Modern Pumping - 012014

modeRN
todAY
PRovidiNg SolUtioNS foR the WoRldWide PUmP iNdUStRY
THE POWER OF
enhanced efficiency from

Bell & Gossett's e-1510
JANUARY 2014
Best Practices
for infiltration
& inflow
solutions
the case for
eddy current
drives
d
rives
lnG
ln
G on
on the Go
CoNteNtS
4
10
JANUARY 2014
industry News
trade Show Profile
Case Studies
12 increase Productivity,
improve Quality
Minnesota manufacturer fabricates wide range of material handling products
16 grinder Pumps for Sewer Renewal

A new best practice for solving infiltration and inflow issues
Water & Wastewater

Solutions
16
20 Repair or Rethink...
maintenance Solutions
24 Pump Selection is Just a Click Away

VSX's multi-platform software, Spaix 4, gives voice to easier pump sales
Pump Solutions
28 iron Scale is No match for KZN Pump

BJM Pumps provide solution for rail spike manufacturer
30 the Power of e
28
Part 1 of a 3-part series

Efficiency Islands: What are they? How do they result in operating benefits?
dewatering Solutions
34 Preserving the mary Rose

NOV Mono plays an important role in restoring historic artifact
motor Solutions
36 eff iciency def iciency

A modern myth surrounding eddy current drives
34
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44 Ahead of All the Angles
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48 Simple Setup the Key to Safety

The first SIL-certified transmitter designed solely for safety system applications
Sealing Solutions
50 Raising Protection Standards

to New heights
52
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Pumping trends
56 the Communication Problem in

Channel Sales
LeadMethod's Justin Johnson discusses solutions for manufacturers and distributors
editoRiAl AdviSoRY BoARd

Terry Bell
Michael Mancini
Drives and Motion Solution Engineer

Baldor Electric Company
Consultant and Trainer,

Mancini Consulting Services
Heinz P. Bloch, P.E.
John M. Roach
Consulting Engineer,
Process Machinery Consulting
Robert G. Havrin
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Engineering Manager
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A Unit of IDEX
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INDUSTRy news
ASHRAE SEEKS PRESENTATIONS
FOR DEVELOPING ECONOMIES CONFERENCE
Presentations are being sought for a conference focused

on the design, construction, and operation of buildings in
developing economies. Organized by ASHRAE along with the
Philippines Chapter, the Efficient, High Performance Buildings
for Developing Economies Conference will take place April 24
through 25, 2014, in Manila, Philippines. It is co-sponsored by
the Air-Conditioning, Heating, and Refrigeration Institute (AHRI)
and endorsed by the International Association of Plumbing and
Mechanical Officials (IAPMO).
Call for presenter proposals are due January 31, 2014. A
400-word abstract addressing a specific topic and speaker
background information are required. Presentations of case
studies, preferably with actual performance data, are of most
interest. Notifications will be issued in February 2014.
The conference addresses the challenges developing countries
face in sustainable construction, such as rapidly growing energy
demand, population density and urbanization, and focuses on
aspects relating to design, construction and operation of high
performance buildings, including the HVAC&R industrys role in
meeting this objective.
The conference seeks to bring people from diverse cultures
and climates together to share building design approaches that
are responsive to local needs, says Ashish Rakheja, conference
co-chair. A key motivation behind the conference is to utilize
traditional construction practices. The papers and presentation
will provide examples of how to apply the latest technology to
achieve cost effective solutions to support high performance
buildings in developing economies.
4 | JANUARY 2014
Papers are sought on the following themes: design criteria

for developing countries (hot and humid climates, thermal
comfort preferences and cultural expectations, impact of
thermal design criteria on energy use and occupant wellbeing), indoor air quality (impacts of outdoor air quality issues,
potential application of natural ventilation), energy efficiency
(indoor environmental quality constraints on energy efficiency,
reductions in emissions of global warming gases through use of
renewable energy, energy impacts associated with water use),
standards and government regulations (green building programs
in developing countries, energy efficiency standards, indoor
air quality and comfort regulations), refrigeration (refrigerants:
limitations and opportunities, applications, e.g. improved food
preservation), and rural communities (water use, lack of energy
infrastructure, combustion using low-grade fuels).
In addition, presentations based on papers and invited
speakers from around the world will focus on the most critical
challenges facing developing economy countries.
ALL-FLO INTRODUCES NEW PRODUCT LINE
All-Flo Pump Company is launching a new line of air operated

diaphragm pumps that will raise the bar on efficiency standards
across the industry. The new line of innovative, stainless steel
and aluminum pumps rolled out in December. For use in a wide
variety of chemical and fluid transfer applications, the new
air operated diaphragm pump line offers an extended set of
improved features over legacy products.
Most notably, the newly designed All-Flo pump boasts a new,
high-efficiency, air valve, built with fewer parts, making it the
most air efficient pump in the industry.
INDUSTRy news
After initial testing, we can confidently say that our new
line will be the industrys most efficient air-operated diaphragm
pump line available, says Paul McGarry, All-Flo sales and
marketing manager for North America. For customers running
our 2-inch pump, they could realize greater than 50 percent
savings in annual operating costs.
This significant cost-savings comes at a good time for
customers. According to the Bureau of Labor Statistics, the price
of electricity hit a record high for the month of October, making
October the eleventh straight month when the average price of
electricity hit or matched the record level for that month.
With Americans now paying 42 percent more for electricity
than they did a decade ago, reducing operating costs for the
customer was at the forefront of our minds when we designed
our new line, says McGarry. Our team of experts spent a
tremendous amount of time engineering this new pump to
ensure it led to significant savings for our customers.
INTERGRAPH LAUNCHES
INTERGRAPH GEOSPATIAL 2014
Intergraph has launched Intergraph Geospatial 2014, a

comprehensive portfolio of industry-leading technologies.
Building upon the foundation introduced in 2013, this release
provides enhanced analytical tools, mobile support and
tremendous cost savings associated with managing big data.
With an ongoing focus on a fully united, modern and
dynamic product portfolio, this powerful release synchronizes
the technologies across all Intergraph product lines, broadening
the reach and availability for fully integrated solutions for all
users of geospatial information.
6 | JANUARY 2014
As todays organizations require the most dynamic

geospatial solutions for driving enhanced decision-making,
we are excited to share this release, introducing new mobility,
analytics and big data management tools, says Mladen Stojic,
president, Hexagon Geospatial. We are also continuing to
develop creative and intuitive interfaces, smarter workflows
and automated technologies that support the entire geospatial
information lifecycle, transforming multi-source content into
dynamic and actionable information.
Many organizations must quickly understand and make
sense of massive volumes of geospatial data. In addition,
there is a growing need to integrate mobile and analytics into
the cloud. Thoroughly understanding these requirements, we
continually evolve our products to best meet these needs,
further unleashing the power of geospatial data management for
organizational effectiveness, adds Stojic.
HARTZELL AIR MOVEMENT OPENS OKLAHOMA

SALES REPRESENTATIVE OFFICE
Hartzell Air Movement is pleased to announce that Airetech

Corporation is now their new sales rep office in Oklahoma.
Airetech Corporation has been in business since 1985. The
sales rep office currently sells products into commercial and
industrial markets. Their knowledge in selling dampers and
louvers will help create an easy transition into selling Hartzell
industrial fans. Principal of Airetech Corporation, Chad Smith
states, We are excited about the addition of Hartzell to our
product line because it allows us to provide a complete solution
to our customers in the heavy commercial and industrial
markets.
INDUSTRy news
Oklahoma provides both commercial and industrial markets
for Airetech Corporation, specifically in the petrochemical
and wastewater industries. Chuck Abramson, director of sales
at Hartzell Air Movement explains, Airetech is a good fit for
selling the Hartzell product line because of their knowledge and
history of the ventilation applications in Oklahoma. They have
a strong sales team, dedicated to providing quality solutions for
their customers.
Hartzell Air Movement is a leading manufacturer of industrial
air moving solutions to a variety of markets throughout the
world. The company manufactures in Ohio, Indiana, and
Singapore. Hartzell has been in business since 1875.
HAYWARD FLOW CONTROL

EXPANDS CANADIAN PRESENCE
Hayward Flow Control announces the expansion of its

operations and presence in Canada. Effective January 2014,
Hayward Flow Control will be operating from the Hayward
Canada facility, located in Oakville, Ontario. The 200,000
square-foot warehouse and office facility currently houses the
Hayward Canada Residential and Commercial Divisions. This
facility will now also headquarter the following Flow Control
activities for Canada: Customer Service, Technical Service,
Valve Automation Services, Full-Line Product Warehousing, and
Sales and Marketing Support. The increased presence will allow
Hayward to expand its product offering and distribution for the
Canadian market. Additionally, to further improve our industryleading customer service support, Hayward Flow Control will
now feature bi-lingual (English and French) Customer Service
Representatives located in the Oakville facility.
8 | JANUARY 2014
POSITIVE TRENDS CONTINUE

FOR EQUIPMENT LEASING
The Equipment Leasing and Finance Associations (ELFA)

Monthly Leasing and Finance Index (MLFI-25), which reports
economic activity from twenty-five companies representing
a cross section of the $827 billion equipment finance sector,
showed their overall new business volume for November
2013 was $6.6 billion, up 3 percent from new business
volume in the previous year. Month-over-month, new
business volume was down 13 percent from October. Year to
date, cumulative new business volume increased 5 percent
compared to 2012.
Receivables over thirty days were at 1.8 percent, up slightly
from 1.5 percent in the previous month. Delinquencies
declined from 2 percent in the same period in 2012.
Charge-offs declined to once again match the all-time low
of 0.3 percent from 0.4 percent the previous month. Credit
approvals totaled 76.5 percent in November, a slight decrease
from 77.6 percent the previous month. Forty-seven percent
of participating organizations reported submitting more
transactions for approval during October, a level more in line
with previous months activity after a spike to 82 percent
last month. Finally, total headcount for equipment finance
companies was up 1.4 percent year over year.
Separately, the Equipment Leasing and Finance
Foundation's Monthly Confidence Index (MCI-EFI) for
December 2013 is 55.8, a decrease from the November
index of 56.9, reflecting industry concerns over uncertainty
regarding capital expenditures (capex) and competitive
market pressures in 2014, among other issues.
TRADE SHOW profile
GasketinG/
ConvertinG
expo 2014
answers that
are ahead of
the curve
he Gasket Fabricators Association

strives to help its members
be innovative, profitable, and
successful by aligning them with fellow
professionals who can support and serve
their business needs. In addition to
regular and significant member forums,
the GFA also sponsors the bi-annual
Gasketing/Converting Expo, which has
quickly become a must attend industry
event with large numbers of suppliers
and attendees. Its an easy and costeffective way to meet the best current
and potential customersand learn the
latest technologies and great ideas.
Held this March in Orlando, Florida,
the Gasket/Converting Expo 14 is a
unique and valuable opportunity for
fabricators and suppliers alike to develop
and strengthen profitable relationships.
Presented by the GFA and co-sponsored
by the Fluid Sealing Association
(FSA), the International Association of
Diecutting and Diemaking (IADD), and
the International Sealing Distribution
Association (ISD), the Gasket/Converting
Expo 14 is the place to get answers,
ideas, and opinions to help attendees
stay ahead of the curve.
presented by
NEW FORMAT
FOR BREAKOUT SESSIONS
In an effort to bring the latest technical

and industry information to attendees,
the Gasketing/Converting Expo 14 will
10 | JANUARY 2014
feature a series of targeted sessions on topics that directly impact

the gasketing and converting industries. Industry leaders will
explore and lead in-depth discussions on topics such as:

Adhesives
Innovation
Innovation in equipment
Innovation in materials
Key performance measurement metrics
Social media
Attendees will not want to miss this opportunity to receive

timely and relevant industry information that may help them
solve a problem or develop their next big idea.
Previous Gasketing/Converting Expos typically had two large
technical sessions, but at the Expo 14, these will be replaced
with multiple smaller breakouts sessions that will be held
throughout the day while the exhibit hall is open. Sessions for the
upcoming Expo include: Innovation led by 3M, Innovation of
Equipment led by Associated Pacific Machine Corp., Innovation
of Materials led by Teadit N.A. and Canada Rubber Group, and
Adhesives led by Adchem Corp. and Adhesive Applications.
Non-technical sessions will be available as well.
HOTSPOT FOR INNOVATION
A wide array of exhibitors from manufacturing, material

handling, tooling, converting equipment, and quality inspection
services help make the Gasket/Converting Expo 14 the place to
be for professionals looking to solve a problem or develop the
next big idea. Attendees already familiar with the easy access to
intelligence, research, and the latest technologies through the
GFAs technical webinars and expert presenters will find the same
high-level expertise available at this years event in Orlando.
GO MOBILE
For the first time, attendees will be able to use a mobile app
to find their way and keep their schedules for the Gasketing/
Converting Expo. With the GFAs focus to stay ahead of the curve
when it comes to the use of technology, this app will certainly
help with that goal. The app will be available for all attendees to
download, and will have a number of features to help attendees
get the most out of the Expo.
NETWORKING IN A RELAXED ATMOSPHERE
Professional networking is serious business at the Gasket/

Converting Expo 14, but it doesnt have to be a somber affair.
Several hosted events during the exposition allow attendees and
guests to relax and discuss the trending topics of the industry in a
casual, low-pressure atmosphere. The GFA has reserved poolside
meeting areas on Thursday afternoon exclusively for attendees of
the Gasketing/Converting Expo. The area will serve as a meeting
place for attendees who are not planning to partake in other
activities to gather and network informally. Reserved tennis
courts are also available, welcoming players of all skill levels.
The Gasketing/Converting Expo features a cost-effective
tabletop display format that allows suppliers to have
unprecedented exposure to gasket fabricators and converters
without having to arrange for elaborate displays and logistics.
Attendees enjoy a unique and valuable chance to meet with both
new and existing suppliers. You do not want to miss this one-ofa-kind opportunity to network and conduct business with gasket
industry professionals.
JANUARY 2014 | 11
CASE Studies
Increase
Productivity,
Improve Quality
Minnesota manufacturer fabricates wide range
of material handling products
By Nancy lauseng, Jet edge
hen a
IT PAYS TO PAY
MinnesotaATTENTION
based
Anderson-Crane
manufacturer wanted
Company, a world
to fabricate an
leading material
expansive array of
handling equipment
material handling
manufacturer, has
productsincluding
installed a Jet Edge
screw conveyors,
waterjet cutting system
screw feeders, and
at its fabrication
bucket elevators for
facility in Litchfield,
their global client
Minnesota. With its
base yet also expand
new waterjet system,
its own capabilities
Anderson-Crane
as a job shop for their
is now capable of
local customers, they
cutting complex
turned to Jet Edge to
finished-quality parts
find the right tools for
from virtually any
the job.
material. AndersonLaser-cut parts
Crane Company
often prove too
manufactures a wide
expensive to be
variety of material
Anderson-Cranes Jet Edge Mid Rail Gantry waterjet system features an 8 foot by 13 foot (2.4 meters by 4
practical investments,
handling equipment,
meters) work envelope and SigmaNEST Companion CAD/CAM nesting software to maximize material usage.
but todays waterjets
including screw
It is powered by a 60,000 psi, 50 horsepower Jet Edge iP60-50 waterjet intensifier pump. The system features
are proving they are
conveyors, screw
an eco-friendly Ebbco closed-loop water filtration and chillingsystem that prolongs waterjet component life and
reduces water consumption and sewage fees by recycling water. (Photo courtesy Anderson-Crane Company)
powerful enough for
feeders, and bucket
metal cutting and also
elevators, specializing
precise enough for softer materials. Also, although waterjet
in custom projects. Anderson-Crane conveyors are used around
the world to move everything from chocolate to taconite. The
cutting is a process many manufacturers are familiar with from
company also fabricates hoppers, bins, and gates.
contracted or outsourced jobs, Jet Edge has been making these
tools affordable for a range of industries to bring on-site, where
In addition to manufacturing its own products, Andersonthey can find greater productivity in their shops as well as
Crane operates as a local job shop, building structural
greater quality in their parts.
equipment for local businesses and molds for the plastics
About the Author

Nancy Lauseng is the marketing manager for Jet Edge, a global designer and manufacturer of waterjet systems for
precision cutting, surface preparation and coating removal. For more information about Jet Edge, visit www.jetedge.com,
or call 800.JET.EDGE (538.3343) or 763.497.8700. For more information about Anderson-Crane Company, visit
www.screw-conveyor.com or call 800.314.2747 or 612.359.3535.
12 | JANUARY 2014
#304 stainless steel screw conveyor trough flanges and round inlet and discharge
flanges. They are all inch (6.35 millimeter) thick. (Photo courtesy Anderson-Crane
Company)
These parts are now always cut on the waterjet, and go straight from the waterjet table
to the welding production line with no cleanup in between required. (Photo courtesy
Anderson-Crane Company)
industry. It also offers metal repair services. Founded in 1950 as

an offshoot of its Minneapolis-based sister company AndersonCrane Rubber Company, Anderson-Crane Company has been
steadily growing its fabrication facility and capabilities for
more than sixty years.
Company spokesman Rob Crane attributes his companys
growth and customer loyalty to its commitment to quality
and its expertise in manufacturing custom material handling
equipment.
Anderson-Crane has become recognized as a leader in

quality in the material handling business, delivering products
with a very high attention to detail and finish, Crane says.
We have decades-long customers that include Fortune 500
companies and major multi-nationals. We pay very close
attention to our products fit and finish, assuring all dimensions
are precise and weldments are cleaned. Customers call on
us when they have a special conveyor design that cant be
found in a catalog. We treat our customers projects as unique
JANUARY 2014 | 13
CASE Studies
equipment that deserves close attention
to detail and quality.
PRECISION MATTERS
This meticulous attention to quality

is what compelled Anderson-Crane
to install a precision waterjet cutting
system, Crane notes. Before installing
its water jet, the company had been
cutting parts on a CNC plasma machine

and outsourcing work to waterjet shops.
Due to our high demand for
quality, we have spent a lot of time
cleaning parts that come off our plasma
machine, Crane recalls. We decided
to buy a waterjet because of its clean
cut; our goal is to reduce rework and
part cleaning time. We wanted a
system that cut parts with little or no

edge cleanup required. A laser proved
too costly and a waterjet allowed us to
cut metal (our main working material),
but also softer material such as gasket.
We had been outsourcing waterjet
cutting and were always satisfied with
the edge quality and easy assembly
of its finished parts. With the waterjet
were able to move from raw material
to finished parts in as little time as
possible while improving our products
quality and precision.
Anderson-Cranes new waterjet
cutting capabilities will help the
company maintain its competitive edge,
Crane adds.
Manufacturers in the material
handling industry do not focus on
the same level of quality as we do,
he says. Adding a waterjet to our
fabrication process set the quality bar
even higher. Our goal is to minimize
the time it takes to go from raw material
to assembly. As we implement this,
were striving to consistently deliver a
product with outstanding quality. Were
setting Anderson-Crane even further
apart in an industry where quality and
workmanship are often afterthoughts.
A UNIQUE BENEFIT
In addition to improving its own

products, Anderson-Crane also plans to
grow its job shop business by offering
waterjet cutting services. It plans to cut
primarily mild and stainless steel and
occasionally rubber gasket and UHMW.
Anderson-Cranes Jet Edge Mid Rail
Gantry waterjet system features an 8
foot by 13 foot (2.4 meters by 4 meters)
work envelope and SigmaNEST
Companion CAD/CAM nesting
software to maximize material usage.
It is powered by a 60,000 psi, 50
horsepower Jet Edge iP60-50 waterjet
intensifier pump. The system features
an eco-friendly Ebbco closed-loop
water filtration and chilling system that
prolongs waterjet component life and
reduces water consumption and sewage
fees by recycling water.
Anderson-Crane decided to buy its
waterjet specifically from Jet Edge for a
variety of reasons, Crane notes.
Jet Edges proximity to our shop is a
unique benefit, he says. Being close
to the manufacturer for support and
training is important to us. We also
wanted a dual gantry design, which
we see as a more robust design than
cantilever models offered by other
waterjet firms.
14 | JANUARY 2014
CASE Studies
G rinder Pumps for

Sewer Renewal
a new best practice for solving

infiltration and inflow issues
By Keith mchale,
environment one Corporation (e/one)
ow pressure sewer systems

using semi-positive
displacement grinder pumps
have been employed extensively
to provide central sewer service
to areas where gravity sewer
could not be installed and
to provide a solution for the
renewal of failed gravity systems.
A low pressure sewer system
consists of a network of small
diameter pressure pipes and
individual pumping units that
convey wastewater directly to
a treatment facility or central
sewer. Developed more than
forty years ago, low pressure
sewer systems have a large body
of well documented experiences
that show dependable operation,
long term reliability, and lower
life-cycle and social costs when
compared to gravity sewers.
The primary component of a
low pressure sewer system is a
grinder pump station installed
at each individual property in
the system. The grinder pump
station collects the wastewater,
grinds the solids into small
particles, and discharges it to
the pressurized pipe network.
Because the system is closed and

pressurized, the grinder pump is
capable of transporting sewage
over two miles, depending
on the topography and other
system parameters. The pump
unit is generally smaller than a
household washing machine.
Because it does not rely on
gravity flow, the system provides
more options and flexibility for
siting.
Several manufacturers offer
grinder pumps for low pressure
sewer systems with a semipositive specifically designed
for household wastewater
applications in low pressure
sewer systems.
In addition to allowing for
the passage of the ground solids
without clogging, the geometry
of a semi-positive displacement
pump produces a nearly vertical
pump curve. The flow from the
pump is generally constant,
and is somewhat independent
of the pressure in the system.
In practical terms, the pump
characteristics means that,
unlike a system using centrifugal
pumps, when a semi-positive
The model DH071 grinder pump station from E/One Sewer Systems,
a popular model for single-family homes.
About the Author

Keith McHale, P.E., is a professional engineer with more than twenty years of experience in wastewater collection and treatment,
including gravity and pressure sewer design, and infiltration and inflow (I/I) evaluations. Keith is the I/I project manager for
Environment One Corporation. He holds a BS in civil engineering from the University of Massachusetts at Amherst and is a
member of WEF and NEWEA. For more information about E/One products, call 518.346.6161, email eone@eone.com, or visit
www.eone.com/sewer.
16 | JANUARY 2014
displacement pump is activated, it

will deliver essentially the same flow
rate, no matter where the operating
point is within the allowable range of
operating pressure.
The choice of the semi-positive
displacement principle was made with
input from the ASCE Staff and Steering
Committee more than forty years ago
based on these irrefutable hydraulic
fundamentals. The development of
the wastewater pump began with
no vested interest in any particular
technology, so the developers were
free to start from the ground floor
and devise a unique class of pump,
tailored in every respect to the specific
needs of pressure sewer systems.
In evaluating the equipment for
use in pressure sewer systems, the
designing engineer should begin with
two main choices: first, select the
pump characteristic (HQ curve),
either centrifugal or semi-positive
displacement; second, select the
equipment manufacturer based on
additional pump characteristics,
including:
Performance features
Reliability and track record in the
field
Ease of installation
Serviceability
Preventive maintenance
requirements
Real estimates of operating and
maintenance costs
Initial cost
Life-cycle cost
LOW PRESSURE FOR SEWER

RENEWAL
Most central sewer systems installed

in the past use gravity as the moving
force to transport wastewater to
treatment facilities. Most systems,
however, cannot convey the
wastewater solely by gravity. Gravity
sewers may not always be the best
choice of a new or rehabilitated
central collection system because of
terrain, soil type, groundwater, and
other factors. Excessively hilly or flat
terrain requires deep excavations
and large pump stations. Low
pressure sewers using semi-positive
displacement grinder pumps can be
a cost effective solution to sewer
renewal.
Over time, gravity sewers fail. Root
intrusion, pipe cracks, joint failures,
and other deficiencies allow excessive
groundwater and stormwater to enter
the system. Referred to as infiltration
and inflow (I/I), this excessive flow
has detrimental environmental
and economic effects on the
overall operation of the wastewater
collection and treatment system.
The excess flows, or essentially
clean groundwater and rain water,
can quickly overload the collection
system capacity, resulting in sanitary
sewer overflows (SSOs), backups of
raw sewage into basements, and high
operating costs and equipment wear
due the transport of the excessive
flows.
Limiting the amount of I/I in
sewer systems through infrastructure
renewal measures provides many

economic, social, environmental, and
public health benefits. Renewal of
the collection system infrastructure
includes options to return the
system to an acceptable level of
performance. Repair, rehabilitation,
and replacement are a progression of
the activities employed to address and
renew failing infrastructure. Sewer
replacement is an extensive approach
to infrastructure renewal. Replacement
involves the complete abandonment
of the existing sewer pipe and
the installation of a new pipeline.
Unlike replacement with a gravity
collection system (replace in kind) the
replacement of a failed gravity sewer
with a low pressure sewer system
using semi-positive displacement
grinder pumps can be viable and cost
effective option.
Using small diameter pressurized
pipe buried just below the frontline,
a low pressure sewer system can
be installed with low impact
excavation techniques or with
Grinder pumps are typically installed outside of each home on

the pressure sewer system. Only the access lid and alarm panel
are visible to the homeowner.
JANUARY 2014 | 17
CASE Studies
trenchless directional drilling methods.
Additionally, a low pressure system
eliminates essentially all excessive
flows over the entire service life of the
new system. Repair and rehabilitation
methods used in sewer renewal can
achieve limited I/I reduction. Because
the wastewater in low pressure sewer
systems is pumped under pressure
through flexible sewer pipe, manholes

are not required to change the
direction or alignment of the mainline
sewers. This eliminates the need
to maintain and rehabilitate these
ancillary structures.
Low pressure sewer systems used
to replace failed gravity sewers can
provide a complete sewer renewal with
Gravity sewer main in need of repair.
fewer disturbances to the community

and have minimal environmental
impact. Based on more than forty
years of project comparisons, typical
capital costs for low pressure sewer
systems repeatedly range from 40 to
80 percent lower than gravity systems.
This low capital cost advantage is
enhanced by the lower social costs
including less business disruption,
traffic disruption, damage to adjacent
surfaces, structures, and utilities, and
noise and dust pollution, low pressure
sewers provide.
CASE STUDY: ELWOOD, KANSAS
Elwood, Kansas, sits in the northeast

corner of the state, just across the
Missouri River from the city of St.
Joseph, Missouri. Its a residential
and light commercial town built on
alluvial sand soils deposited over
thousands of years. The gravity sewer
system was barely functional because
of the groundwater infiltration in the
deeply dug system, 15 to 20 feet (4.6
to 6 meters) in some places. Nine lift
stations kept groundwater out of the
system. Manholes and sections of main
were constantly sinking.
The town suffered a devastating flood
in 1993. Following an unusually large
snowpack over the winter, wet weather
continued throughout the spring,
saturating soil and elevating rivers
and streams well into the summer.
Storms dumped heavy rainfall across
Kansasamounts achieving 75- to
300-year frequencies produced record
flooding on the upper Mississippi and
lower Missouri rivers. Levees protecting
Elwood were breached, and the
entire town was washed out. The soft,
sandy soil became a porous, shifting
hydrography that destroyed many
structural foundations and the gravity
sewer system.
The Federal Emergency Management
Agency (FEMA) helped Elwood dig
18 | JANUARY 2014
out and patch up its severely

compromised sewer. With
funding from FEMA, the entire
system was videotaped and
shown to be nearly beyond
repair. At this point, plans
were laid to rebuild with a
more sensible solution for this
vulnerable area.
Instead of installing another
gravity sewer system, the city
decided to use LPS. Other towns
nearby had used the system with
great success. The flat topography
and soil type further made the
case against a gravity system. The
new sewer system was installed
in two phases. The first phase,
installed in 2004, consisted of
245 grinder pump stations. The
second phase, completed in
2008, added another 139 grinder
pump stations.
The gravity system had required
extreme depths to maintain a
downgrade. This, in turn, created
groundwater inflow problems that
led to mains collapsing, manholes
sinking and sections of roadways
sinking. A constant repair requirement
around the clock, a breakdown of

a single station had a catastrophic
effect, as the entire system then
backed up.
Due to this constant operation,
Elwoods lift stations wore out
quickly. Between the electricity
to run the lift stations and the
repairs, the old gravity system
was literally sending money
down the drain. With the pressure
sewer system, the grinder
pumps run for shorter duration
and the closed system doesnt
allow groundwater infiltration,
eliminating collapses of
roadways, mains, or manholes.
CONCLUSION
Grinder pump station installed outside of a home.
accompanied the system and was a

constant strain on the Public Works
Department budget. With nine lift
stations pumping groundwater inflow
As existing infrastructure in
the United States ages, many
communities are replacing their
gravity sewer systems with low
pressure systems. A grinder
pump- driven LPS is a viable and
cost-effective alternative to I/I
challenges. The right pump and a welldesigned system mean elimination of I/I
resulting in lower operating costs, and
a satisfied and secure customer base.
JANUARY 2014 | 19
WATER & WASTEWATER solutions
Repair or Rethink . . .
By Stephen horne,
Kaeser Compressors, inc.
oundsville, West Virginia

is a small city located
along the Ohio River. It
is home to sites like Prabhupadas
Palace of Gold and the retired West
Virginia State Penitentiary. Like any
other U.S. city, Moundsville is also
home to a wastewater treatment
plant that actively supports the
communitys sewage treatment
needs. The plant mainly goes
unnoticeda sign that it is doing
its job well.
However, problems do arise
and when they do, Moundsville
like many citiesmust address
them with one eye on performance
and the other on their budget. When
the Moundsville Wastewater Treatment
Plant in West Virginia chose not to fix a
broken blower unit, but rather to correct
an outdated approach, the result was a
savings of $50,000 to $60,000 a year in
energy costs.
IDENTIFYING
WHATS REALLY
BROKEN
Kaeser blowers wide turndown range and surge-free

characteristics made them the
right choice for Moundvilles
tank aeration problem.
hold pending an evaluation of tank

conditions. The plant had been
experiencing a problem with pin floc in
their activated sludge operation, which
indicated a problem with dissolved
oxygen (DO) levels in the tank. The
studies that followed revealed the
DO levels varied from about 0.5 parts
WASTEWATER GLOSSARY
When the
When too many solids collect in the wastewater
Moundsville
system, the result is frequently pin floca
Wastewater
darker,
gritty sludge particle that can hamper
Treatment Plant
effective wastewater treatment.
experienced a blower
failure, they naturally
assumed they should
repair the failed unit
to keep their system design intact. At
per million to around 6.0 parts per
the time, two 75 horsepower centrifugal
million in a day. These results indicated
the microorganisms that break down
blowers fed air to the plants four
aeration tanks and a third centrifugal
organic waste were dying in anaerobic
zones at times during the day. At other
blower unit served as a backup.
However, plant personnel quickly
times the DO levels were too high,
decided to place the repair on
meaning energy was being wasted.
About the Author

Stephen Horne is the U.S. product manager for Kaesers Omega Blower line, and has over ten years experience with the
design and function of blower systems in wastewater aeration applications. Stephen has also served as Kaesers in-house
engineer for machine modifications and system design. He is a primary blower product and application instructor in Kaesers
Factory Certified Training program. For more information on Kaesers solutions for wastewater treatment facilities and other
blower applications, visit www.kaeser.com/omega.
20 | JANUARY 2014
INSTALLING THE NEW SOLUTION
Next, Moundsville staff back calculated

the air requirements for the individual
tanks. Their calculations supported a
new solution: installing a DO sensor, a
50 horsepower positive displacement
blower, and a variable frequency drive
in line to the secondary aeration tanks.
The proposed air system was carefully
designed to respond to real-time
conditions in the aeration tanks.
The DO sensor would constantly
monitor oxygen levels in the tanks and
output a control signal varying between
4-20 mA. The signal would then be
sent to the variable frequency drive.
Finally, the drive would control the
speed of the blower by changing the
frequency of the motor power supply.
This new air system called for quality
components, including a Danfoss
variable frequency drive and a Kaeser
positive displacement blower.
Plant personnel chose Kaeser
because of the wide turn-down range
and surge-free characteristics. Further,
the blowers power is almost directly
proportional to the speed in constant
pressure applications such as tank
aeration. After the selection of the new
equipment, plant personnel put the plan
in place. Staff programmed the drive to
JANUARY 2014 | 21
WATER & WASTEWATER solutions

maintain a DO level of 2.2 parts per
million and a minimum of 40 percent
blower speed.
SEEING THE RESULTS
After just four days of automatically

controlled DO levels, the pin floc issue
was gone. Whats more, the Kaeser
blower and the Danfoss drive were
saving a lot of energy by operating at
high efficiencies and not producing
excess air. In just the first year, the
Moundsville Wastewater Treatment
Plant saved about $24,000 in power
costs. Plant personnel went on to
perform additional DO studies in the
two remaining aeration tanks. They
discovered the levels were too high,
indicating energy was being wasted.
This time the plant installed a Kaeser
100 horsepower positive displacement
blower with a Danfoss variable
frequency drive and two DO sensors
to control airflow to the two first-stage
tanks.
The two original centrifugal blowers
in working condition did not go to
waste, but were incorporated into the
system as backup units to provide 100
percent redundancy. Moundsvilles
22 | JANUARY 2014
Moundsville Wastewater Treatment Plant personnel performed multiple dissolved oxygen (DO) studies in the aeration
tanks. They discovered elevated DO levels, indicating inefficient energy use.
new system is saving approximately

$50,000 to $60,000 per year in energy
costs, plus they have much better
control of the effluent qualitya big

feat for a treatment plant in a small
city.
MAINTENANCE solutions
VSXs multi-platform software, Spaix 4, gives voice to easier pump sales

By Christin Kubon, vSXvogel Software
uccessfully maintaining a pump

system takes countless man-hours
and sizeable investment capital.
However, one of the most critical steps
in ensuring a pump operates at peak
efficiency and performancepump
selectioncan now be as easy as the
click of a button. Now entering its
second decade, VSXVogel Software
is launching the latest version of
its well established pump selection
software: Spaix. The software has
been successfully used by national
and international customers for
several years. The new multi-platform
concept consisting of desktop-, weband mobile-version is unique on the
market, giving pump users another tool
in their quest to match the right pump
for the right job.
HOW DOES SPAIX 4 PUMPS

WORK?
Spaix 4 Pumps is based on a

completely new technology which has
been tailored specifically to meet the
demands of the modern IT landscape.
Above all, aspects such as internet
security and flexible authorization
models played a major role. In
addition, the new Version 4 offers
existing customers as well as new
clients many interesting possibilities to
further optimize their pump selection
and configuration processes and to
adapt to current market conditions.
The user-specific product data that
is stored in the database program is
linked practically with predefined
selection parameters and calculation
Spaix 4 Pumps is a high-performance application for the computer-supported selection and configuration of
centrifugal pumps. In addition, the software provides valuable support throughout the entire sales process.
methods. As a result, pumps matching

the specifications are displayed for the
user. For selecting the right pump the
users are offered different access points
similar to the previous versions, such
as hydraulic selection or the product
selection browser.
HYDRAULIC SELECTION AND

PRODUCT CONFIGURATION
The hydraulic selection enables the

sizing and configuration of pumps as
per predefined operating conditions,
such as area of application, fluid, flow
rate, and head. The Spaix 4 product
range supports the selection of several
operating points for the first time, even
for different fluids. The sizing can be

done as a single pump or as a parallel
or series connection of several pumps.
In addition, the definitions of limits and
search guidelines have been simplified,
as these can now be compared directly
with the product features of individual
components. Specifically predefined
input templates also make sizing
special pump systems easierfor
example, pressure booster systems,
borehole pumps, or process pumps
without the template being overloaded
with entry fields for simple systems.
The product configuration supports
the user in selecting available options
and is done in several steps, whereby
About the Author

Christin Kubon is a management assistant for VSXVogel Software, who specializes in software and Internet solutions for
the fluid handling industry and develops applications for sizing, selecting, configuring, and selling engineered systems and
components like pumps, valves, and pipes. For more information, visit www.vsx.net.
24 | JANUARY 2014
the program independently checks

whether the selected pump fulfills
all the entered criteria. The pump
performance curves are converted
automatically to the relevant operating
conditions by the software. For highviscous Newtonian fluids the method
according to the latest standards of the
Hydraulic Institute (HI) from 2010 is
used amongst others.
The program supports all common
procedures for adjusting the duty point
(impeller trimming, speed adjustment,
throttling and many others). The
performance curve optimization
procedures can also be used for
multi-stage pumps. The new feature
here is that for the performance curve
optimization using affinity laws various
methods for depreciating the efficiency
are available.
parameters, such as a power control,

graphical aspects are also taken into
account.
FRICTION LOSS CALCULATION

MODULE SUPPORTS DUTY
POINT CALCULATION
With the optionally expandable
functionality of pipe calculations
(additional Spaix PipeCalc module),

the user also receives support in
determining the operating point. On
the basis of defined parameters, the
program determines the pressure
loss for unbranched systems and the
pump volume in accordance with
common international standards (for
sewage and wastewater based on DIN
SIZING OF SPECIAL PUMP TYPES

AND COMPONENTS
Spaix 4 Pumps has been considerably

expanded and improved for the
efficient sizing and dimensioning of
special pump systems. The software
offers the user a multitude of
components, which can be used for the
configuration processfor example,
materials, shaft sealing, bearing frame,
and coupling protection.
Specifically to highlight here are the
consideration of motor performance
curves, magnet coupling sizing, the
treatment of frequency converters as
well as the sizing of borehole pumps.
The sizing of booster sets according to
DIN 1988 is also newly integrated. For
electronically controlled circulating
pumps, as are widely used in heating
technology, there is a calculation
module that calculates the control
curves from the constant speed
curves. As well as various technical
JANUARY 2014 | 25
MAINTENANCE solutions
EN 12056).
table and the
The results are
item numbers as
automatically
applicable. As
assumed for the
a result, clear
pump selection
identifiers are
and calculation
created, which
data sheets are
are also used to
integrated into
integrate external
the current
programs, such
project.
as ERP systems.
For pump
In order to be
manufacturers,
able to manage
it is now
and supply
even easier to
the prices for
define typical
different markets
pipe systems
Spaix works with
with the data
user groupspecific price
maintenance
Calculation of operating and life cycle costs: consideration of different load
program and
groups. Various
profiles, graphic and tabular display of the cost comparison.
considerably
currencies are
speed up the
supported and
recording of friction loss data by the
it is also possible to convert using
program can be flexibly adapted to
selection programs user.
the currency exchange rate. With an
the requirements of any company.
additional module it is possible to
Prices are calculated as per the
display the product availability through
OPTIMIZED PROJECT
selected configuration including all
enabling delivery times on the quote.
components and accessory parts and
MANAGEMENT
By using special interfaces project
As part of the project management,
can be displayed as an overall price or
data can be transferred to external
quotes including detailed datasheets
on the basis of single components.
programs such as ERP and CRM
can be compiled and supplied. The
Using dynamic product codes, the
systems for further editing.
price calculator integrated into the
configuration is linked with the price
CHECKMATE.
When it comes to check
valves, Check-All is king.
Our spring loaded check valves
are assembled to your exact
needs, ensuring absolute
precision and reliability. They
work like they should. Thats
what makes Check-All the only
choice. Plus, most lead times
are less than one week.
Count on the king.
Get me a Check-All.
26Check-All_CheckMateAd_921.indd
| JANUARY 2014
SINCE 1958
Manufactured in West Des Moines, Iowa, USA 515-224-2301 www.checkall.com

9/21/12 9:13 AM
EXTENDED
USER
MANAGEMENT
AND
PERMISSIONS
KEEP UP WITH
CURRENT
MARKET
CONDITIONS
In Spaix 4 Pumps
The user
the calculation
management can
of the energy
be organized
efficiency
with even more
index (EEI) and
detail in Spaix 4
the minimum
Pumps. Program
efficiency index
functions, price
(MEI) is integrated
groups, and
in accordance
product ranges
with the current
can be managed
EU guidelines.
and released
Through the
appropriately
ongoing updating
for different
of the guidelines
The database maintenance program is a multifaceted software to maintain the complete database
user groups. An
companies can
and to influence the functionalities of the selection program.
expanded user
react properly on
authorization
current and future
system makes it possible to
and influence the functions of the
framework conditions in the economic
accurately allocate rights to user
selection program. The person
environment.
groups.
In addition, Spaix 4 Pumps offers the
creating the data decides which
calculation of operating and life cycle
parts of the program are available
RELIABLE AND FLEXIBLE DATA
costs whereas various load profiles can
for which products and which users.
be taken into consideration depending
MAINTENANCE
The modular concept guarantees a
on the use. The cost comparison of the
The data maintenance program
minimum amount of data redundancy
various solutions is shown clearly in
is a versatile piece of software
and displays different product
graphic and tabular format.
to maintain the entire database
structures.
JANUARY 2014 | 27
PUMP solutions
BJM Pumps provide solution

for rail spike manufacturer
By Suzette gibson, BJm Pumps
JM Pumps prides itself on

supplying the right pump for
tough jobs. In the following case
study, a KZN submersible pump was the
choice for a very difficult pumping job.
The customer is the railroad spike
division of a 100-year-old, fourthgeneration, family-owned company that
employs about 100 people. Based in
Alabama, the parent firm manufactures
and sells overhead crane rail systems
and railroad products; sells new and
used locomotive parts; and rebuilds
used locomotives for sale to U.S. and

international markets. The spike division
is one of only two U.S. companies that
manufacture railroad track spikes; it
produces an estimated 36,000 spikes per
day during busy periods.
THE CHALLENGE
Through three shifts per day, seven

days a week, the companys foundry
turns carbon-steel bars into 5/8 inch
by 6 inch (15.9 millimeters by 152.4
millimeters) rail spikes, which it sells to
Class I, regional and short-line railroads

as well as to contractors and industrial
customers throughout North America.
The spikes are precision forged to meet
rigorous standards in specifications
and quality. The companys two
manufacturing lines must run reliably
at optimum speed and efficiency to
dependably meet customers demands
for large orders, high inventories, and
quick turnaround.
During production, as hot, forged
spikes come out of a furnace, they
About the Author

Suzette Gibson is the marketing coordinator for BJM Pumps, LLC. Headquartered in Old Saybrook, Connecticut, BJM Pumps
has been serving the industry since 1983 by supplying quality pumps at a modest price. For more information, call 877.BJM.
PUMP (877.256.7867) or visit www.bjmpumps.com.
28 | JANUARY 2014
are flash cooled by a blast of water; iron scale falls off

the spikes and collects, along with the water, in a sump
below each production line. Once a week, a plant worker
formerly climbed down into the sumpseach about the
size of a desk and seven to eight feet deepand shoveled
the iron scale out by hand. Depending on production
volumes, this job took between a half-day and a full day
of tough, dangerous labor. The cost of this labor and
the risk to employees safety were unacceptable to the
customer, which sought a better solution.
THE
SOLUTION
BJMs industrial
distributor
in Alabama
believed
that the best
solution
would be for
the facility to
pump rather
than shovel
out the sumps.
The salesman
saw a potential
application
for BJMs
KZN Series
heavy-duty
submersible
slurry pump.
Manufactured
of abrasionresistant, highchrome iron
and featuring
a hardened
wear plate,
impeller and
agitator, the
KZN is ideal
for handling
slurries that
contain
especially
heavy solids such as mill scale, sand, gravel, and coal.
The customer agreed to try a 7 -horsepower KZN55 for
thirty days.
Because the scale was so heavy, a foundry worker used
a 4-inch (101.6 millimeter) diameter hose to blast water
into the sump; the water jet and the KZN pumps agitator
worked together to fluidize the scale, creating a slurry
that could be pumped out of the sump as the pump was
steadily lowered to the bottom. The entire process took
about ten minutes instead of a half-day or more; the KZN
was moved as needed from one sump to the other to
handle both production lines.
Following the trial, the customer purchased the KZN,
it has been running without problem for more than three
yearshaving eliminated a dangerous manual process
and generated benefits for the customer in labor and
insurance cost savings, safety, and production uptime.
KZN Series
JANUARY 2014 | 29
PUMP solutions
The Power of
Efficiency Islands : What are they?

How do they result in operating benefits?
PaRT 1 OF a 3-PaRT sERIEs

By Christopher S. Johnson, Xylem Applied Water Systems
ump system efficiency is

interlocked along with other
system components within HVAC
systems. Evidenced by movements
in ASHRAE Standard 90.1,1 system
efficiency has moved to the forefront
when designing HVAC systems. As part
of this movement, the design of end
suction centrifugal pump products has
advanced to enable improved system
efficiencies. This design approach yields
significant benefits to the designers and

operators of HVAC systems for buildings
and facilities. Primary among these
enhancements are improved efficiency
ranges offered by the newest designs.
These efficiency improvements are
best described as enhanced Efficiency
Islands. This paper describes the
Efficiency Islands and how, from a
system perspective, these enhancements
can address new system efficiencies or
lead to the retrofit and improvement of

existing systems.
EFFICIENCY ISLANDS
Lets begin by describing what is

meant by the term Efficiency Island.
Figure 1 shows the Island (shaded
red) with boundaries of the maximum
impeller diameter performance, the
minimum diameter performance and
the iso-efficiency lines (81 percent and
About the Author

Christopher S. Johnson is the global engineering manager for centrifugal pumps in Xylem Applied Water Systems in the
commercial building and HVAC business unit, while also supporting the other business units with crossover products. He has
held leadership roles in sales, application engineering, product management, global sourcing, global product development, and
engineering.
30 | JANUARY 2014
figure 1
Product A
4 x 5 - 9.5
1770 RPM
TOTAL HEAD
HI POR Range:
70% to 120% of BEP
Efficiency Island of 81%

and Above
CAPACITY
figure 2
Product A
4 x 5 - 9.5
1770 RPM
TOTAL HEAD
Flow Width: GPM Range
Efficiency Depth:
Sustained Efficiency
at Reduced Impeller
Diameter
CAPACITY
figure 3
Control Area map with System head Curves
HEAT, FT
above in the illustration). This envelope looks

like and is thus called an Efficiency Island.
As seen in figure 1, there are many Efficiency
Islands which make up the performance curve
for a centrifugal pump. For the best operating
performance, it is desired to have these Islands
be as wide and as deep as possible. Figure 2
demonstrates what is meant by width (in terms
of flow rate) and depth (in reduced impeller
diameter) of these Islands. Figure 1 also
shows the ANSI/Hydraulic Institute Standards2
Preferred Operating Range (POR) which is
defined as the flow range from 70 to 120
percent of BEP. This is the optimal range for
centrifugal pump operation.
HVAC systems have substantial load
variations (flow rates) depending on the load
profile. Coupled with the load variations are
the head variations, which are dependent
on the physical size of the system and
components within the system. One system
head curve does not represent the true
system resistance against which the pump
must operate. Previous work has identified
both lower and upper system head curves as
applicable in heating and cooling systems.3,4
An example of the upper and lower system
head curves and the control area is shown
in figure 3. The area between the upper and
lower system head curves is known as the
control area (blue region). Pump operation can
occur within this zone, not just at the upper
and lower boundaries or on a single system
curve within the boundary.
As figure 3 illustrates, operation in a narrow
band of flow and pressure requirements
simply doesnt happen in the majority of these
systems. So to provide efficient systems the
Efficiency Islands need to be wide, deep and
with high efficiency levels. Narrow flow width
for iso-efficiencies and rapid drop in efficiency
as the impeller diameter is reduced, are not
desirable to achieve the most efficient system
operation.
When considering operation with a
constant speed drive to meet the variations
of a typical load profile, one can readily
see that control valve throttling moves the
pump on its curve and dissipates significant
energy wasted energy and added operational
cost. To handle normal load profiles, a
variable speed drive is preferred to enable
load variations to be achieved with overall
improved system efficiency. Newer designs
employing enhanced Efficiency Islands enable
the engineer or operator to improve the system
efficiency using either fixed or variable speed
pump operation.
System Curve
Inner Valves Closed
Outer Valves Closed
MODERN HVAC CENTRIFUGAL PUMP

DESIGN OBJECTIVES
Modern designs should utilize the most

sophisticated and cutting edge computational
FLOW RATE, GPM
JANUARY 2014 | 31
PUMP solutions
COMPARATIVE RESULTS
To examine how a modern HVAC

centrifugal pump design improves
efficient operation, flow and efficiency
can be viewed from a slightly different
perspective; that of efficiency versus
flow rate as a percentage of BEP with
particular emphasis on the Hydraulic
Institute Preferred Operating Range.
The following illustrations will
compare the results of a modern
design effort to several current end
suction products in the HVAC market.
The majority of the new product sizes
follow this example. The illustrations
compare Product A (4 x 5 9.5)
performance to Product B (4 x 5 - 9.5)
and Product C (4 x 5 9.25) at 4
pole 60 Hz speed (1800 RPM). More
conventional efficiency comparisons
32 | JANUARY 2014
figure 4
efficiency vs flow Rate as % of BeP
Product A vs Product B
maximum impeller diameter @ 1750 RPm
EFFICIENCY, %
fluid dynamics design tools available

to achieve improvement of efficiency
in three aspects:
Higher efficiency levels
Wider efficiency ranges (from a
flow rate perspective) at constant
diameters
Sustain higher efficiency levels as
impeller diameters are reduced.
FLOW RATE, % OF BEP

Product A
are also provided, as well as operating

cost analyses for several heating load
profiles and design conditions.
MAXIMUM DIAMETER
EFFICIENCY COMPARISONS
This comparison of maximum

diameter efficiencies is done using a
Product B
percentage of BEP flow. The Hydraulic

Institute (HI) recommends a Preferred
Operating Range (designated POR) as
70 to 120 percent of BEP flow rate.
This ensures a consistent comparison
is made among pumps with somewhat
differing BEP flow rates. A comparison
of the actual HI POR flow rates for
EFFICIENCY, %
figure 5
efficiency vs flow Rate as % of BeP
Product A vs Product C
maximum impeller diameter @ 1750 RPm
FLOW RATE, % OF BEP

Product A
A LOOK AHEAD
Xylem has redesigned the complete

line of its best-in-class Bell & Gossett
1510 pumpnow called the Series
e-1510 brandand the single stage
end suction centrifugal pumps
launched at the 2014 Air-Conditioning,
Heating, Refrigerating Exposition (AHR
Expo).
In part 2 of this series, well
compare efficiency at maximum and
reduced diameter impellers while also
examining the traditional view of flow
versus TDH. The enhanced Efficiency
Islands that result from these tests
further illustrate the advantages found
with the power of e.
Product C
NOTES
each competitor at maximum and

reduced diameter is also provided.
Figure 4 illustrates the efficiency
advantage for Product A in the HI POR
band compared to Product B. At the
same percentage of BEP flow, Product
A has higher efficiency. At the same
efficiency level, Product A offers a
wider flow rate range.
Figure 5 compares the maximum

diameter efficiency of Products A and
C. At the same efficiency, the range of
BEP flow is greater for Product A than
Product C. For example, the flow range
of Product C at 83 percent efficiency is
from 90 percent of BEP to 113 percent of
BEP. The flow range for Product A at 83
percent is from 78 to 115 percent of BEP.
1. ASHRAE 90.1 2010 Energy Standard for

Buildings
2. ANSI/Hydraulic Institute Standard 9.6.3
2012, Guideline for Allowable Operating
Region
3. Simplified Analysis of Flow in Closed Loop
Hydronic Systems, Bell & Gossett Technical
Brochure TEH-802P, August 2001
4. Variable Primary Flow Systems, Bell &
Gossett Technical Brochure TEH-910, 2010
JANUARY 2014 | 33
DEWATERING solutions
Preserving
Mary Rose
the
NOV MONO
plays
aN iMpOrtaNt rOle iN
restOriNg histOrical artifact
By Yvette Jacobs, Nov mono
n 1545, off the south coast of England, an invading

fleet of French vessels entered the Solent Channel,
approaching the awaiting forces of King Henry VIII
and his flagship, the Mary Rose. The Battle of Solent was
underway soon thereafter, a short and indecisive footnote in
military history that nonetheless claimed a famous casualty.
After she unloaded one side of cannons on the French
armada, the Mary Rose turned around and was caught in an
upending gust of wind. Reports at the time claimed that, in
the chaos and fury of the firefight, the lower gunports were
left open, allowing water to rush into the hull and drag the
Mary Rose and roughly 400 of her crew to the bottom of the
Solent, where she lay until discovered by British journalist
and amateur diver Alexander McKee in the 1960s. However,
the process of reclaiming and preserving this piece of
history would take many more decades still, and only
recently has one chapter come to a close.
PLAYING A CRUCIAL ROLE
When a number of Moyno pumps were switched off

recently, it marked the end of a twenty-year operation to
preserve the remains of an historic Tudor warship, the Mary
Rose. The progressing cavity pumps from Moyno have
been used to help spray the fragile timbers of the Mary Rose
with a mixture of water and waxa crucial stage in the
preservation process that has now come to an end.
The race to preserve the remains of Henry VIIIs flagship
began after she was recovered from the bottom of the
Solent, where she had lain since sinking some 430 years
earlier. Moynos association with the ship began in 1994,
when pair of industrial progressing cavity pumps were
chosen for duty/standby roles to help spray the hull
continuously with a solution of Polyethylene Glycol (PEG)
to stabilize its waterlogged timbers. The pumps provided
a continuous stream of PEG to 360 spray nozzles located

around the ship, and were supported by four smaller Moyno
pumps, which operated the heating and cooling circuits that
maintained the PEG at an optimum spray temperature.
EPSILON PROGRESSING CAVITY PUMPS
The Epsilon range of industrial progressing cavity pumps

combines proven pump technology with a number of
innovative features designed to benefit the end user.
Moynos experience, combined with an effective program
of customer feedback, has resulted in a range that has
characteristics of reliability, efficiency, and low operating
costs.
Available in a choice of cast iron or stainless steel
materials, the Epsilon range possesses a bloc construction
that has reduced overall dimensions and can offer benefits
when space restrictions apply. Other significant features of
the range are the incorporation of Moynos PowerDrive TM
transmission. The PowerDrive has proved its worth in many
About the Author

Yvette Jacobs is the global marketing manager for NOV Mono, a global leader in the design and development of the
progressing cavity pump. Brands include Chimineer, Mono, Moyno, and Tarby. For more information, visit www.moyno.com.
34 | JANUARY 2014
Performance data
Model
Size
K Build
1850
550
427
348
Four
Two
1277
E1BK
E1D
925
E1AK
E1C
E19K
616
E1B
E18K
414
E1A
E17K
315
Capacity GPM
250
Capacity GPM
Single
E1E
991
727
Number of Stages
Model
Size
E16K
163
E15K
97
253
E19
E18
218
E17
156
E16
113
E15
E14K
63
E14
44
50
E1X
26
E13
E13K
15
E12
7
E11
58
87
Differential Pressure - PSI
87
175
350
how Moyno pumps can provide consistently high levels

of performance year after year and simply go on giving
excellent service.
Until she sank in 1545, the Mary Rose was one of the
largest ships in the English Tudor fleet. She is now the
only sixteenth century warship on display anywhere in the
world, and forms the centerpiece of a new 27million ($44
million US) museum that has been built at Portsmouth
Historic Dockyard. The new museum also holds many
thousands of the 19,000 Tudor artifacts that were
recovered along with the vessel.
Differential Pressure - PSI
Moyno applications where it reduces cost by eliminating

the need for a double universal joint. With no wearing
parts, the PowerDrive offers greater lifetime cost savings
over conventional drive train designs and extends intervals
between routine maintenance. This high pressure pump is
reliable and efficient when handling abrasive materials,
high viscosity fluids, and high head applications.
Epsilon has been developed thanks to a combination
of careful research and many years of experience of
Moyno pumps operating in various industries. Reliability,
efficiency, and value for money are critical to our
customers, but so is simplicity. When the opportunity to redesign a popular E-series pump range presented itself, NOV
Mono was determined to make the Epsilon even easier to
install and maintain.
RELIABLE PERFORMANCE UNTIL THE JOB IS DONE

After ten years of operation when maintenance was
required on a gearbox, the Moyno pumps were also
inspected and found only to need one stator component
replacing. The pumps then returned to operating at speeds
of 279 revolutions per minute, circulating 528 gallons
(2000 liters) per minute of PEG solution around the spray
system. Six additional Moyno Industrial E range pumps
were later added to increase the capacity of the heating
and cooling circuits.
The ships timbers had to be kept fully moistened at all
times, so the pumps used had to be totally reliable if the
timbers were to be properly preserved, comments senior
sales engineer Mike Burton. This project really has shown
JANUARY 2014 | 35
MOTOR solutions
Efficiency
Deficiency
A modern myth surrounding
eddy current drives
By gary Patterson, dynamatic / drive Source international
ddy current drives,

known alternately
as magnetic
drives or eddy current
couplings, have been
a trusted and reliable
means of controlling
pump speed dating back
to before World War II.
They enjoyed a period
of widespread growth in
the municipal water and
wastewater treatment
industries during the two
decades beginning about
1965. The Clean Water
Act of 1972 fueled the
expansion of wastewater
treatment processing and
supplied federal funding
to municipalities facing
new requirements for
better levels of wastewater treatment. During this period,
eddy current drives were routinely selected for variable speed
pumping applications, such as raw water pumps, return- and
waste-activated sludge pumps, effluent pumps, filter pumps,
and various pumping stations where response to demand
made variable speed the best choice for process and energy
considerations.
THE CASE FOR EDDY

CURRENT DRIVES
An eddy current drive

controls speed by
regulating a DC excitation
coil on a magnetic rotor,
rotating concentrically
with a steel drum, driven
at by the motor at full
speed, as illustrated in
figure 1.
The slip between the
input drum and the output
rotor produces a slip
loss, proportional to
slip speed and the driven
load. Thus, the efficiency
of the drive, plotted as
a function of speed,
illustrates an approximate
Figure 1
one-to-one relationship,
as shown in figure 2.
Because a common reason for choosing variable speed is
to reduce energy consumption, this efficiency performance
may leave engineers and specifiers wanting something better.
When variable frequency drives were developed and began
to gain a foothold in the market, they boasted efficiency well
in the 90s, across the entire speed spectrum. This promise of
better efficiency fueled a shift in the market thought to justify
About the Author

Gary Patterson is a water and wastewater specialist for Dynamatic / Drive Source International, owner of the Dynamatic
brand of eddy current adjustable speed drives, brakes, and controls. For more information, call 800.548.2169 or visit
www.dynamatic.com.
36 | JANUARY 2014
100%
100%
90%
90%
80%
80%
70%
70%
60%
50%
Pump Load
50%
40%
ECD Loss
40%
30%
30%
20%
20%
10%
10%
0%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
PERCENT SPEED
Figure 2: Eddy current drive efficiency versus output speed
preference of VFDs, even to the point of removing existing

eddy current drives to achieve better energy performance.
CORRECTING MISPERCEPTIONS
OF EDDY CURRENT DRIVES
However, a comparison of efficiency exaggerates the

differences and ignores associated losses not considered
0%
pen
ECD Efficiency
Valv
eO
60%
ed
los
C
lve
Va
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
PERCENT SPEED
Figure 3: Eddy current drive losses when applied

to a centrifugal pump
in the calculation of VFD efficiency. Its more instructive to

examine the losses in a system, as this is a truer indication of
energy consumption and associated electrical costs.
A variable speed pump behaves according to wellknown affinity laws, such that the load bhp decreases in
proportion to the speed reduction cubed. When applying
the eddy current drive efficiency to a centrifugal pump load
JANUARY 2014 | 37
MOTOR solutions
100%
100%
90%
90%
80%
ECD Efficiency
70%
Pump Load
80%
70%
60%
ECD Loss
60%
50%
VFD Published
Efficiency
50%
40%
VFD Published
Losses
30%
VFD Real Losses
20%
10%
0%
40%
30%
20%
10%
0%
50%
25%
75%
100%
PERCENT FLOW
Figure 4: Eddy current drive and VFD performance

vs. percent flow
curve, the associated losses prove to be much lower than

one might expect, as shown in figure 3.
Figure 3 also illustrates an often-overlooked fact: The
pump only operates above the speed necessary to overcome
static head and produce a useful flow. This is usually no
lower than 75 percent of rated speed; in this example, 80
percent. If we expand the X-axis to include only the speed
0%
0%
25%
50%
75%
100%
PERCENT FLOW
Figure 5: Comparing unreported VFD losses
range from 80 percent and above, we can approximate the

performance from zero to full flow, as in figure 4.
Figure 4 now includes published VFD efficiency and
associated losses, in order to compare for those of eddy
current drives. Note that while efficiency still appears to
favor VFDs, the actual loss comparison is quite close. The
eddy current drive actually exhibits less loss than the VFD
above 90 percent flow.
However, most VFD installations include losses not
considered in the efficiency calculation.
VFD input harmonic currents induce losses in feeders,
transformers and harmonic mitigation devices often
necessary for the safe operation of the VFD. These losses
are usually impossible to quantify accurately, but result
in marginally higher kilowatt-hour usage nonetheless.
In a similar manner, the output waveform of a VFD is
not purely sinusoidal. This causes additional losses to
appear in the motor, which must be supplied by the
system. These losses are also very difficult to isolate and
quantify, but are generally acknowledged to exist.
Many VFD installations require air conditioning or
powered ventilation to provide adequate cooling to the
VFD itself, which is sensitive to ambient temperature,
due to the electronic nature of the equipment. In
addition to the extra cost for this cooling equipment,
the cost of powering the air conditioning is substantial.
A rule of thumb holds that each 1 kilowatt of heat load
requires 3 kilowatts of power.
ACCURATE COMPARISON AGAINST VFD DRIVES
When these additional losses are considered, the eddy

current drive solution is as good or better than the VFD, as
shown in figure 5.
These results have been demonstrated in actual
installations. Figure 6 shows actual field results comparing
eddy current drives and VFDs on identical pumps in the
same application.
38 | JANUARY 2014
600.0
Most such comparisons

will exhibit a crossover
point where the VFD power
consumption will exceed
that of the eddy current
drive. Experience has shown
that above such a crossover
speed, the eddy current drive
uses less energy than the
VFD. In the illustrated case,
average speed of operation to
be about 90 percent. Under
this condition, the customer
estimates saving $7000 per
year in electrical costs.
550.0
KW Usage
500.0
450.0
400.0
350.0
300.0
250.0
200.0
60.00%
70.00%
80.00%
90.00%
100.00%
% Speed
VFD
Eddy Current
Savings - kW difference x hrs x kW hour rate
@90% Speed-Efficiency Difference = VFD kw - Eddy Current kW = 410 - 390 = 20 kW (from chart)
Yearly Savings (50% Running time @ $.08 per kwh) = 4380 HRS x .08 x 20KW = $7008
Figure 6: Eddy Current vs. VFD KW Usage for 500 HP 880 RPM Motor
LONG-LASTING,
RELIABLE OPERATION
Eddy current drives are

acknowledged to be
unfailing workhorses in
pumping applications.
Many installations remain
in service after nearly fifty
years of continuous duty.
Many others would probably
still remain, had they not
been replaced by VFDs, in a
misguided quest for better
efficiency.
JANUARY 2014 | 39
POWER GENERATION solutions
Time to LNGo !
TM
Dresser-Rands first small-scale

liquefied natural gas plant has
successful start
By Charles ely, dresser-Rand
he market for liquefied natural gas, or LNG, is on

the rise. And with the increase in demand comes a
correlating increase in innovation. Dresser-Rand recently
designed, constructed, and commissioned its first small-scale
liquefied natural gas plant, a demonstration plant that has
reached a key
milestone with the
initial production
of LNG. Extended
performance and
endurance testing is
underway. DresserRand is already
stocking plants that
are ready to ship
today.
EXCITEMENT
OVER LNG
"We are very

excited about this
technology for
small-scale LNG
production, which
allows for very
small stand-alone
plants that are portable and can be moved to support changing
requirements and needs, says Dresser-Rand president and
chief executive officer Vincent R. Volpe, Jr. The standard
LNGoTM plants are sized to produce approximately 6000

gallons [22,712.5 liters] of LNG per day. There is substantial
Dresser-Rand scope potential in this offering including our
newly introduced MOSTM reciprocating compressor, Guascor
engines, Enginuity control systems, and project management
to integrate all
of these and
the process
components into
compact, portable
packages.
"Our
development
process began in
earnest less than
one year ago,
says Volpe. In this
timeframe, our
organization has
taken the process
and designed,
built, and
commissioned an
entire plant. This
development cycle
time to market is
amazingly short, and is a tribute to our internal processes, as
well as to the men and women of our development team, and
our Painted Post Operations.
About the Author

Charles Ely is the general manager of distributed LNG solutions at Dresser-Rand, among the largest suppliers of rotating
equipment solutions to the worldwide oil, gas, petrochemical, and process industries. For more information, visit
www.lng.dresser-rand.com or call 800.372.2608.
40 | JANUARY 2014
SPECIFICATIONS
Compliant with NFPA 59A
and 49CFR Part 193 design
criteria for LNG
Meets NEC Class 1, Division
2, Group D, T2A for
certified hazard areas
commissioning services, as well as

routine operations, monitoring, and
maintenance contracts, to ensure
ongoing reliable and available
operations.
"Now that we have produced LNG
with our demonstration plant, we are
in the enviable position of imminent
market launch, Volpe adds. "Given the
short cycle times that we embedded

into our production plans, we believe
that anticipated orders booked in the
next several months will convert to
shipments in 2014. As those units are
placed into service and gain operating
experience and run time, we believe
that the incoming stream of orders will
then progressively grow over time."
Ambient rating: -40 to 110

degrees Fahrenheit (-40 to
43.3 degrees Celsius)
Module assembled footprint:
110 x 50 x 14 feet (h) [33.5
x 15.25 x 4.25 meter (h)]
Input natural gas:
707 MSCFD
Nominal inlet condition
35 psig, 60 degrees
Fahrenheit (15.5 degrees
Celsius)
Output LNG:
6,000 GPD
10-85 psig
-230 to -252 degrees
Fahrenheit (-145.5 to
-157.7 degrees Celsius)
PRODUCTION OPTIONS FOR

SALE OR LEASE
Building on interest of over ninety

qualified leads, Dresser-Rand has been
talking to potential clients for several
months for commercial operation.
Depending upon the nature of the
application, these leads are broadly
classified as plants that would either be
for sale or for lease.
In the "for sale" category, DresserRand would provide the liquefaction
process and, depending upon the
plant configuration, potentially also
include the associated ancillary
gas processing equipment, a power
module and full turn-key installation
and commissioning. In the "rental"
or "lease" space, the Dresser-Rand is
evaluating several options, including
potential market channel partners, and
expects that, over the coming weeks,
it will determine which approach is
expected to be the most needed by the
market.
FULL TURN-KEY INSTALLATION

For all users, Dresser-Rand can
provide full turn-key installation and
JANUARY 2014 | 41
POWER GENERATION solutions

UPSTREAM APPLICATIONS
Upstream applications include,

among others, the monetization
of flared gas to increase revenues
for oil companies and reduce
their environmental impact, the
production of stranded natural gas
fields, which are not close to existing
pipeline infrastructure, on-site fuel
supply for drilling and hydraulic
fracturing equipment converted to
run on LNG, and applications for
coal bed methane for fueling mining
vehicles. Downstream applications
include the production of vehiclegrade LNG, allowing LNG to
compete effectively with diesel fuel
on a cost-per-energy-content (BTU)
basis.
CUTTING TRANSPORTATION
COSTS
As LNGo plants enable the

"distributed" production of LNG
on a small-scale, the technology
eliminates the need for the costly
trucking of LNG long distances from
large, centralized plants to LNG
fueling depots, as is the practice
today. Further, Dresser-Rand believes
that its approach to short cycle time
will enable LNGoTM plants to be
installed and operating in months
rather than years. The short cycle
times will allow owners to see quick
returns on their investment, as well
as matching the supply and demand
of LNG as local markets develop.
A MARKET ON THE RISE
Driven by rapidly expanding

global shale gas development
and continued price differentials
between natural gas and oil, DresserRand predicts that the market
for distributed, small-scale LNG
production plants will grow from
early adopters in North America
to a broad, robust market for users
around the world. North America
is the most rapidly growing market
and the substantial price disparity
between diesel fuel and low priced
natural gas has oil-field service
operators, oil and gas companies,
shipping and delivery companies,
and downstream fuel distributors/
marketers across the region
converting drilling rigs, industrial
mining equipment, transportation
fleets and retail fueling stations along
the United States interstate highway
system to LNG fuel.
42 | JANUARY 2014
PROCESSING solutions
Ahead of All the Angles

New Primo 200E an advancement in pelletizing machinery
By Ruth Ploch, maag
The Primo 200Es Cutting Chamber
o maintain a leadership position amid rapidly

changing pelletizing techniques and pellet forms,
a manufacturer must be founded on state-of-the-art
technology and on comprehensive know-how. Automatik
Plastics Machinery has built a longstanding tradition in
development, production, and global sales and distribution.
The companys latest offering, Primo 200E, is a new singleside mounted dry-cut strand pelletizer with an extra-large
cutting width of 7.87 inches (200 millimeters). Primo 200E

combines a broad range of skillfully designed product
features delivering user friendliness and productivity.
HIGH MARKS FOR UNIQUE CUTS
Among single-side mounted strand pelletizers the Primo

200E scores highly thanks to its unique cutting geometry
with the shortest unguided length between the feed rolls
About the Author

Ruth Ploch is the marketing manager for Maag, a worldwide leading manufacturer of gear pumps, pelletizing systems, and
filtration systems for demanding applications in the plastics, chemical, petrochemical, and food industries. Its subsidiary
Automatik Plastics Machinery has been manufacturing innovative pelletizing systems of the highest quality for several
decades. It is the world leader in underwater strand pelletizing systems. She can be reached at ruthploch@maag.com.
44 | JANUARY 2014
and the cut. This

geometry enables
optimum straight
cutting of both hard and
very soft plastic strands,
all in top quality.
The Primo 200E is
particularly suitable
for compounding of
thermoplastics, for
functional and additive
masterbatch production
and for the production
of color concentrates
up to a line throughput
rate of 1.65 tons (1.5
tonnes) per hour.
VERSATILE CUTTING
Highlights of the Primo
200E are its cutting
tool sets for hard,
abrasive and soft,
flexible plastics. The
pellet dimensions can
be quickly changed by
means of an optional
automatic pellet
length adjuster. This is
done using a second
Primo 200E
drive motor for the

feed mechanism with
an integrated speed
control.
When processing
abrasive products and
at high production
temperatures, the Primo
200E can optionally
also be equipped with
a separately driven,
highly wear-resistant
metal feed roll instead
of the standard
elastomer feed roll.
The design of the
Primo 200E makes it an
outstanding choice for
the efficient production
of micro-quantities of
color master batches
and concentrates. It is
easy to clean, features
a low-deposit cutting
chamber and enables
short retooling times,
and the cutting and
tool changing process
is likewise quick
and easy.
JANUARY 2014 | 45
PROCESSING solutions
CASE STUDY:
GABRIEL-CHEMIE GROUP
The Gabriel-Chemie Group specializes

in dyeing and finishing plastics. The
company was founded in 1950, and
today is one of Europe's leading
master batch manufacturers. The
privately owned independent concern
is based in Gumpoldskirchen, Austria.
It operates subsidiaries in Germany,

the United Kingdom, Hungary, the
Czech Republic, and Russia. Having
just launched the product in 2013,
Automatik Plastics Machinery sold the
first three units of its new Primo 200E
strand pelletizer model to Austrian
master batch manufacturer GabrielChemie GmbH.
After a short test phase with a trial

machine, Gabriel-Chemie found
the decision easy. The Primo 200E
delivered outstanding pelletizing
quality and high levels of userfriendliness, while its ease of handling
for batch changing made cleaning
and retooling much quicker, enabling
significant savings to be made in
production. The Primo 200E received
further plaudits thanks to its depositfree cutting head design, compact size,
and low running noise.
MAXIMUM RELIABILITY
Automatik Plastics Machinery places

the greatest value on maximum
reliability, and that commitment is
reflected in the strong and rugged
design of this cantilevered pelletizer.
Another special feature of the new
machine is that the feed geometry is
designed without major deflections,
so the plastic strands are not subjected
to pre-tensioning prior to cutting.
This means that even highly fragile
polymers such as polystyrene or highly
filled master batches can be pelletized
in high qualities, nearly without longs
or dust.
A NEW APPROACH FOR THE

NEXT GENERATION
Automatik Plastics Machinery actively

seeks to help customers with new
developments to enhance production
efficiency and make their operations
run more energy-efficiently, as
well as offering retrofit options to
upgrade machine versions. This
approach extends machine service
lives, meaning use of energy and
commitment of other resources is
delayed and ultimately reduced
because the next generation of
pelletizing machinery will incorporate
further updated production strategies
to make them even more efficient.
This next generation of machines
will be built by a new generation of
staff who will in turn be able to call
upon a reservoir of ideas accumulated
by Automatik Plastics Machinery
over many decades in the form of its
extensive portfolio of patents. Some
twenty to thirty patents are registered
every year, ensuring that Automatik
Plastics Machinerydespite being
a medium-sized manufacturing
companyis able to retain its position
as the world market leader in its
specialist field of thermoplastics
pelletizing.
46 | JANUARY 2014
VALVES & CONTROLS solutions
sk any engineer, getting the

job done with fewer steps is
the mark of a good design.
Simpler is better, and nowhere is that
maxim more true than when it comes
to functional safety. Now plant safety
teams get simple setup and faster, safer
performance, right from the start.
SAFETY STRAIGHT OUT OF THE BOX
The first SIL-certified

transmitter designed
solely for
safety system
applications
Instead of a costly, overcomplicated process

transmitter that must be adapted for safety use, the
One Series Safety Transmitter is the first SIL 2-certified
transmitter designed solely for safety system applications.
Only the One Series Safety Transmitter comes with an
internal high-speed relay for the fastest emergency shutdown. And that
simple design means fewer nuisance tripsfor greater safety, productivity,
and throughput.
The new One Series Safety Transmitter is available in versions that monitor
temperature and pressure. Its features include an exclusive design that means
fewer nuisance trips and greater safety and productivity, an internal high-speed
safety relay for the fastest emergency shutdown, greater affordability than adapting
a process transmitter for safety applications, and a higher safe failure fraction that
simplifies SIL achievement.
MAKE IT EASY, MAKE IT WORK
By
Wil Chin,
United
electric
Controls
The One Series transmitter provides a 4-20 mA NAMUR standard output with exclusive
I Am Working diagnostics. Set point and deadband (reset point) are 100 percent
programmable. The instrument is password protected to prevent unwanted parameter
changes; eliminating the risk of tampering. In addition, LED backlighting enhances viewing of
process variables, parameters, and status in dimly lit areas.
A unique, high-speed safety relay output is incorporated for local alarm or emergency
shutdown. Discrete outputs deliver diagnostics and relay status voting logic input to the safety
About the Author

Wil Chin is the vice president of marketing and business development, United Electric Controls. United Electric Controls
(UE), and its divisions, Applied Sensor Technologies and Precision Sensors, are international manufacturers of durable and
reliable pressure and temperature switches, controls, and sensors. For more information, visit www.ueonline.com/st or call
617.926.1000.
48 | JANUARY 2014
PLC to determine appropriate action. The transmitter

is certified for use in SIL 2 safety instrumented
systems, and is capable of SIL 3 per IEC 61508. It has
configurable self-diagnostics and achieves a safe failure
fraction of 98.5 percent. Relay response time is less than
100 milliseconds.
SIMPLE SETUP, FEATURE RICH

Additional features include
large digital display that provides process variable,

status, self-diagnostics and field programming
information.
100 percent programmable solid-state relay (switch
set point and deadband.)
effectively replaces a gauge, transmitter and a
switch to reduce potential leak paths.
certified for use in SIL 2 plant safety applications
with FMEDA report available.
worldwide hazardous location approvals for Class I,
Divisions 1 and 2 (Zones 1 and 2).
ONE AND DONE
For new SIS designs and plant safety upgrades, the One
Series Safety Transmitter provides a simple and costeffective solution. The flexible design of the One Series
translates to fewer nuisance trips for greater productivity,
economic savings compared to adapting a process
transmitter, faster emergency shutdowns thanks to its
internal relay, and a simplified SIL achievement.
SPECIFICATIONS AT GLANCE
Outputs
4-20 mA analog (NAMUR NE 43 standard, accuracy tested in
real time)
Safety Relay Output (SRO)Solid state relay rated at 0-240
VAC @ 5 amperes, programmable for set point and deadband
SRO StatusIndicates status of the safety relay output
IAW OutputIndicates device health status
Relay Response Time

Less than 100 milliseconds
SFF
98.5 percent; PFDavg 2x10-3
Risk Reduction Factor

806 to maximize safety integrity level (SIL) when used as a
component in a safety-instrumented function (SIF)
Redundant and diverse instrument amplifiers and A/D
converters
Diverse S/W algorithms process sensor data in parallel to
ensure integrity
Certified for use in SIL 2 safety systems by exida, with SIL 3
capability
Polyester-coated bright yellow aluminum Div. 1 Ex d
castingeasily identifies SIF safety transmitter
FMEDA report available upon request
JANUARY 2014 | 49
SEALING solutions
Raising
Protection
Standards
to New Heights
By deWayne Polley, emerson industrial Automation
hen seeking to protect industrial machinery from

leaks and heat, two names within Emerson Industrial
Automation's family of brands are raising the
standard for what operators can expect. Morse and
Kop-Flex are fast becoming the go
to names in machine protection.
Emerson Industrial Automation's
engineers and product specialists
have
MORSE RAIDER PLUS
Morse Raider Plus speed reducers

utilize advanced finishing
techniques, additional bearings
and special seals to arm them for
leak-free performance, guaranteed
for eighteen months. Ideal for
conveyors, mixers and
bucket elevators in the
food, beverage and grain
industries, the Raider
Plus' computerized gear
centering optimizes the
gear mesh for reduced heat
and debris formation, eliminating
unnecessary backlash and delivering high
efficiency and long life.
A patented roll-burnished journal finish
extends seal life up to four-fold, and exclusive doublelip seals on both input and output shafts provide leak-proof
operation in highly contaminated applications. The Raider Plus
also features an exclusive non-metallic quill liner that reduces
fretting and corrosion, and eases motor removal. Large, singlerow ball bearings absorb radial and thrust loads on higher
input speeds, while heavy-duty tapered roller bearings on all

output shafts handle inherent gear load and provide maximum
overhung load capacity.
LEAK-FREE GUARANTEE
A key design component of this

reducer is a second input
bearing that reduces wear
and fatigue on the input
seal. The second input
bearing minimizes
shaft movement during
motor installation and
operation. We tracked
the performance of
the Raider Plus and
are confident the
materials and assembly
of this product support an
eighteen-month leak-free
guarantee.
Four unit modelsthe U:
a universal style with an output
shaft, the Q: a c-face-style with
an output shaft, and both styles with
hollow outputsare available from stock
with a center distance range of 1 to 6
inches (25 to 152 millimeters), ratios from 4:1 to
3600:1 and output torques from 82 to 22,416 foot pounds.
All Raider Plus housings, motor adaptors, covers and
mounting bases have cast iron single-piece construction for
maximum strength and dependability. Forged bronze worm
gears, precision manufactured to AGMA specifications,
provide greater tensile strength than cast bronze. The integral
About the Author

DeWayne Polley is the gearing product specialist for Emerson Industrial Automation, Power Transmission Solutions. He can be
reached at dewayne.polley@emerson.com or 606.564.2267. For more information, visit www.powertransmissionsolutions.com.
50 | JANUARY 2014
worm and shaft are hardened

to 58RC for extra strength
and durability. The speed
reducers are all factoryfilled with FDA-approved
polyglycol synthetic
lubricant for enhanced
rating and reduced thermal
rise.
Standard shear
spacers are not
engineered to survive
the unbalance forces
that develop when
turbo drivetrains hit
a torque overload at
high speeds (3,60020,000 revolutions
per minute), says Joe
KOP-FLEX HIGHCorcoran, manager
SPEED SHEAR SPACER
of global services and
COUPLING
training for Emersons
Developed to protect gasKop-Flex coupling
turbine-powered generator
business. Coast down
drives during electrical
from high speed can
faults, the Kop-Flex highbe unpredictable with a
speed shear spacer coupling
standard shear spacer, and
uses a patented doublemore damage can result.
tube design, precision
"This design takes the
machining and bearings,
standard shear spacer
and special metal treatments
concept to a whole new level
to help provide predictable
of technology, says Corcoran.
shear during torque overloads
We start with a comprehensive
on turbo drivetrains,
understanding of the
allowing safe coast down
material properties of
of systems turning at up
each unique unit, and
to 20,000 revolutions
use metal treatments,
per minute. The shear
testing, precision
spacer is also ideal for
machining and special
drives on compressors,
bearings to create a
pumps, fans and trains
custom shear spacer for
subject to shock torques.
each application.
The patented shear
During manufacture,
cartridge uses special
the spacers parts
bearings between
are heat-treated with
two tubes to maintain
a sample from the
concentricity and overall
same metal batch.
centering after highSamples are tested to
speed separation. The
determine exact shear
double-bearing design,
strength, and test data
precision grooving, shot
is used to design and
peening and a corrosion
machine a precision
resistant coating combine
shear groove on the
to increase fatigue
spacer. Polishing the
resistance and promote
surface minimizes stress
reliable operation over
concentrations, and shot
the life of the coupling.
peening compresses
The high-speed shear
the surface layer to
spacers are available
minimize chances of
in all catalog coupling
crack growth. A special
sizes capable of handling
corrosion resistant
speeds up to 20,000
coating is also available
revolutions per minute
to further stabilize the
and millions of inchsurface.
A high performance coupling high-speed shear spacer cartridge shown being checked for
pounds (or NewtonOur tests show we're
runout during installation and alignment on the gearbox end of a drivetrain.
meters) of torque.
able to predict the static
shearing force within
TAKING THE HEAT (AND MORE)
1.5 percent on a finished unit, and we have successfully run
The high-speed shear spacer is an improvement over standard
these cartridges at high speeds after separation to validate
shear spacers and shear pins, which can create issues when
they can provide ample time for equipment coast down,
used above 3600 revolutions per minute due to balancing
adds Corcoran. Many units have been in the field for years
issues and fretting potential when using pins.
and are operating with great success.
JANUARY 2014 | 51
MODERN PUMPING products

fRANKliN eleCtRiC
C1 Series Clean Water Cistern Pumps

Franklin Electric Co. Inc. releases the C1 Series stainless steel submersible cistern pumps designed for
use in gray water/filtered effluent service applications, with the ability to pass solids up to 1/8 inch in
diameter during normal operation without impacting the life of the pump. The C1 Series is constructed
of a 304 stainless steel motor and outer shell with engineered polymer hydraulics providing superior
corrosion resistance and abrasive handling.
Additional pump features:
Robust thermoplastic discharge head to avoid breakage during installation and operation
Removable 5 inch wide base for secure and reliable mounting
Motor lead connection is protected with a rubber boot and secured with a stainless steel strain
relief
Unique bottom suction design allows for maximum fluid drawdown without compromising
durability or overall pump life
The C1 Series is available in flow ratings of 10, 20, and 30

gallons per minute, with a maximum shut-off pressure of over
100 psi and is available with a high quality 115 V or 230 V,
horsepower motor.
Featured Product Release

For more information, visit www.franklin-electric.com.
lUdeCA
tab@lign
Laser shaft alignment goes mobile with tab@lign. To keep pace with
the times and meet the expectations of its customers, Ludeca is pleased
to announce tab@lign, a unique tablet-based solution for pump-motor
alignment which combines the PRFTECHNIK laser measurement
technology with a tablet and smartphone devices. The tab@lign app runs
on Apple and Android mobile devices. It can be downloaded free of
charge from the Apple App Store or Google Play.
foX theRmAl iNStRUmeNtS

ft2A thermal mass flow meter
and temperature transmitter
Fox Thermal Instruments has revamped its product line with the redesigned FT2A
Thermal Mass Flow Meter. The FT2A is the newly-improved version of the widely
popular Model FT2 flow meter, and it features an even more robust design. Fox has
taken a hard look at its most trusted product - the Model FT2, brought it back to
the drawing board, and revolutionized the design of the flow meter in order to offer
Fox customers an even more robust flow meter for harsh industrial environments.
Furthermore, to expand to the Building Automation industry, Fox has broadened the
communications options available on the FT2A to include BACnet MS/TP. For more
information, visit www.foxthermalinstruments.com.
52 | JANUARY 2014
AShCRoft
g2 Pressure transducer
It only takes a small formation of ice deep inside the inlet cavity of a pressure
transducer to destroy the sensing element. To prevent this, Ashcroft engineers
have developed a unique media isolation method for the G2, T2, and
KM15 pressure transducers. Along with consistent performance in extreme
temperatures, these transducers are designed to withstand other harsh operating
conditions, including high shock and extreme vibration. A wide choice of
pressure ranges, outputs, electrical terminations, and process connections help
make them the perfect fit in nearly any installation. For more information, call
800.328.8258 or visit www.ashcroft.com.
eleCtRo-ChemiCAl deviCeS (eCd)

CA-6 Colorimetric online Analyzer
The CA-6 precision online sequential sampling analyzer is easy to install, weighing less
than 40 pounds. it can be wall mounted or simply set on a bench. Next connect the
sample, waste and reagent lines to the analyzer and provide power, the CA-6 will begin its
preprogrammed analysis sequence. The CA-6 is available with up to 4 channels (optional)
each from a separate sample point. A simple, user-friendly menu structure and touchscreen
interface makes it easy to access information or customize analyses. The CA-6 utilizes
photometric differential absorbance to analyze over twenty common parameters, including
aluminum, silica, phosphate, iron, and sulfate. It offers repeatability of 2 percent on
the absorbance value if the turbidity <80 NTU and drift of 2 percent per month on the
absorbance measurement. For more information, contact Joe Bradley at 949.336.6060,
800.729.1333, sales@ecdi.com, or www.ecdi.com.
iRiSS
CAP-4-US
Combination infrared Window/
Ultrasound Port
IRISS, a leader in the permanent electrical safety
devices (PESDs) market, announces the addition of
a combination infrared (IR) window ultrasound port
product, the CAP-4-US. As their newest innovation,
the CAP-4-US enables companies to efficiently detect
electrical faults before running into failure. As a
mission-critical resource, electrical assets must
be continually monitored to prevent
failure which can cost companies
thousands to millions of dollars in
loss due to damaged equipment from
arc flash or electrical fire, production
downtime, personnel injury, and
so on. IRISS R&D recognized the
industry need for a PESD that
leverages a multi-technology
approach for electricians to find
failure points in critical electrical
assets such as transformers and
switchgear. Many electrical failures
are caused by gradual degradation
of equipment such as insulators,
switches, and connectors. The IRISS
CAP-4-US makes detecting
these electrical faults safer
and more efficient. For
more information, visit
www.iriss.com.
gRUNdfoS
mle variable Speed motor

The intelligent MLE motor system greatly simplifies
pump commissioning and startup for each of the
models where it is offered. For decades, Grundfos
has manufactured its own MLE motors to match its
energy-optimized, high performing pumps. Now
Grundfos is expanding that effort to include motors
sizes that are well suited to HVAC/R applications.
These advanced Grundfos products provide a systems
approach, which, through intelligent technology, adapts
precisely to current demand to deliver performance,
energy efficiency and reliability. The integrated, energyoptimized MLE system consists of a sensor, system
controller, VFD drive and standard asynchronous motor
all in one. For more information, visit www.grundfos.us.
JANUARY 2014 | 53
MODERN PUMPING products

gRoSChoPP, iNC.
Pl7300 Planetary gearbox

Groschopp, Inc. releases an additional five ratios to
their standard PL7300 planetary gearbox product
line. In addition to our current robust design, we
have nearly doubled our yield torque creating a
longer life and use in a wider range of applications.
This expands the 18 Standard Ratios from 5:1 to
1000:1. Groschopps planetary reducer product
lines provide gearmotor specifiers with costeffective alternatives for high torque solutions.
Groschopp offers a standard NEMA 23 or 34
mounting and customized mountings and output
shafts. Groschopps planetary reducers provide
optimum torque capacity for an array of designs.
For more information, call 800.829.4135 or visit
www.groschopp.com.
flUid ComPoNeNtS
iNteRNAtioNAl
St51 flow meter
Designed for high performance,

the ST51 Flow Meter is an
explosion-proof instrument that
is easy-to-install and requires
virtually no-maintenance to
deliver a truly best cost solution
in wastewater digester gas systems.
The ST51 features a no-moving parts
design thats non-clogging and operates
over a wide flow range with low-flow
sensitivity. Its packaged in an explosionproof transmitter, and the calibration
is matched to the users actual gas
composition and installation conditions.
The ST51 Flow Meters thermal mass flow
sensing element has no moving parts
and no orifices to clog or foul, providing
virtually maintenance-free service in dirty
biogas applications. The flow element is
constructed with a 316L stainless steel
body and Hastelloy C-22 thermowell
sensors to resist corrosion. It also includes
built-in temperature compensation circuitry
for accurate, repeatable measurement
year-round as temperatures rise and fall
seasonally. For more information, visit
www.fluidcomponents.com.
NetZSCh PUmPS
NoRth AmeRiCA, llC
tornado t2 Rotary lobe Pump

Full Service in Place has replaced the old concept of Maintenance in Place for
which rotary lobe pumps are known. Netzsch accomplished this by replacing the
timing gears with a timing belt thus eliminating the need of draining and changing
the messy oil required to lubricate the timing gears. Completely free access to the
pump chamber along with a front-loaded cartridge seal integrated with the rotor
allows servicing work to be done not only quickly but easily. Other unique features
of the T2 make it possible to replace the lobes and mechanical seals in less than half
the time it takes with conventional rotary lobe pumps. For more information, call
610.363.8010, email npa@netzsch.com, or visit www.netzschusa.com.
ABB
terra 53 fast Charger

ABB recently launched the Terra 53 DC fast charger, a 50kW model with multi-standard
extensibility, also offering variants of 20kW, 30kW, and 40kW. The new charger was awarded the
UL rating for compliance with North American safety directives, including the requirements of UL
2202, Electric Vehicle (EV) Charging System Equipment, and CSA C22.2 No. 107.1-01, General
Use Power Supplies. The Terra models are also compliant with the Federal Communications
Commission (FCC) Federal Code of Regulation (CFR) Parts 15B and 15C, pertaining to radio and
frequency emitting devices. The Terra family of DC fast chargers have been deployed widely
throughout Europe and more recently in the United States, Canada, and Mexico. For more
information, visit www.abb.com.
54 | JANUARY 2014
vAl-mAtiC
Shut-off valves
Check out Val-Matics array of Shut-off Valves consisting of their CamCentric Plug Valves, American-BFV Butterfly Valves, and EnerG
AWWA Resilient Seated Ball Valves. Cam-Centric Plug Valves include
features such as a fully encapsulated plug, welded nickel seat, Grit
Guard Seals to protect the valve shaft, bearings, and seals, V-Type
packing, and Packing Overload Protection (POP) Shims to protect
packing from being overloaded during adjustment. The American-BFV
Butterfly Valve features a ductile iron disc for added strength allowing
the disc to have a smaller cross section and providing improved
headloss characteristics. The EnerG Ball Valve features the advantages
of a standard fusion bonded epoxy interior and exterior coating and
when fully open provides 100 percent flow area equal to the pipe
size representing a significant savings in pumping costs. Both the
American-BFV Butterfly and EnerG Ball Valve feature the unique
Tri-Loc Seat Retention System assuring seat integrity and allowing for
easy adjustment or replacement in the field. For more information, visit
www.valmatic.com.
mAgNeteK, iNC.
enrange mhR Radio Controller

The patented Enrange MHR Radio Controller integrates
the components of a radio receiver and hydraulic
controller into a convenient single unit, reducing costs,
and freeing up valuable space. When packaged with one
of the Magneteks transmitters, it provides a total wireless
system for operating mobile equipment including boom
trucks, truck mounted cranes, derrick diggers, concrete
pumpers, and trenchers. The MHR Radio Controller
also provides precision control of mining equipment
such as continuous miners,
locomotives, drills, bolters,
longwall shears,
battery haulers,
scoops,
muckers, and
load haul
dumps. An
informative
graphic display
with a user interface
is integrated
into the MHR
for in-field
programming
of system
settings. Twoway 2.4 GHz
FHSS feedback
is available,
providing
operators
with precise
information about
equipment performance.
Numerous analog, digital, and frequency
inputs and outputs are also available which can be
programmed in a variety of configurations. For more
information, visit www.magnetek.com/mhr.
SeePeX
md Plastic-Bodied dosing Pump

Now certified to meet the NSF 61 standard for use in
treating water and wastewater, seepex pumps are also
certified safe to use for sodium hypochlorite, ferric
chloride, sodium bisulfate, potassium permanganate,
sodium silicofluoride, calcium fluoride, polymers, and
most other chemicals commonly used in water and
wastewater flocculation, clarification, sterilization, and
buffering. The NSF Standard 61 for Drinking Water
System Components-Health Effects is the ANSI Standard
for drinking water system components. It is intended to
minimize any negative effects on the health and safety of
the public and the environment. The certification process
required toxicity and leaching tests with actual pumps
and components with the actual chemicals. All pump
components that come in contact with pumped material
must be traceable back to the mill, foundry or chemical
plant producing the raw materials. Vendor certification
requires periodic audits of the production facilities,
actual parts and purchase records. For more information,
call 937.864.7150, email sales@seepex.net, or visit
www.seepex.com.
JANUARY 2014 | 55
PUMPING trends
The Communication
Problem in Channel Sales
LeadMethod's Justin Johnson discusses solutions for manufacturers and distributors
eadMethod, headquartered
in Bend, Oregon, is a lead
and channel management
software company that works with
industrial manufacturers which
sell through outside reps and
distributors. Co-founder and CEO
Justin Johnson talked about the
challenges that manufacturers and
their distributors face throughout the
sales process. He can be reached at
jjohnson@leadmethod.com or 800.390.5578.
Modern Pumping Today: How does an industrial
manufacturer sales process work? What is unique about their
process?
Justin Johnson: Industrial manufacturers generally sell through
a direct sales force or through a channel of outside reps and
distributors. The latter is most common for manufacturers in
the fluid handling market, and it certainly comes with some
challenges.
Inherent to a distributor sales force model is a lack of
communication and understanding between separate entities
on the status of their leads and sales pipelines. Manufacturers
send leads to their distributors but rarely get feedback on
what happens with those leads, the opportunities they
represent, forecasted sales, or the pipeline as a whole.
MPT: What are the challenges with how leads are currently
managed in the channel sales process?
Justin Johnson: There are a few problems with the current
lead process. The first is visibility. Manufacturers need to be
able to clearly visualize and understand what is happening to
the leads they send to distributors. Right now, manufacturers
distribute leads by emailand then often lose track of them.
Sales and marketing managers at these manufacturers have
no way of knowing how quickly reps are following up or if
theyre following up at all.
This lack of visibility is a real issue when you look at the
statistics around sales and leads. According to the Harvard
Business Review, 47 percent of leads are contacted after 24
hours or not all. Meanwhile, 43 percent of the time the sale
goes to the company that makes the first contact, according
to Gartner Research. Sales managers dont have the tools
they need to understand their channel sales, and the result is
missed opportunities.
The second challenge is communication and the lack of
a feedback loop. Since manufacturers and distributors have
different systems and tools to manage their sales process, they
dont have a centralized way to communicate about leads,
opportunities, and sales performance.
56 | JANUARY 2014
MPT: What other services have tried to solve this problem?

Justin Johnson: There are several CRM (customer relationship
management) software products on the market, but they dont
address the specific needs of manufacturers that sell through
a channel distribution network.
CRM systems are complicated, feature-heavy, and
require every user to login to the system; that combination
just doesnt work for an outside sales channel. Plus, most
manufacturers use their own systemand no distributor
wants to access thirty different CRM systems from thirty
different manufacturers.
The lead management solution needs to be simple and not
disrupt the current sales process.
MPT: What is LeadMethod and how does it provide a
solution to manufacturers that sell through outside sales
channels?
Justin Johnson: LeadMethod is a lead management and sales
performance software built for manufacturers that sell through
channel distributors. We developed this system because we
clearly recognize and understand the challenging relationship
between manufacturers and distributors in their sales process.
LeadMethod is a powerful, yet easy to use web-based
software program that automates the lead capture and
distribution process. It helps manufacturers clearly understand
what is happening with their leads. Manufacturers can
confirm that leads are being followed up by distributors and
how quickly that happens. They can also see the opportunities
and sales projections in the pipeline.
LeadMethod also features powerful reporting and analytics
surrounding the data provided by sales reps. Manufacturers
have a dashboard showing them sales performance details
about each of their reps and distributors and the ROI for each
of their lead sources, allowing them to identify opportunities
and weaknesses in their channel sales process.
MPT: What benefit can technology bring to managing
the lead process? And what types of companies does
LeadMethod work with?
Justin Johnson: There is a huge opportunity for companies
to save time, improve efficiencies, and ultimately sell more
products. In fact, a study by the Gartner research group tells
us companies that automate their lead management process
can increase revenues by 10 percent or more in only six
months.
Most of the companies that we work with are in the fluid
handling business (pump, valve, motor, seal manufacturers),
but we are also talking to companies in the electronic
chip business and other industrial sectors. Any company
that sells through outside distribution could benefit from
LeadMethod.

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