May 2014

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2 May 2014 www.pump-zone.com PUMPS & SYSTEMS
From the Editor
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and
additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the right to determine qualications. Annual subscriptions: US and possessions $48, all
other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send
changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2014 Cahaba Media Group, Inc. No part of this publication
may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descrip-
tions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors,
and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any
advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba
Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission
yourself or to allow others to republish your submission. Submissions will not be returned. Volume 22, Issue 5.
is a member of the following organizations:
T
he global water crisis claims 5,500 lives
each daymore than war, natural disasters,
AIDS or hunger. It is a sobering problem but
not an impossible one to solve.
Wine to WaterDoc Hendley was a
30-year-old bartender who spent his work-
ing hours pouring expensive wine for wealthy
patrons. He woke up one night with a vision
that led him to research the life-threatening
efects of poor sanitation and bacteria-flled
drinking water. Te vision turned into his lifes
missionto provide clean water access to one
person, one family, maybe even a whole village.
He realized that he could make a diference by
asking the fortunate, wine-drinking popula-
tion to contribute to the cause. Ten he turned wine into water.
During the past 10 years, his passion to help solve the worlds water crisis has pro-
vided clean water to more than 250,000 people in 17 countries. He is not stopping
there. Tere are still 780 million people who do not have access to clean water or proper
sanitation. Hendleys nonproft organization, Wine To Water, brings clean water to
the people who need it. Some major pump companies are doing their part, too.
Water to PeopleGive clean water to people, and their lives will change. Only 10
percent of the worlds wastewater gets treated. Te rest goes into lakes, rivers and oceans.
UN Water estimates that 10 percent of the global disease burden could be reduced
with improved water supply, sanitation, hygiene and water resource management.
By merging philanthropic eforts and pump technology with human compassion and
involvement, pump companies like Grundfos make a diference. Grundfos involves its
employees through programs such as Walk for Water. Te company developed strate-
gic partnerships and created technology and programs to enhance the eforts.
People to LifeTe gif of clean water brings people to life. Access to clean water
and proper sanitation lowers the risk of disease. It allows women opportunity because
they no longer spend their days collecting water. Children can play and go to school.
Time spent collecting water is greater than the combined hours worked in a week by
employees at Wal-Mart, United Parcel Service, McDonalds, IBM, Target and Kroger,
according to Gary White, cofounder of Water.org.
Xylem Watermark partners with nonproft organizations to develop clean water
solutions, hygiene education and disaster recovery in water-deprived communities.
Pumps & Systems is proud to bring you special coverage this month of Te Gif of
Clean Water (page 22). Tis is just three chapters of a huge global story. If we can turn
wine into water, we can give water to people, which brings people to life. Visit www.
pump-zone.com for more coverage and resources on how you can help.
EDITORIAL
Editor
Michelle Segrest
msegrest@pump-zone.com 205-314-8279
Managing Editor
Lori K. Ditoro
lditoro@cahabamedia.com 205-314-8269
Associate Editor
Amanda Perry
aperry@cahabamedia.com 205-314-8274
Assistant Editor
Savanna Lauderdale
slauderdale@cahabamedia.com
Contributing Editors
Laurel Donoho
Joe Evans, Ph.D.
Lev Nelik, Ph.D., PE, APICS
Ray Hardee
CREATIVE SERVICES
Senior Art Director
Greg Ragsdale
Art Director
Jaime DeArman
Web Content Editor & Web Advertising Trafc
Robert Ring
Print Advertising Trafc
Lisa Freeman
lfreeman@cahabamedia.com 205-212-9402
CIRCULATION
Audience Development Manager
Lori Masaoay
lmasaoay@cahabamedia.com 205-278-2840
Circulation Coordinator
Jeff Heine
jheine@cds1976.com 630-739-0900
ADVERTISING
National Sales Manager
Derrell Moody
dmoody@pump-zone.com 205-345-0784
Mary-Kathryn Baker
mkbaker@pump-zone.com 205-345-6036
Mark Goins
mgoins@pump-zone.com 205-345-6414
Addison Perkins
aperkins@pump-zone.com 205-561-2603
Vince Marino
vince@pump-zone.com 205-561-2601
Administrative Assistants
Ashley Morris
amorris@cahabamedia.com 205-561-2600
Sonya Crocker
scrocker@cahabamedia.com 205-314-8276
Publisher Walter B. Evans, Jr.
VP of Sales Greg Meineke
VP of Editorial Michelle Segrest
Creative Director Terri Jackson
Controller Tim Moore
P.O. Box 530067, Birmingham, AL 35253
Editorial & Production
1900 28th Avenue South, Suite 200
Birmingham, AL 35209
205-212-9402
Advertising Sales
2126 McFarland Blvd. East,. Suite A
Tuscaloosa, AL 35404
205-345-0784

Doc Hendley turns wine into water and
impacts developing communities.
Motors | Automation | Energy | Transmission & Distribution | Coatings
Features that make a difference:
Dual rated for 60 Hz and 50 Hz @ 190-220/380-415 V
Optimized ventilation system for cooler operation
Robust feet design for the toughest applications
Frames 182/4T and larger have two eyebolts for easy mounting in any position
Oversized diagonally split aluminum terminal box that exceeds IP55 requirements. (Ideal for easy
installation and tough environments).
Terminal box is rotatable in 90 degrees increments for easy installation
AEGIS
ring inside (optional) to extend bearing life when used with VFDs
IP55 ingress protection is standard
Suitable for VFD operation per NEMA MG1 part 31.4.4.2
Color coded leads for easy installation
Motor paint resistance exceeds 500 hours of salt spray test
Transforming Energy into Solutions www.weg.net/us
Please contact your authorized WEG distributor or go to weg.net/us for further
information or additional specications.
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Table of Contents
May 2014
Volume 22 Number 5
Cover photo courtesy of Wine to Water
24 WINE
TO
WATER
A bartender serves hope.
T H E G I F T O F
C L E A N WA T E R
36 Smart Couplings Enhance a Failing Hot Oil Pump at a Wastewater
Treatment Plant
By Marc W. Yarlott, P.E., & M. Azeem, C.Eng., Veolia Environnement North America
Vibration and maintenance were reduced with the installation of carefully selected equipment.
42 Intelligent Water Capabilities Improve San Franciscos
Aging Infrastructure
By Alan Hinchman, GE Intelligent Platforms
Fully integrated systems are critical for utilities when upgrading equipment and instrumentation.
44 Pressure Sensor Specication for Operation in Residential, Commercial,
Municipal & Irrigation Pumps
By Greg Montrose & Karmjit Sidhu, American Sensor Technologies
Material of construction, environmental conditions and IP ratings should be considered to
maintain operating efciency.
48 Cloud-Based Monitoring & Control Is an Alternative for
Irrigation Systems
By Edward Desalle, Net Irrigate
With fewer technical requirements, they provide lower-cost options for underserved industries.
Water Handling Systems
36
SPECIAL
SECTION
28 WATER
TO
PEOPLE
Pump technology makes a dierence.
32 PEOPLE
TO
LIFE
Clean water builds communities.
The Triton Screw Centrifugal Pump combines the benets of Vaughans UNMATCHED
RELIABILITY with the advantages of highly efcient, non-clog performance. Tritons screw
centrifugal impeller is ideal for handling thick sludges, large solids, shear sensitive uids
and delicate or highly abrasive material.
- Steep performance curves
- Heavy-duty power frames
- Expedite pumps and parts availability
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP
Thomas L. Angle, P.E., MSc, Vice President Engineering,
Hidrostal AG
Robert K. Asdal, Executive Director,
Hydraulic Institute
Bryan S. Barrington, Machinery Engineer,
Lyondell Chemical Co.
Kerry Baskins, VP/GM, Milton Roy Americas
Walter Bonnett, Vice President Global Marketing,
Pump Solutions Group
R. Thomas Brown III, President,
Advanced Sealing International (ASI)
Chris Caldwell, Director of Advanced Collection Technology,
Business Area Wastewater Solutions,
Sulzer Pumps, ABS USA
Jack Creamer, Market Segment Manager Pumping
Equipment, Square D by Schneider Electric
Bob Domkowski, Business Development Manager
Transport Pumping and Amusement Markets / Engineering
Consultant, Xylem, Inc., Water Solutions USA Flygt
David A. Doty, North American Sales Manager, Moyno
Industrial Pumps
Walt Erndt, VP/GM, Crane Pumps & Systems
Joe Evans, Ph.D., Customer & Employee Education,
PumpTech, Inc.
Ralph P. Gabriel, Chief EngineerGlobal, John Crane
Bob Langton, Vice President, Industry Sales, Grundfos Pumps
Larry Lewis, President, Vanton Pump and Equipment Corp.
Todd Loudin, President/CEO North American Operations,
Flowrox Inc.
John Malinowski, Sr. Product Manager, AC Motors, Baldor
Electric Company, A Member of the ABB Group
William E. Neis, P.E., President, Northeast Industrial Sales
Lev Nelik, Ph.D, P.E., APICS, President, Pumping
Machinery, LLC
Henry Peck, President, Geiger Pump & Equipment Company
Mike Pemberton, Manager, ITT Performance Services
Scott Sorensen, Oil & Gas Automation Consultant & Market
Developer, Siemens Industry Sector
Adam Stolberg, Executive Director, Submersible Wastewater
Pump Association (SWPA)
Jerry Turner, Founder/Senior Advisor, Pioneer Pump
Kirk Wilson, President, Services & Solutions, Flowserve
Corporation
James Wong, Associate Product Manager - Bearing Isolator,
Garlock Sealing Technologies
Editorial Advisory Board
Table of Contents
Practice & Operations
Departments
2 From the Editor
8 News
52 Trade Shows
54 Business of the Business
By Paola Conti & Anand Gnanamoorthy,
Frost & Sullivan
Equipment Demand Increases to Solve the
US Aging Water Infrastructure Problem
58 Efciency Matters
By Paul McGarry, All-Flo Pump Co.
With Minimized Compressed Air Usage, AODDPs
Provide an Energy-Efcient Solution
63 Maintenance Minders
By Todd Loudin, FLOWROX
Guidelines for Progressive Cavity & Peristaltic
Pump Maintenance
68 Motors & Drives
By Mark W. Harshman, Siemens
Determine Total Cost of Ownership When
Selecting Medium-Voltage Drives
72 Sealing Sense
By FSA member Randy Wacker, P.E.
Prevent Gasket Blowout
Whats Most Important?
75 HI Pump FAQs
By Hydraulic Institute
NPSHR & Booster Pumps
84 Index of Advertisers
84 Pump Users Marketplace
88 Pump Market Analysis
Columns
12 Pump Ed 101
By Joe Evans, Ph.D.
Test Submersible Wastewater Pumps
& Motors Frequently to Accommodate
for Changing Conditions
14 Pumping Prescriptions
By Lev Nelik, Ph.D., P.E.,
Pumping Machinery, LLC
Suction Valve Throttle Versus Vacuum
16 Pump System Improvement
By Ray Hardee,
Engineered Software, Inc.
How a Piping System Works
76 Progressive Cavity Pumps Provide Optimized
Operation in Multiple Pulp & Paper Processes
By Nimish Sheth, UniqueFlo
The addition of a cardan joint helps resolve wear and failure and delivers
improved angularity and smooth transmission of radial and axial loads.
80 Some Chemical Applications Require the Range of a
Positive Displacement Pump
By Edison Brito, Pump Solutions Group
Many positive displacement pumps deliver the same ow rate
regardless of static head.
52
Forget what you know about ordinary drives
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your bottom line.
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What do the Internet of Things and the
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NEWS
NEW HIRES, PROMOTIONS & RECOGNITIONS
XYLEM Wins Corporate Excellence Award
RYE BROOK, N.Y. (April 7, 2014) Xylem Inc. received
the 2014 Corporate Excellence Award from Charities@
Work in recognition of their employee engagement activi-
ties. Each year, Xylem Watermark ofers employees ways to
help with the global water crisis.
Xylem Inc. is a global water technology provider, www.
xyleminc.com. Xylem Watermark is the global corporate
citizenship and social investment program of Xylem Inc.,
www.xylemwatermark.com. Charities@Works purpose is
to provide employers with an ef cient way to enhance their
employee engagement programs, www.charitiesatwork.org.
MADS NIPPER & DIETER
SAUER, Grundfos
DOWNERS GROVE, Ill.
(April 7, 2014)
Grundfos named Mads Nipper
CEO and group president. He
will be joining the company
August 1, 2014. Te company also appointed Dieter Sauer
as president and general manager of its Water Utility
business.
Grundfos provides pump solutions water technology.
www.grundfos.com
GORDON VAN DYKE, QuantumFlo
DEBARY, Fla. (March 31, 2014) Gordon
Van Dyke was named Turf and Landscape sales
manager for QuantumFlo.
QuantumFlo manufactures and distributes
packaged pump systems. www.quantumfo.com
RICHARD BURMESTER & AUSTIN AMOS,
Motion Industries
BIRMINGHAM, Ala. (March
24, 2014) Motion Industries
announced that Richard
Burmester has been named
senior vice president and group
executive for the realigned
Southwest sales group. Austin Amos has been named
senior vice president and group executive of the newly
formed Midwest sales group.
Motion Industries is an industrial parts distributor.
www.motionindustries.com
TIM GRIFFIN, Wood Group Mustang
GREENVILLE, S.C. & HOUSTON (March
19, 2014) Wood Group Mustang promoted
Tim Grif n to vice president, industrial opera-
tions, leading the companys North American
industrial division based in Greenville, S.C.
Wood Group Mustang provides services to
the global energy industry. www.woodgroup.com
ABAKANs CermaClad Awarded Innovation of the
Year by NACE International
MIAMI (March 13, 2014) Abakan Inc. announced that
its 72-percent owned subsidiary, MesoCoat, Inc., received
the National Association of Corrosion Engineers Materials
Performance Corrosion Innovation of the Year Award
in the Coatings and Linings category. Abakan develops,
manufactures and markets nanocomposite materials,
fabricated metal products and metal composites. www.
abakaninc.com
GEIGER PUMP & EQUIPMENT COMPANY Receives ISO
9001 Certifcation
BALTIMORE (March 13, 2014) Geiger Pump &
Equipment Company announced that its SK Systems
Division received approval for ISO 9001 Registration.
Geigers SK Systems Division works in engineering,
design, project management and fabrication.
www.geigerinc.com
Gordon Van Dyke
Dieter Sauer Mads Nipper
Richard
Burmester
Austin Amos
Tim Griffn
MERGERS & ACQUISITIONS
SAINT-GOBAIN SEALS
acquired LS Kunststof echnologie
GmbH March 31, 2014
PROCESS & POWER, INC.
acquired Jack Tyler Engineering March 30, 2014
HOOVER CONTAINER SOLUTIONS
acquired Container Company Ltd. March 10, 2014
EXONE
acquired MWT - Gesellschaf fr
Industrielle Mikrowellentechnik mbH March 6, 2014
EXONE
acquired Machin-A-Mation March 6, 2014
TV RHEINLAND
acquired Ristek Solutions March 6, 2014
For details about industry M&A activity, subscribe to
Pump Industry Insider and visit www.pump-zone.com.
PUMPS & SYSTEMS www.pump-zone.com May 2014 9
DARRYL MCCORMICK &
MARK MONROE,
Asahi/America
MALDEN, Mass. (March
3, 2014) Asahi/America,
Inc. added two new mem-
bers to its sales team
Darryl McCormick and
Mark Monroe.
Te company will also
move its corporate head-
quarters to Lawrence,
Mass., in October 2014.
Asahi/America, Inc. specializes in
providing solutions for fuid handling
systems. http://asahi-america.com
KERRY BASKINS, Milton Roy Americas
IVYLAND, Pa. (Nov. 1, 2013)
Kerry Baskins has been named vice
president, general manager for Milton
Roy Americas. Milton Roy produces
highly engineered products and equip-
ment. www.miltonroy.com
AROUND THE INDUSTRY
IDA Selects San Diego for 2015 World
Congress
TOPSFIELD, Mass. (May 21, 2013)
Te International Desalination
Association (IDA) announces that it
has selected San Diego as the site for its
2015 World Congress. Dates are Aug.
29-Sept. 4, 2015, and the Congress will
be held at the San Diego Convention
Center. Tis will be the frst time since
1999 that the IDA World Congress
will take place in North America.
IDA is a nonproft association that
serves more than 2,400 core members
in 60 countries and reaches an addi-
tional 4,000 af liate members. IDA is
associated with the United Nations.
www.idadesal.org.
To have a news item considered, please send the
information to Savanna Lauderdale,
slauderdale@cahabamedia.com.
Darryl McCormick
Mark Monroe
c
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NEWS
MAY
OFFSHORE TECHNOLOGY CONFERENCE
May 5 8, 2014
Reliant Park
Houston, Texas
301-694-5243 / www.otcnet.org
WINDPOWER CONFERENCE
May 5 8, 2014
Mandalay Bay Convention Center
Las Vegas, Nev.
202-383-2500 / www.windpowerexpo.org
IFAT
May 5 9, 2014
Messe Muchen, Germany
+49 89 949-11358 / www.ifat.de
INDOWATER
May 7 9, 2014
Grand City Convex
Surabaya, Indonesia
+49-40-3999905-25
www.indowater.merebo.com
JUNE
ECWATECH
June 3 6, 2014
Moscow, Russia
+7-495-225-5986 / www.ecwatech.com
AWWA-ACE
June 8 12, 2014
Boston Convention & Exhibition Center
Boston, Mass.
800-926-7337 / www.awwa.org
PUMP SCHOOL
June 11 12, 2014
Atlanta, Ga.
770-310-0866 / www.pumpingmachinery.com
SIEMENS AUTOMATION SUMMIT
June 23 26, 2014
Walt Disney Worlds Contemporary Resort
Orlando, Fla.
www.usa.siemens.com
EASA
June 29 July 1, 2014
Hynes Convention Center
Boston, Mass.
314-993-2220 / www.easa.com
SEPTEMBER
PUMPTEC-USA
September 10 11, 2014
Georgia World Congress Center
Atlanta, Ga.
770-310-0866 / www.pumpconference.com
PUMP USERS SYMPOSIUM /
TURBOMACHINERY
Sept. 23 25, 2014
George R. Brown Convention Center
Houston, Texas
979-845-7417 / www.pumpturbo.tamu.edu
WEFTEC
Sept. 27 Oct. 1, 2014
New Orleans, La.
New Orleans Morial Convention Center
www.weftec.org
NOVEMBER
POWER-GEN INTERNATIONAL
Nov. 12 14, 2014
Orange County Convention Center
Orlando, Fla.
918-831-9161 / www.power-gen.com
PUMP-TEC ISRAEL
Nov. 18 19, 2014
Haifa, Israel
770-310-0866 / www.pumpingmachinery.com
To have an event considered, please send the
information to Savanna Lauderdale,
slauderdale@cahabamedia.com.
CALENDAR
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PUMP ED 101
By Joe Evans, Ph.D.
PumpTech Inc.
P&S Editorial Advisory Board
Test Submersible Wastewater Pumps &
Motors Frequently to Accommodate
for Changing Conditions
First of Two Parts
A
ll pumps should be tested regularly, but wastewater
pumps are at the top of the list because they are especially
susceptible to changing system conditions. Even if a pump
operates at its best ef ciency point (BEP) at startup, many
conditions will change during its lifetime of operation,
including:
Malfunctioning gate and check valves
Partial blockages in the pipeline
Air accumulation at a high point
New branches entering a force main
Clear water systems can experience similar challenges,
but the content of the pumpage makes wastewater systems
more vulnerable. Tese changes can have a major efect on
the pumps operating point on its H/Q curve. Submersible
wastewater pumps can be more challenging because they are
out of sight and ofen out of mind.
Wastewater pumps can be problematic when operated at
of-BEP conditions because of the size of their impellers. Te
large width that is required for solids passage increases the
radial forces on higher-head pumps. Tis leads to increased
shaf defection, which will reduce seal, wear ring and bear-
ing life. In addition to radial loading, operation to the lef
of BEP can lead to damaging suction and
discharge recirculation cavitation.
To encourage frequent testing, I devel-
oped two simple submersible pump feld
test spreadsheets. One uses a fow meter
for fow measurement and allows for
the plotting of multiple test points. Te
spreadsheet that will be reviewed in this
column uses a drawdown test to measure
pump fow. Drawdown is still the most-
used procedure for measuring fow in
smaller and remote lif stations.
Figure 1 shows the pump test portion
of the spreadsheet. Te bottom right sec-
tion is the drawdown test, and the bottom
lef section tests for total dynamic head
(TDH). Te gray cells are the entered
data, and the yellow ones are the calculated data. Te equa-
tions used for the calculations are shown to the right of the
cells. Te submersible motor testing portion of the spread-
sheet will be featured in next months column.
DRAWDOWN ANALYSIS
We will begin with the drawdown analysis. Usually, a draw-
down test measures the time required to remove one foot
of water starting at the pump on level. Te reason one foot
is a preferred distance is that it provides for an ample time
measurement, and fow changes little over a single foot.
Te distance can be measured with a laser device, a plumb
bob, or a rod with starting and ending marks. It is best to
shut of the invert once the pump start level is reached to
obtain the greatest accuracy. If this cannot be accomplished,
choose a time during the day when infow is minimal. As
seen in Figure 1, entering the wet well diameter, drawdown
distance and drawdown time is the only data needed if the
system has no infow.
Te spreadsheet calculations measure the wet volume per
foot, the drawdown volume and the fow rate based on that
information. In the example shown in Figure 1, the fow
rate is 1,585 gallons per minute (gpm). If infow occurred
Figure 1. The pump test portion of the spreadsheet
C1 SERIES C1 SERIES BOTTOM SUCTION CISTERN PUMP
Designed for use in gray water / ltered efuent service applications, the
C1 Series cistern pump provides high performance and long life in less than
ideal water conditions. Intended specically for use in a cistern
or tank, C1 Series pumps are suitable for use in agricultural,
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during the drawdown test, an infow test can be performed
immediately following drawdown. If the infow is small, a
2- to 3-inch rise is all that is needed to calculate the infow.
If an infow test is performed, the infow volume is used for
the fnal gallon-per-minute calculation. It is always best to
perform two or three drawdown tests to obtain the most
accurate results.
TOTAL DYNAMIC HEAD CALCULATION
Pump head is measured with a high-quality pressure gauge
at the pump start water level, immediately afer pressure has
stabilized. Te TDH is calculated by taking into account
the gauge to water level elevation, the pipe friction from
the pump discharge to gauge location and the velocity
head. Friction head loss is determined using a friction table.
I considered calculating it but decided that a friction table
for the proper piping material and fttings would provide a
more accurate value. Discharge velocity head is calculated
using the piping inside diameter at the gauge location, and
the fow rate that is calculated during the drawdown test.
As with the drawdown calculation, the equations used to
calculate TDH are shown to the right of the calculator.
Notice that a cell for pump suction diameter and a calcu-
lation for suction velocity head are included. Some people
believe that when a submersible pump incorporates an exter-
nal suction bell, suction velocity head must be subtracted
from the TDH calculation. If a user belongs to that group,
he or she should enter the suction diameter in that cell. If the
user does not believe this, he or she should enter a diameter
large enough to reduce suction velocity head to zero.
In Figure 1, a 19-inch suction diameter provides for a zero
velocity head at the suction. Te discharge gauge reading
was 51 feet, but when the calculator includes the gauge to
water level elevation, friction in the piping and the discharge
velocity head, the TDH is calculated at 71 feet. Tis pump
tested at 1,585 gpm at 71 feet, which is approximately 97
percent of BEP fow. Wouldnt it be nice if all pumps ran
this close to their BEP?
In Part Two in the June issue, I will review the submers-
ible motor testing portion of the spreadsheet. Tese tests
will provide more pump hydraulic test results based on
motor performance and will also provide phase voltage and
current unbalance calculations. P&S
Joe Evans is responsible for customer and employee education at PumpTech
Inc., a pump and packaged system manufacturer and distributor with branches
throughout the Pacifc Northwest. He can be reached via his website www.
PumpEd101.com. If there are topics that you would like to see discussed in
future columns, drop him an email.
PUMPING PRESCRIPTIONS
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC
P&S Editorial Advisory Board
Suction Valve Throttle Versus Vacuum
Last of Two Parts
I
n my April 2014 column in Pumps & Systems, I quizzed
readers, asking if the pump suction behavior depended
on the discharge (system) side of a pump. Tis quiz also
referenced a video that can be viewed at www.pump-
magazine.com and go to Q&A, Question 120.
Two tests were conducted during the video. One dropped
the suction pressure in front of a pump by throttling the suc-
tion valve. Te second introduced a vacuum at the supply
tank with the suction valve open. In the examples, water
was recirculated to the supply tank (see the dashed line in
Figure 1) instead of the more common situation in which
it is pumped from one tank to another. Te readers were
asked to explain the diferences in the two testswhy the
tank vacuum had such a diferent efect on cavitation when
compared to the suction valve throttle.
THE BEST READER ANSWER
Te best answer received was from Jim Gagnon, P.E., senior
engineer, from CH2M HILL in Cincinnati, Ohio.
Gagnons Response
I watched the YouTube video that you posted, and I think I
have the solution. In the frst experiment, the pumped fow
rate decreased when you throttled the suction-side valve
because closing the valve added dynamic head to the system.
Te result is that the operating point moved to the lef on
the pump curve, and the fow rate decreased.
In the second experiment, the pump fow rate did not change
when you pulled a vacuum on the tank headspace because
the pump system is a closed system. Te change of pressure
in the tank afected the suction-side and the discharge-side
equally, so no dynamic head or static head change occurred.
Te system curve did not move, and as a result, the operat-
ing point did not move. However, cavitation became evident
(air bubbles in the fow meter) because reducing the pressure
in the tank decreased the net positive suction head available
(NPSHA) in the system to the point that the pump started
to cavitate. Im looking forward to fnding out if I am correct.
Neliks Response
You are correct, Jim! Normal fow control of the pump/
system is accomplished by closing or opening the discharge
side valvealmost never by its suction side. Closure of the
valve increases the losses across the discharge valve, and its
opening decreases the losses. New system curves are created
that intersect the pump curve at new operating points (see
Figure 2).
Once the discharge valve moves the pump to a new
operating point, its suction characteristics begin to change.
It requires less net positive suction head required (NPSHR)
at a lower fow and more at a higher fow (see Figure 3).
Keep in mind that a diferential pump head is the
Figure 2. Connection between the discharge
performance (H-Q) and cavitationNPSHR
Vacuum
V
vac
V
s
V
d
P
P
d
P
s
Figure 1. System sketch illustrating the example in the video
Image 1. Dr. Lev Nelik conducts the experiment shown in the video.
diference between the discharge head and the suction head. If
the same pressure reduction is applied to the supply tank and
delivery tank (as in the second example in the video, the tank
was the same), the head (pressure) does not change. Te added
vacuum cancels out on both sides. Te suction and discharge
gauge readings change but by the same amount.
However, if only the suction side is afected (as in the frst
example with the suction valve closure) but the discharge side
remains the same (the pump discharge side sees the same pres-
sure because of the same tank level), a diference exists between
the suction and discharge pressures. For example, the pump head
(diferential pressure) increases, and according to the H-Q curve,
the pump hydraulically moves to a lower fow and at a lower
NPSHR. Tis moves the fow farther away from cavitation.
Another tweak can still be made to the example system from
the video. At my next Pump School, I will discuss how the
NPSHR curve also changes at low fow (compared to the fow
in Figure 2) and which pump design features are modifed. For
more information about the Pump Schools, visit www.pumping-
machinery.com/pump_school/pump_school.htm. P&S
Dr. Nelik (aka Dr. Pump) is president of Pumping Machinery, LLC, an Atlanta-based
frm specializing in pump consulting, training, equipment troubleshooting and pump
repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He
can be contacted at www.pump-magazine.com.
Figure 4. Development of cavitation, starting from the incipient
bubble formation and eventually developing to highly unstable
bubble activity, their collapse, and damage of the impeller blades
Head, ft
NPSHR
3
3%
NPSHA, ft
A lot of bubbles
More bubbles
Incipient
Figure 3. Point at which cavitation develops
PUMP SYSTEM IMPROVEMENT
By Ray Hardee
Engineered Software, Inc.
How a Piping System Works
M
y last column (Pumps & Systems, April 2014)
explained why resistance in implementing pump
system improvement programs ofen occurs. Because pump
systems touch many disciplines and departments within
an operating plant, it is dif cult for everyone involved to
clearly understand how a piping system operates.
In this months column, a piping system will be discussed,
including the individual items and how they work together
as a total system. It will explain the systems operation so
that everyone in the plant can visualize its function.
Figure 1 shows a demineralized water supply system con-
sisting of a pump, two tanks, a water treatment unit, pipe-
lines and a control valve. Te elements can be grouped into
three general categories based on how the energy is used in
the piping system.
Te pump element is the only component that adds
hydraulic energy to the fuid in the system. Te process ele-
ments consist of the equipment required to create the prod-
uct or provide the service. Hydraulic energy is consumed
when the fuid passes through the process element to make
demineralized water. Te control valve regulates the fow
rate through the system to improve the product quality and
system ef ciency.
Te system is designed to produce 600 gallons per minute
(gpm) of demineralized water for use throughout the plant.
Figure 1 shows the elevations, levels and pressures in the raw
water and demineralized water tanks. Te distribution piping
to provide demineralized water to plant loads is not shown
because tanks and vessels make excellent locations to divide
complex systems into more easily understandable subsys-
tems. Te distribution system can be assessed separately. To
understand how the system operates, each element needs to
be evaluated, starting with the pump.
PUMP ELEMENT
Te pump adds hydraulic
energy to the piping system.
Te pump curve for the raw
water pump (see Figure 2)
shows the pump head, ef -
ciency and power consump-
tion for its range of opera-
tion. A pump must always
operate on its curve. Looking
at the pump curve at a fow
rate of 600 gpm, the pump
produces 209 feet of head.
For this pump to achieve the
fow rate of 600 gpm, the
209 feet of head produced by
the raw water pump must be
accounted for in the process
and control elements in the
system.
Figure 1. Demineralized water system
Figure 2. Pump performance curve for the raw water pump
PROCESS ELEMENTS
Te tanks provide a recognized system
boundary and an easily determined
value for the hydraulic energy that
remains fairly constant during opera-
tion. Te locations, elevations and
pressure of the tanks are determined
by the needs of the process along with
the space constraints of the plant.
In Figure 1, a 102-foot elevation
diference between the liquid level
in the raw water and demineralized
water tanks exists. Tis diference in
elevation must be overcome by the
pump and is referred to as the eleva-
tion head.
In addition, a 10 psi diference
in pressure between the raw water
and demineralized water tanks must
be overcome. Converting the pres-
sure value for feet of fuid results in
an additional 23 feet required by
the pump. Tis pressure diference
between the tanks is referred to as
pressure head.
Te diference in elevation and
pressure must be overcome regardless
of the fow rate through the system.
As a result, the elevation head and
pressure head values are combined
and referenced as static head. Te
resulting static head for this system is
102 feet + 23 feet or 125 feet of fuid.
Te losses in the pipelines are
caused by the friction between the
moving fuid and the stationary pipe-
lines. Te pipeline head loss can be
calculated using the Darcy equation,
with examples found in any fuid text-
book. In this system, the head loss
because of pipe friction is 2.6 feet of
fuid when 600 gpm of water fows
through the system.
Te fnal process element in this
example is the water treatment unit.
According to the manufacturer, a
pressure drop of 5.6 psi, or a head loss
of 12.9 feet, occurs with a fow rate of
600 gpm.
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Adding the static head, the dynamic losses of the pipe-
line with a 600 gpm fow rate and water treatment unit, the
energy consumed by the system is:
h = 125 f + 2.6 f + 12.9 f = 140.5 f
CONTROL ELEMENT
Te control element regulates the fow into the demineral-
ized water tank to maintain a constant tank level. Because
600 gpm is the plants demineralized water demand, it is
also the average fow rate through the control. A fow rate of
less than 600 gpm causes the tank level to decrease, result-
ing in insuf cient fow to the other plant loads. A fow rate
greater than 600 gpm causes the tank to overfow, resulting
in a waste of demineralized water.
ENERGY BALANCE
As previously mentioned, the pumps provide all the fuid
energy to the system. Te process elements consume energy
as fuid passes through the system to make the product or
provide the service. Te control elements consume energy
to regulate the fow of fuid through the system required to
optimize the process.
Based on the energy usage, the following expression can
be assumed:
h
pump
= h
ProcessElements
+ h
ControlElements
Rearranging the formula above, the head loss associated
with the control element required to limit the fow rate
through the system to 600 gpm is:
h
ControlElements
= h
pump
h
ProcessElements

= 209 f 140.5 f
= 68.5 f
The pump element is the only component that adds hydraulic energy to
the fuid in the system. The process elements consist of the equipment
required to create the product or provide the service.
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Converting the head loss to diferential pressure, a 29.7-
psi pressure drop across the control valve is required to regu-
late the system fow at 600 gpm.
GAINING A CLEAR PICTURE
As mentioned in last months column, pushback while
implementing system improvements happens because of
a lack of understanding about how the system operates by
those involved in the process. Te results determined that
many detailed calculations were needed to understand this
relatively simple process. An electric motor is driving the
pump, and the plant electrical engineer is familiar with the
volts, amps, power factor and motor
ef ciency needed to determine the
motor power required to drive the
pump. Te plant mechanical engineer
is familiar with the pressure, head,
fow and pump ef ciency required to
calculate the power required by the
pump. Te process engineer under-
stands the water purifcation process
along with the necessary pressure
and fows required to make a quality
product. Te plant engineer knows
how much pressure and fow rate
is needed by each load to meet the
plants pure water needs. However,
a clear understanding of how the
total system operates, how much this
system costs to operate and how ef -
ciently it is operating is missing.
Using the system information cal-
culations, Table 1 shows the hydraulic
Element Item Head (ft) Cost
Pump
Process
pump
209.0 $284,400
Process
Elevation
head
-105.0 $142,880
Pressure
head
-23.0 $31,300
Pipeline -2.6 $3,540
Water
treatment
-12.9 $17,550
Sub total -140.5 $191,190
Control
Control
valve
-68.5 $93,210
Table 1. The energy balance for the system
hydrauilc energy usage in the demineralized
water system including all associated costs
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energy usage and associated costs. Note the energy sup-
plied by the pump is consumed by the process and control
elements.
Notice that the diferential pressure across the control
valve represents approximately 33 percent of the total
energy developed by the pump. Tat appears to be a high
percentage, but it is less than the
66 percent consumed by the pro-
cess. Tose are interesting fgures,
but demineralized water is required
for the plant to make its products.
Speaking in abstracts (feet of head),
it is dif cult to get a handle on what
is occurring.
Look what happens when the asso-
ciated costs are considered. Using
data from the pump curve, the head,
fow and ef ciency of the raw water
pump at 600 gpm can be determined.
Ten the horsepower supplied to the
pump shaf can be calculated. Using
the ef ciency of the electric motor,
the amount of electrical power con-
sumed can be determined. With the
pump running 8,000 hours per year
(hrs/year) and a power cost of $0.10
per kilowatt hour (kWh), the oper-
ating cost of the raw water pump is
$284,400 per year. Now the energy
usage for each item in the system and
its associated cost can be seen.
Te information in Table 1 looks
more like a balance sheet for the
energy costs of the process. With
this information, everyone in the
plant has a much better idea of how
the system operates and the true
costs involved. With accurate cost
data, management can evaluate this
system like any other plant expense.
Questions can be asked and discus-
sions started about ways to reduce
operation costs and improve system
ef ciency.
In next months column, an exist-
ing system will be evaluated, consid-
ering diferent improvements, and
the results will be explained. P&S
Ray Hardee is a principal founder of Engineered Software, creators of PIPE-FLO
and PUMP-FLO software. At Engineered Software, he helped develop two train-
ing courses and teaches these courses in the U.S. and internationally. He is a
member of the ASME ES-2 Energy Assessment for Pumping Systems standards
committee and the ISO Technical Committee 115/Working Group 07 Pumping
System Energy Assessment. Hardee was a contributing member of the HI/
Europump Pump Life Cycle Cost and HI/PSM Optimizing Piping System publi-
cations. He may be reached at ray.hardee@eng-software.com.
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A
single Cambodian mother of three
spent the majority of each day
begging for rice and walking many
miles to gather water. Te work was
back-breaking, and she had little hope.
Te 40-pound buckets were heavy, and
the water was flthy.
Her children were sick.
Tree years later, one small well with
a hand water pump has changed their
lives.
Te mother now has time to work
and can earn an income to support her
family. Her children can play and go to
school.
Te well provides enough clean
water to meet the familys basic needs.
Tere is enough extra water to main-
tain a garden, grow food for her chil-
dren and to share with neighbors.
Her children are healthy. And she
will never again have to beg for food.
Tis is one of hundreds of success
stories Doc Hendley can tell from frst-
hand experience.
He is the founder of Wine To Water,
the nonproft organization that built
the well for the Cambodian mother,
one of 600 wells drilled in underde-
veloped regions by the humanitarian
group.
Since 2004, Wine To Water has
provided clean water to more than
250,000 people in 17 countries.
Impacting one life at a time hasnt
always been easy, Hendley says, but it
is worth it.
I get to see lives change forever just
by giving these people clean water, he
says. In the end, this changes me.
IT COULD HAVE BEEN A SONG
Ten years ago, Hendley was 30 years
old and working as a bartender and
part-time musician in Raleigh, N.C.
One night, he couldnt sleep. Te
phrase Wine To Water was spinning
in his head, but he couldnt understand
why.
Te songwriter and ministers son
felt that maybe it had something to
do with the biblical story of Water to
By Michelle Segrest
WI NE
TO
WAT E R
T H E G I F T O F
C L E A N WA T E R
Wine his father had told him. Maybe
it was inspiration for a song.
I wrote down the words to begin
writing the song, but when I saw the
words on the page, I just had a feeling
in my gut, Hendley recalls. I was a
bartender and knew a lot about wine,
but I knew nothing about water. I
began to research water on the Internet
and was shocked at what I found. I had
no clue.
He was inspired by the sobering
information about the global water
crisis. Instead of writing a song, he cre-
ated the concept for an organization
that would help provide clean water
for people who didnt have it.
Te original concept was simple.
Hendley would use his connections
in the food and wine industry to orga-
nize wine-tasting fundraisers and then
donate the money to global water
projects. Wine symbolizes fortune in
our society, he explains. Te goal of
Wine To Water is to give the fortunate
population the opportunity to fght
for those who cannot fght for them-
selvesand to give them the gif of
clean water.
THE DREAM BECOMES REALITY
Tree hundred people attended Wine
To Waters frst event in February
Women and children in the developing world spend about 152 hours each day collecting water from distant, often polluted sources.
They carry it in 40-pound jerry cans on their backs. Wine to Waters wells free them from this burden.
2004. More successful fundraising
events followed.
It was important to Hendley that
the money be donated to a charity that
would ensure him the funds were being
used to support his new passionthe
worlds water crisis.
He connected with Samaritans
Purse, an international organization
dedicated to helping victims of war,
poverty, natural disasters, disease and
famine.
Kenny Isaacs and Franklin Graham
(son of the legendary evangelist Billy
Graham) were leaders of Samaritans
Purse and took an interest in Hendleys
passion.
Tey suggested that he visit one of
the worlds most dangerous and war-
torn hot spotsDarfur, Sudan.
Hendley spent the next year living
there.
At the height of the government
genocide in Darfur, Janajaweed ter-
rorists used water as a weapon. Tey
destroyed water bladders and
dumped rotting corpses into
primary water sources.
Hendley witnessed frst-
hand the impact of poor san-
itation and the human sufer-
ing that results when people have no
access to clean water.
He watched people die. He escaped
death many times. Some members
of his team were killed. Trough this
experience, he developed the mission
for his own organization.
Hendley discovered that more than
half the wells in Darfur were broken.
He didnt have the funds to build new
ones at about $10,000 each, but he had
a solution.
We didnt have expensive machines
to replace the wells, but we began to
fx the wells using local people and
local materials. Hendleys team could
restore a well for about $50 each.
CREATIVE SOLUTIONS
Within four years, Wine To Water
helped provide clean water solutions
to four more countries. In 2009, CNN
named Hendley one of its Top 10
Heroes of the Year. Tis gave Wine
To Water exposure, which helped the
organization grow.
Wine To Water still uses local people
and local materials, but now it has
raised enough money for machines to
drill new wells. Tey have developed
water fltration systems, ceramic flters,
bio-sand flters and microfber mem-
brane flters.
Tey have formed partnerships with
companies like Sawyer, which makes
flters for hikers and campers. Each
Sawyer flter can create enough clean
water for 100 people for 10 years.
In Haiti and Cambodia, more than
18,000 ceramic flters have been pro-
duced by local workers. In some areas,
used to support his new passion the
d
d
p
h
it
ing that r
people lack access to clean water.
That is more than 2.5 times the
U.S. population.
780
M I L L I O N
Wine To Water founder, Doc Hendley, uses local people and local materials to provide clean water solutions to the worlds developing communities.
rainwater harvesting systems have been
created.
Each new area produces a new set
of challenges. A solution that works
for one area may not work for another
area, Hendley explains.
Hendleys team is currently drilling
in a remote spot in the Amazon jungle
at the Brazil, Colombia and Peru bor-
ders. Tey found the water, but cant
extract it. Tey need specially engi-
neered pumps to produce the water to
the surface, but they must be cost ef -
cient. Te remote area is not accessible
to larger drilling rigs.
We are constantly searching for
solutions to problems like these,
Hendley says.
AN EXCEPTIONAL LIFE
Before his inspiration for Wine To
Water, Hendley recalls feeling like a
failure.
I came from a family of exceptional
people, Hendley says. Tey all were
exceptional in athletics and academics,
and they were exceptional spiritually. I
never really did anything successfully.
Still, the desire for success was not
what inspired him.
I didnt set out to build
a successful nonproft, he
says. I just wanted to see
if I could maybe give clean
water to one family or
one village. I walked through that frst
door, and there was another open door
on the other side that led to the next
thing. I met the right people along the
way who helped me and joined my
mission.
It hasnt always been easy.
I have been in some of the worst
places in the world and experienced a
lot of ups and downs, he says. It has
been a long process.
We are still very small and still very
grass roots, but we are doing a lot with
a little. We are doing extraordinary
work and changing a lot of lives.
And to see the smile on the face of an
independent Cambodian mother who
can now give her children food and the
gif of clean water Well, this is what
keeps me going. P&S
Michelle Segrest is editor of Pumps & Systems.
For more photography and statistics, visit
www.pump-zone.com/giftofcleanwater.
Learn more about Wine To Water at
www.winetowater.org. For more information
about the global water crisis, visit
www.unwater.org and www.water.org.
h th t f t n n i h hild n f d nd th
people die each year from a water
related disease. That is almost the
entire population of Los Angeles.
3.4
M I L L I O N
Each location provides new challenges for
creative solutions. Wine To Water has provided
clean water to more than 250,000 people in 17
countries since 2004.
F
or many years, the people of Dei,
Uganda, a small fshing village of
the shore of Lake Albert, depended on
a contaminated lake for their drinking
water. For these villagers, water was not
a source of wellbeing. It was a birthing
ground for sickness and disease and
caused frequent cholera outbreaks.
Te lack of access to safe water
stripped them of opportunities for
education and work and contributed
to a devastating cycle of poverty.
When basic needs are not met,
we know that water is the diference
between life and death, says George C.
Greene, III, co-founder and CEO of
Water Missions International, a non-
proft engineering organization. Fatal
waterborne diseases spread rampantly
in untreated drinking water.
Since it was founded in 2001 by
Greene and his wife, Molly, Water
Missions International has provided
relief to more than 2.4 million people
in developing countries and disaster
areas.
A TECHNOLOGY SOLUTION
Te people at Water Missions
International had the heart and the
determination but needed the appro-
priate pumping technology.
Five years ago, Water Missions
president and chief operating of cer
George Greene IV made a simple call
to Grundfos, a global pump manu-
facturer, but this was not an average
inquiry about pumping equipment.
Te conversation aligned a crucial
need with the technology required to
develop a holistic solution that now
provides life-sustaining freshwater
resources to thousands.
In 2008, Water Missions International
began using Grundfos SQFlex, a
versatile pumping system, to draw
groundwater in remote areas in which
water is scarce and the power supply is
either unreliable or non-existent.
SQFlex pumps are ftted with a per-
manent magnet motor that allows for
the ef cient use of energy from several
alternative supply options, including
solar or wind.
Building of this innovative technol-
ogy, Grundfos created LIFELINK,
a water management solution that
combines modern pumping tech-
nology with a sustainable model for
ongoing fnancial management. A
By Helen Mubarak
WAT E R
TO
P E OP L E
T H E G I F T O F
C L E A N WA T E R
solar-powered SQFlex pumps ground-
water into an elevated water tower for
storage. Te water is then gravity-fed
into an automatic water-tapping unit.
Using a mobile banking system, vil-
lagers pay a nominal fee to draw water
from the system. Te funds fnance the
ongoing service and maintenance of
the system, ensuring sustainable oper-
ation for many years. LIFELINK also
provides real-time monitoring capa-
bilities for analyzing project perfor-
mance. Water Missions International
began using LIFELINK in 2011.
We are so grateful for everything
Grundfos does to support our eforts
to reach out to people in desperate
conditions, says George Greene IV.
Tanks to their innovative technol-
ogy, support from the foundation,
employee-organized Walks for Water
and employee giving through the
Water2Life campaign, we have been
able to provide safe water for thou-
sands of people in need.
Afer learning more about the non-
proft organization and its mission,
Grundfos executives discovered that
their corporate values aligned perfectly
with Water Missions Internationals
goal to provide communities in the
developing world with safe water.
Our relationship with Water
Missions makes sense in so many ways,
says Terry Teach, director of business
development for Grundfos North
America. Tey seek to deliver clean
water to people in need. We are in the
business of moving water. Tey focus
on remote areas around the world.
We build products that use solar or
wind power to pump that water. Tey
Children and teachers at a local school now have access to clean water thanks to the eorts of Grundfos and Water Missions International.
Photos courtesy Grundfos
believe in the importance of making
water treatment systems viable for
many years.
Our LIFELINK technology fea-
tures an innovative payment model that
prevents the mismanagement of funds
and fnances system maintenance.
EMPLOYEES GET INVOLVED
Many Water Missions International
projects use SQFlex or LIFELINK
technology, but a couple locations
are especially important to Grundfos
employees because of their role in rais-
ing funds for the installations.
Since 2012, Grundfos North
America employees have hosted Walk
for Water events in their communi-
ties to raise money for Water Missions
International.
Te Walk for Water is a non-compet-
itive, educational event that represents
the trek of those who walk almost four
miles per day to provide their families
with what is ofen contaminated water.
Halfway through the 3.5-mile walk,
participants fll three-gallon buckets
with water, simulating the true burden
of life in a developing nation.
Grundfos partnership with Water
Missions International has allowed us
to connect incredible technology with
incredible need, Teach says.
Our expertise in the water indus-
try gives us a unique opportunity to
help those who go through so much to
obtain their daily water.
Last year, Grundfos hosted events in
Chicago, Toronto
and Kansas City,
Mo. Employees,
partners and spon-
sors raised more
than $55,000 to
help fund three
safe water systems to the Dei, Uganda
community.
Today, the 10,000 residents of Dei
have access to safe water daily and no
longer fear waterborne illnesses.
Grundfos support of Water
Missions International shows that its
values are more than words on a page,
says Lauren Jernigan, regional coordi-
nator for Water Missions International.
Tousands of Ugandans wake
up each day with access to safe water
thanks to the 2013 Walk for Water
events hosted by Grundfos facilities in
North America.
COMMUNITY EFFORTS
Te inaugural Walk for Water was in
Kansas City, Mo., in 2012. It raised
$50,000 for two LIFELINK systems
in Dauphine and Rossignol, Haiti.
Teach visited Haiti shortly afer the
systems were installed.
As we drove through Haiti, we saw
quite a few water systems that had been
installed and then abandoned, Terry
says. Te people need long-term, sus-
tainable solutions to lif themselves out
of poverty.
Te women and children of the two
villages no longer spend hours each
day walking to a contaminated water
source to gather water in fve-gallon
buckets. Access to clean water close to
home has given them time for educa-
tion and work and prevented sickness
from waterborne diseases.
What Water Missions International
is doing with Grundfos help is truly
transforming peoples lives, Teach says.
Tanks to the installation of sustain-
able safe water systems, Haitians are
not only able to signifcantly improve
their health, but they are also able to
better their overall well being and qual-
ity of life.
Teach and the team from Water
Missions International were greeted in
Dauphine by the cheers of hundreds of
villagers.
Right: Children enjoy safe
water at a local school.
Left: Villagers ll their
buckets with clean water
at the local market.
t h l b t l l ti
C
a
M
p
s
th
h
f t t t
On average, every $1 invested in
water and sanitation provides an
economic return of $8. (United
Nations Development Programme)
$1
Lack of community
involvement causes
50 percent of other
projects to fail.
A village leader explained Grundfos
contribution to the crowd, pointing
toward a company fag fying in the
heart of the village, indicating the loca-
tion of the new water station.
It was very moving to see this area
of hope and progress, Teach says.
Grundfos employees can take great
pride in being a part of that. Tanks to
those who participated in the Kansas
City Walk for Water, the entire village
of Dauphine has access to safe, sustain-
able water.
Te team also visited Gorman,
a village in which Water Missions
had installed a water system to draw
groundwater into a water tower.
Since the pump and tower were
installed, the villagers were able to
build a school that supports about
200 children whose water-fetching
duties previously prevented them from
receiving an education. Because vil-
lagers pay a small fee for their water,
Water Missions International can
sustain the system and
invest the proceeds into its
maintenance. Te 4,900
villagers of Dauphine and
Rossignol now have safe
water every day.
Elsewhere in Haiti, the main source
of water is typically a heavily contami-
nated, garbage-flled river that is used
for bathing and washing clothes. In a
country where houses are made of plas-
tic tarps and metal scraps and where
electricity and paved roads are scarce,
clean water is a step toward growth.
Our trip to Haiti was both
heart-wrenching and heartwarming,
Teach says.
It was so sad to witness the extreme
poverty and bleak living conditions
of people across the island. I will
never forget the moment when the
children of Dauphine presented me
with a Grundfos fag in gratitude of
the life-changing gif they had just
received.
SUSTAINABLE SOLUTIONS
Part of the money raised for both
Uganda and Haiti was used toward the
training needed to sustain the technol-
ogy and the hygiene lessons needed
to prevent contamination. From the
genesis of a project to implementation,
the two companies have sustainability
in mind. Education is as important as
technology.
Tis summer, Grundfos will once
again host Walk for Water events at its
facilities throughout North America.
To learn more about Water Missions
International, visit www.watermis-
sions.org. P&S
Helen Mubarak is public aairs coordinator
for Grundfos North America. She may be
reached at hmubarak@grundfos.com.
Top Left: Participants of the 2013 Kansas City Walk for Water pause halfway through
the walk to ll their buckets with water. Top Right: Participants of the 2013 Chicago-
land Walk for Water ll their buckets at a local pond, simulating the true burden of life
in the developing world. Bottom Right: Participants of the 2013 Kansas City Walk for
Water begin a four-mile journey to and from the water source.
5
M I N U T E S
A 5-minute shower in America
uses more water than the average
person in a developing country
slum uses for an entire day.
T
he ongoing Syrian confict has forced
more than one million refugees
into Jordan, already one of the worlds
10 most water-deprived countries. Te
Mafraq City Zaatari refugee camp is
experiencing a particularly signifcant
water shortage. It opened in July 2012
with 100 refugee families and is now
home to more than 120,000 Syrians.
It is the worlds second largest refugee
camp behind Dadaab in eastern Kenya.
For more than fve years, Xylem
Watermark has partnered with Mercy
Corps, an international humanitarian
organization, to solve challenges of
epidemic water scarcity. With fund-
ing from the United Nations and
a $150,000 grant from the Xylem
Emergency Response Fund, Mercy
Corps worked to create water infra-
structure improvements for Zaatari.
Te efort began with the construc-
tion of two new deep wells close to the
Zaatari camp. Te wells are ftted with
a submersible pump, backup generator
in case of power grid interruptions, a
chlorination facility, adequate onsite
water storage, booster pumps, site secu-
rity and amenities to increase access to
fresh water.
At full working capacity, the two
wells can provide enough water to
meet the daily needs of approximately
88,000 Syrian refugeesabout 73
percent of the total population of the
camp. Providing the Zaatari camp with
its own water supply has alleviated
the pressure on other water resources
used by local communities. Trough
the new infrastructure, local residents
now have access to the same volume of
water per person as they did before the
Syrian refugees began arriving.
Tis is one example of how Xylem
Watermark has addressed the complex
development challenges of the worlds
water crisis since 2008. Trough
partnerships with fve primary inter-
national nonproft organizations
Mercy Corps, Water For People,
Planet Water Foundation, China
Womens Development Foundation
and Fundacin Avinathe company
delivers sustainable water solutions
through school- and community-based
projects, disaster response eforts, and
disaster risk reduction projects that
secure water in vulnerable areas.
From 2011 to 2013, the partnership
with Mercy Corps supported disas-
ter risk reduction projects in China,
Colombia, Ethiopia, Indonesia, Nepal
and Tajikistan. Activities in these
projects included the construction of
food walls and analysis of dewatering
systems. Te focus has been on water,
sanitation and hygiene education for
By Michael C. Fields
P E OP L E
TO
L I F E
T H E G I F T O F
C L E A N WA T E R
students, teachers and families.
Trough these eforts, Xylem
Watermark and Mercy Corps reached
more than 950,000 people. Te part-
ners responded to 22 water-related
disasters in 18 countries, providing
clean water to more than 720,000
people. Jordan and other communities
have received advanced fltration sys-
tems, water-saving network improve-
ments and improved sanitation tools.
An active employee engagement pro-
gram is critical to the projects success.
Xylem employees are educated about
the global water crisis, take a leadership
role and rally their colleagues. Tey are
given the opportunity to experience
these water challenges through Global
Volunteer Trips. Employees receive
paid leave to participate, allowing
them to see frst-hand how their eforts
to solve water issues make a diference
for real people around the world.
LONGTERM SUCCESS WITH
REALTIME MONITORING
Nearly half of all water projects eventu-
ally fail without proper ownership and
accountability. Xylem Watermark pri-
oritizes the monitoring and evaluation
of its projects with Water For People.
Trough Field Level Operations
Watch (FLOW) technology, an open-
source Android application, volunteers
in the feld are empowered to analyze
water source functionality and report
fndings in real time to a public, online
database. Tis technology allows for
the long-term tracking success of
completed projects, and it quickly
addresses non-functional water points.
Company employees teach local lead-
ers how to repair and maintain these
water points, ensuring that any break-
down can be addressed immediately.
CASCAS DISTRICT OF PERU
Te innovative, sustainable and fexi-
ble approach to problems has allowed
the partnership with Water For People
to thrive and support other local
As part of every tower build with Planet Water Foundation, Xylem volunteers provide WASH education.
In this image, volunteers use a game of tag to teach students about germs.
programs. One example is the Cascas
district in Peru.
While Peru has a rapidly growing
economy, approximately 30 percent of
Peruvians live in poverty, and only 85
percent have access to improved water
sources. Only 72 percent have access to
adequate sanitation.
An agricultural economy, Cascas
is the capital of the province of Gran
Chim. Te total population is
14,191, and 68 percent of them live in
rural areas with no access to sanitation
and fresh water solutions.
Te project involved the construc-
tion of a water system for the commu-
nity of Jolluco. Te frst water system
completed in the district now provides
water to more than 1,000 people daily.
Te project also implemented water,
sanitation and hygiene (WASH) edu-
cation programming in four schools
and created a plan for building the
capacity of water and sanitation com-
mittees. Improving the communitys
water system was the frst step toward
a sustainable solution to the sanitation
crisis and ultimately transfers owner-
ship of local water systems to commu-
nity members.
Since 2008, the partnership
between Xylem Watermark and Water
For People has provided more than
230,000 people with clean water solu-
tions. More than 60
employee volunteers
have participated in
global trips with Water
For Peoples World
Water Corps.
TUMKUR, INDIA, AQUA TOWER
Trough a partnership with Planet
Water Foundation, a U.S.-based non-
proft development organization,
Xylem Watermark focuses on schools,
children and rural communities in
China, India, the Philippines and
Cambodia that lack access to clean, safe
water. For the August 2012 project in
the Mount View and Dodderi Schools
of Tumkur, India, the mission was to
build one Aqua Tower serving 1,000
people and ofer WASH curriculum to
provide clean water and sanitation and
hygiene education.
Before the project, the Tumkur area
sufered severe drought. Many wells
dried and were unable to provide
consistent water to the community.
Te Dodderi Government School
drilled deeper bores to alleviate the
situation. In both schools, the need
to purchase bottled water has lessened
since the completion of the project.
Te instances of sickness and diarrhea
have decreased following the success-
ful installation of the Aqua Towers and
deployment of the WASH program.
More than 150 employee volunteers
have joined Planet Water Foundation
in the feld to build water towers and
provide sanitation and hygiene educa-
tion to local school children. To date,
48 water tower installations have been
completed throughout China, India,
Students and Xylem employees
celebrate the completion of a
water tower at a project
in China with nonprot
partners Planet Water Foundation
and China Womens
Development Foundation.
T j l i l d TUMKUR IN
a child
dies from a
water-related
illness.
The majority of illness is
caused by fecal matter.
More people have a mobile
phone than a toilet.
E V E R Y
21
SECONDS
the Philippines and Cambodia. More
than 48,000 people now have clean
water, proper sanitation and hygiene
education.
STEPPING PUMPS AID
RURAL FARMERS
Farmers comprise almost one-third of
the global population. A third of those
are subsistence farmers who produce
a minimal amount of food annually.
In India, more than 140 million farm-
ers work each day to cultivate enough
crops to feed their families. Tey haul
water to their felds and face a daily
battle to keep their crops watered.
Dozens of worldwide philanthropic
organizations are working to help sub-
sistence farmers by providing seeds,
rudimentary equipment or donating
the time of volunteers. Products such
as Xylems Saajhi Stepping Pump, a
manual advanced stepping pump that
was engineered, designed and vetted
within rural agricultural markets, has
helped increase production.
Tough the product design is simple,
the research behind it embodies what
the rural farmer needs in a water man-
agement system. Te technology is
designed for the smallholder farmer.
During development, extensive in-feld
customer profling and research
identifed the irrigation needs of the
rural farmer and the key elements for
product longevity.
Saajhi Stepping Pumps have been
placed in more than 10 countries
including Asia, Africa and South
America. Impact studies are being exe-
cuted to measure the economic, social
and environmental efects of this pump
within rural communities.
ESSENCE OF LIFE STRATEGY
Te Stepping Pump is part of Xylems
Essence of Life (EOL) business strat-
egy, a planned portfolio and
channel construct. EOL lever-
ages an exclusive hybrid value
chain that brings together the
citizen sector (private and
non-governmental organiza-
tions), business and government
partnerships.
Tis collaboration provides a sus-
tainable engagement strategy, driving
rural customer shared value that is sup-
ported by technology and synergistic
rural community market and channel
leadership.
Trough Xylems small form factor,
direct-current and human-powered
pumping solutions have been created
to diferentiate water management
systems that contribute to sustainable,
secure smallholder irrigation prosper-
ity. EOL addresses the aspirational
nature inherent in many rural commu-
nities and unlocks rural enterprise.
THE IMPACT
In 2010, Xylem Watermark achieved
its frst milestone by reaching more
than 500,000 people with clean water
and sanitation solutions. In 2011, it
committed to reaching one million
more by 2014. Trough partnerships,
Watermark has reached more than 2.3
million people since 2008.
Each partner provides crucial
on-the-ground expertise and ofers a
geographic breadth of social impact.
Te full spectrum of water challenges
are addressed by providing fnancial
support, water technology, sanitation
equipment and hygiene education.
P&S
Michael C. Fields is the director of Corporate
Citizenship for Xylem Inc. For more informa-
tion, visit www.xyleminc.com and
www.xylemwatermark.com.
Xylem employee volunteers
with Water For People test
the ow of a stream while
in the eld in a remote,
mountainous region of Peru.
h d l
O N L Y
10
PERCENT
of the worlds wastewater is treated.
The rest goes into lakes, rivers
and oceans.
SPECIAL SECTION
A
service provider operates a sludge drying facility that
is located within the Stickney Water Reclamation
Plant for the Metropolitan Water Reclamation District of
Greater Chicago (MWRDGC) in Cicero, Ill. Te facility,
which processes wet sludge into dried pellets for use as an
agricultural and commercial fertilizer product, represents
one process of the overall plant. Te drying and pelletizing
occurs in a pelletizer that indirectly heats the sludge using
hot oil pumped through a series of trays at more than 570 F.
HOT OIL PUMP
Te hot oil pump operates at an oil temperature of 570 F,
while the motor is at ambient temperature. Te coupling
alignment is dif cult to set and must be completed when
the pump and motor are cold and again when hot because
of the efects of thermal expansion. Te pumps had an ini-
tial running vibration of more than 0.25 inch per second
(in/sec). A 0.1 in/sec measurement would be the maximum
acceptable vibration and it is recommended that vibration
Smart Couplings Enhance a Failing Hot Oil
Pump at a Wastewater Treatment Plant
Vibration and maintenance were reduced with the installation of carefully selected equipment.
By Marc W. Yarlott, P.E., & M. Azeem, C.Eng., Veolia Environnement North America
Above: Image 2. The installed magnetic coupling
SPECIAL
SECTION
Water Handling
Systems
SPECIAL SECTION
Ultimately, a new type magnetic coupling based on induc-
tion rotor technology was selected. Tis technology has the
following characteristics:
A minimum misalignment tolerance of 0.1 inch in any
direction because of the air gap between the motor and
load
Fits within American National Standards Institute and
National Electrical Manufacturers Association standard
dimensions so no modifcation to the motor, pump or
base required
Transfers 125 horsepower at 1,800 rpm
Provides transfer of 140 percent of full load torque in a
locked rotor condition, leading to a
140-percent to 150-percent increase
in motor current, which can be
detected using a current sensing relay
set to trip afer a user-adjustable dura-
tion (typically 20 to 40 seconds)
Te selected design is a second-
generation magnetic coupling that
increases torque transfer as the per-
centage of slip increases. Figure 1
shows the comparison between this
design and eddy-current magnetic
coupling designs.
Initially, the standard air gap within
the selected coupling was thought to
provide adequate space to accommo-
date thermal growth. However, the
coupling also had additional air gap
spacer shims that allow the air gap to
be increased for even more misalign-
ment correction. Adding shims usu-
ally reduces the overall efective trans-
fer of torque, leading to a decrease in
pump speed.
Te amount of pump speed reduc-
tion depends on the couplings
horsepower rating, the actual load
horsepower and the number of shims
inserted, but it is normally less than
2 percent with the selected coupling
when properly sized. For systems in
which full fow is not needed or throt-
tling valves or recirculation loops are
used to reduce fow, the selected cou-
pling ofers signifcant energy savings.
In this case, however, more than a
nominal amount of pump speed/fow
reduction was not desired.
INSTALLATION
Prior to the installation, a new/rebuilt
is less than 0.05 in/sec for a signifcant improvement in
reliability.
Typical failures included mechanical pump seals, valves,
drain plugs and fangeswhich were all leaking oil. Because
of the oils temperature, many of these failures resulted in
smoke because the oil started to burn upon leaking. Te
high vibration and load stress resulting from the thermal-
expansion-driven misalignment was causing particularly
high failure rates for the No. 4 pump, the primary ther-
mal oil supply pump. Tis pump had a signifcant number
of failures and had to be rebuilt three times in 18 months
according to records in the computerized maintenance
management system.
COUPLING ALTERNATIVES
Because of the ongoing misalignment-related issues, facility
management researched the latest in fexible coupling tech-
nology. Each coupling type reviewed for the hot oil pump
had distinct pros and cons.
Fixed, direct and rigid style couplings sufered from the
transfer of vibration and axial loading when thermal growth
of the pump shaf occurred, causing perpendicular stress
loading on the motor and pump axial bearings. Traditional
fexible couplings (for example, elastomeric, grid or gear)
provided some axial load relief but did not resolve the par-
allel misalignment created as the pump base and structure
experienced vertical growth with increased temperature.
Te vertical misalignment caused torsional loads on the
motor and pump bearings, in addition to loads on the cou-
pling that caused vibration of the motor
and pump.
Finally, magnetic couplings were con-
sidered. Magnetic couplings are ideal for a
hot oil pump application because no phys-
ical contact between the motor and load
is allowed. Te magnetic air gap provides
enough clearance to allow for vertical and
axial changes in dimension to occur with-
out impacting the couplings torque trans-
fer, and vibration cannot be transmitted
between the load and motor. Te air gap
also provides a thermal break that protects
the motor from the extreme heat of the
pump and acts as a shear pin during a load
seizure, protecting shafs and connected
equipment from severe damage.
However, potential limitations in mag-
netic technologies had to be addressed.
First, axial thrust and end play on either the motor or pump
could be a concern because magnetic couplings could allow
too much movement in the axial direction. Second, during
a load seizure, the magnetic coupling must transfer enough
torque to automatically cause the motor overload circuits to
trip and shut down the system to protect the magnetic cou-
pling from damage caused by overheating.
Magnetic Coupling Selection
Based on a review of the available technologies, magnetic
couplings provided the best combination of performance
and benefts for the hot oil pump system. However, the eval-
uation and selection criteria for a magnetic coupling for the
hot oil pump application were critical. Te coupling needed
to meet all performance requirements and had to ft within
the existing motor and pump with minimal rework.
Because a locked rotor condition (resulting from a seized
pump bearing or failed impeller) can create an overheat-
ing hazard that can damage the coupling, selecting a mag-
netic coupling that can transfer more than full-rated torque
during locked rotor conditions was important. By doing
so, the coupling will cause an increase in motor amperage
inside the motor starter for a measurable time, allowing the
motors protective circuitry to automatically disconnect
power. Axial end play concerns also needed to be addressed
because thrust inside the motor housing may cause axial
movement in the motor rotor and shaf, particularly in
rebuilt motors that may not meet original manufacturing
specifcations.
Figure 1. Comparison between induction rotor and eddy-current magnetic coupling
designs
rotating assembly was installed in the pump. While the rated
capacity of the motor on this system is 125 horsepower, his-
toric power readings and pump curves indicated that this
pump was operating at approximately 95 horsepower at the
time of installation.
Te coupling was installed with the induction rotor
mounted to the motor shaf, and
the magnet rotor was connected to
the pump shaf. Te standard air gap
between these coupling halves is 0.1
inch per side with no additional shims
installed. However, one problem that
was encountered during the installa-
tion was 0.03 inch of axial movement
in the motor shaf. Given this axial
movement and the known levels of
additional thermal shaf growth, an
additional 0.05-inch air gap spacer
shim was inserted. Te total available
air gap was increased to 0.125 inch
on each side of the magnet rotor, and
this increase had a negligible impact
on the pump speed.
First, the installation procedures
required tightening the induction
rotor half of the coupling onto the
motor shaf. Jacking bolts were then
used to center the magnet rotor inside
the induction rotor before its hub
was tightened onto the pump shaf.
Without end play or thermal growth,
the magnet rotor would normally be
perfectly centered. In this case, the
magnet rotor would grow toward the
motor as the pump heated. Terefore,
the air gap was set with 0.115 inch
on the load side and 0.135 inch on
the motor side, with the expecta-
tion that it would be nearly centered
afer thermal growth occurred during
operation. Tis style coupling can be
of-center axially or in a parallel or
angular way by the full distance of
the air gap (as long as the sides do not
touch) without any negative efects.
Te motor was energized and the
pump was allowed to reach operat-
ing temperature. Termal, rpm and
vibration data were collected to determine performance.
Vibration readings initially indicated looseness in the
pump. During inspection, it was determined that the pump
foot was loose. Afer tightening the foot, vibration levels
dropped to well below acceptable limits.
Another noted beneft was thermal isolation. Te air gap
SPECIAL SECTION
efectively insulated the motor from the 503 F temperatures in the
pump. Te pump side of the coupling remained relatively cool at
119 F because of air cooling, but the motor side of the coupling was
at an even lower 105 F. It is expected that reduced operating tem-
peratures will extend grease life in the motor bearings, thus increas-
ing motor bearing life.
Figure 2. Air gap cross section drawing
Image 1. Infrared image showing the thermal isolation
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SUMMARY
Post installation, vibration levels on the motor and pump
fell to well below 0.05 in/sec in all dimensions (see Table
1). Tis vibration level was well within acceptable limits and
far below the more than 0.25-in/sec levels recorded on three
other identical hot oil pumps. Te air gap also served in an
insulating capacity, keeping the pump shaf heat from trans-
ferring to the motor.
Te couplings air gap eliminated the need to perform
laser alignment and can signifcantly reduce vibration
levels that result from misalignment. Te pump can grow
thermally without increased vibration or a loss of torque
transmission capacity. Downtime, maintenance and costly
equipment repairs will be reduced during the systems oper-
ating life. Perhaps most important, no noticeable efect was
seen on the pumps fow rate, and the overall sludge drying
process was unafected. P&S
M. Azeem is the reliability engineer for the Veolia Chicago
biosolids project at the Stickney Water Reclamation Plant in
Cicero, Ill. Azeems focus is on improving and maintaining the
reliability of this technical plant.
Marc Yarlott is an internal asset
management consultant with Veolia North
America with a focus on improving asset life cycles for
Veolia projects across North America. He may be reached at
marc.yarlott@veolia.com.
The authors would like to thank the engineers at Flux Drive
for their technical support on this project.
Motor speed (1,790)
pump speed (1,720 rpm)
70 rpm (3.9 percent reduction)
Outer motor horizontal vibration 0.045 in/sec
Outer motor vertical vibration 0.011 in/sec
Outer motor axial vibration 0.027 in/sec
Inner motor horizontal vibration 0.045 in/sec
Inner motor vertical vibration 0.039 in/sec
Inner pump horizontal vibration 0.011 in/sec
Inner pump vertical vibration 0.006 in/sec
Inner pump axial vibration 0.006 in/sec
Pump operating temperature 503 F
Coupling operating temperature 119 F
Table 1. Post-installation operation data
e cycles for
M
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SPECIAL SECTION
W
ater utilities face aging infrastructure, declining
revenues, increasing service level expectations and
many regulations. In addition, resources for water and
wastewater capital programs are limited, which makes
infrastructure modernization, expansion and technology
upgrades dif cult.
Utilities can address these critical challenges while deliv-
ering the best return on investment to ratepayers or private
sector investors. In many instances, utilities cannot easily
raise water and sewer rates or purchase new equipment.
Tey must become as ef cient as possible with the assets
they have. To make the best decisions for planning and opti-
mization, they must look at their operations holistically to
understand and predict what is happening with their equip-
ment and operations.
Te technology and solutions are available. Tey revolu-
tionize what is possible for water and wastewater utilities.
Trough integration of business and automation systems
and platforms, relationships between the data can be con-
nected. Intelligence can be delivered to the right people at
the right time.
Some fully integrated systems can predict what is going
to happen. In these systems, machines, data, insights and
people are connected. In the water industry, a fully inte-
grated system is key to helping large, city-based systems and
small rural utilities harness sofware quickly and afordably.
For example, the San Francisco Public Utilities
Commission (PUC), a department of the City and County
of San Francisco and the third largest municipal utility in
California, provides drinking water and wastewater ser-
vices, hydroelectric and solar power to 2.6 million resi-
dential, commercial and industrial customers throughout
the San Francisco Bay Area. Tis article discusses how this
utility improved its operations and service with a fully inte-
grated system.
THE WATER DISTRIBUTION SYSTEM
Te water entering the system is among the purest in
the world, starting in the Sierra Mountains of Northern
California, where water is captured from spring snow
melts and stored in the Hetch-Hetchy watershed, an area
of Yosemite Valley. Te San Francisco PUC operates a large
and complex water transmission and treatment system that
moves water from the Hetch-Hetchy reservoir to the San
Francisco Bay Area through a series of reservoirs, pipelines
and treatment systems. Te system operates with only a few
pumps and is sustained almost completely on gravity to
move the water more than 200 miles.
Since no fltration is required, the water is provided
directly to residents. Tis is not always practical, however, so
water is also diverted to a number of reservoirs throughout
the San Francisco Area to be used as needed. Watersheds in
close proximity also feed these reservoirs, and any water that
comes from them is fltered in two larger California water
treatment plants: the Harry-Tracy Treatment plant in San
Bruno and the Sunol Valley Treatment plant in Sunol. Each
can produce up to 180 million gallons per day (MGD).
Te San Francisco PUC saved $1.3 million by standard-
izing on a high-availability solution that delivers results
for a sustainable advantage. It connects the equipment to
processes, data and peopleanytime and anywherefor
smarter, faster decisions across the utility.
Built on a scalable, synchronized, hot-standby redun-
dancy control platform, this solution ensures uninterrupted
control of applications and processes with total transpar-
ency. Te technology provides enhanced speed and perfor-
mance, increased memory, built-in hardware redundancy
and ease of use. A modern controls infrastructure allows
end users to link data from multiple platforms, such as:
SCADA systems
Computer maintenance management systems
(CMMS)
Intelligent Water Capabilities Improve
San Franciscos Aging Infrastructure
Fully integrated systems are critical for utilities when upgrading equipment and instrumentation.
By Alan Hinchman, GE Intelligent Platforms
Financial systems
Automated meter reading (AMR)
Geographic information systems (GIS)
Tis is critical because it provides the foundation to com-
bine all the utilitys data from standalone and disconnected
platforms, allowing robust communication and the move-
ment of data between multiple platforms.
To maximize ef ciency and data dissemination, a system
requires a controller with the appropriate input/output
(I/O) connections, starting with an I/O network using
PROFINET, which is designed to be ultra-fast and easy to
set up. With this type I/O fexibility, utilities can connect to
a full range of I/O from simple discrete to safety and process
I/O.
In addition, high-performance computing at the control-
ler is critical for collection and dissemination of process and
operational data. Confgurations such as modular industrial
PCs in a stack with programmable logic controllers (PLCs)
provide a control and computing solution capable of run-
ning a human/machine interface, historian, analytics and
other higher-level applications.
Furthermore, a modern control infrastructure helps mini-
mize failure and obsolescence risks. Todays controllers are
Ethernet-based, featuring high availability redundancy,
expandable open architectures, upgradable central process-
ing units and cloud-based capabilities to help drive uptime,
fexibility and longevity.
In the San Francisco PUCs case, rather than arbitrarily
removing water infrastructure technology and equipment
based on a generalized timeline of when these water assets
may require replacement, adding layers of technology to
the equipment allows the assets to communicate better
with their operators help extend the life of these expensive
pieces of equipment. Te senior engineer of the PUC in San
Francisco likened this upgrading process to pulling out a
brain and putting in a new one in just a matter of hours,
compared to months or years of rebuilding.
REAL-WORLD RESULTS
Downtime was virtually eliminated because of robust, dual-
redundancy capabilities, which are imperative for the San
Francisco PUC because it has to ensure that water and
essential services are delivered 100 percent of the time. Te
controllers have dedicated, redundant links to one another
and operate synchronously with little overhead added to
the control applicationtransferring all the applications
variables, status and I/O data on every scan with speed and
transparency. It synchronizes the system at the beginning
and end of each logic scan execution to keep all variable data
the sameproviding rapid and bumpless switchover.
Te San Francisco PUC is also saves time and money by
protecting investments with fexible, scalable, open architec-
tures that also support legacy applicationsnow and in the
futureand reduces engineering costs with easy confgura-
tion and quick startup and maintenance. Complementing
the time and money savings is an increase in productivity
that results from fast, powerful synchronization and the
ability to maintain individual system components without
interruption.
Another beneft of implementing the high-availability
solution is that the water treatment plants decreased the
cost of spare parts. When the U.S. is losing about 7 billion
gallons of treated water per year because of the countrys
aging water infrastructure, fexibility could make a substan-
tial diference. Additionally, the smaller form factor of the
solution allows for more water capacity.
Ef ciency gains are also realized through high-speed
memory sharing, which enables multiple devices to transfer
large amounts of data over a fber optic deterministic net-
work at speeds up to 20 times faster than Ethernet. Te use
of fber optic connections allows the PUC to easily oper-
ate in high-noise areas and cover large distances in real time.
Adding to the ef ciency gains is that the PUCs knowledge
base was sustained, reducing training overhead.
CONCLUSION
For a utility to be viable in todays world, the business must
use automation platforms to leverage their capabilities.
Te outcome is lower operating costs, quicker response to
changing needs and easier training. By replicating systems
faster across the utility, implementation costs are low-
ered, risk is decreased and completion time is accelerated.
Additionally, operators can create solutions without putting
added demands on IT.
Creating consistency, ef ciency and accountability and
enabling collaborative information with a holistic approach
are keys to success. At that point, utilities can optimize every
aspect of water operations for high performance in todays
connected world. P&S
Alan Hinchman is a global market director for GE Intelligent
Platforms. He focuses on the water and oil & gas industries,
meeting with companies to help them get the most from their
technology. Hinchman is based in Charlottesville, Va. He may
be reached at geip@lpp.com.
SPECIAL SECTION
P
ressure sensors are used in pumps to measure water
pressurization and as part of monitoring and control
systems. Typically, an of-the-shelf pressure sensor will
not survive application-specifc operating conditions.
Environmental conditions can also cause standard pressure
sensors to fail. To ensure that pressure sensors maintain
the operating ef ciency of water pumps while minimizing
service calls, several factors should be considered when
specifying a sensor for pump systems in water service.
MEDIA COMPATIBLE MATERIALS
Pressure sensors used in pumps will contact water with vary-
ing pH levels and quality depending on water purifcation
processes and added chemicals. Many new oil and gas felds
also produce some levels of hydrogen sulfde (H
2
S) and salt
water that must be pumped and stored in tanks prior to
discharge. Pressure sensors must be able to work reliably in
these elements without failure.
Units constructed from standard materials using austen-
itic steels (including 304 and 316) and ferritic steels (such
as 13-8PH, 15-4PH and 17-4PH) can handle all types of
water. However, these materials may not be suf cient to
prevent common corrosionsuch as pitting, crevices, stress
cracking, intergranular corrosion and galvanic corrosion.
Te corrosion rate depends on the liquid temperature,
introduction of oxygen and water type. Nickel- and cobalt-
based superalloys help maintain system reliability and safety
because they resist corrosive acids. For example, a special
nickel-based alloy provides excellent resistance against pit-
ting and attack by micro organisms, enabling pressure sen-
sors to be specifed for use in shallow and warm waters with
high levels of oxygen. Titanium and a nickel-molybdenum-
chromium alloy give pressure sensor technology greater
resistance to pressure and corrosion in water depths down
to 7,500 feet and with an external pressure of approximately
3,800 psi. See Table 1 for material recommendations.
Pressure sensor end users must ask the manufacturer to
state the sensor materials of construction of the assembly
and the materials compatibility to avoid costly failures in
the feld. Pressure sensors constructed from a one-piece
316L stainless steel sensing element also ofer excellent
liquid compatibility for residential and commercial water
applications. A one-piece design ensures that outside media
does not permeate the sensor body.
OPERATING ENVIRONMENT
Depending on the pump systems location, pressure sensors
may be exposed to climate extremessuch as in Canada
and Alaska, where the temperature ofen falls to -60 F (-50
C), or in Texas, where they will experience extreme heat and
humidity. Pressure sensor threads must seal the media from
low to high temperatures with a dry sealsuch as national
pipe taper (NPT) or a metal-to-metal conical seal. NPT
threads can be used up to 10,000 psi (700 bar). However,
caution must be taken against incorrect installation torque.
Beyond 10,000 psi, an NPT thread must be avoided, and
the units must be specifed with a metal-to-metal seal.
Pressure transducers used on outdoor applications must
withstand ambient temperature and rain, snow, icing and
dirt. Corona discharge from lightning strikes and electro-
magnetic interference from electrical polluterssuch as
Pressure Sensor Specifcation for Operation
in Residential, Commercial, Municipal &
Irrigation Pumps
Material of construction, environmental conditions and IP ratings should be considered to
maintain operating effciency.
By Greg Montrose & Karmjit Sidhu, American Sensor Technologies
Water Type 17-4PH
Stainless
316L Stainless
Steel
Nickel Alloy
718
Fresh water Yes Yes Yes
Deionized water No Yes Yes
Ground water No Yes Yes
Brackish water No Yes Yes
Seawater No No Yes
Table 1. Material recommendations for pressure sensors based on
water type
wireless radio systems, valves and variable drive motor sys-
temscan cause stray voltages and leakage currents to be
transmitted through pipes. Tis can ofen
disrupt sensor operation. Pressure sensors
with custom electronics and a sensing ele-
ment to withstand 500 volts of direct cur-
rent isolation work best in these extreme
electrical conditions (see Image 1).
SEALED CONSTRUCTION
Rain, ice, dust and pressure washers can
cause water to seep into sensor housings,
causing electronics to short. Sealed gauge
reference pressure sensors protect elec-
tronics from these conditions. Ingress
Protection (IP) ratings can help end users
understand the environment in which the
sensor will surviveincluding high pressure, washdown
or submersion. In certain cases, a submersible pressure
transducer will be specifed. Te area in which the sensor
is threaded and installed could become fooded, requiring
that the electronics be protected from submersion.
WATER HAMMER
Te opening and closing of system valves, such as solenoids,
can cause a pressure transient within a water pump above
the measurement range in a shockwave. An internal welded
restrictor plug reduces the inside diameter of the sensors
pressure port so that when the pressure spike hits the face of
the plug, it feeds through the hole at a slower pace, dampen-
ing pressure spikes before reaching the sensors diaphragm.
Te restrictor plug, commonly called a snubber, also
reduces the overall length, cost and potential leak points in
the system.
In this confguration, the liquid must be free of dirt,
lint, iron flings, sand and grit to avoid clogging the plug.
For some pressure sensing technologiessuch as thin flm,
bonded metal foil strain gauge and capacitive with very low
signal outputthis is the only way to limit the diaphragm
Image 1. This explosion-proof pressure sensor has an
all-welded housing; one-piece thick, 316L diaphragms;
and a cable end with engraved housing built to keep
hazardous media out, eliminating the chance of water
permeation and eventual sensor failure.
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SPECIAL SECTION
travel. Terefore, the user must install
a mesh flter in front of the snubber.
With inorganic, bonded semicon-
ductor technologies, inorganic mate-
rials are molecularly difused onto
a metallic surface in the presence of
certain gases. Te high level of raw
output provides signifcant deranging
of the sensing element, allowing the
use of large cavities without clogging
(see Image 2).
With deranging, pressure sensors
with this 5,000 psi (350 bar) sensing
element can maintain high, full-range
accuracy from 0 to 1,500 psi (100 bar)
and ofer over-pressure capabilities of
10,000 psi (700 bar). Tis is useful
in compression pumps, on hydraulic
fracturing trucks, and during icing
conditions on casing and tubing lines.
ELECTRICAL OUTPUTS
Depending on the distance and
environment, certain output signals
can experience signal loss or gener-
ate signal noise. Water pressure sen-
sors can be packaged with high-level
voltage, current and frequency out-
puts. A 4-20-milliampere output
signal is recommended for transmis-
sion lengths of more than 15 feet in
environments with electrical noise.
Frequency output signals are also used
by niche manufacturers to provide
direct pump feedback into a variable
frequency drive. With a signal of 1 to
6 kilohertz, pump manufacturers can
save electronic component cost. P&S
Karmjit Sidhu is vice president,
Business Development, for AST.
Greg
Montrose is
marketing
manager at AST.
For more information on American Sensor
Technologies, visit www.astsensors.com or email
info@astensors.com.
Image 2. Openings for pressure
transducer diaphragms offered with
inorganic bonded semiconducter
technology
From left to right:
-inch NPT male without snubber
-inch NPT male with snubber
-inch NPT male
T
G
M
m
m
For more informatio
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SPECIAL SECTION
T
he Internet of Tings (IoT) was a term coined by Kevin
Ashton in 1999. Te term was used to describe the
phenomenon of machines and devices being connected to
each other and people. It was forecast that the next stage
of exponential growth in the evolution of the Internet
(beyond personal computers and mobile phones) would be
connecting the 50 billion devices and machines on planet
earth.
Flash forward to 2014, and Kevin Ashtons vision is
becoming a reality. Between 2011 and 2014, the number of
connected devices increased from 2 billion to just more than
5 billion. Research by the Gartner Group estimates that the
installed base of connected devices and machines will grow
to 26 billion units by 2020. Considering how many peoples
daily lives have changed, this trend is apparent. Today, it is
dif cult to purchase a new television that is not Internet
enabled. Likewise, Googles $3.2-billion acquisition of Nest
early in 2014 suggests that connected thermostats are not a
fad but are here to stay.
What does the Internet of
Tings mean for the pump
and controls industry? Is IoT
just a new buzz phrase for
SCADA?
SCADA VERSUS
MACHINE-TO-MACHINE
COMMUNICATION
Assessing the impact that IoT
might have on the pump and
controls industry begins with
understanding the principle
diferences between modern
machine-to-machine com-
munications and more tradi-
tional supervisory control and
data acquisition (SCADA)
systems.
SCADA has three main
attributes:
Capital intensive
Customized
Mission critical
Conversely, machine-to-machine remote monitoring
solutions generally have the following attributes:
Low cost
Interoperable
Complimentary
For well-capitalized organizations with large-scale, mis-
sion-critical pumping operations, traditional SCADA will
be the likely model for years into the future. An organiza-
tion, such as a large oil and gas operating company, will
demand a highly secured and tailored solution so that its
remote monitoring needs are not sacrifced.
However, these requirements are not universal among
all end users of pumps and controls. Additionally, not all
Cloud-Based Monitoring & Control Is an
Alternative for Irrigation Systems
With fewer technical requirements, they provide lower-cost options for underserved industries.
By Edward Desalle, Net Irrigate
Remote monitoring equipment for an irrigation pump
end users have the capital, human and technical resources
to use SCADA. Tey also do not have mission-critical
requirements. End users who ft this criteria can look to the
Internet of Tings because IoT is essentially democratiz-
ing remote monitoring.
AGRICULTURAL CONTROL & MONITORING
Agriculture is one example of an industry that may ben-
eft from machine-to-machine communication. Te most
recent U.S. Department of Agriculture Farm and Ranch
Irrigation Survey indicates about 800,000 pumps operate in
agricultural irrigation. Each year, between April and August,
irrigators typically spend one-third of their day driving to
and from each of their irrigation systems to ensure that the
equipment is functioning properly.
In a state such as Arkansas, farmers typically manage 20
to 40 irrigation pumps. In this situation, pumps are ofen
spread throughout 10 square miles, and a SCADA system
would be convenient and would simplify operations.
However, the upfront capital costs and technical expertise
required to support it do not create a compelling return
on investment. Tis limitation has changed in recent years
because cellular data coverage has expanded to rural areas,
and stand-alone remote terminal units (RTUs) are con-
necting equipment directly to the Internet via the cellular
network.
Additionally, the increase of smart phone and tablet
computing has simplifed the distribution and consump-
tion of sofware, increasing the value proposition. Te
days sitting in front of a dedicated workstation to remotely
monitor equipment have ended. Likewise, modern RTUs
have become event driven. End users can receive proactive
text messages or push notifcations when critical pumping
conditions occur. An additional beneft of this decentral-
ized model is that little to no upfront capital investment is
required. A farmer can simply add or remove RTUs for the
pumps as needed.
IoT also brings intelligent logic to the cloud rather than
placing it on isolated programmable logic controllers
(PLCs) and/or proprietary servers within a private network.
Once the bulk of the logic is entered in the cloud, it allows
for many integration possibilities and fexible business rule
changes. For example, suppose 2,000 irrigation pumps are
connected by RTUs within the same rural county, which
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SPECIAL SECTION
has a dedicated electrical utility provider, and the utility
provider changes its kilowatt-per-hour rates for peak pump-
ing times. A cloud-based system could more easily interface
this data and make intelligent irrigation scheduling rec-
ommendations to present to the farmers. Taking that idea
further, it could intelligently control the pump to optimize
ef ciency. Weather data, crop yields and water tables may all
be factored into the equation for further optimization.
RESIDENTIAL APPLICATIONS
Te market sizes of the applications for which SCADA is
not always appropriate are signifcant. Another area is the
15 million households in the U.S. that use groundwater
wells for their household water consumption rather than
a public utility. Tese households pump water every day,
and little intelligence into their pumping habits and asso-
ciated efects on the water table are available. Residential
grinder pumps also represent a signifcant opportunity for
remote monitoring. Sewage overfow can be catastrophic to
a homeowner and having a device, such as a grinder pump,
accessible through a smart phone is as critical as being con-
nected to a home security system or thermostat.
FUTURE SYSTEMS
As all the grand visions of connected pumping systems are
considered, it is important to remember that the democrati-
zation of remote monitoring within pumps and controls has
just begun. Te frst step involves equipping existing pumps
and controls (within the appropriate market segments)
with afordable RTUs that upload the bulk of the monitor-
ing and control logic data to the cloud. Todays challenges
involve making the devices simple and robust enough for
industrial applications and creating scalable distribution
models so that the network efect ultimately produces
positive externalities.
Unlike other remote monitoring technologies that have
acquired critical mass during the last few years in other
industries, pumps and their associated engines or electrical
control panels are typically serviced by skilled technicians.
For a critical mass to be reached, this distribution limita-
tion may need to be considered. Pump systems that oper-
ate on 120 volts may become connected to the Internet at
a faster rate than systems that operate on 480 volts because
of the skill level required to comfortably work inside a 480-
volt control panel. Such constraints should be considered
as pumping system monitoring and
control are transitioned to the cloud.
SCADA has been benefcial for
many verticals within the pump and
controls industry for more than 50
years. Several end users within these
verticals, such as agricultural irrigators,
have been underserved because of the
costs and complexity of the systems
and the segments less critical functional
requirements. Evidence suggests that
the IoT is democratizing remote moni-
toring across other market segments
and can potentially link disparate sys-
tems with greater ease, ideally produc-
ing long-term economic value. P&S
Edward DeSalle is the CEO
and founder of Net Irrigate, a
manufacturer of wireless irri-
gation monitoring technology
for the agriculture indus-
try. DeSalle is an alumnus
of the Kelley School of Business at Indiana
University where he received his MBA with a
focus in new product marketing and manage-
ment. He may be reached at
edesalle@netirrigate.com or
800-961-9549, ext. 55.
ness at Indiana
TRADE SHOW COVERAGE
T
he American Water Works Association (AWWA) Annual
Conference & Exposition is an annual event for water
industry professionals. Tousands of water professionals
attend to network and learn about upcoming regulatory
updates and stay current with water sector trends. It features
more than 900 expert speakers, pre-conference workshops,
professional sessions divided into 18 tracks, opportunities
to earn continuing education credits or professional
development hours, and more than 500 exhibitors.
Public of cials have opportunities for specialized train-
ing and networking, including three courses on water and
sewer issues and a breakfast event. Tose attending all three
courses earn the AWWA Public Of cials Certifcate.
For those looking to explore solutions, discuss problems
and share experiences in an interactive setting, AWWA
exhibitors and sponsors will lead Roundtable Solution
Sessions. Participants will hear from industry experts and
have the opportunity to network with professionals facing
similar issues.
For more information or to register, please visit www.
awwa.org. P&S
AWWA-ACE
American Water Works Association Annual Conference & Exposition
June 8 12, 2014
Boston Convention & Exhibition Center
Boston, Mass.
Exhibition Hours
Sunday, June 8 3 p.m. 6 p.m.
Monday, June 9 10 a.m. 5 p.m.
Tuesday, June 10 10 a.m. 5 p.m.
Wednesday, June 11 9 a.m. Noon
4
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address and support utility needs. Check out these vital sessions:
TUE19 Water Main Rehabilitation:
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WED34 Tunnels, Pipes and
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WED35 Unique Approaches to
Design and Construction
of Water Infrastructure
For a full agenda, visit www.awwa.org/ace14
Register Today!
Boston, Massachusetts
June 812, 2014
I
FAT is a trade show for water, sewage, waste and raw
materials management with a focus on environmental
technology. In 2012, 125,000 visitors attended the event,
with about 75,000 from Germany and 50,000 from other
countries. Te exhibition featured 2,939 companies from
54 countries. Tis years exhibitors include companies that
provide solutions in water extraction, water and sewage
treatment, water distribution and sewers, refuse disposal,
and recycling and other areas.
Tis years event will include company presentations,
panel discussions, country special technical discussions
and special events. Sessions are held in German, English
or simultaneous translation in both languages. IFAT also
ofers 45 live demonstrations of technology and techniques
along with several professional competitions. At the IFAT
Gala Night on Sunday, May 4, the winners of the GreenTec
Awards will be announced. Te award is an environmental
and business accolade with the winner chosen by a jury.
More than 200 projects were entered for consideration.
For more information or to register, please visit www.
ifatde/en/home. P&S
IFAT
May 5 9, 2014
Messe Mnchen
Mnchen, Germany
Exhibition Hours
Monday, May 5 9 a.m. 6 p.m.
Tuesday, May 6 9 a.m. 6 p.m.
Wednesday, May 7 9 a.m. 6 p.m.
Thursday, May 8 9 a.m. 6 p.m.
Friday, May 9 9 a.m. 4 p.m.
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BUSINESS OF THE BUSINESS
T
he U.S. infrastructure for the transmission, treating,
storing and distribution of water requires drastic changes
because of its increasing inability to sustain the new demands
for potable water and water recycling. Te majority of
water treatment plants in the U.S. are sufering from old
infrastructure technology, limited processing capacity and
unpredictable weather. Te overwhelming pressures on
current water systems are forcing municipalities to acquire
new technologies despite the funding shortages. Although
the demand for infrastructure systems is undeniable, the
lack of appropriate funding could undermine the ability of
municipal governments to select the most technologically
advanced alternatives.
Many U.S. water facilities have exceeded or
are exceeding their lifetimes. Because of a lack
of funding, resources are constrained, which
impedes the installation of the most appropriate
technology. However, the absence of any invest-
ment will impose an $11 billion annual shortfall
for drinking water and a $13 billion annual short-
fall in wastewater.
Additionally, $390 billion will be required
for wastewater infrastructure systems and build-
ing new facilities in the next two decades. One
program currently in place by the federal gov-
ernment is the Drinking Water State Revolving
Fund (SRF) with $2 billion allocated for drink-
ing water and $4 billion allocated for wastewater.
Municipal governments are encouraging pri-
vate investment and promoting monetary incen-
tives to raise funds for the necessary projects.
Te driving factors of this initiative include new
pressure from the federal government to improve
water quality and safety, the increasing water
supply costs because of depleted source water, a
decline in the quality of raw-water, and the need
to replace water distribution and wastewater
collection systems for the frst time. Municipal
governments are also considering the population
growth that is overloading current facilities in need of tech-
nology upgrades.
In addition, some municipalities have developed water
conservation initiatives that include setting irrigation days
and creating tax and incentive programs related to environ-
mental and residential appliance upgrades. By 2025, the U.S.
is projected to have medium-to-high water stress, which is
a measurement of the proportion of water withdrawal rate
to the total renewable resources. Tis will be a challenge
for water reuse management technologies that will play an
important role in the future as U.S. water shortages worsen.
For example, in the Midwestern U.S., aging sewers ofen
Equipment Demand Increases to Solve the
US Aging Infrastructure Problem
Manufacturers can provide solutions for aging water and wastewater systems.
By Paola Conti & Anand Gnanamoorthy, Frost & Sullivan
The future of water in the U.S. Source: Frost & Sullivan
overfow afer recurring storms. Over time, this problem will
impact the drinking water supply and ultimately the regions
public health. Similarly, dam infrastructureincluding
structural dams and non-structural runof water manage-
ment damssufers from fooding because of melting snow
from the north. Signifcant upgrades are required to pro-
tect the fresh water supply and the general ecosystem from
carried-down pollutants. Other states struggle with the
opposite problemwater scarcity. States such as Arizona,
California, Florida and Texas sufer from depleted water
supplies, which are needed continued population growth,
industrial manufacturing and agriculture. As many cities
in these states are growing rapidly, the states must develop
larger capacity to maintain the water supply demand.
THE ENVIRONMENTAL & FINANCIAL REQUIREMENTS
According to the Environmental Protection Agencys Clear
Water Needs Analysis (2004), the wastewater treatment
systems in the U.S. require $69.1 billion in investment or
34.1 percent of the required total investment. Water collec-
tion and conveyance requires $65.3 billion or 32.2 percent.
Combined sewer and overfow correction will need $54.8
billion or 27.1 percent. Stormwater management programs
require $9 billion or 4.4 percent, and recycled water distri-
bution is $4.3 billion or 2.1 percent.
Te states with the largest capital costs for infrastruc-
turesuch as replacement, upgrade, expansion and main-
tenanceare New York, Illinois, California and Ohio.
Te states with the largest need for municipal programs
for the compliance requirements of the National Pollutant
Discharge Elimination System and Clean Water Act initia-
tives are Texas, Florida and Arizona. California and Florida
have the largest need to implement irrigation systems.
As a result, municipal governments want to adopt emerg-
ing technologies that meet strict environmental requirements,
have retroft capabilities and occupy signifcantly less square
footage than traditional systems. When evaluating new water
infrastructure technology, the main challenge for municipali-
ties is the cost versus the efectiveness of a new technology or
process. First and foremost, the systems must prove to be eco-
nomical on a life-cycle basis or at least more economical than
conventional water processing systems. Second, the systems
price needs to align with the allocated funding, and last, the
infrastructure system supply must match the demand for the
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BUSINESS OF THE BUSINESS
application. Simply put, new infrastructure systems must pro-
vide innovative technological solutions at an economical price.
PUMPS ROLE
Pumps are critical in the water and wastewater industry. As
a result, market growth is expected. Te trends driving the
growth in fresh water use and the infrastructure industry
will provide an important market opportunity for pumps
and pump systems through the mid- to long-term. In the
case of pump manufacturers supplying the wastewater
industry, a positive correlation exists between the demand
for wastewater treatment and the demand for industrial
pumps. As opportunities open for municipal governments
to replace aging treatment plants, pump manufacturers
will be able to boost sales revenue because the demand for
pumps will be integrated into new wastewater treatment
systems. Nevertheless, pump manufacturers will be chal-
lenged to produce energy-ef cient pumps at an afordable
price. Clients in the municipal water and wastewater treat-
ment industries will focus on reducing energy and life-cycle
costs, which will provide new opportunities for pump man-
ufacturers to meet those market expectations.
EQUIPMENT DEMAND
Te future of the U.S. water infrastructure challenges each
state to provide clean water to its citizens in an economi-
cally and environmentally safe way. Te course that the
U.S. takes to tackle its aging infrastructure will remain an
important issue in the growth and prosperity of the nation.
Governments at all levels must develop innovative solu-
tions to upgrade their old and existing facilities by seeking
funding from private and public entities. As a result, the
water and wastewater industry is expected to progressively
develop a more favorable climate for equipment manufac-
turers to showcase their equipment and provide the best
alternatives to improve a troubled water and wastewater
infrastructure. P&S
Paola Conti is an industrial automation & process control
research analyst for Frost & Sullivan.
Anand Gnanamoorthy is industry
manager for Frost & Sullivan.
The authors may be reached at
liz.clark@frost.com.
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87th Annual Water Environment Federation Technical Exhibition and Conference
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Conference: September 27 October 1, 2014 | Exhibition: September 29 October 1, 2014
EFFICIENCY MATTERS
E
nergy is the driving force behind global manufacturing
today, and demand has increased exponentially with
each generation. Te global modern economy depends on
its accessibility and, even more so, on its afordability.
Tis energy demand has generated an important discus-
sion in the pump industry, and it begins with the increased
cost of energy during the last decade. Te Bureau of Labor
Statistics reported that the average consumer pays 47 per-
cent more for electricity than they did 10 years ago. While
many producers and consumers are aware of this fact, many
accept it as part of the cost of doing business. Te desire to
decrease the end users cost of doing business motivated a
diaphragm pump manufacturers team to develop a new line
of pumps to meet this energy problem head-on.
Energy comes in many formsliquid fuel, hydraulic,
electrical and pneumatic. Tis article focuses on compressed
air, which powers air-operated double diaphragm pumps
(AODDP). AODDPs are used in many applications but
are most commonly used in the transfer of fuid from one
location to another. A basic assumption is a standard price
for electricity of $0.07 per kilo-
watt hour (kWh). Another
assumption is that a 1-horse-
power (hp) air compressor
yields, on average, 4 standard
cubic feet per minute (SCFM)
of compressed air.
READING AN AODDP
CURVE & DETERMINING
OPERATING COST
To progress further into a dis-
cussion on the operating costs
associated with compressed air
usage in AODDPs, the proper
way to read an AODDP pump
curve must be understood. For
a given operating condition, a pump curve conveys two
important pieces of information:
Te fow rate in gallons per minute (gpm)
What the air consumption rate will be in SCFM
Figure 1 depicts a standard 2-inch AODDP curve, based
on the pump manufacturers design, before making signif-
cant improvements in its overall air consumption. Most
AODDP manufacturers pump curves look comparable. In
a pump curve, the horizontal axis denotes fow rate, and the
vertical axis denotes pressure.
Identifcation of operating conditions (the pumps input
pressure and liquid discharge pressure) is a key step in read-
ing a pump curve. Assume a standard AODDP experiences
a maximum of 20 psi liquid discharge pressure during a
basic transfer application and is operated by approximately
80 psig of air input pressure.
To read the pump curve in Figure 2, begin at the right
of the vertical axis. Trace the curved blue 80 psig air inlet
line until it intersects with the 20 psig horizontal line. Te
With Minimized Compressed Air Usage,
AODDPs Provide an Energy-Effcient Solution
A redesigned air-operated double diaphragm pump allows end users to reduce
their energy costs.
By Paul McGarry, All-Flo Pump Co.
Figure 1. An illustration of a performance curve for a typical 2-inch AODDP
operating point of the pump is at this intersection125
gpm at a rate of 118 SCFM. Using this information, a cost
for operating the pump during a standard 8-hour day can be
determined using the previously agreed upon standard air
compressor yield and cost of electricity.
118 SCFM x 1 hp/4 SCFM = 29. 5 hp
29.5 hp x 0.746 kW/hp = 22 kW
22 kW x $0.07/kWh = $1.54 per hour
Based on these calcu-
lations and the assumed
operating conditions, the
pump costs $1.54 per hour
of operation; $12.32 per
day; $61.60 per fve-day
work week; and $3,203 per
year. Tis average operat-
ing cost can easily be more
than the initial purchase
price of the AODDP. An
installation rarely has only
one AODDPmany instal-
lations can have up to 100
pumps. At $3,203 each in
annual operating costs, the
Figure 2. A pump curve reading at 80 psi at the air inlet and 20 psi of liquid discharge pressure
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EFFICIENCY MATTERS
pumps impact on the cost of
doing business is signifcant.
A MORE EFFICIENT
SOLUTION
Recognizing the impact of the
rising cost of energy on the
cost of operating a standard
AODDP, the pump manu-
facturer developed a line of
pumps that would signif-
cantly reduce the end users
cost of operation. Tis pump
improves overall performance
(with increased suction lif
and fow rate) and uses less
than half the compressed air
of previous models.
Multiple modifcations were made to its original design,
including:
Considerable reduction and optimization of dead
space on the liquid and air side of the diaphragms
An adjustment to the shif point of the main air valve
to allow for a longer operating period during a more
ef cient point in the air valves cycle
Starting with a popular 26-year-old design, the AODDP
manufacturer modifed the shif point
of its air valve, which resulted in a sub-
stantial improvement in overall energy
consumption. On the earlier design,
the pump was signifcantly less ef -
cient near the end of the diaphragm
stroke than it was at the beginning.
Near the end of the stroke, the pump
continued to consume large amounts
of air but displaced progressively less
fuid. By shifing the pump earlier in
the cycle, the pump displaced slightly
less fuid but used substantially less air.
Tis yielded a dramatic improvement
in overall air ef ciency.
Te shape of the diaphragm and the
outer chamber were also optimized to
reduce what is known as dead space.
A pump has zero liquid dead space if
the diaphragm, when fully extended,
conforms 100-percent to the shape of
the liquid chamber.
Te optimized dead space on the
liquid side of the diaphragm resulted
in higher suction lif and higher
Figure 3. Improved efciency curve
displacement per stroke and yielded improved suction lif
and a higher fow rate, respectively. Suction lif on the new
design was increased from 13 feet-water to 24 feet-water,
and the fow rate was improved from 155 gpm to 190 gpm.
Optimizing dead space on the air side of the diaphragm
resulted in the diaphragm moving earlier in the overall
cycle, which improved ef ciency. As
an analogy, think of a balloon con-
nected to a large box and a balloon
connected to a smaller box. Te bal-
loon connected to the smaller box
will infate sooner once air is applied.
In the case of an AODDP, of course,
the box cannot be smaller than the
shape of the diaphragm. Some limits
in the overall design exist. However,
optimizing this space contributed to
the ef ciency improvements, though
not as much as modifying the valve-
shif point.
THE IMPROVED PUMP CURVE
Te redesign resulted in a pump with
dramatically improved energy charac-
teristics (see Figure 3). In Figure 3, the
new design is compared to the average
AODDP from Figure 2.
Starting at the same point (the
intersection of the 80 psi inlet and
20 psi discharge), the curve shows
the operating point of the rede-
signed pump125 gpm at a cost of
65 SCFM. Te cost of operating the
2-inch redesigned pump during a
standard 8-hour day can be:
65 SCFM x 1 hp/4 SCFM
= 16.25 hp
16.25 hp x 0.746 kW/hp
= 12.12 kW
12.12 kW x $0.07/kWh
= $0.85 per hour
Te redesigned pump costs its
owner $0.85 per hour of operation;
$6.78 per day; $3.94 per fve-day work
week; and $1,765 per year. When
compared to the earlier calculations seen in Figure 2, $3,203
annually, the potential exists for dramatically improving the
cost of doing business for the end user, especially an end
user who operates up to 100 pumps. In this hypothetical
scenario, the end user would save about $140,000 annually.
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EFFICIENCY MATTERS
REDESIGN BENEFITS
Te energy cost of several AODDPs will be analyzed from
a diferent perspec-
tive. Instead of decid-
ing to operate the
pump at a certain air
pressure, consider an
application in which
the pump must trans-
fer 8,000 gallons of
liquid every hour, 8
hours per day for an
entire year. In this
application, a basic
transfer application
with a liquid dis-
charge pressure of 20
psi will be assumed.
In this example,
8,000 gallons per
hour is equivalent to
a fow rate of 133 gpm (8,000 gallons/hour/60 minutes).
Te pump operates at 133 gpm against a discharge pressure
of 20 psi.
Te air consumption required to operate this specifc
pump can be determined using Figure 4. Find 133 gpm on
the horizontal axis and move up until it intersects the 20
psi line. Te resulting point is the required operating condi-
tion to meet the 133 gpm requirement. From this point, the
required air operating pressure in psi and the required air
consumption in SCFM can be estimated.
Te point is midway between the two blue lines represent-
ing 80 psi and 100 psi, so the required operating pressure is
estimated to be 90 psi. Similarly, the point also lies midway
between the two red lines, 60 SCFM and 80 SCFM, so the
required air consumption is estimated to be 70 SCFM.
Terefore, the operating cost can be estimated as follows:
70 SCFM x 1 hp/4 SCFM = 17.5 hp
17.5 hp x 0.746 kW/hp = 13.06 kW
13.06 kW x $0.07/kWh = $0.91 per hour
In this example, 8,000 gal-
lons per hour can be trans-
ferred at a cost of $0.91 per
hour. Te total annual cost is
approximately $1,900.
To understand how these
numbers can vary dramati-
cally from one AODDP to
another, Table 1 details the
variations between the pump
manufacturers redesigned
pump, the original pump and
several other AODDPs.
As shown in Table 1, both
the operating pressure and
required SCFM can vary
greatly across these pumps.
AODDP users no longer have
to accept that the high cost
of energy is part of the cost
of doing business, opting to
either raise prices or accept a
lower proft. P&S
Paul McGarry is sales manager for
All-Flo Pump Co. He may be reached at
pmcgarry@all-fo.com.
Figure 4. Operation at 133 gpm with a liquid discharge pressure of 20 psi.
Redesigned
pumps
Original pump
model
Brand A Brand B Brand C Brand D
Required air pressure (psi) 90 82 81 100 120 97
Required SCFM 70 122 108 135 125 175
$ Per hour $0.91 $1.59 $1.41 $1.76 $1.63 $2.28
$ Per 8-hour day $7.31 $12.74 $11.28 $14.10 $13.06 $18.28
$ Per fve-day week
(8-hours per day)
$36.55 $63.71 $56.40 $70.50 $65.28 $91.39
$ Per year (52 weeks) $1,901 $3,313 $2,933 $3,666 $3,394 $4,752
Table 1. The operating requirements of the redesigned AODDP and other pumps
An energy-efcient, 2-inch AODDP
MAINTENANCE MINDERS
Prior to this advancement, the entire pump was removed
for repair and/or seal replacement. Ofen, a full eight-hour
day was required to remove the pump, repair it and place
it back in service. Approximately 25 percent of progressive
cavity pump repairs are mechanical seal repairs. Terefore,
these advancements signifcantly improve the pumps usage
rate and uptime.
Progressive cavity pump users would further improve
their operational ef ciency by selecting pumps that have
greater hydraulic ef ciency, which allows for slower opera-
tion and an overall smaller pump footprint.
NEW SPIRAL TECHNOLOGY
In general, two types of stators can be used in progres-
sive cavity pumpsa standard, round stator and a spiral-
designed stator (see Image 1). Standard, round stators have
A progressive cavity pump with even-wall spiral stator technology and
a 2/3-elliptical stator and rotor
Pump selection is one situation in which the more expensive option
may be a better investment. With time, that decision may be the most
benefcial and cost-effective for end users.
UNMATCHAB L E E XP E RI E NCE
I N F L OW CONTROL
TRANS ACTI ONS
MEMBER FINRA, SIPC
Jordan, Knauff & Company is a knowledgeable and
experienced provider of a comprehensive line of
investment banking services to the pump, valve and
ltratlon lnoustrles (Flow Control).
Our lines of business include: selling companies,
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contact any member of our Flow Control
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312.254.5907
MAINTENANCE MINDERS
P
rogressive cavity and peristaltic pumps are used in
many industries. Part One of this two-part series
discusses progressive cavity pump selection, mechanical
seal maintenance, how spiral stator technology can improve
the performance of these pumps and how the increase in
hydraulic ef ciency means less maintenance and a longer
service life. Part Two will cover why peristaltic pumps are
a good choice in many industries for ease of maintenance
and long life.
Progressive cavity pumps are used in several processes
within the paper industrysuch as pumping calcium car-
bonate, clays, titanium dioxide, and many chemicals. Tey
also appeal to other industriesincluding oil and gas,
mining and chemical. Tey are cost-efective, generate sig-
nifcant pressure and produce high fow rates.
PROGRESSIVE CAVITY PUMP SELECTION
Sizing and selection of progressive cavity pumps can be dif-
fcult for end users. A smaller pump costs less but will need
to operate at a higher speed, which increases the wear rate.
Te mean time between failure will increase with the selec-
tion of the smaller pump.
Tese pumps require regular maintenance. Te seven-
year operating maintenance costs make the initial pump
investment cost seem small. If end users choose the smaller
pump and the high-speed option, they will likely increase
their consumption of spare parts by as much as 50 percent.
Terefore, during the seven-year operating span of a typical
pump, the maintenance costs could be double the costs of
selecting the properly-sized pump.
End users are conscious of capital investment costs, but
the desire to get the order completed and a manufactur-
ers desire to optimize capital investments are, at times, in
confict with selecting the longest-lasting pump with the
least maintenance costs. Pump selection is one situation in
which the more expensive option may be a better invest-
ment. With time, that decision may be the most benefcial
and cost-efective for end users.
SIMPLE MECHANICAL SEALS REPLACEMENT
End users of progressive cavity pumps should consider
mechanical seal maintenance. Many pump users have plant
requirements to reduce inventory and promote standardiza-
tion, and most progressive cavity pump manufacturers can
incorporate many manufacturers mechanical seals. Using
a specifc brand is typically not a problem for progressive
cavity pump manufacturers.
Advancements in mechanical seals for progressive cavity
pumps have been made, and a few manufacturers designs
allow for mechanical seal maintenance without disassem-
bling the frame and motor or the rotor and stator. Tese
designs allow the mechanical seals to be removed and
replaced in 30 to 60 minutes. With this capability, the
pump stays in line, providing for a quick restart.
Guidelines for Progressive Cavity &
Peristaltic Pump Maintenance
Because these pumps require regular attention, end users should carefully consider
the design options.
First of Two Parts
By Todd Loudin, FLOWROX
Image 1. The spiral stator (left) allows for higher pressure per
stage, and the 2/3-elliptical lobe and rotor generate a higher
ow rate than the standard, round stator (right).
MAINTENANCE MINDERS
been used for 80 years. Spiral designs are a recent devel-
opment, and only a fraction of progressive cavity pump
manufacturers ofer this option.
Spiral technology ofen ofers higher ef ciency and
higher pressure and fow capabilities. Tis technologys
stator has a much thinner rubber lining. A standard
round stator has a much thicker layer of rubber inside.
Te lining of the spiral stator pump is even all around
the stator. Standard stator pumps require much lower
tolerances than spiral stator pumpsalso called even-
wall progressive cavity pumps. Lower tolerances result
in less ef ciency and more wear in round stator designs.
Traditional, round stators also sufer extreme wear
during startup. For instance, highly abrasive materials
will slip or leak backward because of the cold rubber,
which has not heated or expanded. Tis expansion of
the thicker rubber in the stator is required to tighten the
tolerances to allow more ef cient pumping. During this
time, the pump will sufer more wear or damage. With
even-wall technology, these extreme tolerances are not
required. Te even-wall technology is more ef cient at
startup and during normal operation.
Spiral Stator Technology Compared to Conventional
Round Stator
Te spiral stator progressive cavity pumps even-wall
technology allows for a more rigid and tighter pump-
ing unit. With the enhanced compression of rotor and
stator friction, back slip and wear are minimized so that
the pump can be used with the same rotor in higher
temperatures. When compared with the conventional
stator design, the even-wall pump experiences less inter-
ference between the rotor and the stator, which results
in a lower starting torque and higher ef ciency.
Improved Hydraulic Performance
When comparing the hydraulic performance of an even-
wall progressive cavity pump to a conventional progres-
sive cavity pump, the even-wall technology results in
higher pressure, lower backfow and higher ef ciency.
Figure 1 compares the relative fow (cubic meters per
hour) versus the counter pressure (bar).
Te relative fow rate drops as the pumps counter
pressures increase. Tis trend refects how the pumps
hydraulic ef ciency decreases because of the coun-
ter pressure increase. When comparing the hydrau-
lic ef ciencies of both pumps at 6 bar (88 psig), the
Figure 1. Relative ow (m
3
/hr) versus counter pressure (bar)
Figure 2. Efciency (percent) versus counter pressure (bar)
conventional pump results in an ef ciency of 81.6 percent
while the spiral stator progressive cavity pump has an ef -
ciency of 93.6 percent. Te results at a counter pressure of
10 bar (150 psig) are similar, resulting in a higher pressure
with lower backfow for the spiral stator technology.
Figure 2 shows the total ef ciency diference measured
from pump power demand. Te conventional pumps maxi-
mum ef ciency is 54 percent, while the even-wall progres-
sive cavity pump has a signifcantly higher maximum ef -
ciency of 63 percent.
Higher hydraulic ef ciency reduces the energy con-
sumed, and it facilitates a longer pump service life. Backfow
can cause a high degree of wear. Te even-wall progressive
cavity pump will have a longer service life because of the
minimized backfow between the rotor and stator.
All the features discussed in this section improve pump
performance but also increase pump costs. Depending
on an applications parameters and conditions, end users
must select the features that are required for their process.
Progressive cavity pumps ofer many advantages. Some are
high fow delivery in a small package, the ability to handle
signifcant slurries and relatively low cost.
Part Two of this series will discuss peristaltic pumps and
how they can be a good choice for handling solids in many
industries. P&S
Todd Loudin is president and CEO of FLOWROX, Incorporated.
He may be reached at 410-935-1723 or
todd.loudin@fowrox.com.
Progressive cavity pump users would further improve their operational
effciency by selecting pumps that have greater hydraulic effciency,
which allows for slower operation and an overall smaller pump footprint.
circle 144 on card or go to psfreeinfo.com circle 143 on card or go to psfreeinfo.com
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MOTORS & DRIVES
M
edium-voltage variable frequency drives (VFDs) have a
long lifetime and play a critical role in many industrial
manufacturing facilities, making total cost of ownership
(TCO) a key factor in purchasing decisions. Medium-
voltage VFDs are typically rated between 2.3 and 13.8
kilovolts (kV) and deliver power ranging from 150 kilowatts
(kW) to 120 megawatts (MW) at motor speeds from 10 to
15,000 rpm (see Image 1).
Automation and related components with shorter lives
and less critical roles will generally have a TCO that is
closely related to the initial purchase price. However, ini-
tial purchase price is only one factor that contributes to the
TCO for medium-voltage VFDs.
In Table 1, the main TCO factors are listed. Te table
shows that price is only one of its many components, and in
many applications, price is not the most important factor,
according to a recent survey conducted by Tritech Marketing
Inc. All survey respondents use or specify medium-voltage
VFDs, including those from the following industries:
Mining
Oil and gas
Chemical/petrochemical
Water/wastewater
Pulp and paper
Engineering, procurement and construction
Te survey shows that purchasers of medium-voltage
VFDs consider several factors when selecting a particular
manufacturer and product (see Figure 1).
Tese factors are listed in order of importance as deter-
mined by adding the percentage of respondents who ranked
each factor as either critical or important:
Reliability97 percent
Customer service/support92 percent
Size of the drive88 percent
Speed of delivery88 percent
Price86 percent
Ability to withstand harsh environments85 percent
Manufacturers reputation81 percent
Range of available options74 percent
Longevity of the VFD is not listed in the survey but is
important. Te longer lifespan indirectly, but signifcantly,
contributes to lower TCO.
Determine Total Cost of Ownership When
Selecting Medium-Voltage Drives
Price, operating costs and reliability are key factors in any TCO calculation.
First of Two Parts
By Mark W. Harshman, Siemens
Image 1. Medium-voltage VFDs are complex products engineered and
built to order for specic applications.
1. Reliability
2. Downtime
3. Required maintenance
4. Customer service and support
5. Manufacturers reputation
6. Spare parts acquisition and stocking
7. Effciency
8. Price
Table 1. Medium-voltage VFD TCO components
Tis two-part series will discuss how
factors other than initial purchase
price work together to generate a TCO
for medium-voltage VFDs. Part One
focuses on calculating TCO and the
factors that have a signifcant efect on
it. Part Two will discuss the components
that make up a highly reliable medium-
voltage VFD. Although this series is
specifc to medium-voltage VFDs, many
of the concepts covered are applicable
to other assets with long lives that fulfll
critical roles in industrial manufacturing
facilities.
Figure 1. The leading factors considered by purchasers when selecting medium-voltage VFDs
For long-lived itemssuch as a medium-voltage VFD with signifcant
operating costs and a key role in a processcalculating TCO is
critical because lower-priced items often have a higher TCO than a
higher-priced alternative.
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MOTORS & DRIVES
CALCULATING TCO
Medium-voltage VFDs have long life cycles, typically mea-
sured in decades. Ofen, a drive will last for the entire life
of an application with appropriate maintenance, yet this is
ofen not considered during purchasing. Purchasing deci-
sions are ofen infuenced by the lowest initial price without
considering TCO.
Plant operations and maintenance personnel recognize
that TCO is critical for optimizing performance for this
type of asset. Tis is especially true for plant managers
because they are responsible for maintaining plant ef -
ciency with maximum performance. Operations and main-
tenance personnel should, therefore, have substantial input
about purchase decisions for large, critical capital items such
as medium-voltage VFDs.
TCO is calculated by determining the net present value
(NPV) of all the costs and savings that result from the pur-
chase, installation and operation of an asset for the duration
of its useful life. Some of the key factors in any TCO calcula-
tion are price, operating costs and reliability.
NPV normalizes all the costs and savings to the present.
Te purchase price is a present value, but any future costs
and savings must be discounted to correctly calculate their
present value, because a dollar saved 10 years from now is
worth much less than a dollar saved today.
For non-critical, short-lived assets with low operating
costs, the TCO is close to the initial purchase price. For
long-lived itemssuch as a medium-voltage VFD with sig-
nifcant operating costs and a key role in a processcalcu-
lating TCO is critical because lower-priced items ofen have
a higher TCO than a higher-priced alternative.
For example, consumers usually buy a short-lived asset
(e.g., motor oil for a car) based chiefy on price, but they
strongly consider reliability, service and operating costs
when buying a carimplicitly, if not explicitly, comparing
the TCO among prospective vehicles prior to purchase.
All industrial purchasers will consider TCO to some
degree when buying a large capital item with an expected
long service life, such as a medium-voltage VFD. Purchasers
will calculate TCO in diferent ways with varying levels of
precision, but the basic TCO concepts will hold true in all
instances.
When calculating TCO, the initial price is the easiest
variable to quantify. Terefore, it ofen gets the most atten-
tion. However, other variables can be just as important,
albeit more dif cult to estimate at purchase time because
they are projected, future values.
For example, greater reliability leads to less downtime
and lower maintenance costs, two critical factors in many
medium-voltage VFD applications that can be dif cult to
put into exact numerical terms. Terefore, most purchas-
ers only include estimated numbers for TCO factors other
than price and then discount these numbers to the present
based on an internal corporate fnan-
cial metric.
Important factors that contribute
directly and indirectly to TCO must
be considered when calculating the
TCO of competing medium-voltage
VFDs. Te advantages and disadvan-
tages of diferent classes of medium-
voltage VFDs should also be consid-
ered. Te frst factors to include are
reliability, downtime and required
maintenancethree closely related
elements that work together to have a substantial efect on
TCO.
RELIABILITY, DOWNTIME & MAINTENANCE
Not by accident, the survey reported reliability as the No.
1 factor when selecting a drive supplier. Reliability is even
more important afer all the costs of a drive failure are
considered.
For example, using a crude TCO calculation, the cost
of a medium-voltage VFD replacement might be only the
purchase cost of the replacement drive. However, this does
not include the engineering that may be required to make
a newer model ft physically or the rewiring necessary to
reconnect the newer model. It also does not include the
installation cost.
Most important, it does not include the cost of down-
time. Downtime costs are usually much greater than even
the fully burdened cost of replacing the drive. Unplanned
downtime is especially devastating and costly.
If a refnery produces 60,000 barrels per day of
refned products (gasoline, diesel or heating oil)
and one of the dozen or so main pump drives
stop operating unexpectedly, the refnery may
lose from 20 to 100 percent of its capacity for
as long as that drive is not working.
If a refnery produces 60,000 barrels per day of refned
products (gasoline, diesel or heating oil) and one of the
dozen or so main pump drives stop operating unexpectedly,
the refnery may lose from 20 to 100 percent of its capac-
ity for as long as that drive is not working. If no shelf spare
is available or if engineering must be performed to replace
the drive, getting the drives running again may take days or
weeksall while losing hundreds of thousands of dollars
per day in stalled production.
A sophisticated and more accurate TCO calculation
would include downtime costs, giving much greater weight
to drive reliability. One proprietary medium-voltage drive
has a proven track record of two-, fve- and seven-year cam-
paigns with no unscheduled shutdowns. It is also the only
VFD used in nuclear power plants.
Equipment from suppliers with a reputation for reliability
are ofen priced higher than suppliers with newer products
that have not been thoroughly tested by years or decades
of operation. Many purchasers believe that selecting a well-
known, highly reliable drive from a trusted supplier is good
insurance against unplanned downtime and, therefore, are
willing to pay a higher price upfront if reliability claims can
be proven. What creates high reliability in a medium-volt-
age VFD will be discussed in Part Two of this series in the
June 2014 issue of Pumps & Systems. P&S
Mark W. Harshman currently leads a system engineering team supporting
customer applications and developing new opportunities using medium-
voltage drives. He is a graduate of Purdue University and has worked in the
power industry for the last 25 years, managing engineering application and
R&D groups. He has published numerous papers and holds several patents.
Harshman may be reached at 724-339-9480.
A sophisticated and more accurate TCO calculation would include
downtime costs, giving much greater weight to drive reliability.
Comprehensive
Industry Coverage
Positive Displacement Pumps
Centrifugal Pumps
Specialty & Other Pumps
Industrial Valves
Pneumatic & Hydraulic Valves
Industrial Automation & Process Control
Electric Motors & Drives
Actuators
Compressors
Custom Research
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SEALING SENSE
P
art One of this series explained how the clamping force
on a bolted fange connection (BFC) can play a major
role in preventing gasket blowout. In fact, more ofen than
not, it is the single most important factor. Part Two discusses
the two most important strategies to use for applying the
correct clamping force. End users control these strategies.
One involves developing a bolt load solution that optimizes
the inherent strength of the BFC components. Te other
is following an installation procedure that ensures that the
specifed bolt load is reached and evenly distributed around
the face of the gasket.
DETERMINATION OF OPTIMUM CLAMPING LOAD
A BFC is composed of three primary components: the
gasket, fasteners (bolts/studs, nuts and washers) and fanges.
Each component has a role in developing and maintaining
the clamping force. Together, they work as a system to pro-
duce a successful seal. Te state of stress of one component
depends on and afects the state of stress of the others. A
sealing solution that only considers one or two will miss the
opportunity to maximize the clamping force and, therefore,
the gasket seals reliability. Likewise, developing a sealing
solution that does not consider the interaction and strength
of all components can cause blowout.
GASKET
Te gasket provides the properties that create the seal against
the face of the fanges. For the gasket to seal under installed
conditions, a minimum stress value is necessary. Tis value
should include the relaxation that will occur during the gas-
kets installed life. To prevent damage, it also has a maximum
stress value that should not be exceeded, its crush strength,
which can be obtained from the gasket manufacturer. When
a gaskets crush strength is exceeded, the properties that pro-
vide the seal break down. An optimized solution targets a
stress level that is as high as possible above its minimum value
but a comfortably safe margin below its maximum value and
a value that may cause a problem to the bolts or fanges.
FASTENERS
Te bolts provide the mechanical leverage that allows a high
and controlled value of force to be transmitted to the gasket.
Te force from tightening the bolts must be at least high
enough to satisfy the gaskets sealing requirements but not
so high that it creates a problem with the gasket (exceeded
crush strength) or the fange (exceeded strength limit or
cause excessive rotation).
Additionally, the bolt has its own limit that must not be
exceeded during tightening or under the internal pressure
load. Te targeted torque must not exceed this limit, and the
specifcation of the bolts must be known. Two bolts of the
same size and material can have signifcantly diferent limits.
For instance, the yield strength at ambient temperature of an
American Society for Testing and Materials A 193 Grade B8
Class 1 and Class 2 bolt is 30 ksi and 100 ksi, respectively,
for diameters inch and less. Attempting to tighten a Class
1 bolt to a Class 2 bolts level can cause damage that results
in a loss of clamping force.
As mentioned in Part One of this series, the amount of
force required to overcome any incidental loads that would
resist the torque load from compressing the gasket must be
known. Table 1 in Part One provided a list these of items.
FLANGES
Te primary function of the fanges is to transmit the force
from the bolts to the gasket and allow for separating the con-
nected pressure equipment for future maintenance. Tey
must be strong enough to accept this force without damage
and rigid enough to ensure that they do not excessively
rotate across the face of the gasket. In many ways, the fanges
are the most important component of a BFC and are ofen
not evaluated in a clamping solution.
Specifying bolt loads without understanding the implica-
tions to the fanges can result in blowout or, at the very least,
process leakage. Without considering the fanges, such prob-
lems are ofen inaccurately diagnosed as a gasket problem.
To help understand the possible efect of excessive rotation,
Prevent Gasket Blowout
Whats Most Important?
Last of Two Parts
By FSA member Randy Wacker, P.E.
Figure 1 (A, B and C) shows the bending that can occur
when the bolt load exceeds the capability of the fanges to
resist the associated rotation. See the descriptions below:
A. Flange-gasket ft-upNo gasket compression occurs.
B. Non-excessive bolt loadTe gasket defects axially,
mostly toward the outer diameter, because of fange
rotation.
C. Excessive bolt loadTe fange lifs of the inner por-
tion of the gasket creating potentially damaging load
and seal breakdown towards outer diameter of gasket.
As a fange rotates, the compressive gasket stress increases
from the inner to the outer diameter. When excessive, the
gasket stress value can become high enough to cause damage
because the bolt load is transferred across a much smaller
gasket area. Ofen, more leaks are caused from over-tight-
ening than under-tightening, especially from specifying fas-
tener loads that fail to account for a fange pairs limitations.
SEQUENCE TO DETERMINE OPTIMUM BOLT LOAD
To ensure an optimum level of clamping these steps should
be followed:
1. Identify the maximum safe level of stress that the gasket
can accept.
2. Check the bolts for suf cient strength to provide the
initial load that will compensate for anticipated gasket
relaxation and incidental loads that will reduce the
gasket stress.
3. Check the fanges for suf cient strength and rigidity to
transfer the required load to the gasket.
When the optimum load strategy is complete, the maxi-
mum permissible bolt load that will reliably seal the gasket
without damaging any of the BFC components has been
determined. Unfortunately, the reliability of this optimiza-
tion is signifcantly lessened or even eliminated unless the
identifed load is accurately transferred to the fanges. Tis is
the assurance that the second strategy provides the clamping
load, which is the development and following of a validated
tightening procedure.
TIGHTENING PROCEDURES
Engineering has determined what load should be prescribed
for the fanges. Te actualization of this work can only come
to fruition when this load is imparted to the bolts. Tis is
not an easy task. Elastic interaction between bolts during the
tightening process is a formidable obstacle to overcome to
ensure that the gasket stress reaches its targeted value and
is evenly distributed across the sealing face of the gasket.
Following a procedure that ensures that the targeted load
is reached requires skillful and trained mechanics. Other
factors also afect the process, such as improperly installed
piping that can create forces that prevent the intended bolt-
ing load from reaching the gasket.
Elastic interaction is the efect that the tightening of a bolt
has on the other bolts of a fange that have already been tight-
ened. It occurs because the frst tightening pass on a bolt will
relax as subsequent passes are made. Tis is primarily caused
by gasket relaxation and continues until a suf cient number
of tightening passes have been made. Te sequence is impor-
tant. Following a crisscross or star pattern helps more evenly
apply the clamping load to the fange and, therefore, more
evenly distribute the load to the gasket. Te importance of
ensuring that the gasket stress evenly reaches its targeted
value cannot be over emphasized. Te more closely the tight-
ening procedure is followed, the more reliable the joint will
seal. However, what procedure should be used?
Several sources provide good tightening guidance, includ-
ing bolting and gasketing handbooks and many websites.
Te American Society of Mechanical Engineers PCC-
1-2013 Standard, Guidance for Pressure Boundary Bolted
Flange Joint Assembly provides several tightening patterns
and includes guidance on how to group fasteners during the
tightening process in cases with large numbers of fasteners.
One of the best resources is the gasket manufacturers, which
will ofen have more and better experience on the best way
to seal their gaskets. Afer the fasteners have been correctly
numbered and all components are confrmed to be in good
condition and properly prepared, this procedure (abbrevi-
ated for publication) should be followed using a calibrated
torque wrench:
Figure 1. Flange rotationconceptual examples
SEALING SENSE
1. Finger tighten all the fasteners.
2. Make the frst star-pattern tightening pass at 33 percent
of the target torque.
3. Make the second star-pattern tightening pass at 66
percent of the target torque.
4. Make the third star-pattern tightening pass at 100 per-
cent of the target torque.
5. Circumferentially tighten all the bolts at the target
torque. A minimum of two passes is recommended.
Allow a wait period for the bolts to relax and the system
to adjust. Consult the gasket manufacturer for the
recommended time.
6. Circumferentially tighten fasteners at the target torque.
Tis procedure is critical to ensure that the gasket is tight-
ened evenly and to the specifed value. Te results are signif-
icantly more reliable than tightening by feel or experience.
Te benefts include blowout protection and more reliably
sealed BFC.
SUMMARY
Focus on clamping force is central in importance to guard
against gasket blowout. Part One explained the general bal-
ance of forces involved in protecting against gasket blow-
out. Tis Sealing Sense discussed strategies for identify-
ing a maximum permissible bolt load that fanges should
be exposed to and ensuring that the fanges actually real-
ize this load. Use of this guidance ofen requires increased
efort and expertise, but when it is followed, it can provide
confdence that blowout is not imminent and that a reliable
gasket seal will result. P&S
NEXT MONTH:
What are the new piping plans for improved leak
detection in single seals?
We invite your suggestions for article topics as well as questions on sealing
issues so we can better respond to the
needs of the industry. Please direct your
suggestions and questions to
sealingsensequestions@fuidsealing.com.
HI PUMP FAQs
A. Te Hydraulic Institute defnes the required net posi-
tive suction head (NPSHR) of a pump as the net positive
suction head available (NPSHA) that will cause the total
head (frst-stage head of multistage pumps) to be reduced
by 3 percent because of fow blockage from cavitation vapor
between the impeller vanes. Te NPSHR qualifed by this
criterion is referred to as NPSH3. Te full published pump
head will not, however, be achieved (by defnition) when
the NPSHA equals the NPSH3 of the pump (see Figure
9.6.1.1b). Te value of a 3-percent head drop for NPSH3 is
based on accepted industry practice for defning a condition
of head breakdown because of cavitation.
Margin above NPSH3 is necessary for the pump to
develop its full-published performance. Most pumps can
operate satisfactorily with a minimal margin above the
NPSH3 value when operating near the best-ef ciency-
point rate of fow. A greater margin may be required when
operating throughout a wider operating region. P&S
Figure 9.6.1.1b. NPSH3 determination for variable ow rate test
Q. What is NPSH3, and how does it relate to the NPSHR for a rotodynamic pump?
Q. Can reciprocating pumps be used as booster pumps?
A. A booster for a reciprocating power pump is normally
a centrifugal pump but may be a positive displacement
pump under special conditions (see Item 4 in the bulleted
list below). Improper selection and/or installation can
result in increased pulsations and attendant problems.
Some recommendations include:
1. Install a booster as close as practical to the inlet source.
2. Te booster pump must add enough pressure to
the system to provide suf cient NPSHA to the
power pump, allowing for acceleration head, friction
losses and pressure pulsations because of acoustical
resonances.
3. Install a pulsation dampener in the inlet line adjacent
to the power pump liquid cylinder. Consult dampener
and pump manufacturers for the proper location. Te
dampener can ofen be omitted between a centrifugal
booster pump and a low-speed power pump under any
of the following conditions:
Te diameters of the inlet and outlet connections
of a booster are equal to or larger than the inlet
connection of the power pump.
Te diameters of all the piping between the liquid
source and power pump are equal to or larger than
the inlet connection of the power pump.
Te booster pump is sized for the maximum
instantaneous ow rate of the power pump.
Acceleration head is calculated not only between
the booster and power pump but also between the
liquid source and the booster.
4. If the booster pump is a constant-speed, positive-
displacement pump, a self-regulating bypass valve is
required between the pumps. Te booster pump must
be suf ciently oversized to provide the minimum fow
required through the bypass valve. P&S
NPSHR & Booster Pumps
By Hydraulic Institute
Pump FAQs is produced by the Hydraulic Institute as a service to pump users,
contractors, distributors, reps and
OEMs. For more information, visit
www.pumps.org.
PRACTICE & OPERATIONS
P
rogressive cavity (PC) pumps solve many of the issues
that occur in demanding pulp and paper processing
and production. Tey are chosen for many applications,
including:
Te pulper
Te paper machine
Coating kitchen
Waste treatment and recovery
PC PUMP ADVANTAGES
PC pumps are energy ef cient and experience long life in
harsh applications. Self-priming and with a low net positive
suction head required, their positive displacement fow is
proportionate to the speed and independent of discharge
pressure. With their large capacity, PC pumps reach fow
rates up to 1,500 gallons per minute and have high-pressure
capability. With friction losses, pressures as high as 2,000
psi can be achieved.
Tough end users should never let a pump run dry, PC
pumps can achieve a vacuum of 28 inches. Regardless of
fuctuations in media viscosity, temperature or abrasive
characteristics, PC pumps provide low pulsation and
smooth, repeatable fow, providing precise metering in
real-world applications. If the pumped media is shear-sen-
sitive, these pumps are ideal solutions because of their low
internal velocities, which add little energy to the media,
minimizing the degradation of sensitive products.
Despite their gentle characteristics with sensitive fuids,
PC pumps are also non-clogging and can pass solids up to 3
inches in diameter. Tey also provide reversible fow. Other
advantages include:
Pumping of multiphase media
Quiet operation
Simplifed maintenance because no special tools
are required
Decreased downtime for maintenance
Flexible mounting arrangementssuch as vertical
mounts or mounting a twin shaf grinder directly on
the inlet
CARDAN JOINT
All PC pumps have quality manufactured rotors and sta-
tors, and optimizing these components is important.
However, just as important is how each pump handles the
eccentric motion and strong radial and torsional loads.
Initially, this was accomplished with an unsealed pin on
Progressive Cavity Pumps Provide
Optimized Operation in Multiple
Pulp & Paper Processes
The addition of a cardan joint helps resolve wear and failure and delivers improved angularity
and smooth transmission of radial and axial loads.
By Nimish Sheth, UniqueFlo
A heavy duty cardan joint has a set of perpendicular pins to deliver improved angularity and smooth transmission of radial and axial loads, resulting
in maximum uptime and reduced maintenance.
each end of the connecting rod. Te
connecting rod and pin are typically
made from hardened steel or stainless
steel and combine to connect the con-
centrically rotating drive shaf to the
eccentrically rotating rotor. Te pin
is subjected to extreme concentrated
load and lubricated by the product,
which is ofen abrasive, resulting in
premature wear and failure. Te pins
and connecting rod become the sacri-
fcial lamb of the pump.
A sealed pin joint was developed
and incorporated by many manufac-
turers. Tis helped because the pin
operated in a well-lubricated bath,
but it was still subjected to extreme
concentrated loads, and this change
was not a substantial upgrade for the
tougher applications.
Some companies turned to a
crowned gear joint as a solution. Tis
improved the handling of heavy loads
but still had disadvantages. Te gear
joint was protected by a fairly thin
rubber boot. When the rubber was
damaged or wore, the joint failed cat-
astrophically and without warning.
Tis ofen proved to be a dif cult and
expensive rebuild.
One of the better options currently
available is the use of a long, fexible
shaf as the connecting rod. Tis shaf
and connecting rod have no moving
parts and, therefore, no parts to fail.
Te primary issue for a PC pump with
this option is the real estate required
that makes retroft nearly impossible
and new installations costly.
What option is available to solve
these shortcomings of PC pumps?
With their large capacity, PC pumps reach fow rates up to 1,500
gallons per minute and have high-pressure capability. With friction
losses, pressures as high as 2,000 psi can be achieved.
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A PC pump that has a true cardan joint, which uses two
sets of sealed perpendicular or diametrically opposing pins,
provides many advantages. Most notably, it provides the
freedom of angular movement, which facilitates
much smoother transmission of angular
and axial loads. Tis PC pump tech-
nology eliminates premature fail-
ures because of concentrated
loads, which can occur with
a pin joint pump or cata-
strophic failures because of
failed joint seals as in a gear
joint pump, with a much
smaller footprint than fex-
ible shaf pumps. In most
applications, a seal failure
of a cardan joint pump will
have little or no efect on the
pumps ability to operate.
OPERATION IN PAPER
MILL PROCESSES
Understanding the inherent features of
a PC pump will help end users understand why
a PC pump with a cardan joint is good choice for many
applications in the pulp and paper industry. Where is this
equipment providing real-world solutions in paper mills?
Stock & Starch Preparation
PC pumps can be automated and controlled by a program-
mable logic controller to pump diluted paper pulp stock at
precise variable fow rates to ensure the continuous feeding
of the paper machine with optimum ef ciency.
Cationic or anionic starch is cooked, metered and con-
tinuously fed. Te transfer to the head box or size press
requires a solution that can perform at both high and ambi-
ent temperatures. Properly applied PC pumps can handle
fuids with temperatures from just above freezing to 425 F.
Wet End Chemical Preparation
PC pumps can precisely meter product and process addi-
tivessuch as pulping and bleaching chemicals, fllers, cat-
ionic starch, sizing agents, dyes, fxing agents, defoamers,
and retention aidsto the paper stock. Tis fow remains
consistent despite system or temperature fuctuations.
Coating/Color Kitchen
With PC pumps, pigment slurries, latexes, starch, binders
(polyvinyl alcohol, carboxymethyl cellulose), biocides and
other additives can be successfully metered from storage
tanks and containers for dispersion, mixing and cooking.
Tey are equally efective in batch or continu-
ous process operation. PC pumps are key
to the preparation of the coating/color
before the fnal station. Tey can
easily handle these abrasive fuids
while delivering high dosing
accuracy with smooth, pulsa-
tion-free fow.
Precipitated & Ground
Calcium Carbonate
Mineral pigment dispersing
and mixing units rely heav-
ily on PC pumps. Preparing
pigment slurries from cal-
cium carbonate or clay requires
heavy-duty pumps capable of
withstanding these highly abrasive
fuids while delivering unmatched
metering and repeatability.
De-Inking
Improving the handling of chemicals, soaps and coagu-
lants, PC pumps have been problem solvers in de-inking
operations. Since PC pumps do not require check valves,
which are prone to failing and sticking, these quiet pumps
provide years of hands-free operation. Tis is important
for maintenance staf safety, considering the dangerous
and corrosive nature of many of the liquids being moved
throughout a paper mill.
Wastewater
In many situations, this part of paper production is a drain
on the mills operating budget. Te treatment of liquid and
dewatered sludge, focculants and ef uents in this area are
necessary but do not usually add to the mills profts. Tis
makes PC pumpswith their limited wearing parts, small
footprint and quick maintenance turnarounda great
budget-conscious choice for this area of the mill. P&S
Nimish Sheth is the president of Uniquefo LLC. He has
served as head of global supply chain management for 15
years. For more information, email sales@uniquefo.com or
visit www.uniquefo.com.
Cardan joint
C
hemical manufacturing includes complex processes. In
fact, chemical manufacturing processes are so intricate
that, typically, several unit operations exist within an
overall process. Tese may include cracking, distillation
and evaporation, gas absorption, and scrubbing and
solvent extraction. Within these operations, transferring
is the process of transporting fuid from one point to
anotherstands out because it is important to the whole
manufacturing process. Fluid transfer is a jack-of-all-trades
with responsibilities along the whole chain. Some examples
are moving raw materials into storage tanks, raw materials
into blending or mixing tanks, fnal formulations into
holding tanks and fnished products into intermediate bulk
containers for delivery or two-gallon jugs for store shelves.
Because of transferrings importance, facility operators
should identify the best pumping technology for the
jobone that is versatile, reliable and ef cient. For
many years, centrifugal pumps were the go-to technol-
ogy. However, positive displacement (PD) pumps
specifcally sliding vane and eccentric disc pumpscan
be the right pump technology for many chemical trans-
fer operations.
THE CHALLENGE
In a basic explanation, the volume of fuid sent from
Source Tank A will increase in Destination Tank B (see
Figure 1). As this operation occurs, the only variable
in the hydraulic system is the static head, which will
change as the level in Tank A decreases and the level in
Tank B increases.
In many cases, when the tanks are large enough, the
static head variation is assumed to be insignifcant, and
a centrifugal pump is sized for a specifc performance
point. In reality, a centrifugal pump operates in a range
in the curve of its hydraulic performance. Te size of
this range is specifc to each application and should be
evaluated.
In Figure 1, the performance of an equivalent PD
pump is the yellow line (QM), which represents what a
PD pump must do to deliver the same volume in the same
time as the centrifugal pump that is operating in a specifc
range. Also, PD pumps, particularly those with self-adjust-
ing volumetric ef ciency capabilities, such as eccentric disc
or sliding vane pumps, will consistently deliver the same fow
rate across all pressure variations, regardless of the pumping
systems static head. As the discharge pressure changes, PD
pumps provide a consistent fow rate.
A centrifugal pumps operating range becomes more criti-
cal when the fuid must be transferred from one source tank
to several points or tanks within the plant. In this case, the
operating range will be wider, and the delivery parameters
will be diferent from tank to tank. Chemical manufactur-
ers have traditionally chosen centrifugal pumps for transfer
applications for the following reasons:
Some Chemical Applications Require the
Range of a Positive Displacement Pump
Many positive displacement pumps deliver the same fow rate regardless of the static head.
By Edison Brito, Pump Solutions Group
Figure 1. Typical transferring process
Tey are commonly the frst choice for moving water-
like fuids. PD pumps are usually considered when the
fuid is viscous.
Tey are a well-known technology and familiar to most
operators.
Tey are believed to have a lower initial cost than PD
pumps. However, this is not necessarily the case.
In reality, PD pumps can quantifably counteract these
advantages. PD pumps are appropriate for fuids with high
viscosity, but they can easily move other fuids, from lique-
fed gases and water-like liquids (sliding vane pumps) to
medium and very viscous fuids (eccentric disc and sliding
vane pumps). PD technologies have operated successfully
in the chemical manufacturing industry for more than a
century, and their initial costs can be similar when all the
equipment, accessories and controllers are evaluated. In
many cases, the total cost of ownership is lower over a PD
pumps operational lifespan.
Centrifugal pumps work best when they operate at their
best ef ciency point (BEP). Unfortunately, the BEP is rarely
realized for an extended period during fuid transfer opera-
tions, resulting in fow rates that can fuctuate constantly.
Many facility operators are willing to accept fuctuations in
fow rate. However, consistent of-BEP operation can lead
to potential problems in the equipments operation, the
production process and how the chemical is formulated.
Note that the system, not the pump, dictates the operating
conditions in which the pump must work.
During the chemical process, the amount of fuid sent
must adhere to specifc guidelines and quantities that are
sometimes only known by the chemical manufacturer. In
these instances, a centrifugal pump will not provide con-
stant fow unless it is controlled with proportional-integral-
derivative loops, fow meters, recirculation lines and variable
speed drives. Tese components complicate the pumping
system and introduce electric and electronic components
that may be required to
operate in hazardous areas
and require special ratings.
By comparison, the fuid
delivery rate of a PD pump
that features self-adjusted
ef ciency will be more
consistent than a cen-
trifugal pump. In chemi-
cal manufacturing, these
PD pumps also provide a
more reliable production
rates in terms of chemical quality. Contrary to self-adjusted
volumetric ef ciency technologies, centrifugal pumps lose
ef ciency as their components (wear rings, internal casing
tongue or the impeller casing clearance) wear. Also, when
a centrifugal pump operates to the lef of its BEP, radial
loads increase because the pump generates pressure along
its volute by reducing the fuid velocity. Tis type opera-
tion will increase shaf defection at the seal faces, increasing
seal wear and adversely afecting the pumps life expectancy.
Working to the lef of the curve will also increase axial loads
that can potentially overload the thrust bearings, especially
in open-impeller and difuser-type, multistage centrifu-
gal pumps. Finally, as a centrifugal pump operates close to
the zero-fow point (zero ef ciency), the temperature may
increase to levels that can be harmful to heat-sensitive
chemicals or products, negatively afecting safety.
When a centrifugal pump operates to the right of its per-
formance curve, other problems can develop. Specifcally,
the net positive suction head (NPSH) required increases,
which may cause cavitation. Because the fuid transfer pro-
cess in the chemical industry is managed in batches, insuf -
cient NPSH may be more complicated to detect. However,
it will deteriorate the pumps operational capabilities con-
tinuously, meaning that the pumps ability to handle cavita-
tion will be compromised.
Other potential performance-robbing concerns for cen-
trifugal pumps in chemical-transfer applications include:
Mechanical issuesCaused by vibration, which may
reduce mechanical seal life, during of-BEP operation
OverheatingCaused by low-fow operation
Product leakage along the pump shafBecause of
shaf defection (overhung impellers)
Dry runningCan cause pump problems but may
result in a catastrophic failure for a magnetically driven
pump because the pumped media lubricates it
Inability to strip lines
Inability to self-prime
Table 1. Real-world example of the total cost of operation for a PD pump versus two centrifugal pumps
Notes:
1. Pump types compared are PD sliding vane and ANSI centrifugal.
2. Yearly operating cost is based on 3,000 hours of operation at a rate of $0.1 per kilowatt hour, or $223 per
pump horsepower.
3. These costs are based on pumping an aqueous solution with a specic gravity of 1 at 300 Saybolt seconds
universal at 126 gallons per minute (gpm) at 80 psig for the PD pump and a range of 114 gpm at 190 feet
to 130 gpm at 165 feet for the centrifugal pumps (see Figure 2).
Susceptibility to cavitationCan occur because of
entrained gases
Fluid-handling capabilities afectedCan be com-
promised with changes in fuid viscosity, which can
occur because of modifcations and adjustments in the
process or temperature changes
Centrifugal pumps are acceptable options in many fuid
transfer applications and have been proven to perform reli-
ably for many years. However, a more ef cient and reliable
option may be available for many fuid transfer operations
in chemical manufacturing.
THE SOLUTION
Unlike centrifugal pumps, the design of PD pumps allows
them to produce a constant fow at a given speed regardless
of discharge pressure, which is critical in chemical manufac-
turing, which require precise dosing rates. Specifcally, two
pump types are ideal for chemical fuid transfer applica-
tions: sliding vane and eccentric disc.
Sliding vane pumps feature a series of vanes in the pump
rotor that slide out as they wear, which means that the
pump delivers volumetric consistency throughout its life
or until the vanes require replacement. Sliding vane pumps
also ofer zero shaf leakage (magnetic coupling); non-gall-
ing operation, stainless steel or ductile iron construction for
corrosive liquids; chemical-duty mechanical seals; low-to-
medium shear and agitation; and self-priming and dry-run
capabilities, even in an explosive or hazardous environment.
Tis pump type features a disc inside a pump cylinder.
Te disc is driven by an eccentric bearing on the pump shaf.
Tis creates four distinct pumping chambers that increase
and decrease in volume as the disc is rotated by the eccen-
tric bearing, producing suction and discharge pressures as
the chambers move in pairs that are 180 degrees apart. Tis
operation ensures that the fuid passes through the pump
at a constant and regular fow rate and eliminates pulsa-
tion within the pumped fuid. Because the pump does not
depend on clearances to facilitate product fow, any slip or
loss in volumetric ef ciency is negligible. Additionally, with
the mechanical sealless option, products that are dif cult to
seal and prone to crystallization cannot adhere to any sur-
faces and cause damage, which eliminates a maintenance
concern.
Because of the sliding vane or eccentric disc pumps
method of operation, they ofer many benefts to fuid
transfer:
Constant fow across the required range of pressures
Low-shear operation, important when handling many
raw materials in chemical production
Dry-run capability and ability to strip discharge lines
Ability to work to some levels with compressible fuids
One drawback of rotary PD pumps is that they should
not operate against a closed valve on the discharge side
because they do not have shutof head. Tis potential
Figure 2. Combined operation
problem is overcome, however, with the placement of a
relief/safety valve on the discharge side of the pump. Table 1
illustrates a real-world example of the total cost of operation
for a PD pump versus two competitive centrifugal pumps.
While the initial cost of a PD pump could be a few hundred
dollars more than a centrifugal pump, the monetary savings
through the frst fve years can be signifcant.
Because a PD pump relies on less horsepower to operate,
its annual operating costs can be nearly 60 percent lower
than that of the centrifugal pump. Because of this, the
total cost savings that are realized when a PD pump is used
increase throughout its life cycle. Evaluation of the range
of operation of a centrifugal pump and the equivalent PD
pump is shown in Figure 2.
To compare the pumping technologies, the range of opera-
tion of the centrifugal pump and the equivalent PD pump
must be fully defned (see Figures 1 and 2 and Equation 1).
H and Q are the total dynamic head and the fow. When the
curves of the system and the pump are defned, c, M, Q repre-
sent known constants of the quadratic equations. To simplify
the mathematical analysis, the pump curve is expressed as a
second-degree curve, although depending on the nature of
the impeller, this can be another polynomial or logarithmic
equation. Because the volumes (V
A
, V
B
) and their changes
over time (H
1
, H
2
, H
A
, H
B
) are known, QM can be simply
evaluated by dividing the volume pumped by t
f
. P&S
Edison Brito is the sales & business development director for Latin America
and former global market segment director for the chemical market for Pump
Solutions Group (PSG). He may be reached at edison.brito@psgdover.com
or 973-780-7985. PSG is comprised of several pump companies, including
Abaque, Almatec, Blackmer, Ebsray, Finder, Griswold, Maag, Mouvex, Neptune,
Quattrofow and Wilden. For more information, visit www.psgdover.com.
Equation 1
Where:
S
A
and S
B
= the areas of source Tank A and destination Tank B, respectively.
Volume V
A
= Volume V
B
is the amount of fuid transferred.
H
1
, H
2
, R = the points where the curves intercept the H Axis (Q = 0, or zero fow), which are known for a given system
H
1
and H
2
= static heads geometrically defned
R = a characteristic of the pump curve
H
A
and H
B
= the fnal condition at a given variation in time of h
t
f
= the time that the PD pump operates to deliver the same amount of fuid as the centrifugal pump while operating in a range
PUMP USERS MARKETPLACE
INDEX OF ADVERTISERS
A. W. Chesterton Company . . . . . . .47 100
Advanced Engineered Pump, Inc. . .84 145
All-Flo Pump.. . . . . . . . . . . . . . . . . . . .9 115
American Water Works
Association (AWWA) . . . . . . . . . . .52 117
Badger Meter, Inc.. . . . . . . . . . . . . IBC 101
Blue-White Industries . . . . . . . . . . . IFC 102
Burns Dewatering Service, Inc. . . . .85 146
Carver Pump Company . . . . . . . . . .20 118
Check-All Valve Mfg. Co. . . . . . . . . .56 119
Continental Pump Company . . . . . .87 147
Corrosion Fluid Products Corp. . . . .87 148
Dan Bolen & Associates, LLC. . . . . .87 149
Dreisilker Electric Motors, Inc. . . . . .86 150
Electrical Apparatus Service
Association (EASA) . . . . . . . . . . . .69 120
Flowmatic Corporation. . . . . . . . . . .60 139
Flowrox Inc. . . . . . . . . . . . . . . . . . . . .45 121
FluxDrive Inc.. . . . . . . . . . . . . . . . . . .17 116
Franklin Electric Co. . . . . . . . . . . . . .11 103
Frost & Sullivan . . . . . . . . . . . . . . . . .71 140
Godwin, a Xylem brand . . . . . . . . . .21 122
GPM USA . . . . . . . . . . . . . . . . . . . . .40 134
Houston Dynamic Service, Inc. . . . .86 151
Hydraulic Institute . . . . . . . . . . . . . . .71 141
JDA Global. . . . . . . . . . . . . . . . . . . . .39 123
JDA Global. . . . . . . . . . . . . . . . . . . . .84 152
Jordan, Knauff & Company . . . . . . .64 142
Load Controls, Inc. . . . . . . . . . . . . . .18 124
Load Controls, Inc. . . . . . . . . . . . . . .85 153
LobePro. . . . . . . . . . . . . . . . . . . . . . .86 166
LUDECA, Inc.. . . . . . . . . . . . . . . . . . .53 125
LUDECA, Inc.. . . . . . . . . . . . . . . . . . .55 126
Magnatex Pumps, Inc. . . . . . . . . . . .86 154
Master Bond Inc.. . . . . . . . . . . . . . . .85 155
Meltric Corporation. . . . . . . . . . . . . .85 156
National Pump Company . . . . . . . . .46 127
Neptune Chemical
Pump Company. . . . . . . . . . . . . . .41 133
Pump Users and
Turbomachinery Symposia . . . . .79 104
Rosedale Products, Inc. . . . . . . . . . .67 143
Royal Purple, LLC. . . . . . . . . . . . . . . .1 105
Ruthman Companies . . . . . . . . . . . .51 106
Scalewatcher North America Inc. . .85 157
Scenic Precise Element Inc.. . . . . . .86 158
Schneider Electric. . . . . . . . . . . . . . . .7 107
seepex, Inc. . . . . . . . . . . . . . . . . . . . .49 128
SEPCO. . . . . . . . . . . . . . . . . . . . . . . .61 135
SERO Pump Systems. . . . . . . . . . . .87 159
Sims Pump Co. . . . . . . . . . . . . . . . . .65 108
Sims Pump Co. . . . . . . . . . . . . . . . . .87 160
Singer Valve Inc. . . . . . . . . . . . . . . . .50 137
SJE-Rhombus. . . . . . . . . . . . . . . . . .59 138
Skinner Power Systems, LLC. . . . . .38 129
St. Marys Foundry . . . . . . . . . . . . . .86 161
Summit Pump, Inc. . . . . . . . . . . . . . .85 162
Thompson Pump . . . . . . . . . . . . . . .13 130
Trachte, USA . . . . . . . . . . . . . . . . . . .84 163
Tuf-Lok International . . . . . . . . . . . . .85 164
Tuthill Transfer Systems . . . . . . . . . .77 136
United Rentals Inc. . . . . . . . . . . . . . BC 109
Vanton . . . . . . . . . . . . . . . . . . . . . . . .19 110
Vaughan. . . . . . . . . . . . . . . . . . . . . . . .5 111
Vertifo Pump Company . . . . . . . . . .67 144
Vesco. . . . . . . . . . . . . . . . . . . . . . . . .87 165
Watson-Marlow Pumps Group . . . .10 131
WEFTEC . . . . . . . . . . . . . . . . . . . . . .57 114
WEG Electric Corp. . . . . . . . . . . . . . . .3 112
Zoeller Company. . . . . . . . . . . . . . . .15 132
* The Index of Advertisers is furnished as a courtesy, and
no responsibility is assumed for incorrect information.
Advertiser Name Page RS# Advertiser Name Page RS# Advertiser Name Page RS#
800.433.7642 meltric.com
OFF
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PUMP USERS MARKETPLACE
GO WITH THE PROS!! LOBEPRO ROTARY PUMPS
912-466-0304 www.LOBEPRO.com Made in USA
To learn more or get a custom quote, email PumpSales@lobepro.com
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Serving the Pump &
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DAN BOLEN JASON SWANSON
CHRIS OSBORN DEBORAH SHAW
9741 North 90
th
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(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com
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EXECUTIVE SEARCH/RECRUITING
EMPLOYMENT
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T
he Jordan, Knauf & Company (JKC) Valve Stock
Index was up 15.0 percent during the last 12 months,
while the broader S&P 500 Index was up 19.8 percent. Te
JKC Pump Stock Index was up 33.8 percent for the same
time period.
1

Te Institute for Supply Managements Purchasing
Managers Index (PMI) increased 0.5 percentage points
over Februarys level to reach 53.7 percent in March. Te
New Orders Index increased 0.6 points to 55.1 percent.
Te Production Index registered a substantial increase of
7.7 points more than Februarys reading of 48.2 percent,
representing the largest month-over-month increase in pro-
duction since June 2009. Order backlog also had a healthy
5.5 percent increase.
Te Department of Labor reported that total nonfarm
employment rose by 192,000 jobs in March. January and
February employment numbers were revised up by a total of
37,000 jobs increasing the number of private-sector jobs to a
record 116.09 million, fnally replacing the 8.8 million posi-
tions lost during the recession. Employment in government
was unchanged during the month. A decline of 9,000 jobs
in the federal government was ofset by an increase of 8,000
jobs in local government. Federal government employment
has decreased by 85,000 jobs during the past year.
According to the U.S. Energy Information Administration
(EIA), total U.S. crude oil production grew 15 percent last
year to 7.4 million barrels per day. Texas and North Dakota
led the growth. Since 2010, North Dakotas crude oil output
has increased 177 percent, and Texass has increased by 119
percent. Five states and the Gulf of Mexico supplied more
than 80 percent of production in 2013. Texas provided
almost 35 percent. Te ofshore Gulf of Mexico produced 17
percent, followed by North Dakota at 12 percent, California
and Alaska at almost 7 percent each and Oklahoma at 4
percent.
Te West Texas Intermediate (WTI) crude oil spot price
increased to an average of $101 per barrel in February and
March from an average of $95 per barrel in January. Te EIA
expects WTI crude oil prices to average $96 per barrel in
2014.
On Wall Street, the Dow Jones Industrial Average was
up 0.8 percent in March. Te S&P 500 Index rose 0.7 per-
cent while the NASDAQ Composite Index decreased 2.5
percent, its worst monthly performance since October
2012. During the frst quarter 2014, the S&P 500 and the
NASDAQ Composite gained 1.3 percent and 0.5 percent,
respectively. However, the Dow Jones Industrial Average was
down 0.7 percent. P&S
Reference
1
Te S&P Return fgures are provided by Capital IQ.
Jordan, Knauff & Company is an investment bank based in Chicago, Ill.,
that provides merger and acquisition advisory services to the pump, valve and
fltration industries. Please visit www.jordanknauff.com for further information
on the frm. Jordan Knauff & Company is a member of FINRA.
Figure 2. U.S. energy consumption and rig counts
Figure 3. U.S. PMI index and manufacturing shipments
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Source: Institute for Supply Management Manufacturing Report on Business and
U.S. Census Bureau.
Figure 1. Stock indices from April 1, 2013, to March 31, 2014
Source: Capital IQ and JKC research. Local currency converted to USD using historical
spot rates. Te JKC Pump and Valve Stock Indices include a select list of publicly-traded
companies involved in the pump and valve industries weighted by market capitalization.
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.

Industrial Oval Gear Flow Meters
Control. Manage. Optimize.
Badger Meter Industrial Oval Gear (IOG) fow meters
provide economical and versatile solutions for a variety
of liquid fow applications. Ideal for measuring viscous
and caustic fuids, IOG fow meters provide high
accuracy and excellent repeatability at a wide range of
fow rates and temperatures. Its compact stainless steel
design is ofered in 1/43 inch pipe sizes with local
monitoring and system interfacing options.
Download the brochure at
www.badgermeter.com/IOG3
or call 800-876-3837 for more
information today.
2014 Badger Meter, Inc.
Trademarks appearing in this advertisement
are the property of their respective entities.
2014 United Rentals, Inc.
UnitedRentals.com/Pumps | 800.UR.RENTS
Following our recent acquisition, United Rentals is
now the second largest provider of pump rentals
in North America. Our team is proud to provide the
best equipment, tools and solutions in the industry.
Youre building the future. Were here to help.
#URPumpSolutions

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