Modern Pumping - 052014

Modern
todAY
Providing SolutionS for the WorldWide PuMP induStrY
MAY 2014
PUMPING
GREEN ENERGY
FROM FOOD
WASTE
Know Your
Base Plate
oPtions
urethane
stators
increase
PumP life
Plcs Boost
uPtime
ContentS
4
10
MAY 2014
industry news
trade Show Profile
Case Studies
12 turning a harbor into a haven
Water & Wastewater

Solutions
18 uniform distribution in headers

and distribution Systems
12
Part 1 of 2
Maintenance Solutions
22 Know Your Pump Base Plate

installation options
Part 1 of a 3-Part Series
Pump Solutions
24 A revolution in Pump eff icieny

All-Flo's A200 pump reduces energy costs, improves performance
Part 2 in a 4-Part Series
dewatering Solutions
38
28 A Simple design for tough Jobs
Motor Solutions
30 exceeding expectations
Moyno's new urethane stators increase pump life for wastewater treatment plant
Power generation
Solutions
34 AnSi/AShrAe/ieS Challenges Solved

with Software
40
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266

@modPumpmag
Processing Solutions
38 food Waste to green energy

Landia's chopper pumps sustain Biogen's renewable energy process
valves & Controls

Solutions
40 going for the gold
Jeff fletcher Associate Publisher

jeff@modernpumpingtoday.com
ranDY armisteaD Associate Publisher
randy@modernpumpingtoday.com
J. camPBell Editor
jay@modernpumpingtoday.com
Donna camPBell Editorial Director
donna@modernpumpingtoday.com
Ruggedized PLCs will boost processing uptime at Lapland gold mine
Sealing Solutions
46 Playing it Cool
scott GorDon Art Director

scott@modernpumpingtoday.com
Joel DorninG Assistant Art Director
joel@highlandspublications.com
Mechanical seal primary rings for sealing refrigerants and other low viscosity liquids
chris Garmon General Manager

chris@modernpumpingtoday.com
Special feature
linDeY scott Circulation Manager

lindey@highlandspublications.com
48 hear no evil, See no evil,

Speak no evil
Jamie willett Circulation Consultant

jamie@modernpumpingtoday.com
inGriD BerKY Administrative Assistant
How online reviews shape how well your business does both online and off
52
russell haDDocK COO/Publisher

russell@modernpumpingtoday.com
Modern Pumping
Products
nancY malone National Sales Manager

tonYa BrowninG Account Executive
ranDY moon Account Executive
Kristi neil Account Executive
Featured Product Release: BADGER METER ModMAG M1000 Electromagnetic Flow Meter
Pumping trends
56 tapping into the Power of e
Bell & Gossett's Mark Handzel explains the growing need for energy efficient systems
editoriAl AdviSorY BoArd

Terry Bell
Drives and Motion Solution Engineer

Baldor Electric Company
Heinz P. Bloch, P.E.
Consulting Engineer,
Process Machinery Consulting
Robert G. Havrin
Director of Technology,
Centrisys Corporation
Michael Mancini
Consultant and Trainer,

Mancini Consulting Services
John M. Roach
Engineering Manager
for New Product Development,
Trebor International, Inc.:
A Unit of IDEX
Lisa Roe
Business Development Manager,

Wastewater Pumps
Xylem Inc.: Flygt
Greg Towsley
Director of Regulatory and

Technical Affairs, Grundfos
Trey Walters, P.E.
President, Applied Flow Technology
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tim Garmon
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larrY DauGhetY
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Vice President
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INDUSTRy news
TEKNOR APEX WINS SPIS
2014 INNOVATION IN BIOPLASTICS AWARD
SPI: The Plastics Industry Trade Association will present the

second annual Innovation in Bioplastics Award to Teknor Apex
for the development of Terraloy PLA compounds which exhibit
both high impact and heat resistant properties. SPIs Bioplastics
Council noted that Teknor Apexs free-flowing resins, used in
both injection molding and extrusion/thermoforming processes,
streamlines the PLA crystallization process, eliminating the
post-annealing or post-crystallization process.
"Teknor Apex is honored to receive the Innovation Award
from the SPI Bioplastics Council," says Edwin Tam, manager of
new strategic initiatives. "The work of our Terraloy technical
team, headed by technical manager Greg Anderson, along with
our research partner Cerestech Inc., has enabled us to enhance
polylactic acid in areas such as heat resistance, impact
resistance and processability while retaining key bioplastic
values such as FDA compliance, high bio-based content, and
compostability."
Tam cited a life cycle analysis showing that Teknor
Apex's Terraloy PLA compounds with high heat distortion
temperatures produced 125 percent less greenhouse gas than
high-impact polystyrene and 40 percent less than low-density
polyethylene.
It is so exciting that the SPI announces this prestigious
award at the Biopolymers Symposium, says Barbara Fowler,
conference director for Smithers Rapra. Teknor Apex has a
long history of innovations in bioplastics and truly deserves
this recognition.
4 | MAY 2014
Innovations such as this are what keeps the plastics industry

on the cutting edge of technology, adds SPI President and CEO
William R. Carteaux.
ASHRAE 2014 ANNUAL CONFERENCE

ANNOUNCED FOR SEATTLE
While abundant rain and thriving evergreens keep the city

of Seattle green and lush, the city has taken the concept of
green to a whole different level. Sustainability is promoted in
all aspects of life, which makes Seattle the perfect location for
ASHRAEs 2014 Annual Conference, which takes place June 28
through July 2.
The Technical Program kicks off June 29, with interactive
programs and a networking coffee break, and concludes July
2. The program addresses broad topics in the application
of technology to practice, specific applications in ground
source heat pumps, operations and maintenance and indoor
environmental quality, as well as new reports on research taking
place worldwide.
Featured is a track on Ground Source Heat Pumps State of
the Art: Design, Performance and Research, which addresses
all aspects of design that lead to optimally performing systems
in addition to avoiding common pitfalls that lead to poorly
performing systems.
The Conference also features the second annual ASHRAE
Research Summit, which presents innovations in HVAC&R
research with particular emphasis on high performance building
design and its role in a clean energy economy, and brings
together researchers to present and discuss the latest research.
INDUSTRy news
Researchers present papers, seminars and forums or participate
in panel discussions. Also, highlights on ongoing ASHRAE
funded research are presented.
Attendees also can take part in courses offered by the
ASHRAE Learning Institute, including two full-day professional
development seminars and seven half-day short courses. New
is a course on building demand response and the coming
smart grid.
ASHRAE also offers its Building Energy Assessment
Professional (BEAP) and Building Energy Modeling Professional
(BEMP) exams on July 1.
The Conference takes place at the Sheraton Seattle and the
Washington State Convention Center. To register or
for more information, visit www.ashrae.org/seattle.
What
which produces and manages the AHR Expo. We know the

interest in renewable energy resources is growing rapidly, so
it is especially encouraging to see such a wide-spread interest
across all segments of HVACR professionals at the Show.
Stevens adds that there has also been a steady growth in the
number of exhibitors showcasing renewable energy products in
their booths. This is an area where weve seen many long-time
exhibiting companies expand their lines, as well as many newer
exhibitors with more dedicated product offerings. For example,
since we were last in New York in 2008, the number of
exhibitors showcasing solar-related products more than doubled
to 66 from 29.
Products 2014 Ahr expo Attendees Came to See
2014 AHR EXPO ATTENDEES: INTEREST IN

RENEWABLE ENERGY RESOURCES GROWS
According to a post-Show survey of visitors that

attended the 2014 AHR Expo, 41 percent of the
more than 2,000 respondents said they came
to the worlds largest HVACR event seeking
products related to Renewable Energy Resources
(Geothermal, Solar, etc.). When these sample results
are projected across the 42,000 plus visitors, more
than 17,000 HVACR professionals came to New York
to find products and solutions that could replace
conventional energy with more sustainable options.
Were not surprised, says Clay Stevens,
president of International Exposition Company,
6 | MAY 2014
INDUSTRy news
The 2015 AHR Expo will be held at Chicagos McCormick
Place, January 26 through 28. For more information visit
www.ahrexpo.com.
BLACOH FLUID CONTROL LAUNCHES

BLACOH UNIVERSITY ELEARNING WEBSITE
Blacoh Fluid Control, a leading manufacturer of pulsation

dampeners and fluid control products designed to improve
pump system performance and reliability, recently launched
Blacoh University (www.blacohu.com), an online e-learning
application for industry professionals. According to Blacohs
president Andrew Yeghnazar, Blacoh University is a
learning tool dedicated to the discovery, development and
communication of knowledge relating to fluid dynamics and
control across a variety of industries.
With the launch of Blacoh University, Blacoh introduced
a companion website to the companys existing site with
functionality similar to other learning management system
(LMS) applications. LMS refers to various software applications
ranging from systems for managing training and educational
records to the distribution of online educational courses with
features focused on interactive learning.
As a manufacturer headquartered in the US, Blacoh delivers
products to the marketplace through a global distribution
network supported by sales offices around the world. We
are formalizing the way in which we train and coach our
distributors, and expanding our horizons by providing learning
tools for plant maintenance personnel and the engineering
community, says Mr. Yeghnazar. This is not just about
8 | MAY 2014
providing information. There is an enormous amount of data out

there. Were taking that information and presenting it in a way
that makes it relevant and useful.
Blacoh sees this new endeavor in e-learning as a natural
expansion of its core business. In the complex world of fluid
processing and liquid handling systems, Blacoh manufactures
highly engineered products to solve problems commonly
associated with industrial and municipal pumping systems.
Blacoh University course curriculum for distributors covers the
basics of pulsation dampening in applications using various
types of positive displacement pumps. Courses designed for the
engineering community provide more in-depth analysis of fluid
processing systems in general and design related issues such as
acceleration head, water hammer and hydraulic surge.
James Burke, director of engineering at Blacoh, was
instrumental in developing Blacoh Universitys Engineering
Series. For engineers in our industry, much of what we know
comes from experience and tribal knowledge. Its not taught
in school or included in company training programs. We
focused on what was lacking, gathered detailed and reliable
content from trusted experts, and developed e-learning courses
specifically for engineers.
Each Blacoh University instructional video is followed with
an online interactive exam and participants are able to track
their progress as they go along. Blacoh University certifications
are awarded for completing courses in the Distributor Series.
For the Engineer Series, certificates with course information
and credits for professional development hours (PDH) are
provided.
TRADE SHOW profile
ACE14
Uniting the world of water
he American Water Works Associations Annual

Conference and Exposition (ACE14) at the Boston
Convention and Exhibition Center, Boston, will bring an
estimated 11,000 water experts to Boston June 8 through 12, is
the longest running water conference in the world, having first
convened in 1881. The event features several hundred expert
presentations and an exposition of more than 500 companies
showcasing the latest innovations in water technology. The
ACE14 agenda features speakers on hundreds of critical water
issues, including conservation and drought management,
infrastructure and affordability, desalination and water reuse,
emerging contaminants and new treatment solutions, and
more.
THE SHOW BEFORE THE SHOW
Dont miss the opportunity to get an early look at the

many new water industry products and services available.
All attendees are welcome as AWWA kicks off the ACE14
Exposition with a Sneak Peek Reception. Spend time
networking with colleagues while visiting the exhibitors.
Complimentary drink tickets and hors doeuvres will be
available, all made possible by the generous support of the
exhibitors. Admission is by conference badge only; registered
spouses and guests are welcome.
INNOVATION AND CONNECTION
The AWWA Pavilion (booth 1128) offers attendees looking

for the perfect location to find solutions, connect with the
water community, and relax a place to do all three. Stop by
the AWWA Pavilion to network with fellow attendees, relax
on comfortable seating or treat yourself to a complimentary
massage. This fun and interactive area is just the place to learn
how to get involved and take advantage of the many resources
provided by the Association.
10 | MAY 2014
Motivated attendees can also join in the Innovation

Pavilion presented by Imagine H2O (booth 1834),
to visit with the developers of award-winning water
technology solutions. A key innovation partner with
AWWA, Imagine H2O is a nonprofit that inspires
people to solve water challenges; and their Business
Innovations Program empowers entrepreneurs and
innovators to develop market-based solutions to water
challenges.
Featured Innovation Pavilion exhibitors include
Imagine H2O
NBD Nanotechnologies, Inc.
ReFresh
WatrHub
WaterSmart Software
Wellintel
PROFESSIONAL SESSIONS
Organized by technical topic, this years program

presents solutions to water sector challenges in defined
tracks of professional sessions that span the entire
four-day ACE14 program. You will find sessions on key
topics that address the full spectrum of the issuefrom
research to planning to treatment to management. It's
the one-stop conference for the topics of your choice.
A sample of volunteer committee meetings and affiliate
events at ACE14 includes the following:
Strategic Leadership for Utility Management
Regulatory Compliance: Tomorrow's Solutions Today
Potable Reuse: Trends and Opportunities
Pathogens and Emerging Contaminants: Identification
and Monitoring
Water Treatment: Enhanced Design Principles
Optimizing Distribution System Operations
A GUEST OF HONOR
Former mayor of New York City Rudolph Giuliani

will address more than 2000 water professionals from
throughout North America during the opening general
session. Sponsored by HomeServe, a leading provider of
home emergency repair service plans, Mayor Giulianis
address will cover his experience as a two-term mayor
of Americas largest city and will include his insights on
the myriad of challenges facing municipal leaders today.
His remarks will also delve into security concerns facing
communities and address the risk facing Americas water
and wastewater infrastructure, while inspiring the water
community to take on the challenge of leading U.S.
utilities down the road to infrastructure renewal.
Mayor Giuliani understands from his unique
experience the critical role that our water systems
and those who build and care for themplay in the
health and safety of our communities, says AWWA
chief executive officer David LaFrance. His presence
at the ACE14 opening general session underscores the
importance of the work water professionals accomplish
24/7, every day of the year.
MAY 2014 | 11
CASE Studies
Turning a Harbor into a Haven

By Kent Crawford, Blackmer
and Pump Solutions group (PSg)
Harbor Fuel 1 is outfitted with Blackmer GX & X Series

pumps, a 2--inch (63.5 millimeter) model for highcapacity fuel transfer, and a 2-inch (50.8 millimeter)
version for operations that require lower flow rates.
Boston Yacht Haven meets

the vessel-fueling needs of
its high-end client base with
the reliable assistance of
Blackmer GX and X Series
sliding vane transfer pumps
ne of the great things

about language is that two
words can have essentially
the same meaning, but when you
read or hear them they create very
different images in the mind. For
instance, two nautical terms have a
common definition: a place (or inlet)
providing shelter for ships, boats or
other vessels. But when you say the
word harbor, the image that comes
to mind is an area near the coast
teeming with all type of watercraft activity, from sailboats and
yachts to barges and oceangoing oil tankers. Say the word
haven, on the other hand, and a completely different image
is created, one that is more idyllic or

tranquil, a place of refuge.
The Boston Yacht Haven may
actually be located in Boston Harbor
in Massachusetts, but its name has
been chosen well and is an indicator
of the facilitys true intentions, which
are spelled out on its website: This is
a place where luxury floats in the air.
Where mega-yachts sit majestically in
an exclusive 100-slip marina. Where
newly renovated deluxe guest suites
indulge in every way. And where the surroundings are a
unique blend of beauty and history and a shimmering urban
landscape. This is Boston Yacht Haven.
About the Author

Kent Crawford is the regional manager, USA and Canada, for Blackmer and Pump Solutions Group (PSG). He can be
reached at kent.crawford@psgdover.com. For more information on Blackmer and the companys full line of pumps and
compressors, visit www.blackmer.com or call 616.241.1611. Blackmer is a member of Dover Corporations Pump Solutions
Group (PSG), which is comprised of several leading pump brandsAbaque , Almatec , Blackmer, Ebsray, Griswold,
Maag, Neptune, Mouvex, Quattroflow and Wilden . More information is available at www.psgdover.com.
12 | MAY 2014
Harbor Fuel 1 Captain Jackie Gilmanfondly known

as the fuel-barge ladypulls hose in preparation for
a fueling operation. Blackmer GX & X Series pumps
(foreground) help optimize the fuel transfer.
The facilitys
fueling for a wide array
reputation is such that
of vessel types and
gallonage requirements.
in May 2013 Yankee
Magazine gave it its
The fueling services are
2013 Editors Choice
performed by a fleet
Award for Best Lodging
of barges that carry
in Greater Boston
the fuel to where it is
needed then transload
(and when was the last
time something named
it into the vessels fuel
Yankee had something
tanks.
nice to say about
A typical day with
Harbor Fuels starts
Boston?), saying, this
luxury lodging offers
at about 5:30 in the
morning, explains
harbor views, spacious
suites decorated in
Jackie Gilman, captain
nautical style and a host
of the Harbor Fuel 1
of shared amenities.
fueling barge, which
was put into service
This is a first-class
facility with first-class
in June 2012. Were
Harbor Fuels has built its reputation on providing safe, reliable fuel-transfer operations for vessels
a mobile unit so we
amenities that caters to
that traverse Boston Harbor. The use of Blackmer pumps has only helped to enhance that reputation.
a first-class clientele,
can go in and out of
says Kevin Lussier,
any destination we
general manager of the Boston Yacht Haven. As such, we
need. We fuel all ferries, commercial boats, private yachts,
know we have to provide first-class service in every instance.
anywhere from 100 gallons (378.54 liters) a day to 100,000
gallons (378,541.18 liters) a week. A typical fueling process
ALWAYS ON CALL
depends on the gallon amount, anywhere from 100 to 500
gallons (378.54 to 1892.71 liters) we can do in five to ten
One of the most important services that Boston Yacht Haven
minutes tops. A maximum amount off the barge would be
provides to its clients is at-the-dock fueling. To do this, Boston
10,000 gallons (37,854.12 liters) and it would take an hourYacht Haven contracts with Harbor Fuels, a company that
specializes in delivering marine diesel for high-speed, in-slip
and-a-half at the agreed-upon gallon-per-minute rate.
MAY 2014 | 13
CASE Studies
As with any fueling operation, strict
regulations and safety measures must
be followed in order to ensure that
all barge personnel, clients and the
environment are protected from harm
during the fueling process.
When were fueling a yacht we can
come right alongside, make sure we
are 100 percent secure and prepare
14 | MAY 2014
for the fueling operation, whatever the

gallon amount is, continues Gilman,
who calls herself the fuel-barge lady.
We do the paperwork, make sure we
have good communication and activate
the pump with an electronic key card.
Our computer is very smart in that it
remembers every customer, the name,
size of the boat, the gallons, everything.
FINDING THE PERFECT PUMP
While the goal of Harbor Fuels is safe,

efficient, reliable delivery of fuel where
and when it is needed, that would
not be possible if the delivery barges
did not incorporate the best pumping
equipment. In the search for the ideal
pumps for its fueling applications,
Harbor Fuels turned to Hall Trask
Equipment Company, Braintree,
Massachusetts, a longtime supplier of
pumping technology from Blackmer,
Grand Rapids, Michigan, which is
a founding member of the Dover
Corporations Pump Solutions Group
(PSG ), Oakbrook Terrace, Illinois. Hall
Trask Equipment is a third-generation
supplier of pumps, valves, meters and
tank equipment for use in industrial
fluid transfer and transport applications
in New England.
Weve been a supplier of Blackmer
pumps for more than forty years, and
weve sold a number of thousands
of Blackmer pumps and been very
happy with the applications they
fill for us, says Mike Trask of Hall
Trask Equipment, who, along with his
brothers, Paul and Billy, are following
in the footsteps of their grandfather and
father in the family business. Weve
supplied Blackmer sliding vane pumps
for this Harbor Fuels barge that was
commissioned last year for high-flowrate filling of vessels throughout the
harbor. This application needed to have
very low maintenance and high output
and we chose the Blackmer pump to
meet the needs of the barge.
Specifically, Harbor Fuel 1 is
outfitted with a 2-1/2-inch (63.5
millimeter) GX Series pump that can
deliver high-capacity flow rates up
to 121 gallons (461 liters) per minute
and a 2-inch (50.8 millimeter) X Series
model that delivers 70 gallons (264
liters) per minute at lower speeds.
Each pump also features a variablespeed control so that the speeds can be
closely monitored, which increases the
safety of the fuel-transfer process no
matter the flow rate.
The high-speed pump we generally
hook up to a larger vessel when were
fueling a larger volume, so anything
over 500 to 1000 gallons (1892.71
to 3785.41 liters) and up were going
to use the high-capacity versus lowcapacity pump, which is best for
deliveries of around 400 gallons
(1514.16 liters) at a rate of about 60
gallons (227.13 liters) per minute, says
Gilman.
The Blackmer GX and X

Series pumps are able to
reliably meet the fueling
demands of Harbor Fuels
because they feature
Blackmers unique sliding
vane method of operation
that enables the vanes to
self-adjust for wear while
maintaining desired flow
rates and also providing
excellent self-priming
and dry-run capabilities.
The mechanical seal
and ball-bearing
construction provide
maximum reliability
while the symmetrical
bearing support assures
even loading and wear.
Maintenance is also quick
and easy as any worn
vanes can be replaced
without needing to remove
the pump from the vessel.
When were out
fueling, No. 1 is safety and
No. 2 is performance,
says Gilman. I feel safe
when Im out there,
Harbor Fuel 1 Captain Jackie Gilman, center, and Boston Yacht Haven General Manager Kevin Lussier, right, have seen their fueling
operations optimized with the use of Blackmer Sliding Vane Pumps, which were recommended by Mike Trask, left, Officer, Hall Trask
Equipment Co., a longtime Blackmer distributor.
MAY 2014 | 15
CASE Studies
After a year of operation on Harbor Fuel 1, Captain Jackie Gilman was completely sold on the safety and performance
of Blackmer pumps: Theyre wicked awesome, she exclaims.
the Blackmer pumps are trustworthy,

and the performance has been 100
percent. Every single delivery has been
outstanding, the numbers are right on,
the pressure is right on, the gauges are
right on. The quietness it deliversit is a
nice, soothing, perfect delivery process.
16 | MAY 2014
Usually the higher flow rate, like

125 to 130 gallons (473.18 to 492.1
liters) per minute, the pumps going to
be louder, but the faster the volume
coming through the Blackmer pump,
down the pipe, through the hose into the
boat, it really quiets down.
Blackmer GX Series Sliding Vane Pump
In the end, we recommended

Blackmer pumps for this application
because of their high efficiencies and
performance throughout the lifetime of
the pump, adds Trask. In fuel-transfer
applications, whether on a barge or a
truck, Blackmer pumps always stand
out due to their high efficiencies and

longevity.
CONCLUSION
In order for the Boston Yacht Haven

to deliver the ultimate service
experience for its clients, a lot of
disparate parts need to work in perfect

harmony.
Our clients rightfully expect a bestin-class experience every time and thats
what we strive to provide them every
day, says Lussier. That means that
we cant compromise on the quality,
performance and reliability of any
aspect of our operation. Thats where the
Blackmer pumps really shine. We place
a lot of strict performance demands
on them and they have responded
beautifully every time we have asked
them to.
That level of reliable performance
also means that after more than a year of
captaining Harbor Fuel 1 and working
with the Blackmer pumps, Gilman
harbors no fears that the Boston Yacht
Haven fueling process will continue to be
nothing other than an idyllic operation.
When were out there on the water
doing our job we have the Blackmer
pumps on board and they help us
deliver the fuel safely and efficiently,
she says. These Blackmer pumps have
been wicked reliable and have proven
themselves time and again to be efficient.
They deliver 100 percent every time. I
trust themtheyre wicked awesome.
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MAY 2014 | 17
WATER & WASTEWATER solutions
By david l. russell, global environmental operations, inc.
figure 1
if you are designing
ooling applications
a sprinkler system for
and many spray
Liquid Sprays
fire protection be sure
applications
require uniform
to have your design
Blade
Entrainment
reviewed and designed
distribution of the cooling
Separator
by the sprinkler company
fluid over the affected
and the fire marshal.
area. Examples include,
Defer to their wishes
spray lines, spray towers,
because it is their system.
certain types of air
pollution control spray
systems, filter backwash
WATER AND NONsystems, fire sprinkler
COMPRESSIBLE
systems, and other types
FLUIDS
of cooling lines where
The same technique
Liquid Recycle Pumps
the cooling fluid is a gas
can be used for the
rather than a liquid (see
headers and the laterals
A liquid spray section for a scrubber (source: U.S Environmental Protection Agency in
collaboration with North Carolina State University).
figures 1, 2, and 3).
coming off of them.
In all these
The application is
applications, the conventional analysis can be time consuming
straightforward: How does one get uniform distribution along
and involve many repetitive steps. In the environmental field,
the length of the pipe even if there is liquids being pumped
there is also the challenge of making sure that a collection or
from the pipe or drawn into the pipe? The distribution system
distribution trench has uniform flow over the entire length of
needs to be tailored to the piping system. The key is the head
the trench. Again, the analysis can be difficult, repetitive, and
loss through the pipe.
time consuming. However, some help is at hand.
TWO SYSTEMS: COMPRESSIBLE GASSES AND

NON-COMPRESSIBLE LIQUIDS
There are two types of systems, one using compressible

gasses, and the other using non-compressible liquids. The
analytical approach to both is similar, but the gas system
requires additional analysis for compressibility of the gas.
Far too often we have seen systems where the pressure close
to the distribution header is quite adequate, but as the flow
approaches the end of the lateral line from the header, the
pressure is low, and as a result, the flow is low, sometimes
much less than the design figure. It is this unequal distribution
which can cause unequal cooling or cleaning in a production
line or spray system.
Here are some simple design tips that will allow
development of effective collection and distribution systems
wells for both liquids and gasses. One note of warning though,
ORIFICES AND PIPE LOSSES
The formula for energy losses through a nozzle or orifice plate

is the same, just the coefficient of discharge is different. That
formula is shown in Equation 1:
Equation 1
Q = Cd*Ao*(2gh) 0.5
Where:
Cd is the discharge coefficient.
Ao is the area of the orifice, and
2gh is the acceleration of gravity times the
hydraulic head.
About the Author

David L. Russell, P.E., is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., a
specialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projects
ranging from environmental process designs and hazardous wastes to water systems and wastewater treatment. He can be
reached at 770.923.4408 or by visiting www.globalenvironmental.biz.
18 | MAY 2014
figure 2
Filter Tank
Wash Troughs
Filter Sand
Graded Gravel
Perforated Laterals
Filter Floor
Cast-Iron Manifold
would be to analyze the pipe at each

perforation. The flow at one location is
Q, just before some nozzle or junction
that takes away a finite amount of flow
(q) for a new value of for the flow (Q-q)
after the junction. From hydraulics, that
means that if the pipe size is the same,
there is a new velocity [V-vq= (Q-q)/
Ap], where Ap is the inside area of the
pipe, and the new velocity is (V-vq). This
means that the next set of friction losses
in the pipe must be evaluated for a very
short distance until the next opening or
perforation.
If there are n perforations, the
computation would require n+1 different
frictional calculations for head loss and
friction in the length of the perforate
pipe, and might require a number of
different piping sizes, decreasing to the
end of the pipe. Thats just unrealistic
and extremely cumbersome.
A LOOK AHEAD
Next month, in part 2 of this analysis,

well continue to examine these
calculations and their benefits, plus
look closer at formulas for compressible
flow as well as for the calculation of
expansion factor as it relates to the
change in the density of an ideal gas.
A cut away of a sand filter which shows the manifold and the perforated headers.
figure 3
22.4 m
15 m
Sprinkler
Head
Sprinkler
Pipe
Supply Main
Layout of a fire sprinkler system.
All of it has to be in the same

appropriate units. The coefficient of
discharge is between 0.59 and 0.61 for
most orifice plates, depending upon
Reynolds Number for the fluid system.
Others have reported slightly higher loss
coefficients, between 0.60 and 0.66.
The higher coefficients were determined
experimentally on piping systems which
had four openings around the pipe (see
M. Duchene and E. McBeans writeup in the American Water Resources
Associations Water Resources Bulletin,

Vol 28, No 3, June 1992).
The challenge in the design is to get
the losses and the flow through the
orifice holes equal to the flow in the
pipe. This can require a bit of ingenuity
in the design process. The ideal situation
is to design the distribution system so
that the flow and the losses at the end of
the pipe are zero.
Without going into a lot of discrete
math, one way of designing the system
MAY 2014 | 19
MAINTENANCE solutions
Know Your Pump Base Plate

Installation Options
Part 1 of a 3-Part Series
umps can be found mounted in

many different ways; there are
times and places to do things at
least cost, and times and places to do
it with uncompromisingly high quality.
Over the course of the next three
installments, this article will familiarize
the pump users with the important
aspects of base plate installation and
some of the preferred options availabale.
Before considering the most prevalent
pump base plate installation options, we
need to know more about how pump sets
are typically shipped to the purchaser
or installation site. In general, process
pump manufacturers are asked to provide
pumps as a set or assembled package
comprising pump, driver and base plate
(see figure 1).
After ascertaining correct shaft
separation to accommodate the selected
coupling, and pre-aligning the two shaft
centerlines within perhaps 0.020 inches
(0. 5 millimeters), pump manufacturers
(whom we assume to be our base plate
providers) spot-transfer mounting holes
from pump and driver to the base plate
mounting pads. The pump and base plate
provider then proceeds to drill and tap
bolt holes that have a diameter of about
0.060 inches (1.5 millimeters) less than
the mounting holes (through-holes)
in pump and driver. Mounting bolts
are inserted at this stage of the pump
assembly and the complete pump set is
now considered ready for shipment as a
pre-aligned mounted package to the
designated recipient.
Receiving the conveniently mountedfor-shipping package has, over the
past few decades, led to the erroneous
By heinz P. Bloch,
Process Machinery Consulting
figure 1
figure 2a
A base plate-mounted API610-style multi-stage pump

at a Rebuild-Upgrader's Shop (source: HydroAire, Inc.,
Chicago, Illinois)
Steel base plate with sleeved anchor bolt (left) and

leveling screw (on right). A thick steel washer (chock)
is shown between leveling screw and foundation (see
reference 1).
assumption that the entire package can

simply be hoisted up and placed on a
foundation. However, doing so is not
best practice; in fact, how pumps are
shipped has relatively little to do with
how they should best be installed in the
field (see reference 1). The old OEM field
service person knew about this issue,
but wise old field service folks are no
longer employed at the OEM and the
ones in charge today just want things
done fast. Users are not blameless in the
matter. They often allow work to proceed
without either specification or procedure.
Some users award contracts to the lowest
bidder and then hope for the best.
figure 2b
Foundation
Bolts
Sleeve
ENSURING LEVEL MOUNTING
We need to observe that best practices

companies (BPCs) will not install the
equipment as a mounted set. To
ensure level mounting throughout, pump
and driver are removed from the base
plate. The base plate is now placed on
About the Author

Heinz P. Bloch, P.E., is one of the worlds most recognized experts in machine reliability and has served as a founding
member of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME,
in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight
decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at heinzpbloch@gmail.com.
22 | MAY 2014
a foundation into which hold-down

bolts or anchor bolts (see figure 2) were
encased when the re-enforced concrete
foundation was being poured (see
reference 2). Leveling screws are then
used in conjunction with laser-optical
tools or a machinists precision level to
bring the base plate mounting pads to
flat and parallel condition. Flatness and
parallelism are measured side-to-side,
end-to-end and diagonally. BPCs require
a readily achievable accuracy of 0.001
inches per feet (~0.08 millimeters per
meter). The nuts engaging the anchor
bolts are secured next and the hollow
spaces within the base plate as well
as the space between base plate and
foundation filled with epoxy grout.
For proper stretch and long life, these
anchor bolts (see figure 2) must have
a diameter-to-length ratio somewhere
between 1:10 and 1:12. The anchor
bolts are provided with sleeves or other
flexible fill. The sleeves prevent entry
of grout and accommodate the differing
amounts of thermal growth of a concrete
foundation relative to that of a steel base
plate.
After the epoxy grout has cured, pump
and driver are placed on the base plate
and aligned to criteria that conform
with best practicesessentially the
workmanship guidelines and reliabilityfocused practices of modern plants
(see references 1 and 2). The driver is
being aligned to the pump by adding or
removing shims from under the driver;
dial indicators monitor an occasional
soft-foot condition at the drivers feet.
When the pump is bolted down, soft
foot and pipe stress are observed on
dial indicators. As the pipe flanges
are bolted up to the pump nozzles,
sensitivity to piping being flanged up is
closely monitored. Any dial indicator
movement in excess of 0.002 inches
(0.05 millimeters) will require making
corrections to the piping and using force
to pull piping into place is never allowed
if the resulting dial indicator movement
exceeds 0.002 inches (0.05 millimeters).
In essence, process pumps should never
be allowed to become pipe supports.
figure 3
Mounting Bar
ANSI pump set on a stilt-mounted base plate (source: ITT/Goulds, Seneca Falls, NY)
the entire installation was thought to

equalize piping-induced forces. Among
the few advantages of stilt-mounting are
low initial cost and ease of floor cleaning
in food processing facilities where
hygiene is very important.
However, there are serious
shortcomings since stilt-mounting will not
allow pump vibration to be transmitted
through the base plate to the foundation
and into the subsoil. Proper foundation
mounting permits transmission of
vibration which can result in a significant
increase in mean time between failures
(MTBF), longer life of mechanical seals
and bearings, and favorably low total life

cycle cost (see reference 3).
REFERENCES
1. Bloch, H.P., and A. R Budris. Pump Users
Handbook: Life Extension, 4th Edition
(2013). Fairmont Press (ISBN 0-88173-7208).
2. Bloch, H. P., and F. K. Geitner. Major Process
Equipment Maintenance and Repair, 2nd
Edition. Gulf Publishing Company (ISBN
0-88415-663-X).
3. Bloch, H. P. Pump Wisdom: Problem Solving
for Operators and Specialists (2011). John
Wiley & Sons (ISBN 978-1-118-04123-9).
STILT MOUNTING
Plants which use stilt mounting (figure 3)

often fall short of achieving best-possible
equipment reliability. Best practices
plants secure their pumps more solidly
on more traditional foundations. Stiltmounted pump sets lack overall stiffness
but have been used for small ANSI pumps
where the sideways-move capability of
MAY 2014 | 23
PUMP solutions
A Revolution in Pumping Efficiency

All-Flos A200 pump reduces energy costs, improves performance
PArt 2 in A 4-PArt sEriEs
By Paul Mcgarry, All-flo Pump Co.
raditional air operated double diaphragm pumps

(AODDP) operate in a very specific way. Compressed
air enters the pump through the main air valve and
the main air valve spool, in an alternating fashion, directs
compressed air behind the left and right diaphragm,
exhausting the air appropriately.
Figure 3: Cutaway of All-Flos A200
The left and right diaphragms are connected via a rod

that runs through the center of the pump and therefore
their movements are interconnected. As the air pressurizes
behind the right diaphragm, the right diaphragm inflates
outward to the right pulling the rod, causing the left
diaphragm to move inward and to the right.
Figure 4: Liquid suction
About the Author

Paul McGarry is the All-Flo sales and marketing manager for North America. To learn more, visit www.all-flo.com, and
www.aoddpumpefficiency.com.
24 | MAY 2014
Illustrated in figure 3, as the

left diaphragm moves inward, the
movement creates suction and fluid
is drawn into the pump chamber from
the bottom suction port. Alternatively,
as the diaphragm moves outward,
fluid is discharged out of the top
discharge side of the pump.
In figure 4, you can see that balls
within the AODDP act as check
valves, ensuring proper suction and
discharge of the process fluid.
During this process of alternating
suction and discharge, air is
consumed and transformed into the
mechanical energy of the diaphragm
movement and exhausted from the
air discharge port of the AODDP. As
shown in the earlier example, this
can sometimes be costly in terms of
air consumption and the resulting
operating cost of a traditional AODDP.
reduce operation costs for its users.

After three years of research and
development, All-Flo has released the
A200 pump, using less than half of
the compressed air of previous models
and increasing overall performance in
both suction lift and flow-rate.
To reduce the air consumption and
increase performance, All-Flo made
several modifications to its original

AODDP design:
Significant reduction and
optimization of dead space on
both the liquid and air side of the
diaphragm
Adjusting the timing of the shift
point of the main air valve,
AN ENERGY EFFICIENT
SOLUTION
The rising cost of energy and its

impact on standard AODDP operation
costs were the driving factors
behind the development of All-Flos
new line of pumps, designed to
MAY 2014 | 25
PUMP solutions
allowing for a longer operating period in a more
efficient point of the air-valves cycle
OPTIMIZING DEAD SPACE
In Figure 5, the diaphragm on the left is shown

fully extended. Optimizing the dead space results
in higher liquid displacement per stroke and a
higher suction lift, that translates into higher selfpriming ability. As a result, the dry lift of this design
improvement resulted in an increase from 13 feet
(3.96 meters) H 20 to 24.4 feet (7.44 meters) H 20. The
higher displacement per stroke led to a maximum
flow-rate of 190 gallons (719.23 liters) per minute, a
large improvement compared to the previous limit of
165 gallons (624.59 liters) per minute. By optimizing
the dead space on the airside of the pump, the new
design boasted higher air efficiencies, allowing the
diaphragm to be displaced earlier in the air-valve
cycle.
IMPROVED AIR-VALVE TIMING
The timing of the shift point of the air-valve also

plays a key role in the overall efficiency of the pump.
All-Flos earlier design was substantially less efficient
near the end of the diaphragm stroke than it was at
the beginning, as it continued to consume air while
displacing very little liquid.
By changing the pumps timing so that the valve
would shift earlier in the cycle, the pump had
a negligible loss in liquid displacement and a
substantial decrease in air consumption, resulting in
a dramatic increase in the pumps overall efficiency.
During the design process, the pumps timing
was optimized, resulting in a final production
design which consumed 45 percent less air than its
predecessor.
Figure 5: Dead space of a diaphragm
Total Head in Feet (Meters)
Pressure Inlet/Outlet PSIG (Bars)
Discharge Flow - Liters/Min.
Discharge Flow - U.S. Gals./Min.

Figure 6: A200 improved efficiency curve
26 | MAY 2014
A200 OPERATING COSTS

65SCFM x 1 hp/SCFM = 16.25 hp
16.25 hp x 0.746 k W/1 hp = 12.12 kW
12.12 kW x $0.07/1 kWhr = 0.85$/ hr
THE A200 PERFORMANCE CURVE
Using the same approach to reading a pump curve as in

part 1 of this series, figure 6 shows how the All-Flo A200
pump compares to the average AODDP used in the earlier
example.
Reading the chart from the same point, 80PSI inlet and
20PSI discharge, you can see that the pump yields 125
gallons (473.18 liters) per minute at a cost of 65 SCFM.
With this information, we can calculate the operating
cost for the A200 pump, as we did in the earlier example,
for an eight-hour day.
Based on these calculations and the assumed operating
conditions, we can see that the All-Flo A200 pump costs
$0.85 to operate for one hour. If the A200 pump was to
operate for eight hours per day, 5 days a week, it would
cost $1,768 per year to operate.
On an annual basis the results are dramaticthe new
design consumes 45 percent less air than the previous
model, resulting in a savings of approximately $1400 per
year for each pump. With the A200 pumps, if a factory ran
100 AODDPs for

eight hours each
day, the user would
save more than
$140,000 annually.
THE A200
DIFFERENCE
Energy is the
engine behind all
of our economic
activity, but when
confronted with
rising energy costs,
customers are left
with few choices
raise prices or
accept a lower
profit in order to
remain competitive.
However, with
AODDPs, users
have a third option,
improving manufacturing techniques and equipment with a
new All-Flo A200.
In subsequent articles we will evaluate air consumption
of the new A200 model compared to typical other
AODDPs as well as highlight some real world applications
where improvements in overall air-efficiency yield better
bottom lines for those involved.
MAY 2014 | 27
DEWATERING solutions
A Simple
Design for
Tough Jobs
By daniel langrish, eurof lo fluid handling ltd.
he Dragflow dredging and slurry pump has a very

simple design making it easy to use and service. The
agitator picks up materials which are too coarse for
pumping and puts solids in suspension; the pump which is
positioned above then sucks them in easily. All wear parts
are made of long life high chromium content. The action of
agitator rejects material that is too large,
thus preventing it from blocking the filter.
The maximum solid handling capacity of
Dragflow Dredging and slurry pumps is
4.72 inches (120 millimeters) and largest
discharge in the range goes up to 13.78
inches (350 millimeters).
VARIETY AND DURABILITY
Euroflo supply these pumps to a

wide variety of applications. In deep
foundation works Dragflow hard Iron
submersible slurry pumps are used for
pumping a CM10 bentonite mix as part
of the construction process. These pumps
are very tough and abrasion resistant,
traditionally standard pumps have been
used for these slurry pump applications,
but with foundation depths that exceed 98.43 feet (30
meters), the standard slurry pumps are put under extreme
pressure that can cause premature failures.
Dragflow hard iron submersible slurry pumps offer a
variety of HD (high depth) versions of these pumps for hire
or sale to work in deep foundation works that exceed 98.43

feet (30 meters), more typically the working parameters of
these pumps is between 131.23 to 213.26 feet (40 to 65
meters) deep, but in more extreme application these slurry
pumps can be put to work in applications that exceed
328.08 feet (100 meters).
POWER WHERE YOU NEED IT
Dragflow dredging and slurry pumps

can be supplied in both electrical and
hydraulic powered formats. They are
used for the dredging of canals and
harbours, clean- up of locks, extraction of
gravel or sand, emptying of caissons and
bulkheads. In mining Dragflow feature in
the clean-up of settling tanks, extraction
of coal, minerals and foundry sand. For
industrial applications Dragflow slurry
pumps are used for the extraction of slag,
forge scale, calcines, sludges, settling
sludges, petroleum, and tar residues.
Dragflow hard iron submersible slurry
pumps have been selected on a variety
of projects because of their ability to
pump very abrasive bentonite slurries charged with sand
and gravel with a density of 1.3 kg/dm 3 at these operating
depths. Euroflo have supplied pumps to carry out a variety
of trials for the recovery of submerged aggregate, as well as
many other applications throughout the quarrying process
About the Author

Daniel Langrish is the digital marketing executive for Euroflo Fluid Handling Ltd., who has been providing expert industrial
and submersible pump services for more than fifteen years, and specialize in the electrical submersible pump industry.
Euroflo exclusively represents Dragflow submersible slurry pumps. For more information, visit www.euoflo.com.
28 | MAY 2014
for mixing and pumping abrasive

materials.
PROGRESS REPORT
For one of our customers in the

republic of Ireland, Euroflo supplied
6-inch (152.4 millimeter), 50
horsepower, 37.5 kilowatt hard
Iron dredging pump, that was used
to recover submerged aggregate.
This aggregate which is made up
of 60 percent sand, 30 percent
gravel, and 10 percent stone with a
maximum diameter of 2.36 inches (60
millimeters). The pump extracted 100
tons (90.72 tonnes) of solids per hour
at a depth of 49.21 feet (15 meters).
permanent position on a ladder at

the front of a self-propelled vessel
for dredging with 656.17 feet (200
meters) of floating discharge pipe.
This submersible pump was powered
initially by one of Euroflos 80KVA
portable rental generating sets, before
a unit was eventually purchased and
mounted on the vessel. After eighteen
months it had produced in excess of

200,000 tons (181,436.95 tonnes)
of high quality silica sand, which is
equates to approximately 500 tons
(453.59 tonnes) per day. Pumping
high concentrations of sand takes its
toll on the pump over time, so every
six months the pump is returned to
Euroflos service center.
TAKING ON CORROSIVE FLUIDS
Using a Dragflow hard iron

submersible dredging pump gives
you an advantage, as they can handle
slurries including stones at higher
depths than horizontal surface pumps.
It is also very important to verify the
percentage of stone and their diameter
when selecting the pump to ensure a
correct selection is made.
Pumping abrasive slurries with low
pH is very challenging as conventional
pumps fail in highly corrosive
environments. Euroflo are able to offer
effective solutions in a large number
of these applications using specialist
pumps. Euroflo supplied an African
copper mine with 6-inch (152.4
millimeter) Dragflow submersible
hard Iron slurry pumps which were
constructed from cast 316 stainless
steel, which made them a unique
special build. These pumps were
produced to work in these extreme
environments, typically working in
liquids with a pH value of between 2
and 3 which is highly acidic.
SAND RECOVERY
Sand recovery / winning are

applications Euroflo have been very
successful in providing a suitable long
term solutions, using Dragflow hard
iron submersible dredging pumps
with agitators. Euroflo conducted
trials initially to prove the ability
of the pump to recover a high
concentration of sand in suspension.
Euroflo for this project used an 8-inch
(203.2 millimeter), 50 horsepower,
37.5 kilowatt submersible hard iron
dredging pump with agitator which
after successful trials was subsequently
purchased. This submersible dredging
pumps was then attached to its
MAY 2014 | 29
MOTOR solutions
Exceeding
Expectations
Moynos new urethane stators increase pump life for wastewater treatment plant
By Adam downey, nov Mono group
he City of Hamilton, Ontarios

Wastewater Treatment Plants
collect both sanitary and
combined sewage (wastewater).
The collection system services not
only the City of Hamilton, but also
the surrounding areas including the
towns of Dundas, Ancaster, Water
Down, Glanbrook Township, and
the former city of Stoney Creek. The
City of Hamiltons Woodward Avenue
Wastewater Treatment Plant began
operations in 1964 and today averages
108 million gallons (409 million liters)
per day with a peak capacity of over
158 million gallons (600 million liters)
per day.
The City of Hamilton Wastewater
Treatment Plants have continuously
battled with the abrasive quality of the
processed water. The abrasive sludge
has caused shortened life for their
nitrile stators and became an issue due
to the cost of continuous maintenance
and replacement stators.
ENHANCEMENT OF THE
WINDERMERE BASIN
Moyno partnered with the City of

Hamilton to test the new Urethane
stators in their abrasive municipal
sludge application. The successful
operation of the City of Hamiltons
wastewater treatment is vital to the
surrounding environment, especially
the Hamilton Harbor and its
ecosystem. The Windermere Basin is
Moyno pump installed in Hamilton, Ontario WWTP.
located in the east end of Hamilton

Harbour, at the mouth of Red Hill
Creek. Over the years, its ecosystem
had been significantly altered and
impacted by human activities.
This project transformed the
degraded body of water, with limited
diversity, into a healthy, diverse
Great Lakes coastal wetland. The
improvement plan involved creating
a wetland and constructing hydraulic
controls, a fish way, a power building,
islands, containment dikes, and local

landscaping.
Overall, this project helped create
a new aquatic habitat not commonly
seen on this scale. The environmental
benefits will also support increased
populations of healthier aquatic and
bird species that live in the cleaned up
Windermere basin.
The basin also enhances the
landscape in an industrialized zone
located in Hamilton's east end and
About the Author

Adam Downey is the new product development manager at NOV Mono and can be reached at adam.downey@nov.com. NOV
Mono comprises a group of specialist companies offering progressing cavity pumps, artificial lift systems, industrial mixers,
heat exchangers, grinders, screens and aftermarket replacement parts and services, across a broad spectrum of industrial
sectors including water and wastewater, oil and gas, chemical, pulp and paper, food and beverage and agriculture. For more
information about Moyno, Inc., call 877.486.6966 or visit www.moyno.com.
30 | MAY 2014
will provide social benefits to city

residents.
"This program of work represents a
large-scale project that we could not
have completed without the generous
support from our federal and provincial
partners," says Hamilton Mayor Bob
Bratina. The mayor went on to note
how the Windermere Basin project
created a unique wetland area, vastly
improving the habitat for local fish and
wildlife. All of these efforts contribute
to our local goals for the remediation of
Hamilton Harbour," Mayor Bratina adds.
"Our government is proud to have

invested in cleaning efforts that will
help the environment, improve quality
of life for Hamilton residents and that
has created jobs."
Improvements and innovations like
these are key to Building Together,
the province of Ontario's long-term
plan to repair, rebuild, and renew the
province's infrastructure. Since 2003,

Ontario has invested approximately
$85 billion in infrastructure. Building
modern, efficient infrastructure has
created or preserved close to 100,000
jobs each year, on average, making
Ontario's economy more productive
and improving quality of life, now and
in the future.
PLAYING A VITAL ROLE
Representatives from the governments

of Canada and Ontario, and the
City of Hamilton have affirmed their
commitment to improving the public
health and quality of life.
"Investing in local infrastructure
renewal will build stronger
communities and improve Hamilton
residents' daily lives," says the
Honorable Jeff Leal, Minister of Rural
Affairs for Ontario. "The Wastewater
Treatment and Windermere Basin
projects demonstrate the Ontario
government's ongoing commitment to
work with our federal and municipal
partners to address the province's
infrastructure priorities."
The project will enhance the quality
of life for visitors and residents in the
City of Hamilton and contribute to
public health improvements and the
protection of the environment. The
positive results of this work will also
help remove Hamilton Harbor from the
Area of Concern list under the Canada
U.S. Great Lakes Water Quality
Agreement.
PREPARING FOR THE FUTURE
The success of the Moyno urethane

stator far exceeded their expectations.
The City of Hamilton has ordered five
additional new urethane replacement
stators for their pumps after the first
urethane stator outlasted the nitrile
stator by more than ten times and
continued to run without failure. As
the City of Hamilton continues to
expand, the Moyno urethane stator
will lower maintenance costs and
significantly reduce down time for the
city of Hamiltons wastewater treatment
operation.
"The improved wastewater treatment
system and Windermere basin are major
achievements," says the Honorable
Peter Kent, Minister of Environment.
MAY 2014 | 31
POWER GENERATION solutions
Ansi/AsHrAE/iEs
Challenges solved
with software
By david Carrier, Quantumflo, inc.
NSI/ASHRAE/IES, Standard 90.1 2010; also referred

become the de-facto pumping control standard. Manufacturers
to as the Energy Standard for Buildings, has created
are required to establish a well-planned direction on
the need for innovation in many industries. In the
how these controls are used to optimally reduce energy
world of pressure booster control, it can be argued that in
consumption within a project site. ANSI/ASHRAE/IES 90.1
recent history there has
(Standard 90.1) took this
not been a more seminal
energy efficiency even
event than the impact
further by considering
of this new standard.
all infrastructure,
10.4.2 Service Water Pressure Booster Systems.
Standard 90.1 rewrites
machinery, lighting,
Service water pressure booster systems shall
the laws governing water
etc. within the building
pressure control and
in order to facilitate a
be designed such that:
delivery. This design
sustainable design that
change affects the control
considers all disciplines
a. One or more pressure sensors shall be used
structure and, in some
of construction. It is a
to vary pump speed and/or start and stop
cases, the location of
directive to architects
pressure control devices.
and mechanical and
pumps. The sensor(s) shall either be located
As a result, QuantumFlo
electrical engineers
needed to develop a
to produce more
near the critical fixture(s) that determine
solution that did not
LEED compliant and
the pressure required, or logic shall be
move these controls, but
sustainable structures
instead utilized advanced
that optimize the energy
employed that adjusts the set point to
system technology
usage for lower carbon
to simulate the same
footprints.
simulate operation of remote sensor(s).
effect. QuantumFlos
b. No device(s) shall be installed for the
GreenFlo logic is a
CHALLENGE
new and innovative
The most significant
purpose of reducing the pressure of all of
algorithm that began
challenge for
shipping in January
QuantumFlo regarding
the water supplied by any booster system
2014 on all QuantumFlo
Standard 90.1 is under
pump or booster system, except for safety
packaged systems in
Section 10, Other
order to fully comply
Equipment, specifically
devices.
with the newly adopted
10.4.2, Service Water
standard.
Pressure Booster
c. No booster system pumps shall operate
Systems. GreenFlo
when there is no service water flow.
OVERVIEW
directly addresses the
Variable speed pressure
challenge outlined in
boosting has clearly
point a.
About the Author

David Carrier is chief executive officer of QuantumFlo, Inc., a leader in the manufacturing and distribution of advanced,
variable speed controlled, packaged pump systems for commercial plumbing, HVAC, municipal, irrigation and industrial
market applications. He can be reached at 386.753.9702 or via dave@quantumflo.com. For more information, visit
www.quantumflo.com.
34 | MAY 2014
Genius E end suction low pressure/high flow VFD booster
The inclusion of 10.4.2a is

monumental for constant pressure
booster design, which has always
maintained that the discharge pressure
of the system must never change.
Now Standard 90.1 states that the
control point (pressure sensor) should
be moved to the top of the building.
This entails that the booster pressure
will adjust in consonance with system
demand minus the friction loss in
the piping run. The booster system
set point will now change when it
should have never changed in the
past according to the flow rate of the
system. This means that as the system
begins to reduce in gallons per minute,
the set point will now change due to
decreased friction-loss in the piping at
the reduced flow.
In the past, the designer would add
up the following conditions to arrive at
a booster set point:
Genius V - vertical multi-stage high pressure/low flow VFD booster
1. Static height of the plumbing

system in feet, converted to PSI
2. Residual pressure in PSI required
at the remote fixture (top of
system)
3. Friction losses at 100% design
flow, to deliver that water to the
remote fixture
Since the friction loss (Item 3)
changes as the flow rate changes,
a rise in residual pressure would
occur at lower flows causing the
pressure at the top of the system
to change according to the piping
friction at the actual flow rate. This
causes a slight rise in pressure at the
roof when the pump is at or near its
no-flow condition. This is why some
manufacturers would suggest that
hydro-pneumatic tanks mounted at the
roof could be employed to store this
extra pressure.
Standard 90.1 has determined that

the level of inefficiency caused by
this recovered friction is sufficient
enough to require the pump to be
further reduced in speed. Therefore, a
remote-mounted sensor would provide
for a pressure which never changes
at the roof of the building due to the
sensor being located there. It has been
referred to as the 80/20 Rule for
boosters. Eighty percent of the time
a typical water pressure booster is at
twenty percent capacity or less. If the
sensor is now moved to the roof there
is no longer a pressure change as it will
track only the target pressure required
there. Without this pressure change
(recovered by the variable frequency
drives, VFDs) these tanks now become
useless in remote mount applications as
they rely on the former pressure change
that no longer exists. Without pressure
change, there is no water storage.
MAY 2014 | 35
POWER GENERATION solutions

Many manufacturers have to comply with this new
standard by advising the plumbing contractor that the sensor
provided (loose) by them must be mounted and wired by a
third-party trade (electrical or controls contractor). This added
step creates a substantial additional cost to the plumbing
contractor as he will need to hire an electrician to complete
this work. This is not a good solution to the problem as most
packaged boosters are built and pre-engineered as complete
plug and play systems. Field installed components reduce
the reliability.
SOLUTION
reading energy consumption through a variety of values

streaming from the variable frequency drive in real time. The
circuit activates at low flow conditions and changes the set
point according to the pressure entered in the GreenFlo
mode activation screen. The system resets to this new set
point and when the demand rises above these conditions,
it reverts back to the design set point. By using a softwarebased solution, the system can continue as a true preengineered product that has been factory tested at simulated
jobsite conditions.
When the GreenFlo icon is visible, this verifies to the
user that the system is operating in full compliance with
The best way to address the control challenge of Standard

90.1 is through the application of simulation logic.
QuantumFlos GreenFlo is pre-engineered algorithm in
their pump systems. There is no advantage to shipping a
machine that relies on the additional labor and expense of
other trades to wire a remote sensor back to the controller,
usually at the bottom of the building. This complicates the
job and injects an additional contracting discipline into a
plumbing system that should work correctly out of the box.
GreenFlo is the solution to the problem of pretesting
equipment as if it were already installed on the site before
it is shipped. This algorithm is built into the current iQFlo
software package and is completely automatic in operation.
The GreenFlo Mode Indicator appears on the main
screen to inform the user when the mode is active. This is an
icon that shows to the immediate left of the QuantumFlo logo
on the main system screen.
When the system is in a low flow condition, rather than
monitoring the remote sensor at the roof, GreenFlo is
WhisperFlo high flow/high pressure/low noise VFD booster
36 | MAY 2014
Standard 90.1 through GreenFlo in

lieu of the remote mounted transducer,
and it still complies with the code
which reads:
or logic shall be
employed that adjusts
the set point to simulate
operation of remote
sensor(s).
GreenFlo is completely field
adjustable by the commissioning
agent using the virtual toggle and set
value. Since no plumbing system is the
same, this allows the user to adjust the
amount of friction to suit any project
need in the field.
SUMMARY
Pump system manufacturers have two

choices to modify their systems to be
in compliance with Standard 90.1.
They can provide a transducer, shipped
loose, to be mounted at the remote

point in the field by a contractor,
or they can provide an algorithm
within the system that simulates the
same effect. Since QuantumFlo is
streaming data at 115,000 bits per
second, GreenFlo takes advantage
of this superior logic strategy and
makes compliance with Standard 90.1
invisible to the plumbing contractor.
GreenFlo requires no additional
equipment, is available at no cost
increase to the plumbing contractor
as logic is standard in all QuantumFlo
systems, and is fully automatic in
operation.
The goal of QuantumFlo as a
manufacturer is to provide the
contractor with a product that would
not add any additional cost in the
effort of meeting the requirements of
Standard 90.1 by creating a built-in
algorithm like GreenFlo instead of
requiring other external components to
be installed.
As the leader in pressure boosting
and controls technologies, QuantumFlo
is committed to providing innovative
leadership as the demands of the
industry dictate. GreenFlo is
Prodigy economy series duplex VFD booster
another way they provide contractors

and consultants with products that
create opportunity through energy
efficiency and sustainable design,
superior quality of workmanship and a
commitment to industry leadership.
MAY 2014 | 37
PROCESSING solutions
Landias chopper pumps sustain Biogens renewable energy process

By Soren rasmussen, landia, inc.
Biogens GwyriAD AD plant, a key component of the Gwynedd regions commitment to renewable energy (Biogen 2014).
piped digester mixing system that utilizes pumps

made by Landia is helping Biogen with its successful
new $8.5 million (5 million) food waste to green
energy operation near Caernarfon in North Wales. The
GwyriAD anaerobic digestion plant first includes a Landia
MPTK chopper pump that mixes 12 percent dry solids in a
buffer tank.
A further two MPTKs resuspend grit (when existing
diffusers are not running) by the use of a pressurised ring
main with four jetting nozzles, equally spaced around the
base of a tank containing 9 percent dry solid digestate.
At a maximum particle size of 0.47 inches (12
millimeters) and temperature of 140 degrees Fahrenheit
(60 degrees Celsius), digestate at dry solids 8 percent is
also pumped by two more Landia MPTK chopper pumps
at a flow rate of 9510 to 19,020 gallons (36 to 72 cubic
meters) per hour at a maximum total head of 49.21 feet (15
meters).
The system at Biogen, the UKs leading food waste
anaerobic digestion specialist, further includes a 4.0
kilowatt 1500 revolutions per minute DG Landia pump to

transfer digestate at dry solids 15 percent (but still liquid)
maximum particle size 0.79 inches (20 millimeters), at a
flow rate of over 5200 gallons (20 cubic meters) per hour.
Landias chopper pumps play an important part in the
process, says Biogens Julian Stelmasiak, proving very
capable of handling the different cycles of food waste.
In addition to renewable electricity (for 700 homes),
Biogens GwyriAD AD plant also creates high quality
biofertilizer for farms in the Gwynedd region, as well as
helping the local council make a major reduction in the
amount of waste sent to landfill.
Landia UK, which is celebrating its twentieth anniversary
in 2014, also has its pumps and mixers in operation
at Biogens Milton Ernest plant in Bedfordshire, where
renewable energy is generated from nearly 52,000 tons
(47,000 tonnes) of pig slurry and food waste per year
generating 1.8 megawatts of green electricity and produces
over 36,000 tons (33,000 tonnes) of a nutrient rich
biofertilizer.
About the Author

Soren Rasmussen is the director of Landia, Inc. For more information Landias range of applications, call 919.466.0603, email
info@landiainc.com, or visit www.landia.com.
38 | MAY 2014
Landias MPTK
chopper pump
plays a vital
role in Biogens
success.
The plant will process over

12,000 tons (11,000 tonnes) of
food waste per year by means
of anaerobic digestion and will
generate 3500 megawatt hours
per year of renewable electricity
for the nationwide grid. The
location of the plant also allows
the biofertilizer produced as part
of the process to be used on local
farmland.
The food waste will be collected
from local households and will
help Gwynedd Council meet its
landfill diversion and recycling
targets and avoid substantial fines
for failing to meet those targets.
The plant also provides a local
facility to recycle food waste from
commercial customers in the area.
All the material being delivered to
the plant will be carried in covered
vehicles by licensed carriers.
The facility is designed to ensure
that, when operational, controls
are incorporated to limit noise and
odour at source. All tipping and
handling operations will take place
in a fully sealed and insulated
building. Bespoke, high quality air
filtration systems are incorporated
within the building to ensure that
odours are controlled at source
and do not leave the confines of
the site ensuring that there is no
negative impact on air quality
for local residents and passing
vehicles.
The plant is fully licensed and
regulated by Natural Resources
Wales under The Environmental
Permitting (England and Wales)
Regulations 2010, and Animal
Health under Animal By-product
Regulations (2005).
Gwynedd Council has
introduced a weekly service to
collect food waste, in order to
maximise the collection of food
waste, and increase its recycling
performance.
MAY 2014 | 39
VALVES & CONTROLS solutions
Going for the
Gold
Ruggedized PLCs will boost
processing uptime at Lapland gold mine
By risto haavisto, ABB finland
BB is upgrading the automation

system at Agnico Eagle's
gold mine in Lapland, with
eight of its latest ruggedized PLCs
for controlling equipment in harsh
conditions and extreme climates. The
PLCs will control the sedimentation
process of the concentrating mill at
Europe's largest gold mine: Agnico
Eagle's mine in northern Finland,
which is 93.21 miles (150 kilometers)

inside the Arctic Circle near the town
of Kittila.
FACING DOWN A BIG FREEZE
ABB won the original contract for the

main automation system at the gold
mine, and configured and installed
electrical automation based on its
800xA Extended Automation system
and industrial IT architecture. The

project involved a large amount of
ABB automation components including
ABB's 800 series operator interface
panels and AC500 PLCs for the
underground control of pumps, air
conditioning, the motors used in ore
crushing and processing, and so on.
However, a number of items of plant
equipment came with automation from
About the Author

Risto Haavisto is the sales manager for ABB Finland. ABB Inc. is a leader in power and automation technologies that enable
utility and industry customers to improve their performance while lowering environmental impact. For more information
about ABBs PLC offerings, visit www.abb.com/plc.
40 | MAY 2014
They were very happy with the PLCs

that provided control in the hot and
humid underground environment
and turned to the supplier of these
main automation vendor ABBwho
proposed a solution based on the XC
PLC. XC is an 'extreme conditions'
variant of the well-known AC500 PLC
family that is installed underground.
It has built-in protection against a

very wide variety of threats posed by
harsh environmental and operating
conditions including high and low
temperatures, high humidity, low air
pressure, salt mist and hazardous
gases, and vibration and shock. In
this case, the new ABB XC PLCs will
be installed at the mine's above-
other vendors, including PLCs that

were supplied with the sedimentation
facility that forms part of the mine's
concentrating mill. The PLCs were
normal industrial grade types, but
housed in freeze-protected cabinets
located outdoors. Since installation,
however, this facility has suffered a
number of process stoppages because
of the environment at the mine which includes very wet and humid
conditions and winter temperatures
as low as -40 Fahrenheit (-40 degrees
Celsius). If a process stoppage happens
in winter the impact can be severe,
as the weather can quickly add to the
problem by freezing and blocking
pipelines.
There have been some four or five
stoppages a year, stemming from power
outages, extreme cold temperatures,
or water droplets that form on the PLC
modules when the cabinet doors were
opened. In wintertime, condensation
can happens in secondsalmost the
instant the cabinet doors are opened
and the benefits of the cabinet's
ingress protection are lostbecause
of the very low temperatures and
the moisture-laden air around the
concentrating mill. The same problem
can also happen in springtime, as
temperatures can swing between -13
and 59 degrees Fahrenheit (-25 and 15
degrees Celsius) from night to day
leading to heavy condensation.
TIME TO UPGRADE
The mine operators decided to

upgrade this part of the control system
to improve reliability and uptime.
MAY 2014 | 41
VALVES & CONTROLS solutions

ground processing
centerwith some
I/O modules located
at a remote water
pumping location
and connected using
ProfiNET.
Mining is one
of the key target
applications for
this PLC. The harsh
environment at
Kittila poses no
problem for the
XC PLC which
can operate in
temperatures
from -22 degrees
Fahrenheit (-30
degrees Celsius), with reliable system
start-ups in temperatures as low as
-40 degrees Fahrenheit (-40 degrees
Celsius), more than meeting the
problems that might arise. Its circuit
boards are conformably coated to
protect against moisture ingress.
And the PLC is protected against
vibration and shock and will tolerate
a lot of mechanical stresssuch as
accelerations up to 4 g from random
42 | MAY 2014
vibrations up to 500 Hz, or 2 g from

sinusoidal vibration. This built-in
protection means that the ABB PLCs
are being installed in standard uninsulated stainless steel cabinets
without any need for freeze-protection
heaters.
NEW DESIGN POSSIBILITIES
Ruggedized PLC technology opens

up new design possibilities, allowing
automation to be
sited right where the
control I/O is needed,
in many cases without
high-specification
environmental
protectionas at this
mine is deep inside
the Arctic Circle.
Agnico Eagle's gold
mine in Finland is
located in Kittila, in
the northern Lapland
region. With an
estimated lifetime
to 2037, Kittila's
reserves are estimated
at almost 33 million
tons (29.94 million
tonnes). The mine employs over 600 staff
and contractors, most of whom are local
residents, making a big contribution
to the regional economy. Ore was
originally mined from two open pits,
starting in 2008. Since 2010, the mining
has moved underground. Some 3000
tons of ore is currently transported daily
to the surface crusher using underground
haul trucks via a 1.86 mile (3 kilometer)
long ramp access system.
SEALING solutions
Playing It
Cool
Mechanical
seal primary
rings for sealing
refrigerants
and other low
viscosity liquids
By Matthew Brennan, Metallized Carbon Corporation
esigning mechanical seals for sealing refrigerants

PASSING THE TEST
and other low viscosity liquids has been a difficult
The table presents a list of typical physical characteristics of
the M-444 mechanical seals. The following are definitions of
problem for seal manufactures for many years. It has
now been established that mechanical seals with antimony
terms and descriptions of methods used to obtain the physical
characteristics. Physical
impregnated, carbon-graphite
characteristics of carbon/graphite
primary rings and solid silicon
M-444 PHYSICAL CHARACTERISTICS
materials are sensitive to part
carbide counter face rings can
size, shape and grain direction.
solve this problem. Metallized
Apparent Density (gm/cc)
2.30
Carbon Corporation, a global
To obtain the data presented
here, specimens were tested with
leader in the manufacture of
Hardness-Shore Scleroscope C2
90
the length dimension oriented
oil-free, self-lubricating, carbonCompressive (psi)
40000
graphite materials for severe
parallel to the grain direction.
service lubrication applications,
Transverse (psi)
12000
announces the availability of
Apparent Density (ANSI/ASTM
mechanical seal primary rings
C 559) is the mass per unit
Tensile (psi)
9000
for sealing refrigerants and other
volume including permeable
Modulus of Elasticity (psi x 106)
4.2
low viscosity liquids.
and impermeable voids and
pores.
Neutral Atmosphere (F)
1100
M-444: MORE THAN
Hardness (ANSI/NEMA CB1)
ORDINARY
is a materials resistance
Oxidizing Atmosphere (F)
700
Low viscosity liquids are
to permanent deformation,
Coefficiant of Thermal Expansion (in/in/F x 10-6)
2.3
difficult for mechanical seals
particularly indentation or
because the hydrodynamic
scratching. Shore Scleroscope
2
8
Thermal Conductivity (Btu/hr/ft /F/ft)
film that they create between
hardness is determined by
the two rubbing seal faces is
dropping a diamond pointed
Pressure Tight
Yes
extremely thin. In order for this
weight on a specimen from a
Modable to Size
Yes
extremely thin hydrodynamic
standard height. The rebound
film to lubricate the two sealing
up a graduated scale indicates
Corrosion Resistance Classification
C10
faces, the seal faces must stay
hardness. Six readings taken
highly polished and they must
on opposite sides of the
Composition
CGSB
run in very close proximity
specimen are averaged to
to each other. It is the selfobtain an accurate value.
polishing characteristic of the M-444, antimony impregnated,
Compressive Strength (ANSI/ASTM C 695) is a materials
carbon-graphite material and the high dimensional stability
ability to withstand a uniaxial crushing load. Values are
of both solid silicon carbide and antimony impregnated
obtained from the ultimate crushing force per unit of cross
carbon-graphite that enables these two materials to run in the
section. Ultimate strength and yield strength are identical.
required close proximity. Ordinary mechanical seals with resin
Transverse Strength (ANSI/NEMA CB1) is a materials
impregnated, carbon-graphite primary rings do not have the
ability to withstand a transverse or flexural load. Values
self-polishing characteristic or the dimensional stability that is
are obtained by loading to failure a rectangular beam
required for sealing these low viscosity liquids.
suspended on two knife edges.
About the Author

Matthew Brennan is the president and CEO of Metallized Carbon, an ISO certified and producer of the Metcar brand of solid,
oil-free, self-lubricating materials. For additional information about the company and its services, visit www.metcar.com or
call 914.941.3738.
46 | MAY 2014
Tensile Strength (ASTM C

given grade for use in seal ring
749) is a materials ability
applications. The internal cavity
to resist being pulled apart.
of a standard ring is pressurized
Values are obtained from
with air. Its outside diameter
the uniaxial force at rupture
is coated with a leak detecting
per unit of cross section.
fluid. An absence of bubbles
Modulus of Elasticity
(after two minutes at 100psi)
(ASTM C 747) is a constant
defines acceptability.
which expresses the ratio
of stress per unit area to
BUILDING ON SUCCESS
corresponding strain per
Low viscosity liquids such as
Freon refrigerants, liquid oxygen,
unit length, the distortion or
strain being within the elastic
liquid carbon dioxide, propane,
limit. Specimens are vibrated
ethylene, and acetone are
in the transverse mode, and
now being successfully sealed
Metcar Grade M-444 offers self-polishing characteristics and dimensional stability
values are calculated from
using mechanical seals with
Metcar Grade M-444, antimony
the resonance frequency.
Temperature Limit is the highest
is measured using a vitreous
impregnated, carbon-graphite primary
temperature that a material
silica dilatometer which indicates
seal rings. Since its inception in 1945,
Metallized Carbon Corporation has
can tolerate without significant
dimensional changes of a specimen
thermal decomposition or loss
when subjected to heat.
been manufacturing high-quality,
in strength; this varies with the
dependable bearing solutions for severe
Thermal Conductivity is a materials
operating environments. With over
amount of oxygen present. Metcar
ability to transmit heat. Values
demonstrates an unusual ability to
are obtained from the cooling
fifty years of Application Engineering
increase in strength with increase
characteristics of a heated probe
experience, Metallized Carbon offers
in temperature.
brought into contact with a
the field expertise and data necessary
Coefficient of Thermal Expansion
to provide solutions for a wide variety
specimen.
(ASTM E 228) is the change in
Pressure Tight (a function of
of industries, supplying completely
machined components as well as
unit length per change in degree
permeability) is a specification
materials for customer machining.
of temperature. Linear expansion
indicating the suitability of a
MAY 2014 | 47
SPECIAL feature
Hear No Evil,
See No Evil,
Speak No Evil
How online
reviews shape
how well your
business does
both online
and off
By Brad Miller
dmit it, youve heard it before. As a

business owner or salesperson, are
there times when customers claim
you have bent the truth to get a sale? Maybe
stretched a truth here and there to get that
customer, close that deal, or get a problem
customer off your back? Or maybe you had
a difficult customer whom you believed
was unreasonable and would do anything
to keep bugging you about a problem? Or
has a customer complained about a product
you suppliedthat the OEM is no longer
backingwhich leaves the issue in your lap?
This is business. We deal with it every
day. From the good customers to the difficult
ones, we all want to close that deal, make
the sale, and get paid. However, even with
the most ethical business practices in place,
communication lines can get crossed and
someone can feel theyve been slighted.
Since the modern business age began back
in the 1920s, with telephones first installed
in offices, this has pretty much been the
business reality.
COMPANY IMAGE:
THE REFLECTION IN THE MIRROR
In the past, company or product reviews

were things you could cherry-pick to find
the perfect reflection of your company.
You controlled the message of who and
what your company is, was, andmost
importantlywill be in your advertising. All
those other times where things didnt go as
planned? No need to worry about those; so
long as you control the narrative, all is well.
However, a few disgruntled ex-employees
might have something negative to say about
your business. What if they feel you may

have played a little fast-and-loose with
the commitments? Perhaps the sales or the
opportunity didn't pan out favorably. They
had a job to do and for whatever reason (be
it individual, managerial or even market
issues) it didn't work. This is typical in
business. Hopefully your customers will
extend you the courtesy of realizing there
are two sides to every story.
Before today this was never really an issue
for business; however, the above model is no
longer relevant to todays operational model.
It has changed and as long as the internet
is the driving force of business it will never
change back. The revolution occurred and
most of businesses don't even know what
happened.
HOW YOU LOOK NOW
Compare the above business scenarios from

the past with how they happen today. If
you have a customer who thinks the sale
has gone poorly and the client is left with a
broken pump or defective part, whereas this
client was on his or her own, thats not the
case anymore. In a few cases, the customer
might feel theyre entitled to further
attentioneither in the form of a refund
of the purchase price or your time to voice
their complaint.
Today, though, your upset customer could
simply log onto one of a half dozen popular
review sites and begin a lengthy dissertation
on your negative business transaction
meaning your name online will be destroyed
by a one-star review. That review may look
like nothing to you, but in an increasingly
About the Author

Brad Miller is a leading voice in the role of online marketing and communication for industrial pump manufacturers.
Questions, comments, criticisms? Send Brad your web questions at thetacticsfactory@gmail.com.
48 | MAY 2014
PaRtiaL LiSt oF
PoPuLaR REViEW
SitES
Google+
Answerme.Org
Citysearch.com
That search term you held organically

for years that generated so many leads
could from now on cost you up to
$10 per click, and thats just a single
keyword out of hundreds.
THE NEGATIVE BIAS

AND THE SILENT MAJORITY
Statistically speaking, negative reviews
are much more common than positive

oneseven if an overwhelming number
of your customers feel positively about
you. Even though an opportunity exists
for positive reviews, most customers
whom you deal with dont feel
compelled to comment on their positive
experience. Everything worked out the
way I expected, they think, why bother
Yelp.com
Angieslist.com
Foursquare.com
Glassdoor.com
Careerbliss.com
connected online world this little star

carries more weight than almost all your
marketing efforts with the web for how
your site will place online.
THE SEARCH IS ON
Search online for some of your favorite

brands and you will notice that many
of them carry reviews. This connectivity
will spread across all other industries
over the next few yearsincluding
industrial pumps and their ancillary
components. OEMs, distributors, and
after-market service providers best pay
attention because tomorrows business
success can depend on you listening to
and embracing this today.
This is because an outside review
of your company is precisely what the
dominant online search engine, Google,

wants. To Google, a user review is an
accurate display of how good you are as
a company. What you say your company
is and how you see yourself is irrelevant
to Google. They arent interested in your
marketing efforts, just the end result. To
Google, this means putting the best
solution to the search query, pairing up
a users search with the best possible
answeran answer that will be heavily
influenced by online reviews. Negative
reviews can knock your website from
page 1 to page 10 for a search, and
one of the only ways you can get back
to that page 1 position will now be via
pay-per-click, further costing you money.
MAY 2014 | 49
SPECIAL feature
posting a review online? When
given the same opportunity,
however, an angry customer wants
to lash out and strike back, and the
anonymity of the internet provides a
forum to do so.
In most cases, even if the
comments arent anonymous,
negative reviews are protected as
free speech and cannot be taken
down via litigation. There have
already been multiple lawsuits and
almost all, save for a very small
selection, have lost. The negative
reviews stayed up.
HOLDING (AND POSTING)

A GRUDGE
Remember the speech? The one

where you told your newly hired
salesperson that if the company
does well, he or she will prosper
too? Thats how its supposed to
work, but sometimes you and a
member of your sales staff may not
see eye-to-eye on what prosper really means. Eventually, this
salesperson is likely to leaveeither by their or your choice.
In the past this situation was simply a short-term problem but a
long-term win for the company: the company keeps the clients
and the "problem" salesperson moves on to another job.
Today, however, that ex-employee with a grudge can hit
back. Several online employee review sites carry the same
weight as the independent customer reviews to Google. Now
instead of the salesperson simply fading off into the sunset,
your company receives a three-paragraph indictment of your
working conditions being like a gulag, your pay scale steals
from the employees, and you are not to be trusted under any
circumstance.
Are such reactions extreme? Of course, but theyre also
protected under free speech andonce posted online
impossible to remove. Potential new suppliers looking
into doing business are online can find hundreds of new
opportunities to sell their wares, and to them, youre just one
possible candidate. Unfortunately, you dont get to make a
first impression on these potential new business contactsthe
internet has already done it for you.
LETS MEET IRL
For the past few decades, trade shows, technical expositions,

and educational conferences have played a major role
in building business networks for the industrial pump
industry. Theyll continue to do so, but just as the dating
scene has changed from the disco clubs of the 1970s to the
online matchmaker sites of today, more and more business
connections make first contact online rather than IRL (in real
life). However, real life consequences stem from these online
interactions. Imagine sitting in a would-be clients conference
room, ready to close a deal on a new product , but right before
the contract is offered you get this comment tossed casually
your way Oh, one last thing, can you please explain all these
negative reviews of your company?
Ironically, they will most likely have their own negative
reviews, but they can use your negative reviews to work a deal
50 | MAY 2014
more lucrative to them.

An online negative review
can mean the difference of
between 10 to 20 percent
of your profit from a sale
all due to the perception
of the product or company.
That loss can add up
quickly, and suppliers are
now beginning to take
notice.
This is not just an
external problem either.
Remember that salesperson
you had to let go in the
earlier example? That
persons perfect replacement
is out there ready to jump on board and help you expand
your business. However, in researching your company, that
bright, energetic, and talented professional took notice of
your disgruntled ex-employees review and is having second
thoughts. Not only that, but what effect do you think that
review has on your remaining staffs morale? Knocks on your
companys reputation can have internal consequences too.
REPUTATION MANAGEMENT
Concerns like these have led to the creation of a new

online business service: reputation management. These are
specialized SEO firms companies can hire to go online to
correct and remove these online reviews. How much is your
businesss reputation worth to you? Professional reputation
management services can charge up to $20,000 for removing
a single websites negative review. If you go online and see
how many negative reviews some of your favorite items
have, you will grasp the scale of this problem. Currently all
major tech corporationsincluding Amazon, Apple, and
Microsoftquietly have created departments employing
hundreds of people whose singular job is to scour the web and
nullify negative reviews. If these corporations, who are the
established powerhouses of industry, are investing so heavily
into this you know the true scale online reviews will play in
the future.
Burying a negative review for an SEO is extraordinarily
difficult and depending on how vindictive and knowledgeable
your customer or ex-employee is they can put these reviews
into hundreds of sites, sowing your future growth as a company
with an electronic minefield. As many review sites read one
another, one review can spread to the others quickly. Its a race
today between the online uneducated versus the educated.
Most people today only see reviews for simple goods and
services, but once they figure out that their review carries
significant weight online you can be sure they will exercise it
to its fullest potential.
If you rely on the internet for business, the following is
critical for you to accept as gospel: Google and all other
search engines do not care who you are, what your business
is, what or who you say you are or how ethically you conduct
your business. To search engines you are just a tiny speck of
data and binary code, and your businesss reputation is steadily
becoming a series of hundreds of small yes-or-no answers from
uncontrollable outside sources. How those reviews align with
your company will determine not only your online placements
but possibly your future survival as a business.
MODERN PUMPING products

BAdger Meter
ModMAg M1000
electromagnetic flow Meter
Badger Meter introduces of the M1000 electromagnetic flow meter, an
addition to its accurate, high-performance ModMAG M-Series family.
Combining a general purpose detector with an amplifier representing
the next generation of electromagnetic flow meter signal processing,
the M1000 is available in an easy-to-use, "no frills" package with a
streamlined feature set for use in a wide range of industrial applications.
The M1000 electromagnetic flow meter achieves an accuracy rate of
0.3 percent and its rugged design ensures exceptional reliability in
demanding environments. The meter features a non-intrusive open flow
tube that virtually eliminates pressure loss, and with no moving parts to
impede the flow stream, maintenance is kept to a minimumeven in
less than ideal fluid conditions. The
M1000 also offers superior vibration
resistance when mounted on
vehicles. A wide selection of liner
and electrode materials provides
maximum fluid compatibility and
Featured Product Release
minimum maintenance over a long
operating period.
For more information about the ModMAG M-Series M1000

electromagnetic flow meter, visit www.badgermeter.com.
geMS SenSorS & ControlS

Bl Series latching valve
The BL series latching valve allows the user to pulse the valve and have it change
state. The voltage does not need to be constantly applied in order to hold it in
a state. These valves are ideal for controlling larger pneumatic valves in remote
applications where power is limited or when the temperature of the media cannot
be impacted as it flows through the valve. The larger pneumatic valves can close
and open large pipes and these latching valves control them. The term Latch
refers to the valve in the open state where supply pressure goes to the external
valve. The unlatched state is when the supply is cut off and the external valve is
exhausted to ambient. Applications include natural gas plunger lifts, natural gas
separators, gas chromatography, and irrigation systems. For more information, visit
www.gemssensors.com.
helWig CArBon inC.
helwig Bearing Protector Shaft grounding System

Helwig Carbon launches a new line of shaft grounding systems to protect motors from bearing
failure, a major cause of motor downtime. The stock kits fit most motors and various shaft sizes.
They are easy to install, maintain, and work effectively in contaminated environments. Helwigs
grounding assemblies divert static and induced electrical currents in the motor shafts away
from the bearings, protecting them from pitting and potential damage.
Several methods are available to reduce or eliminate the path the induced electrical currents
can travel. Among these Helwigs Bearing Protector is the best choice. The Helwig Bearing
Protector will give years of service while maintaining low shaft potential, minimizing your
chance of having stray currents pass through the bearings. The Bearing Protector is a cost
effective way to keep shaft voltage to a minimum.
For more information, contact Marvin Herche at 414.362.6241 or
marvin.herche@helwigcarbon.com, or visit www.helwigcarbon.com.
52 | MAY 2014
vAl-MAtiC
Swing Check valve

Val-Matics Swing Check Valve, with its rugged construction and full flow area, is the most
specified check valve for municipal and industrial water and wastewater applications. Its
smooth unrestricted design can provide significant savings in pumping costs over other
check valves with reduced ports. The available closure options of lever and weight, air
cushion, and lever and spring allow the valve to be used effectively in a wide range of
pumping system applications. The Val-Matic Swing Check Valve meets NSF/ANSI 372. To
learn more about this and other Val-Matic products, visit www.valmatic.com.
Bell & goSSett

ett
technoforce XlS enhanced Pump Controller Station

Xylem Inc., a leading global water technology company focused on addressing the
worlds most challenging water issues, introduces its Bell & Gossett TechnoForce
XLS pump station, helping building owners/operators improve water management,
while realizing efficiency and cost savings in commercial, industrial and specialty
applications.
The TechnoForce XLS enables facility managers to meet a variety of design
specifications by providing energy-efficient and reliable control to up eight pumps
from a single system solution to meet head and flow requirements of a building.
Providing up to 300 pounds per square inch (PSI) of pressure boosting with vertical
multi-stage pumps and stainless steel piping, the system quickly moves water to
where it is needed.
The new TechnoForce XLS is compliant with American Society of Heating,
Refrigeration and Air-Condition Engineers (ASHRAE 90.1) and Underwriters
Laboratories (UL) safety standards. It is also pending certification by the American
National Standards Institute (ANSI)/National Sanitation Foundation (NSF-61).
To learn more about Bell & Gossett or the TechnoForce XLS pump station, visit
bellgossett.com/package-pumping-systems/pressure-booster-packages/technoforce-xls.
dAKotA
inStruMentS
6A03 Acrylic flow Meter

Dakota Instruments 6A03
line of acrylic flow meters
are unique meters offered
with interchangeable direct
reading scales for air, water,
argon, oxygen, carbon
dioxide, nitrogen, helium, and
hydrogen. Dual scales display
flow rates in both metric and
English units. Optional scales
can be developed for diverse
flow conditions, facilitating
OEM applications. The 6A03s
yellow Back Plate enhances
the readability of scales and
minimizes eye fatigue. These
flow meters are supplied
with in-line 3/4 female
NPT connections. For more
information, call 800.879.7713
or 845.770.3200, email info@
dakotainstruments.com, or visit
www.dakotainstruments.com.
nord drive SYSteMS

92.1 and 93.1 Series gearboxes
The 92.1 series, easily identified by its high-strength lightweight

design, is a universal housing offering foot, face (B14) and shaft
mount as standard. An optional B5 mount is available. The 92.1
series is cost effective when compared to the 93.1 and is ideal for
cooling, due to its large surface area.
The 93.1 series is characterized by the closed design and comes
as shaft and flange mount (B14) as standard. Optional drilled and
tapped holes can be provided for foot mount requirements. In
addition, an optional through-bolt, B5-flange is readily available.
Because there are no cavities to this design, NSD tupH surface
conversion system is available.
For more information, visit www.nord.com.
MAY 2014 | 53
MODERN PUMPING products

leWA
g5K 500 and g5K 800 Quintuplex Pumps

Lewa plunger pumps according to API 674 are used wherever high hydraulic power
is needed, especially in the oil and gas sector and the process industry. These pumps
are characterized by their compact construction and low weight, which is particularly
significant for offshore installations. To meet the special requirements of customers
even better, Lewa now offers a new generation of pumps with splitted gear housings.
This special feature significantly facilitates maintenance, permitting the use of a
fully balanced crankshaft which generates less noise and vibration, thus reducing
wear. With drive powers of up to 800 kilowatts, Lewas new design for plunger pump
includes a split gear box and improved maintenance possibilities. The divided gear
housing of the new quintuplex pump permits the use of a fully balanced crankshaft
and facilitates maintenance. For more information, visit www.lewa.com.
univerSAl floW MonitorS

CoolPoint vortex Shedding flowmeter
Universal Flow Monitors, Inc. has seven Coolpoint vortex shedding flowmeters
with an Intrinsic Safety option. The transmitter is 2 wire 4-20mA and has approved
barriers and no display, alarm or pulse output. It meets requirements for NEC Class
I, Division 1, Group D environments. This meter is especially useful in wastewater
treatment plant headworks, screening buildings, grit buildings, sludge treatment
buildings and other places where there is potential exposure to gases from sewage or
sludge. It is suitable for measuring clean process waters and chemical solutions. For
more information, call 248.542.9635 or email ufm@flowmeters.com.
eleCtro-CheMiCAl deviCeS, inC.

dual Channel universal transmitters
Wastewater treatment technicians who need to measure turbidity and dissolved oxygen
(DO) or pH levels in secondary clarifiers will find the dual channel T80 Universal
Transmitter and Triton TR6 Turbidity Analyzer from Electro-Chemical Devices, Inc. (ECD)
can be easily combined with the S80 Intelligent Sensors to measure DO, pH or five other
common liquid parameters. The dual channel T80 Transmitter features self-configuring
electronics, which provide a fast, easy plug-and-play monitoring solution for waste water
treatment. The T80 Universal Transmitter eliminates the need to buy multiple transmitters
to monitor turbidity, DO, pH, ORP, pION, conductivity or resistivity. The Triton TR6
Sensor measures suspended solids or turbidity in four selectable dual ranges featuring
pre-set low and high ranges from 0 to 4000 NTU. Its sophisticated optical IR sensor
emits a beam of 850 nm (near infrared light) into a water sample where it is scattered by
particles suspended in the water. The amount of light reflected back to the sensor by the
particles is correlated to the turbidity or suspended solids present. Contact Joe Bradley at
949.336.6060, 800.729.1333, sales@ecdi.com, or visit www.ecdi.com.
Jet edge
dominator and X-Stream hydraulic intensif ier Pumps

Jet Edges Dominator and X-Stream Series hydraulic intensifier pumps are available
in a wide range of sizes from 30 to 200 horsepower and are capable of producing
pressures from 60,000 to 90,000psi and flow rates of 0.6 to 4 gallons per minute for
water jet cutting and surface preparation applications. The pumps feature a reliable
tie-rod design that eliminates threads on the high-pressure cylinders, end caps, and
hydraulic cylinders, reducing the likelihood of cracking, and increasing component
life. Matched-metal components prevent galling of hydraulic components. Jet Edge
intensifier pumps also feature patented Metal-on-Metal seal technology the cuts in
half the number of seals needing to be replaced, reducing downtime for seal changes.
For more information, visit www.jetedge.com or call 800.JET.EDGE (538.3343) or
763.497.8700.
54 | MAY 2014
AMeriCAn StAndArd
AccessPro toilet
The AccessPRO toilet boasts comfortable 16 -inch Right Height styling, with
an elongated bowl for added user comfort and accessibility. For easy installation,
a floor template, adjustable trapway kit, and slow-close seat are all included
with the toilet. This two-piece toilet features a 3-inch flush valve and 2 1/8-inch
trapway that provides reliable flushing performance. The AccessPRO also leverages
the American Standard PowerWash bowl cleaning technology for a quiet, yet
powerful, flush that scrubs the bowl with pressurized water from the rim during
each flush to remove every last trace of paper and waste. Thanks to these topquality features, the AccessPRO achieves the highest bulk removal score on the
Maximum Performance (MaP) test, an independent report of toilet performance.
This toilet can successfully flush 1000 grams (2.2 pounds) of waste while using a
water-saving 1.28 gallons per flush (gpf). This earns it WaterSense-certification from
the U.S. Environmental Protection Agency (EPA) for providing high performance
while consuming 20 percent less water than standard toilet models. For more
information, visit www.americanstandard.com.
enovAtion ControlS
Murphy PowerCore MPC-20 Controller

Enovation Controls announces its newest controller: the Murphy PowerCore MPC-20. This new
unit gives users complete control with its highly flexible software. Operators can change setups
in the field by easily configuring their exact requirements through the user interface of the
MPC-20 without a computer. Aimed at engine-driven dewatering and irrigation applications,
the MPC-20s flexibility allows it to be used for numerous other applications ranging from
slurry to diversion to frost protection and more. The MPC-20 is the perfect controller for harsh
environments. It withstands extreme heat, bitter cold and shock-prone areas. The rugged unit is
configurable with its free configuration tool, which allows users to easily edit parameters and
set new factory defaults. The MPC-20 can be purchased as a stand-alone controller or as the
ML2000 panel. For more information call 918.317.4100 or visit www.fwmurphy.com.
MoYno inC.
eZstrip tr Muncher
EZstrip has revolutionized the way in which grinders,
PC pumps, and associated products are Maintain-InPlace (MIP) reducing a day-long maintenance operation
to a few hours. The EZstrip TR Muncher offers a
competitive solution to solids grinding and sludge
conditioning. With the ability to maintain
the grinder in place without removing the
equipment, maintenance is reduced by
more than 70 percent for significant
cost savings. Equal Thrust Offset
(ETOS) cutters capture and reduce
large solids for effective maceration.
Angled cutter stack upflow design
rejects hard materials reducing the
risk of damage to the cutter teeth.
Cantilever design eliminates the need
for lower mechanical seals or bearings
reducing breakdowns and repair costs.
Built-in trash trap with clean-out ports
catch any rejected materials. Low
cutter tip speeds, low power and low
noise level. Each Muncher is supplied
with a programmable logic controller
(PLC) to protect the machine against
damage and overloads. Munchers
can be supplied to comply with the
ATEX Directive 94/9/EC. For more
information, visit www.moyno.com.
diAlight
SafeSite led high Bay

At 18 pounds, the 100-277VAC SafeSite
LED High Bay is rated to operate in ambient
temperatures ranging from -40 to 149 degrees
Fahrenheit (-40 to 65 degrees Celsius)
and boasts a T5 temperature rating at 122
degrees Fahrenheit (50 degrees Celsius).
The highly efficient SafeSite High Bay ships
standard with 6kV surge protection and is
IP66/NEMA4X certified. The SafeSite High
Bay is also available with custom in-house
designed optics including medium and wide
distribution types. For more information, visit
www.dialight.com/safesite125LPW.
MAY 2014 | 55
PUMPING trends
Tapping into the
Power of e
Bell & Gossetts Mark Handzel explains
the growing need for energy efficient systems
arlier this year, Xylems Bell & Gossett brand introduced

the Series e-1510 single stage end suction pump and
ecocirc XL large wet rotor circulatorboth of which
focus on high-efficiency offerings. Mark Handzel is vice
president of product regulatory affairs and director of the
Americas, HVAC/commercial buildings market segment
for AWS. His responsibilities include strategy, business
development, marketing, product management and
engineering in the Americas. He spoke with Modern Pumping
Today to discuss the market forces driving high-efficiency
products.
Modern Pumping Today: What were you seeing in the market
that affirmed a need for high-efficiency equipment?
Mark Handzel: There has always been some interest in pump
efficiency, but with energy costs increasing, the need for
efficiency systems has encouraged consulting engineers to
design systems that use less energy. To help reduce the need
for more power plants, the interest in better efficiency pumps
will continue to grow. Energy efficient systems will expand
building systems capabilities and help drive down energy
usage and operational costs.
MPT: Your appearance at the 2014 AHR Expo in New
York City highlighted Bell & Gossetts new high-efficiency
products. How would you describe the reaction?
Mark Handzel: AHR Expo offered the perfect opportunity to
announce our latest products. Efficiency was the buzzword of
the event and having new, highly efficient products was key
to our success at the show. The team hosted dozens of trade
media representatives, filmed videos for the virtual trade show
and interacted with hundreds of show attendees.
MPT: Christopher Johnstons three-part series on Efficiency
Islands recently concluded in our magazine. How would
you best summarize the operating benefits from the Power
of e to engineers and users alike?
Mark Handzel: Bell & Gossetts Efficiency Island white paper
helped demonstrate the value of Efficiency Islands and drew
a lot of interest from media and customers. Pump designs
56 | MAY 2014
of old typically had a Best Efficiency Point where the pump

efficiency was maximized. This point typically covered a very
limited flow range of the pump. Modern hydraulic design
techniques allow us to design pumps today that offer a broad
flow range where the Best Efficiency is maximized.
The Efficiency Island refers to these Best Efficiency Ranges.
They are highly desirable because a pump never operates at
just one point on the curve. The operating point is constantly
changes depending on the control type and system design.
MPT: Your appearance at the AHR Expo emphasized benefits
for HVAC and plumbing attendees, but what other industries
and applications are prime for high-efficiency offerings?
Mark Handzel: There are many applications where pumps
are moved to transport clean-water like a HVAC or plumbing
system. These applications could be in industrial, municipal
or general applications and they could all benefit from high
efficiency products like the e-1510 and ecocirc XL.
MPT: As you introduce new options for your customers, what
value do you place on relationships with distributors and
trade associations?
Mark Handzel: Distributors and trade associations are vital
to our efforts. Distributors have local relationships with
consulting engineers, mechanical contractors and wholesalers
and carry insight and expertise about new products and
Efficiency Islands to the people it matters to most.
With regulatory efforts consistently changing, trade
associations help us stay up-to-date. By knowing what is
happening within the industry, we can set and achieve
reasonable goals for our products and our customers' needs.
MPT: How can you achieve the best position to strongly
promote these lines across all business markets?
Mark Handzel: Premier brand recognition, strong distribution
partners and innovative products are all key to attaining
the best position for products like the e-1510 and ecocirc
XL. Bell & Gossett benefits from all three and has a strong
pipeline of other new products coming up to help meet the
needs of energy efficiency within the industry.

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Modern

12 turning a harbor into a haven

Water & Wastewater

18 uniform distribution in headers

22 Know Your Pump Base Plate

24 A revolution in Pump eff icieny

28 A Simple design for tough Jobs

34 AnSi/AShrAe/ieS Challenges Solved

P.O. Box 660197 | Birmingham, Alabama 35266

38 food Waste to green energy

valves & Controls

40 going for the gold

Jeff fletcher Associate Publisher

Ruggedized PLCs will boost processing uptime at Lapland gold mine

scott GorDon Art Director

chris Garmon General Manager

linDeY scott Circulation Manager

48 hear no evil, See no evil,

Jamie willett Circulation Consultant

russell haDDocK COO/Publisher

nancY malone National Sales Manager

56 tapping into the Power of e

editoriAl AdviSorY BoArd

Drives and Motion Solution Engineer

Heinz P. Bloch, P.E.

Consultant and Trainer,

Business Development Manager,

Director of Regulatory and

Trey Walters, P.E.

President, Applied Flow Technology

312 Lorna Square | Birmingham, Alabama 35216

No part of this publication may be reproduced or transmitted in any form or by any

SPI: The Plastics Industry Trade Association will present the

Innovations such as this are what keeps the plastics industry

ASHRAE 2014 ANNUAL CONFERENCE

While abundant rain and thriving evergreens keep the city

which produces and manages the AHR Expo. We know the

Products 2014 Ahr expo Attendees Came to See

2014 AHR EXPO ATTENDEES: INTEREST IN

According to a post-Show survey of visitors that

BLACOH FLUID CONTROL LAUNCHES

Blacoh Fluid Control, a leading manufacturer of pulsation

providing information. There is an enormous amount of data out

TRADE SHOW profile

Uniting the world of water

he American Water Works Associations Annual

THE SHOW BEFORE THE SHOW

Dont miss the opportunity to get an early look at the

INNOVATION AND CONNECTION

The AWWA Pavilion (booth 1128) offers attendees looking

Motivated attendees can also join in the Innovation

Organized by technical topic, this years program

Former mayor of New York City Rudolph Giuliani

Turning a Harbor into a Haven

Harbor Fuel 1 is outfitted with Blackmer GX & X Series

Boston Yacht Haven meets

ne of the great things

is created, one that is more idyllic or

About the Author

Harbor Fuel 1 Captain Jackie Gilmanfondly known

for the fueling operation, whatever the

FINDING THE PERFECT PUMP

While the goal of Harbor Fuels is safe,

The Blackmer GX and X