TONYA BROWNING Account Executive

CURTIS FROST Account Executive

RANDY MOON Account Executive

Terry Bell

Drives and Motion Solution EngineerBaldor Electric Company

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

Process Machinery Consulting

Robert G. HavrinDirector of Technology,Centrisys Corporation

Michael Mancini

Consultant and Trainer,Mancini Consulting Services

John M. RoachEngineering Manager

for New Product Development,Trebor International, Inc.:

A Uni t of IDEX

Lisa Riles

Business Development Manager,Wastewater Pumps Xylem Inc.: Flygt

Greg TowsleyDirector of Regulatory andTechnical Affairs, Grundfos

Trey Walters, P.E.President, Appli ed Flo w Tech nolog y

EDITORIAL ADVISORY BOARD

Power GenerationSolutions

42 WR®525 Eliminates Falures inFeedwater Pumps

Non-galling, non-seizing material saves company four to five million dollars

Processing Solutions 44 VAF Solves High Volume River Intake

for Canadian Paper Mills

Valves & ControlsSolutions

46 Wireless Controls for Use

in Hazardous Locations

Sealing Solutions 48 Designing Formed Diaphragms

for Optimum Performance and

Manufacturability

52 Modern Pumping

Products Featured Product Release: MEGGITT SENSING SYSTEMS MachineryMate MAC050 and MAC100

Pumping Trends 56 The Cutting Edge Flygt's Lisa Riles looks at the challenge facing municipal wastewater and a different type of solution

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4 | JULY 2014 www.modernpumpingtoday.com

INDUSTRY news

XYLEM RELOCATES NORTH CAROLINA BRANCHTO LARGER FACILITYXylem, a leading global water technology company focused onaddressing the world's most challenging water issues, announcesthe relocation of its Garner, North Carolina, branch. ThisXylem branch features Godwin products and Flygt pumps fo rconstruction and mining. This new location will feature a larger

office and shop with over 10,000 combined square feet, whichwill better accommodate our staff and customer needs. Thelocation has a large yard for storage of additional inventory ofpumps, HDPE pipe, and accessories.

The branch is convenient to all major local highways. Thisfacility will serve as a regional hub located midway between oursouthernmost branches and our headquarters in New Jersey. Itwill provide an ideal location to s tage equipment in response tosevere emergency weather events anywhere on the east coast.

"This new facility will allow us to continue to provide the highlevel of service local customers expect when they call Xylem.Our continued growth in Garner year after year needs a newspace for this continued growth and effort. We look forward toeven more efficient customer service that this new facility will

allow," says branch manager Dave Donahue.Regional manager Jarrod Williamson adds, "Our goal is to

continue to offer the highest level of service to all our customersin the Triangle area and surrounding eastern and central NorthCarolina counties. We will host an open house at our newlocation later this summer, but for now, we are officially openfor business and fully operational. Branch personnel will remainthe same."

YASKAWA ANNOUNCESNEW WEBSITEYaskawa America, Inc. launchesthe next generation website forwww.yaskawa.com. The goal forthis project was to provide a betteruser experience by improving

navigation, enhancing thesearch engine and offering morecomprehensive content aboutYaskawa’s people, products and solutions.

Feedback provided by users guided Yaskawa’s team toimplement new design elements that optimized functionalityand improved performance in each section. Highlights include

• Focus on people and solutions while increasing productvisibility

• Improved navigation for quick and easy access toinformation

• Utilizing dynamic content to provide the most up-to-dateaccurate information

• Redesigned partner section provides immediate exposure toimportant news and announcements

• Modified search tool and new model number search to findproduct and support information for current and legacymodel numbers

• Mobile-friendly website that will work on mobile devices• Ability to rate content and provide feedback throughout the

site

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INDUSTRY news

RF SYSTEM LABWELCOMES NEW CLIENTSRF System Lab, a world-wide leaderin remote visual inspection andmanufacturer of the VJ-Advance, isproud to welcome new customersin a multitude of industries. RF

System Lab’s customer list includescompanies from industries such as aviation, power generation,oil and gas, chemical processing, manufacturing, and more.

One of RF System Lab’s newest customers in the Aviation andAerospace Maintenance industry is Rolls-Royce. Rolls-Royce,the world’s second-largest maker of aircraft engines, was lookingfor a tool to inspect the inside of casting cavities, integral partsof the turbine engine. They required a borescope that wasboth durable and flexible, which made the VJ-Advance videoborescope, with its 360 degree joystick-controlled articulatingdistal tip and flexible insertion tube, the perfect fit.

Representing the oil and gas industry, Schlumberger isanother company among RF System Lab’s newest customers.Schlumberger, the world’s l argest oilfield services company,

required a low-cost, high-quality borescope to assist them inproviding maintenance services to the petroleum industry.RF System Lab’s VJ-Advance, which is battery-operated andcompletely portable, is an essential addition to their tool kit.

Another new VJ-Advance video borescope user is Nike, Inc.Nike, one of the world’s largest suppliers of athletic shoes,apparel, and a major manufacturer of sporting goods, purchasedthe super-slim 2.8 millimeter VJ-Advance video borescope to

inspect the heads of their line of golf clubs using remote visualinspection (RVI).

Additionally, RF System Lab is excited to have a major powergeneration company, Mitsubishi Hitachi Power Systems, as a newcustomer. Mitsubishi Hitachi Power Systems provides responsiveand proactive service solutions for power providers throughoutthe Americas. They will be using the VJ-Advance video borescope

to assist them in those efforts. NATIONAL PUMP COMPANYACQUIRES BAYOU CITY PUMPNational Pump Company, a wholly-owned subsidiary of TheGorman-Rupp Company, acquired the business of Bayou CityPump, Inc. (BCP). Founded in 1973, BCP is headquartered inPasadena (Houston), Texas and has a service facility in BatonRouge, Louisiana. BCP is a leading manufacturer of and serviceprovider for highly-reliable vertical turbine pumping systemsprimarily for the inland and coastal marine liquid petroleum andchemical transportation markets, both domestically and globally.

Jeff rey S. Gorman, president and CEO of the Gorman-RuppCompany says, “BCP’s strong customer relationships and

long history will help expand sales in targeted niche marketscomplementary to National Pump Company’s significant andgrowing vertical turbine products leadership position.”

FRANKLIN ELECTRIC ANNOUNCESACQUISITION IN BRAZILFranklin Electric Co., Inc. announces that it has acquired BombasLeão S.A., based in Monte Azul Paulista, State of Sao Paulo,

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INDUSTRY news

Brazil. Bombas Leão designs, manufactures, and distributessubmersible groundwater pumping equipment throughmanufacturing facilities in Monte Azul Paulista, Teresina and adistribution facility in Recife. In 2013 Bombas Leão net revenueswere approximately BRL 67 million or about US$ 30 million.

The company believes the transaction will be accretiveto 2014 Earnings per Share (EPS). Gregg Sengstack, Franklin

Electric chief executive off icer, comments,“Brazil is one of the largest ground water pumping marketsin the world and a cornerstone of our developing marketsgrowth strategy. Over the years, the Franklin brand wasestablished in the country principally th rough the importationof our submersible motors by pump companies. In 2008,we acquired Motobombas Schneider, located in Joinville,Brazil, a leading residential pumping systems company withan extensive distribution network. Since acquisition, Franklin(Schneider) Motobombas sales have doubled, and, this month,we are opening a new factory and training center to support thecontinued growth of this business.

Bombas Leão, established in 1964, and owned by the Plazafamily, is a leading supplier of groundwater pumps principally

used in agriculture, industrial and municipal applications. Wehave maintained contact with the Plaza family over the yearsand are pleased with their decision to sell their company toFranklin Electric. The Bombas Leão acquisition will provideadditional submersible pump products, extending the FranklinElectric product offering, expand our distribution reachand further position Franklin Electric as a market leader ingroundwater pumping equipment in Latin America.”

PROJECT WATER INJECTION PACKAGEFOR FLOATING PRODUCTION FACILITYRuhrpumpenrecently sold aWater Injectionpackage thatconsists of quantity

(2) SCE 10X8X16(booster pumps)and quantity (2)SM 6X13X10 (mainpumps). The 2.3MW driver for theSM pump operated by a variablefrequency drive.

The base plate, that alsowill carry the lube oil system,is designed as a three pointsupport version. This is a specialdesign for platforms and FPSO´s(floating production sto rage

and offloading). The three-pointsupport will protect the pump unitfrom stresses due to the twisting of the ship.

The package will be placed on a special FPSO from SevanMarine, the “Sevan Voyageur.” This FPSO from Sevan is a specialdesign (different from the more common standard design of aModified Tank ship). The cylindrical design makes it verticalmodular and extremely stable. ■

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Built on a history ofsuccess, the 43rd

Turbomachinery and30th International PumpUsers Symposia is an eventprofessionals in the industrialpump and rotary equipmentmarkets can’t afford to miss.This annual event features aworld-class technical programcombined with an internationalexhibition complete with full-size equipment and hundreds ofleading companies.

EDUCATION AT ITS CORE

The Texas A&M TurbomachineryLaboratory sponsors the twoannual symposia, held in thefall of each year, to promoteprofessional development,technology transfer, peernetworking, and informationexchange among industryprofessionals. These twoevents are led by engineerswith vast experience in thepetrochemical, process,chemical, utility, contractor,

and consulting fields, alongwith manufacturers of rotatingequipment and fluid-handling equipment f rom aroundthe world.

Both symposia feature lectures, tutorials, casestudies, discussion groups, and short courses, aswell as exhibits of the latest services and full-sizedequipment. These international meetings emphasizethe technology and troubleshooting that users need intoday's challenging workplace.

BY USERS FOR USERS

The Pump and Turbomachinery Symposia continue tobe the only meeting organized by users for users. Themembers of the Advisory Committee, who provide

overall guidance, are recognized leaders in therotating equipment and power generation community.The Symposia provide an outstanding opportunityfor users concerned with maintenance, performance,troubleshooting, operation, and purchase of rotatingequipment. The technical sessions provide anopportunity for attendees to select lectures, tutorials,discussion groups, and case studies that best meettheir personal and professional needs and interests.

Discussion groups highlight this “user-focused”approach that truly elevates the Pump andTurbomachinery Symposia experience. Peer-to-peerinteraction and networking opportunities abound

PUMP AND

TURBOMACHINERYSYMPOSIA 2014The Future Launches from Houston


TRADE SHOW prof ile

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JULY 2014 | 11www.modernpumpingtoday.com

throughout the Symposia events. Topics for this year’s discussiongroups include• Vertical Pump Problems and Solutions• Couplings and Alignment• Monitoring Vibration and Other Critical Machine

Conditions• Subsea Pumps and Drivers•

Centrifugal Pump Operation, Maintenance, and Reliability• Improving Mean Time Between Pump Failures• Monitoring Vibration and Other Critical Machine

Conditions

BREAKING THE CYCLE OF PUMP REPAIRS

One of the founding members of the board of the Pump andTurbomachinery Symposia, Heinz P. Bloch, will presentthe tutorial session “Breaking the Cycle of Pump Repairs.”Achieving the lowest possible life cycle cost (LCC) or lowestcost of ownership is an undisputed goal of most pump usersand the author knows, from fifty-two years of solid engineeringpractice, that pump hydraulics and fluid sealing details havereceived due attention over the years. However, bearing

protection and lubricant delivery components are now oftendecades-old; many no longer reflect best available technologyand "lean and mean" has often morphed into "cheap and risky."Bloch shows why a few truly reliability-focused users enjoypump MTBR’s four time greater than others and why their per-pump maintenance expenditures are often only one-fourth ofthose forced upon their struggling competition. This tutorialdelineates at least ten li ttle-known, but highly important, detailsof major interest to pump users seeking to improve pump lifeand minimize maintenance cost.

THE LATEST SOLUTIONS

The exhibits feature products from many key companiesin the industry. Exhibiting companies normally send their"first-team" players to these symposia; hence, you can getknowledgeable help at the exhibit hall, in addition to seeingmajor exhibits of equipment, designs, and accessories.Prospective exhibitors at this year’s Symposia include

companies such as St. Marys Carbon, Hydro, Ludeca,Cincinnati Gearing Systems, Graphite Metallizing Corp.,Milton Roy, IMI Sensors, SDT Ultrasound, and many others.

SHORT COURSE OPTIONS

The Turbomachinery Laboratory provides continuingeducation opportunities to users of industrial turbomachineryand pumping systems at the annual International Pump UsersSymposium and Turbomachinery Symposium. The f ive shortcourses provide attendees the best of both worlds in terms ofintroducing important developments in the context of today’sindustry, yet also offering detailed at tention and clarity totechnical concerns.

Attendance at a Pump Symposium short course is sure

to provide new insight and greater depth of knowledge toboth newly minted and veteran engineers. Topics for thisyear’s short courses include “Demystifying Piping Plans andSupport Systems,” “Fundamentals of Centrifugal Pump andSystem Interaction,” “Pump Cavitation: Physics, Prediction,Control, Troubleshooting,” “Vibration Problems and Solutionsin Pumps and Turbomachinery,” and the popular “Pumps101” aimed at engineers and technical professionals whoneed a broad-based introduction to basic pump selection,application, and operation. ■

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CASE Studies

ZAPS Technologies manufacturesautomated, real-time waterquality monitoring equipment

in support of professionals involvedin water treatment, water analysis,and environmental monitoring. Theengineers and scientists at ZAPShave combined hybrid multispectralanalysis (HMA)—an opticalmethodology which requires noreagents. The LiquID™ station, aunique stand-alone instrument usesHMA combined with state-of-the-art data analysis software and web-enabled information delivery to rununattended 24/7 while producingthousands of tests per day on flowing

water from raw wastewater to finisheddrinking water, and water from rivers,lakes and marine environments.

THE TECHNOLOGYHybrid Multispectral Analysis (HMA)is a unique combination of advancedoptical, photonic, and statisticaltechnologies applied to the challenge

of providing synchronized highfrequency data for complex watertypes.

Those raw signals are thenautomatically processed intoactionable information bysophisticated computer algorithmsin the LiquID, which identifythe presence and measure theconcentration of a broad array ofsubstances of interest in the sampleflow. This information i s then deliveredto the LiquID station’s secure userinterface or transmitted to a SCADAsystem for analysis by authorized plantpersonnel.

This type of information is required

to control treatment processes inreal time. HMA allows plants tocontinuously adjust treatment basedon current and on-line historicaldata to eliminate over and undertreatment, provide real time watersecurity, and facili tate compliancewith and more effective enforcementof environmental laws.

THE ADVANTAGES

In this way, a continuous, high-resolution historical data record for theLiquID station’s monitoring location-encompassing months or years ofminute-by-minute measurements iscreated, covering each of the differentparameters that the LiquID station hasbeen programmed to monitor. Spikeanomalies and sudden process upsets,as well as diurnal shifts in (for example)influent composition and seasonaltrends in water quality, become easilyvisible.

Because that information wasdetermined quickly and automaticallyby HMA through the LiquID station

instead of by indirect inference,time-consuming wet chemical benchanalysis or bacterial incubationprotocols, the timeliness, cost-effectiveness, and integrity of the dataare improved.

And because the LiquID stationeliminates the need for manualsampling transport and analysis of

ZAPS Technologies, Inc. is a producer of online, real-time, water quality monitoring equipment to aid professionals involved

in water treatment, water analysis, and environmental analysis. For more information, visit www.zapstechnologies.com.

For More Information

Water Quality Insights

through Real Time Data

Water Quality Insights

through Real Time Data

By ZAPS Technologies, Inc.

THE LIQUID™ IMPROVES EFFICIENCY IN POULTRY PROCESSING

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water samples, it allows permit-holdersto focus their resources more directlyon protecting human health and theintegrity of watersheds and aquaticecosystems. It also facilitates betterprocess control by placing each datapoint in the context of the activeprocess, thus ensuring compliancewith wastewater treatment regulationsand enabling more timely and effectiveprocess management.

POULTRY PROCESSING

WASTEWATER

Poultry processing plants convert livebirds into packaged meat products forcommercial sale. Significant quantitiesof water, about 7 gallons (26.5 liters)per chicken (Northcutt and Jones,

2004) are typically used in processingplants to wash the meat, remove andtransport offal, and for cleaning anddisinfection of process machinery.

Poultry processing wastewater(PPW) contains uncollected blood,solubilized fat, urine, and feces, andexhibits levels of BOD, cBOD, TSS,E.coli and nitrates that can be ten timesthe strength of sanitary wastewater. Assuch it can require treatment prior todischarge, either by treatment facilitieson the premises of the processor orby municipal wastewater treatmentfacilities nearby.

Those facilities are hence at risk forBOD shocks and process upsets shouldan unexpected PPW load suddenlypresent in the influent matrix. Notealso that PPW strength can spikemuch higher than average levels if ablood or offal spill occurs within the

processing plant and enters the plant’seffluent stream, or when wastewater

from specific plant operations isaccumulated over an operating shiftand then batched out into the effluent.

CASE STUDY:

DETECTION OF POULTRY

PROCESSING EFFLUENT

A poultry-processing facility inCorvallis, Oregon, produces corn dogs

THIS SECTION SPONSORED BY WWW.RFSYSTEMLAB.US/MPT

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CASE Studies

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Figure 1: Raw influent cBOD data for Nov. 15, 2013 compared with annual average.

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from pre-processed chicken meat,and discharges its effluent into thewastewater collection network leadingto the local wastewater treatmentfacility. Because the poultry processordoes not work with live birds, theirPPW stream contains no offal, feces or

feathers but does contain significantamounts of meat juice from thegrinding and extrusion lines that makethe corn dogs.

The Corvallis, Oregon, MunicipalWastewater Treatment Facility isequipped with multiple LiquIDstations including one to monitor thecontents of the raw influent matrix andanother to monitor the Facility’s finaleffluent. According to Dan Hanthorne,the facility’s manager, processoperators who were studying thereadings from the influent monitoring

LiquID station in 2013 noted transientincreases in cBOD and TSS readingswith a repeat time of about two hours.Each two-hourly surge in cBOD andTSS stood out in the data as a distinctevent. For example, figure 1 showsa single day’s worth of raw influentcBOD data (in red) in which the two-hour spiking pattern is particularlyapparent. The blue line is a year-longaverage of one-day cBOD readings forcomparison. The vertical axis is cBODin mg/liter.

ROOT CAUSE Armed with this data, the wastewatertreatment facility operators wereable to back-trace the cBOD andTSS spikes to a processing facili ty.Although the manufacturer had anon-site pretreatment system whichwas designed to remove high-strengthwastes from their effluent, that systemwas being overwhelmed by pumpedpurges of hot water from the plant’smachinery cooling system whichoccurred at two-hour intervals.

Eventually the pretreatment systemwas damaged by the purges, with theresult being the release of extremelyhigh-strength waste into the publicsewer each time the cooling systemwas purged. Repair of the pretreatmentsystem fixed the problem.

DISCUSSION

It is clear that a single compositemanual measurement of the influentwould not have captured these once-per-two-hour signals in the matrix.Despite the fact that the effluent fromthe poultry facility had a marked

effect on the wastewater treatmentprocess, the flow represented onaverage less than 3 percent of thetotal influent entering the CorvallisWWTF. The cBOD signals extractedfrom that influent stream by theLiquID station became visually andstatistically resolvable due to thedata’s reproducibility, large quantity,and high quality.

This examples demonstrates just oneapplication of how access to real-timecontinuous monitoring furnished bythe LiquID station allows t reatment

plant operators to better understandnot only the processes occurringwithin the plants they manage butalso processes that occur withinthe entire sewage collection andtransport network. With the ability ofthe LiquID station to monitor over 50distinct parameters in applicationsranging from finished drinking waterto raw wastewater influent in freshor saltwater conditions there area number of applications that canbenefit from process optimization,plant stabilization and cost savings. ■


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CASE Studies

Schneider Electric can find hidden revenue in nearly any operating budget. It lies within the energy spend. By implementingmore efficient lighting, energy management systems, HVAC systems, water fixtures, boilers, chillers, cooling towers, andmore. Schneider Electric helps customers manage risk and capture every opportunity to generate more funds for capital

improvements. For more information, visit www.enable.schneider-electric.com .

For More Information

By Merrill Markson

Improving Efficiency

and EffectivenessAcross the BoardSchneider Electric completes energy retrofitsto city facilities in Kirksville, Missouri

(source: City of Kirksville)

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Schneider Electric, aglobal specialist in energymanagement, recently

announced the completion ofa facility improvement projectas part of an energy savingsperformance contract (ESPC)

with the city of Kirksville,Missouri. With more than $4.7million in renovations, theproject is expected to providethe city more than $340,000in annual savings, allowing theproject to pay for itself withina fifteen-year period. Thetechnological upgrades to thecity facilities will dramaticallyimprove energy efficiency,while improvements to themetering infrastructure willprovide essential upgrades to

billing and utility services ofcity government.

RINGING IN THE NEW

The most significant projectcomponent is the replacementof the city’s aging watermetering system. SchneiderElectric worked with the city

This contract

allowed us

to show that

improvements in

efciency and

effectiveness in

government are

important to us

as a community.

—MariMacomber,

city manager,

Kirksville,

Missouri

Technological upgrades toaging infrastructure will

provide more than $340,000in annual savings.

A 4-inch (101.6 millime ter) Badger mete r. Seventeen 4-inch me ters we re changedout to provide more accurate reading and billing to the surrounding counties theyserve (source: Pedal Valve).


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CASE Studies

and its utility building staff to transition more than 7000 newresidential and commercial meters. The city of Kirksvillehistorically had problems with water loss within the system;the new meters will allow the city to limit rate increases andmake the billing process more accurate, which will directlybenefit city residents. To help ensure long-term accuracy,Schneider Electric is also providing ongoing support via

a Revenue Protection Plan, in which monthly billing datais being monitored to identify and report on alarmingtrends, and help prioritize the city’s water meter and waterdistribution maintenance.

Additionally, Schneider Electric replaced the HVAC systemin Kirksville City Hall. This aging system was the biggestenergy and maintenance drain for the city, but prior to theESPC with Schneider Electric, the city lacked the budgetarymeans to retrofit the outdated and failing equipment.The installation of the new HVAC system, which includescompressors, variable volume and temperature (VVT)boxes and ducts, will solve the comfort, maintenance andefficiency issues associated with the old system.

A BRIGHT FUTURE

Other project elements include comprehensiverenovations to the lighting systems across the city’sfacilities, as well as retrofitted building automationsystems. In total, the more than $4.7 million inimprovements will deliver annual savings in excess of$340,000. Schneider Electric worked with U.S. Bancorpto provide a local financing source for a rate below twopercent over ten years.

“Partnering with Schneider Electric on this project hasallowed the city to directly address its most pressingenergy efficiency problems, alleviating financial pressureson the city and its residents by ensuring accurate readingsand elimination of lost revenues,” says Mari Macomber,city manager for Kirksville. “We are now positioned tocontinue to meet a city-wide goal of efficiency in our cityfacilities and services.”

Our meters, because of their age, were

not only reading too high but too low.

The inaccuracies across the system

were extreme. Now, customers canfeel condent in the system and know

they’re being assessed for their actual

usage.

—Mari Macomber, city manager,

Kirksville, Missouri

In today's economic climate, every city’s

budget is so tight and staff members wear

multiple hats. When you can provide a

comprehensive upgrade, rate-payers

can have the condence that they’re

receiving an accurate reading and the

city will know the nal price of the project

the day they sign the contract.

—Jordan Lerner, regional director,

Schneider Electric

The 6-inch (152.4 millimeter) meter installed at a food manufacturing plant. Thiscompound meter features two radio transmitters (sou rce: Pedal Valve).

Orion CE transmitters installed bySchneider Electric. The transmitters enablecity personnel to drive by meters with alaptop and the signal collects the meterreadings (source: Pedal Valve).

A number of 5/ 8-inch (15.86 millimeter)Badger residential meters with Orion CEtransmitters were installed across the city.Schneider Electric, in partnership with city

personnel, we re able to change out 7230meters in six months (source: Pedal Valve).

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“In addition to the physical improvements we’ve providedfor Kirksville’s facilities, we are proud of the economicimpact the ESPC will have on the city and its residents,” says Jordan Lerner, regional director, Schneider Electr ic. “Wewere glad to have the opportunity to help the city with theseimportant HVAC and water metering retrofits, which willbenefit the city of Kirksville for years to come.”

A COMMITMENT TO GROWTH

In the past twenty years, Schneider Electric hassuccessfully implemented over 530 energy savingsperformance contracts (ESPCs) across the nation andhelped clients around the world save close to one billiondollars. ESPCs help publicly funded entit ies make capital

improvements over longer payback periods. Funded bythird-party financing, ESPCs offer many long-term benefitssuch as improved facility efficiency, occupant comfort,financial management and environmental protection.Typically, new, more efficient equipment and upgradedfacility automation systems maximize energy efficiencyand generate utility savings. ■

The main things that made this project

work so well was great, direct, open

communication. When we do these

projects, it’s important that both themunicipal and the technical teams

communicate effectively with one

another.


Schneider Electric 100 percent of what we do is improve

efciency and effectiveness. Kirksville

was a great partner.


Schneider Electric


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ELECTRONIC WATER TREATMENT REDUCES FOULING IN

REVERSE OSMOSIS


WATER & WASTEWATER solutions

Reverse osmosis(RO) is usedin processes

requiring high-quality, purifiedwater, such in semi-conductor processingor biochemicalapplications andcan be used to treatboiler feed water,industrial wastewateror process water. Awater purificationtechnique, it reducesthe quantity ofdissolved solids

in solution. ROuses waterline pressure together with energy consumingpressurizing pumps that increase the required yield. It isessentially a molecular squeezing process that causes watermolecules to separate f rom the contaminants. The separatedwater molecules then pass through to the inside of the

membrane on to aholding reservoir.The contaminantsare washed fromthe membrane andremoved.

One of themajor problemsof RO systemsis the fouling ofmembranes whichcan quickly becomeclogged by hardwater scale resultingin less membranespace for the waterto pass through,

therefore leading tomore pressure being required to reach the necessary yield.The consequences are higher energy use, an increase of thecleaning frequency and a shorter life span of the membranes.This will cause the membrane water treatment process tobecome much more expensive.

Jan de Baat Doelman is president of Scalewatcher Nor th America Inc. The Scalewatcher is an environmentally friendlyalternative to chemical and mechanical descaling. Launched in the 1980s it has successfully treated hard water problemsfor industrial manufacturers as well as water companies, oil producers, farmers, horticulturists, shipping companies,shopping centers, school, universities and government establishments. For more information, call 610.932.6888, email

[email protected], or visit www.scalewatcher.com.

About The Author

By Jan de Baat Doelman, Scalewatcher North America Inc.

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REVERSE OSMOSIS MEMBRANE

A reverse osmosis membrane mustbe freely permeable to water, highlyimpermeable to solutes, and able towithstand high operating pressures.Ideally, it should also be resistant toscaling and fouling by contaminants

in the feed water. Water hardness,also known as limescale, is made upof calcium and magnesium carbonatesand can be found in both city andwell and spring water sources. Hardwater (above 7 grains of hardness)will shorten the li fe of the RO’smembrane. Limescale fouling occurswhen contaminants accumulate onthe membrane surface effectivelyplugging the membrane. The resultsof limescale build-up are a higherpressure drop across the system. Thistranslates into higher operating costs

and eventually the need to clean orreplace the RO membranes.

SCALING AND ELECTRONIC

WATER TREATMENT

Scaling refers to the precipitation anddeposition within the system and willto some extent take place eventuallygiven the extremely fine pore sizeof an RO membrane no matter howeffective the pre-treatment. However,by having proper pre-treatment inplace, it is possible to minimize ROdowntime and maintenance costs.It will maximize efficiency andmembrane life by minimizing fouling,scaling and membrane degradationwhile optimizing product f low.

Electronic water treatment (EWT)is the ideal solution for preventinglimescale build-up in RO membranes.A fit and forget technology it requiresno plumbing, chemicals or salt.To explain the effect of electronicscale removal it is first important tounderstand the major factors thatcause scale.

SUPER SATURATION Aqueous solutions can becomesupersaturated, which means thatthey contain higher concentrations ofdissolved solute than their equilibriumconcentration. Such solutions are notstable and are easily triggered intodropping back to saturation level,forcing the dissolved compound toprecipitate. Even when a bulk solutionis less than fully saturated, scaleformation can occur spontaneouslydue to localized super saturation, ata surface for example with a drop in

calcium carbonate solubility, leadingto the formation of mineral scaledeposits.

In RO, the raw water and itscomponents pass through themembrane filtering the purewater. Therefore there is a steady

process of supersaturation andprecipitation of the water through the

membrane. Within this environmentelectronic water conditions, such asScalewatcher is the ideal solutionfor removing and preventing themembranes being clogged with scale.As electronic water treatment (EWT)changes the shape of the molecules

from rough to smooth, they do notform a matted structure and are

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washed away thereby preventing the membranes from beingclogged which in turn reduces maintenance shutdown andenergy costs.

ELECTRONIC WATER

CONDITIONING

EWT is a non-invasive

system utilizing a solenoidcoil or coils wrappedaround the pipework tobe treated. A continuouslyfrequency changingsignal generator, within aspecified range, suppliescurrent to the coils. Thepulse shaped currentcreates an inducedelectric field, concentricaround the axis inside thepipe. As a consequenceto this arrangement, any

charged particle or ionmoving within the fieldexperiences a so-calledLorentz force generated by the interaction between chargedparticles and magnetic and electric fields.

The treatment influences the initial nucleation, resultingin crystals that do not "stick" together. Untreated waterbuilds up matted structures that continuously grow. Thistreatment creates idiomorphic, scattered crystals, which do

not form matted structures. They have a rotundas shape,which means that they have a larger volume in relationto a smaller surface. This feature makes them sensitive to

water currents and theyare easily flushed out ofthe pipeline. As no newscale layers are formed,

the sheer force of thewater flow will graduallyremove existing layersof scale. The ability toadjust power, frequencyand coil configurationsof products like theScalewatcher on siteenables performance tobe optimized with nodowntime and no pipereplacement.

CONCLUSION

Reverse osmosistechnology is presentlyundergoing rapid growth

in the area of municipal and industrial wastewater reuse.Control of membrane fouling due to scale and particles inwastewater is a major expense in the design and operationof these facilities. Installing a EWT system will savecompanies and organizations downtime and maintenancecosts. ■

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4

5

62

3

1

Across both water treatment and chemicalprocessing plants, keeping equipment clean is oneof the keys to achieving a manufacturer’s promised

efficiency standards and power outputs. However, plantmanagers are sometimes reluctant to incur downtimecosts associated with regular cleaning and push theenvelope for a perceived short-term gain. The chemistsat International Products Corporation saw this problem

and have designed products—such as Micro-90®, aconcentrated cleaning solution, and Micro® AO7, aconcentrated citric acid cleaner—that offer benefits ofeffective cleaning that can be included in a regularlyscheduled maintenance program and of quick applicationwhen necessary conditions arise. Below is a ten-step listfor clean-in-place (CIP) guidelines for filter membranesystems.

When one of the following conditions occur, a cleaningshould be done:

• Flux rate decreases by 10 percent.• Trans-membrane pressure (TMP) increases by 10

percent.• Permeate water quality decreases by 10 percent.

Based on the membrane foulants, Micro-90, MicroA07, or both may be required to clean and return theconditions to their original values. See the list of foulantsbelow to determine which cleaner(s) is needed. If onecleaner is all that is necessary to correct the condition,then that is satisfactory. Sometimes, a pre-soak is useful.In other systems, both an alkaline and acidic cleaner areused for full cleaning.

Review the manufacturer’s membrane specificationsfor operating conditions. For future cleaning, it will bebeneficial to make note of these specifications and havethem prepared for the next scheduled cleaning.

Alkaline cleaning: Prepare a 1 percent Micro-90 solutionin permeate-quali ty water. The volume of cleaningsolution should be sufficient to fill all pipes, hoses,and pumps, as well as fill the membrane elements upto 50 percent of their total volume. This will provide

low pressure and high flux for optimal cleaning. Anadditional 10 percent volume of cleaning solution shouldbe prepared that will immediately be discarded afterthe first pass through the system. This initial 10 percentcleaning will remove the gross contaminants and allowthe subsequent steps to clean more effectively.

For extremely fouled membranes, an initial soak may berequired. This soak time could vary anywhere betweenone to eight hours. (Both Micro-90 and Micro A07 areeffective yet mild cleaners; therefore, excessive exposuretime should not be a factor.)

To clean the system, allow a slow flow rate (20 percentto 30 percent of the membrane manufacturer’s maximumdesign rating) across the membranes. A slow rate impedesthe suspended foulants from refouling the membrane.After several minutes, increase the flow rate incrementallyuntil the maximum rate is achieved.

Continue recirculating. One hour of recirculation isnormally sufficient to effectively clean the membranes.Heating the cleaning solution will significantly improveits detergency. Check the membrane specifications todetermine the maximum operating temperature.

Thomas McGuckin is vice president of research and development for International Products Corporation and can be reachedat [email protected]. For more information or free samples for testing, call 609.386.8770, email [email protected], or visit

www.ipcol.com.

About The Author

By Thomas McGuckin, International Products Corporation

CIP Guidelines for Filter

Membrane System Cleaning

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7

8

9

10Rinse membranes with permeate-quality water until no cleaneris detected. (Micro-90 and Micro A07 will foam when shaken.Transfer a small volume of rinse water to a jar. Cap and shake. If nofoam sits on the surface after thirty seconds, rinsing is complete.)

Throughout the cleaning process, continue monitoring a ll processvariables for any abnormalities (pressure change, temperaturechange, pH drift, and so on).

Acidic cleaning: Prepare a 1 percent Micro A07 solution inpermeate-quality water. Follow steps 2 through 8 above.

Pre-Soak and Cleaner by Foulant Type

Foulant Micro-90 Micro A07

Oil ✔

Grease ✔

Natural Organic Matter ✔

Hard Water Soaps ✔

Scale ✔

Mineral Deposits ✔

Metal Oxides ✔

Dual cleaning with alkaline and acidic cleaners:If both cleaners are necessary, Micro-90 shouldbe used first. Micro-90’s mild alkalinity swellsthe membrane fibers, which allows Micro A07 topenetrate deep within the membrane to remove

the remaining foulants. Complete steps 2 through8 using a Micro-90 solution first. Rinse completely,and follow steps 2 through 9 with Micro A07.

The goal of filter membrane cleaning is to returnthe flux rate as close to 100 percent of the originalas possible, as well as correct the other pressureand water conditions. ■

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MAINTENANCE solutions

In the first two parts this series,we looked at many of the ways inwhich pumps can be mounted as

well as some of the “Best-in-Class”users’ decisions as well as an importantexception to the general guidelines forsecure-in-place installation. In this final

installment, we will discuss the best-practice specifications for alignmentjacking provisions and conclude withan adaptable checklist for base plateinstallation options and guidelines.Of course, no installation checklistcan cover the entirety of pump users’experiences and specifications,but some concerns remain worthyof attention in the majority ofapplications.

ALIGNMENT JACKINGPROVISIONSA best-practices specification willinclude smart alignment jackingprovisions. Note figure 6, where thepurchaser specified an arrangementthat allows insertion (and later removal)of alignment jacking tabs in the x andy-directions next to each of the fourmotor feet.

Portable jacking tabs, figure 6,(inserted in a welded-on bracket)allow driver alignment moves to bemade. Thereafter, the jacking bolts arebacked-off and the entire tab is removed. In careless installations

jack screws are sometimes left tightened against the motor feet.In those instances, motor heat and thermal growth might forcethe feet into these bolts even more, which could cause the entiremotor casing to distort (see reference 4). Note, therefore, thatbacking-off jacking bolts should be one of many installationchecklist items.

If epoxy-filled base plates are par t of the package, pumpsand drivers can indeed be mounted and aligned before the set

is shipped. However, before installinga conventional base plate, the pumpand its driver must be removed fromthe base plate and set aside. Levelingscrews are then used in conjunctionwith laser-optic tools or a machinist’sprecision level. With the help of these

tools the base plate mounting pads arebrought into flat and parallel conditionside-to-side, end-to-end, and alsodiagonally. This takes time and skill.

After installing an epoxy-filled baseplate and leveling it, an epoxy groutcap should be placed on the foundationtop. Some of this epoxy grout shouldflow into the space between thefoundation and the perimeter of themonolithic base plate. There will be noincentive to fill the entire space and thearea of support desired is calculatedsuch that this epoxy grout is loaded toperhaps 50 psi compressive pressure.As an example, a 72 by 24 inch (1830by 610 millimeter) epoxy-filled baseplate would have a 192-inch (4880millimeters) perimeter. Grout supportinga 4-inch (100 millimeter) width wouldconstitute an area of approximately 800square inches. If the total weight of thepump set is, say, 12,000 pounds, thepressure load would be 12,000 / 800 =15 psi—well within 50 psi.

By its very nature, pre-filling a baseplate will greatly reduce problems of entrained air creating voids.

However, because grout materials are highly viscous, properplacement of the epoxy is still important to prevent air pocketsfrom developing (see reference 5).

Outsourcing base plate design, fabrication and pre-filling withepoxy grout has often been found economically attractive. Figure7 shows it ready for shipment.

Conventional grouting methods for non-filled base plates, bytheir very nature, are labor and time intensive (see reference 3).

Heinz P. Bloch, P.E., is one of the world’s most recognized experts in machine reliability and has served as a foundingmember 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

Know Your Pump Base PlateInstallation Options

Part 3 of a 3-Part Series

Removable alignment jacking tabs shown inserted in three offour locations next to the two motor feet shown here (source:Stay-Tru®, Houston, Texas)

Epoxy pre-filled base plate fully manufactured by a specialtycompany, shown ready for shipment (source: Stay-Tru®,Houston, Texas)

Figure 6

Figure 7

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Utilizing a pre-grouted base plate with conventional groutingmethods helps to minimize some of the cost, but the last pourstill requires a full grout crew, skilled carpentry work, and goodlogistics. To further minimize the costs associated with base plateinstallations, a new field grouting method has been developedfor pre-grouted base plates. This new method (see reference 4)utilizes a low viscosity high strength epoxy grout system that

greatly reduces foundation preparation, grout form construction,crew size, and the amount of epoxy grout used for the final pour.

WHAT WE HAVE LEARNED:

PARTIAL CHECKLIST OF FOUNDATION AND BASE PLATE

TOPICS

• Use ultra-stiff, epoxy-filled formed steel base plates (“StayTru®”method or an approved equivalent) on new projects and onoptimizing existing facilities

a) Proceed by first inverting and preparing the base plate; userecommended grit blasting and primer paint techniques

b) Fill with suitable epoxy grout to become a monolithic blockc) Allow to cure; after curing, turn over and machine all

mounting pads flat and co-planar within 0.0005 inch per

foot (0.04 millimeters per meter).d) Next, install complete base plate on pump foundation.

Anchor and level it within the same accuracy.e) At final installation, place epoxy grout between the top

of the foundation and the space beneath the monolithicepoxy pre-filled base plate

• On welded base plates, make sure that the welds arecontinuous and free of cracks.

• On pump sets with larger than 75 kW drivers, ascertain thatbase plates are furnished with eight positioning screws percasing, i.e. two screws (“jacking bolts”) per mounting pad.

a) These positioning screws could be located in removabletabs (i.e., tabs slipped into a welded guide bracket) orfixed tabs (i.e., tabs welded onto the base plate).

b) Pad heights must be such that at least 1 / 8 inch (3

millimeters) stainless steel shims can be placed underdriver feet.

• Conventional base plates must be installed and grouted onfoundation with pump and driver removed. Only then shouldpump and driver be re-installed and leveled.

• Full epoxy and/or epoxy pre-filled steel base plates can beinstalled and grouted on a foundation with pump and driveralready aligned and bolted down on the base plate. ■

REFERENCES

1. Bloch, H. P., and A. R Budris. Pump User’s Handbook: Life Extension, 4thEdition (2013). Fairmont Press (ISBN 0-88173-720-8).

2. Bloch, H. P., and F. K. Geitner. Major Process Equipment Maintenance andRepair , 2nd Edition. Gulf Publishing Company (ISBN 0-88415-663-X).

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

4. Monroe, Todd R. and Kermit L. Palmer. “Methods for the Design and Installationof Epoxy Pre-lled Base Plates” (1997 Marketing Bulletin). Stay-Tru® Services,Inc., Houston, Texas.

5. Barringer, Paul, and Todd Monroe. “How to Justify Machinery ImprovementsUsing Reliability Engineering Principles,” Proceedings of the SixteenthInternational Pump Users Symposium (1999). Turbomachinery Laboratory, TexasA&M University, College Station, Texas.

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PUMP solutions

Like any business decision,choosing the right air-operateddouble diaphragm pump (AODDP)

for your application requires careful

consideration. You wouldn’t hire a newplant manager without verifying thecandidate’s experience. The same goesfor AODDPs. Performing due diligenceis critical. Whether you need one pumpor a thousand pumps, you deservethe best fit and performance for yourinvestment. You should research, askpointed questions, and expect honest,evidence-based answers.

In this final installment of our four-part series, we’re going to look at thethree important questions you shouldask pump manufacturers to make sureyou get the pump that provides the bestmix of performance, efficiency andvalue for your needs.

FIRST THINGS FIRST

For those of you joining our ongoingseries for the first time (and forthose of us who devote the bulk ofour memories to things like websitepasswords and anniversary dates),here’s a quick look back at what wecovered in the previous three articles.

We started out covering the AODDP

basics: how they work, how to readperformance curves and how tocalculate pump operating costs. Then,we moved into an overview of all theways that All-Flo’s A200 revolutionizedAODDP technology, performance andefficiency (by reducing and optimizingdead space on the liquid and air sidesof the diaphragms and improving main

air valve timing). After that, we talkedabout how to compare and contrastpump performance across the industryby using data-driven evaluations to help

you cut energy costs and improve ROI.Now, that we’re all caught up,

let’s get the AODDP manufacturerinquisition underway!

GRADE ON A CURVE

If the most efficient, cheapest pumpon the market doesn’t reliably dothe job you ask it to do, what’sthe point? At the end of the day,

performance is king. In our industry,performance curves are essentialtools for determining and evaluatingperformance. Any reputable pumpmanufacturer should be able toproduce accurate performance curvesfor you to review. Furthermore, theyshould have curves that documentthe performance of pumps withdiaphragms made from the materialsyou’re interested in (most commonlyPTFE, rubber and thermoplastics).

The ability to compare pumpswith diaphragms made from differentmaterials is critical because those

By Paul McGarry, All-Flo Pump Co.

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

A Revolution in Pumping Efficiency

PART 4 IN A 4-PART SERIES

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

Question 1:

Can you provide

performance curves?

Figure 8a: Performance curve measured using PTFE diaphragm.

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diaphragms can impact overallperformance, air consumption andkey factors such as dry suction lift.This difference is evident in the All-FloA200 performance curves included inthe figure 8 graphs. These performance

curves all belong to 2-inch AODDPsthat are identical in every way exceptdiaphragm materials. As you canplainly see, the air consumptionand performance vary from pumpto pump, with PTFE diaphragmsclaiming the most dramatic difference.Pump performance directly impactsefficiency, which, in turn, directlyimpacts operating costs and ROI.

Of course, performance curves aloneprobably won’t dictate your selection.Some materials are just better suitedfor certain applications than others,no matter what the curve says (think

caustic liquids versus water, and soon). That being said, you are entitledto all the data required to make aninformed decision.

DIG A LITTLE DEEPER

A big part of an AODDPmanufacturer’s job is to make sure thatits pumps deliver the performance itpromises. To do this, companies suchas All-Flo develop rigid internal testing

protocols that are used to test pumps,re-test them, and then test them somemore. After each evaluation, pumpcomponents are checked for qualityand reliability, setups are tweaked ifnecessary, and overall performanceis fine tuned. Data from the tests

are used to generate performancecurves. These protocols are extremelyimportant to us, as manufacturers,because we know that, at the end ofthe day, if our AODDPs don’t worklike they say they will, you will buythem from someone else. (We place agreat deal of value on our reputationsand customer satis faction.) Theseprotocols are important for you, as auser, because they ensure quality andaccountability.

When you ask a manufacturer toshare its testing protocol, what you’re

really asking is, “How did you get theinformation I see in your performancecurves?” Because we put so much timeand effort into creating and executingour protocols, they become sources ofpride that we are happy to share withinterested customers. Nothing buildstrust like transparency, and we alwayswant you to feel good about yourchoice.

KICK THE TIRES, SO TO SPEAK

In some ways, buying a new AODDP isa lot like buying a new car. You listenfor the sweet sound of the engine’shum, catch a whiff of that exhilarating“new pump smell”—OK, maybe not.However, just as the test drive is anintegral part of the car-buying process,a figurative test drive can be just asuseful for AODDP purchases. Beforeyou sign on the dotted line, yourmanufacturer should allow you to seehow the pump you’re considering willperform in your reality; to kick the tiresand take it for a spin.

Question 2:

What is your testing

protocol?

Question 3:

Can I perform eld tests

or provide equipment

such as air consumption

meters to verify your

efciency claims?

Figure 8b: Performance curve measured using TPE diaphragm.

Figure 8c: Performance curve measured using rubber diaphragm.

THIS SECTION SPONSORED BY WWW.WATRY.COM

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PUMP solutions

Field testing will help you evaluate apump’s true performance and efficiency.You can even set up multiple tests topit one manufacturer’s AODDP againstanother’s. In lieu of field testing, ifa manufacturer stands behind itspublished efficiency claims, it should

have no problem allowing you to supplyequipment such as air consumptionmeters to verify its data. Supplying yourown equipment will guarantee that youget a fair and accurate reading that youcan trust.

WRAPPING UP

In your business, AODDPs probablydon’t share the spotlight with big-ticketpurchase items such as new oil rigs or themillion-dollar machines that corporatemarketing folks like to point out onfactory tours. But because choosing the

wrong pumps for your needs can costyou hundreds of thousands of dollars ayear in unnecessary operating expensesand unscheduled downtime, it’s worthyour time to make careful, well-informeddecisions. Always perform your duediligence, hold pump manufacturersaccountable, and remember that thevalue of a well-designed AODDP extendswell beyond its initial purchase price. ■

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If you have been involved inpumping, piping, and design,you already know that there are

a number of formulas for calculating

losses. The two most common are theDarcy or Darcy-Weisbach formulasand the Hazen-Williams equations.The first requires the designer toknow something about the internalroughness of the pipe and that he orshe needs to calculate the ReynoldsNumber (Re) to be able to determinethe appropriate friction factor forcomputing losses. The Hazen-Williamsformula by comparison, tends tosimplify the computation by absorbinga lot of the computational work into aC factor used in the computations.

When the designer seeks to designa piping system, he or she is reallyinterested in the head loss per lengthof pipe or the total head losses on

the system. In order to get that usingthe Hazen-Williams formulation,the equation is manipulated into thefollowing:

Where k=1.318 for US customaryunits, and k=0.849 for SI units. WhereD is the diameter of the pipe in inches,Q is the flow rate in gallons perminute. S is the head loss in the pipein terms of psi per foot of piping, and

the equation below expresses thesame result where S is feet of headloss per foot of pipe.

NOTE: The equation has beenmodified to express head losses interms of feet of head per foot of pipe.In metric terms the conversion factoris 10.716

C is dependent upon materialsproperties as in Table 1.

The designer is free to use anyvalue of C in calculating pipe frictionlosses by the Hazen-Williams formula.The selection of an appropriate factor


PUMP solutions

David L. Russell, P.E., is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., aspecialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projectsranging 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

Calculating PipingLosses and TheirEffect on PumpingBy David L. Russell, Global Environmental Operations, Inc.

Calculating PipingLosses and TheirEffect on Pumping

Darcy-Weisbach Formula:

Laminar flow:

Turbulent flow:

Where ε is the pipe roughness, ƒ is the friction factor, Dh is the Hydraulic Diameter (for full pipes it is the insidediameter).

Hazen Williams Equation:

Velocity:

Where k is a conversion factor equal to 1.318 for US gallons,and 0.846 for SI units.

Re is the hydraulic radius, and S is the slope of the energygrade line or head loss per length of pipe. The units have to beconsistent.

Applicable for numbers of Re above 4000 (fully turbulent according to the Moody Diagram)

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in piping design can materially affect the calculated headloss and flow through the pipe. A number of designersroutinely use a C=100 for all municipal installations, moreor less regardless of the type of pipe and its age. Giventhat value, the extreme variation can be up to almost 90percent in velocity and flow.

For calculation of piping losses using the Darcy-Weisbach formula, the value of the friction factor i sthe all-important selection criteria because it directlydetermines the head losses in piping.

Where units are consistent in terms of feet and meters.

The friction factor f is determined from a Moody and thepipe internal diameter are in meters, for English units,the measurements are in feet. The Moody Chart usesε /D, the internal pipe roughness over the diameter atvarious ranges of Re to compute the frictional losses inthe pipes. This is known as relative roughness. The relativeroughness in the diagram below, for fully turbulent flows(right hand values on chart) vary between 0.00001 and0.07, or a factor of approximately 7000 while the frictionfactor varies over a range of 0.008 to 0.1, a factor of12.5. Another way of looking at the data so that we arecomparing similar values is to look at the range of relativeroughness in various piping materials. The following tableshows the absolute value in millimeters for various pipingmaterials:

Table 1: Hazen-Williams Coefficients for Pipe Roughness

Material C Factor low C Factor high C1.85Difference between High

and Low values of C1.85 in %

Asbestos-cement 140 140 9339.79 0

Cast iron new 130 130 8143.2 0

Cast iron 10 years 107 113 5680-6283 10.61%

Cast iron 20 years 89 100 4039.9-5011.9 24.1%

Cast iron 30 years 75 90 2943.5-4124.3 40.1%

Cast iron 40 years 64 83 2195- 3550.5 61.73%

Cement-Mortar Lined Ductile Iron Pipe 140 140 9339.8

Concrete 100 140 5011.9- 9339.8 86.35%

Copper 130 140 8143.2- 9339.8 14.7%

Steel 90 110 4124.3 – 5978.3 44.95%

Galvanized iron 120 120 7022.4

Polyethylene 140 140 9339.8

Polyvinyl chloride (PVC) 150 150 10611.3

Fiber-reinforced plastic (FRP) 150 150 10611.3


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PUMP solutions

Table 2: Calculation of Friction Factor ƒ and Relative Roughness ε/D Values for the Moody Diagram

Surface MaterialAbsolute Roughness

Coefficient –ε in mm

Ratio of maximumto minimum value

In %

Calculated relativeroughness – ε/D Using

4” pipe

Value of f forfully turbulent

flow

Differencein values

of f

Aluminum, Lead 0.001 – 0.002 200% 0.000 01 – 0.000 02 0.0085-0.01 17.6%

Drawn Brass, Drawn Copper 0.0015 0.000 015 0.009

Aluminum, Lead 0.001 – 0.002 200% 0.000 015 0.009

PVC, Plastic Pipes 0.0015 0.000 15 0.009

Fiberglass 0.005 0.000 15 0.009

Stainless steel 0.015 0.000 45 – 0.000 9 0.017-0.02 17.6%

Steel commercial pipe 0.045 – 0.09 200% 0.000 15 0.009

Stretched steel 0.015 0.000 15 0.009

Weld steel 0.045 0.000 45 0.017

Galvanized steel 0.15 0.001 5 0.0023

Rusted steel 0.15 – 4 266% 0.001 5 – 0.04 0.023-0.068 195%

Riveted steel 0.9 – 9 1000% 0.009 – 0.09 0.038-0.065 71.1%

New cast iron 0.25 – 0.8 320% 0.0025 – 0.008 0.0037-0.0088 83.8%

Source: “Absolute Pipe Roughness,” Engineering Design Encyclopedia (www.enggcyclopedia.com/2011/09/absolute-roughness).

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In order to get the following values for the influence ofrelative roughness on pipe friction in the above table, we madea couple of assumptions; 1) the flow was fully turbulent, 2) forsake of argument, we divided the relat ive roughness by a factorof 100 to simulate a 4-inch pipe ( it’s actually 101millimeters)but the values and the extreme range to get the f values fromthe Moody Chart.

A note of caution needs to be injected here. Not all MoodyCharts are the same! In preparing this article we first useddifferent Moody diagrams, and found that some of them havef values which are different by 20 percent or more. There aremany more consistent Moody Diagrams than irregular ones, solook over a few,and select carefully.(NOTE: MostMoody diagramshave the lower lefthand value for fset at 0.008, andthe upper left handvalue for f at 0.1,

but some cut thelower value off at0.01.)

S. W. Churchill,developed anequation whichmodels the Moodychart over its entirerange.

The formula requires the calculation of the Reynolds Number(Re) which is

Where ρ is the density, µ is the dynamic viscosity (kg/(m-s)),

and υ

is the kinematic viscosity of the fluid (m

2

/s). This formulawill model the Moody Diagram (NOTE: View the Excel® program on modernpumpingtoday.com for ease of calculation).

In conclusion, in the design of piping systems, frictionalhead loss can be a significant factor. The Moody diagram

provides a more rational basis for design than thefrequently used Hazen-Williams coefficients becauseit is dependent upon the pipe properties and internalroughness rather than upon the designer’s judgment.The Hazen-Williams formulations lead to understatingpiping losses when compared to the Darcy-Weisbachformula.

In the design of critical infrastructure systems theunderstated head losses can lead to under-sizing

of the piping, higher losses, and lower flows thatare desired at the delivery point. In some of thesecritical situations, such as fire flows, and municipalpipelines, the deliverable quantity of liquid could besignificantly less than required, and sometimes thatcan be life-threatening.

In future articles we will look at the formulation ofa spreadsheet for calculation of head losses and forminor losses. ■

The Churchill Equation:

Where Re is the Reynolds Number, ε /D i s theinternal pipe roughness (see Churchill, S.W.,“Friction Factor Equation Spans All Fluid FlowRegimes,” Chemical Engineering , Vol. 91, 1977).


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DEWATERING solutions

The 1130 foot long Galveston Island Pleasure Pier was

built in 1943 featuring rides, an arcade, an aquarium,a large ball room, named the Marine Ballroom, and, of

course, a fishing pier. The pier was meant as an entertainmentdestination for troops and sailors stationed at nearby facilitiesduring World War II. It was called the “Coney Island o f theSouth” and drew multitudes of visitors who enjoyed theexciting pier features and top name dance bands. It remaineda top regional draw for many years.

Suzette Gibson is the marketing coordinator for BJM Pumps, LLC. Headquartered in Old Saybrook, Connecticut, BJM Pumpshas been serving the industry since 1983 by supplying quality pumps at a modest price. For more information, call 877.BJM.

PUMP (877.256.7867) or visit www.bjmpumps.com.

About The Author

By Suzette Gibson, BJM Pumps

OPTIMAL PUMPINGFOR THE PLEASURE PIER

LIFT STATION

BJM submersibleshredder pumpsprovide a reliablesolution for the “Coney

Island of the South”

Each Model SK22 pump can handleup to 240 gallons(908.5 liters)

per minute ofwastewater at headsup to 59 feet (18meters).

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But, in 1961, the pier was destroyed.Hurricane Carla, ranks as one of themost intense Category 5 hurricanesIn Texas history, barre led throughGalveston with wind gusts as high as170 miles (280 kilometers) per hour.The storm surge reached 10 feet (3

meters). Precipitation totals topped16.49 inches (419 millimeters). To makematters worse, a tornado moved acrossGalveston Island, severely damaginghundreds of structures buildings andcausing eight deaths.

In 1965, the Pleasure Pier was rebuiltfeaturing the Flagship, an over-the-water hotel, anchoring the end of thepier. It would last for forty plus years.Unfortunately, it too was destroyed. Thistime, the hurricane’s name was Ike. In2008, Hurricane Ike damaged the hotelbeyond repair. Ike’s rising storm surge

spilled over the 17-foot (5.2 meters)Galveston Seawall, which faces theGulf of Mexico. The landmark FlagshipHotel, which sat on deep concretepylons, was seriously damaged. Thehotel's siding was peeled off by thestorm, venting top-floor guest suites tothe elements. The elevated ramp, whichpermitting vehicles to access the hotel'slower level, fell into the Gulf. Althoughinitially thought to be repairable, thehotel was finally demolished in 2011.

As they say, the third time is thecharm. In May 2012, the Pleasure Pierwas reopened as an amusement parkfeaturing a 100 foot tall roller coaster, a100 foot (30.5 meter) tall Ferris wheel,plus fourteen other rides, carnivalgames, souvenir shops and restaurants.

The developer of the “new” PleasurePier is Landry’s Inc., a Houston baseddining, entertainment, gaming andhospitality company. It cost $60 millionto complete.

THE CHALLENGE

Pleasure Pier has an approximate

capacity of 7000 people. When youhave thousands of visitors, on a pierjutting out into the Gulf of Mexico,you had better have adequate restrooms available and operating at peakperformance. Raw sewage had to bepumped from the pier based source toshore and connected to the Galvestoncity system.

On a busy ho t day, the last thing Pieroperators want to worry about is rawsewage clogging the system and wipingaway the delightful smells of grilled hotdogs and cotton candy. Having to clearthe pier because of sanitary facility

closures is unacceptable from both acustomer relations standpoint and a lostrevenue standpoint.

BJM Pumps’ Houston basedwastewater distributor, Pumps ofHouston was called upon to evaluate therequirements and provide the optimumpumping solution.

THE SOLUTION

Pumps of Houston recommendedinstalling six sanitary sewage lift stationson the pier equipped to pump the peakload of raw sewage back to shore tobe treated by the City of Galveston’s

wastewater treatment system. Three ofthe six lift stations have been outfittedwith a pair of BJM shredder pumps.Each Model SK22 pump can handle upto 240 gallons (908.5 liters) per minuteof wastewater at heads up to 59 feet (18meters).

The SK22 manufactured by BJMPumps is extremely efficient atshredding potential blockage causingsolids and moving the raw sewagefrom the pier-based sewage lift stationto land-based treatment facility. Theseelectric submersible pumps use aunique shredder action to pass largesolids. A Tungsten Carbide tippedcutting impeller rotates against a spiralshaped impeller plate to shred anysolids.

The 304 Stainless Steel motorhousing helps protect the pumps from

abrasion and premature wear causedby the sandy, saltwater environment.Competitive pumps with aluminummotor housings would quickly erodedue to sand and corrode due tosaltwater. The motor is protected bydouble mechanical seals and a lip sealwhich helps prevent abrasives, suchas sand, from entering into the sealchamber. Unlike competitive pumpswith soft resin or plastic components,the SK22 line, with its hardened castiron rotating assemblies, stand up torough handling and pumping abrasivesandy water.

The thousands of daily patronsexcited about soaring over the Gulf ofMexico on the Iron Shark Rollercoasteror touching the heavens on the 100foot (30.5 meter) Ferris wheel, wantthe assurance that sanitary facilities arenearby and operating effectively. Pieroperators also appreciate the importanceof reliability when it comes tomaintaining their wastewater systems. ■

BJM Pumps SK22 shredder pump, with its hardened castiron rotating assemblies, stands up to rough handlingand pumping abrasive sandy water.

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MOTOR solutions

Bedford Pumps, the UK’s leadingmanufacturer of large submersibleand conventional pumps for the

Land Drainage industry, has recently

installed and commissioned a directdrive variant of their Fish Friendly pumpsfor Cam Pumping Station in the SouthLevel Cambridgeshire Fens. BedfordPumps worked with consultants, HannahReed, in upgrading Cam for WaterbeachLevel IDB to supply a new, fish friendlysolution for this land drainage station.

ASSESSING THE PUMPING STATION

The Fenland area is comprised of mainlyhigh grade agricultural land, much ofwhich is below sea level, considerablybelow flood level, and therefore totallydependent on pumped drainage. CamPumping Station is one of three stationswithin the district and part of a 7000 acre(2857ha) pumped catchment, managedby Waterbeach Level Internal DrainageBoard.

Cam Pumping Station, located closeto the village of Streatham, dischargesdirectly into the River Cam. The pumping station had beenoperating with a combination of old diesel driven and oneelectric pump, but with a requirement for the pumps tobe upgraded combined with new legislation requiring thatmeasures be put into place to reduce eel mortality at pumping

stations, the decision was made to install two new pumps fromBedford’s Fish Friendly range.

INSTALLING THE NEW PUMPS

Bedford Pumps manufactured, installed and commissioned twoDAF (Fish Friendly Direct Drive Axial Flow) pumps for CamPumping Station through consultants Hannah Reed. The pumpshave been installed in a vertical suspended position with belowfloor discharge, in a new sump on the existing site. The pumps

are powered by electric motor through a gearbox with anexternal PTO facility. This offers the ability to drive the pumpby tractor in the event of a power failure. Each pumpset willdischarge roughly 300 gallons (1150 liters) per second at 18.37feet (5.6 meters) head.

In addition to the pumps, Bedford Pumps also supplied

Siphon Breaker Valves and Sub Bellmouth Flow Splitters for theunits. They also undertook the M & E works for the site, takingout the old control panel and replacing it with a new MotorControl Center. This will operate both the new pumps and anexisting pump, which was retained as a stand-by.

A COMPLETE SOLUTION

Bedford Pumps’ new range of Fish Friendly pumps are acomplete solution for eel regulation compliance. There need

Lucy Ogden is the marketing manager for Bedford Pumps Ltd. For further information, email her at lucyo@bedfordpumps.

co.uk, call 01234.852071, or visit the Bedford Pumps website at www.bedfordpumps.co.uk.

About The Author

By Lucy Ogden,

Bedford Pumps

Fish Friendly Pumps

Go Direct DriveCam Pumping Station replacesdiesel for improved efficiency

Diesel engine driving the old pumps at Cam Pumping Station.

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be no changes to the civil structure, nor additional fish scaretactics. Utilising a Fish Friendly pump will even improvehydraulic efficiency with an 8 percent reduction in power

absorbed. Bedford Pumps’ Fish Friendly pumps cover from 105to 2377 gallons (400 to 9000 liters) per second at 6.6 to 45.9feet (2 to 14 meters) head. Fish Friendly pumpsets are availableas a submersible, mixed flow or direct drive variants.

Bedford Pumps Fish Friendly pumps have proven credentialsawarded from independent research consultants in the fieldof water management, VisAdvies BV, following extensiveand stringent trials. The tests prove conclusively that BedfordPumps’ range of submersible and direct drive pumps are

fish and eel friendly with no direct mortality observed fromexposure to the pump, with the official report going so far asto state that Bedford Pumps have manufactured the “best fish

friendly pump on the market.”Bedford Pumps range of Fish Friendly pumps offer a

complete solution for Eel Regulation compliance. There

Documents

Modern Pumping - 072014