Modern Pumping - 102014

mOdERn
TOdAy
PROviding SOluTiOnS fOR ThE WORldWidE PumP induSTRy
PUMP STATION UPGRADE
Reduces oPeRating costs
OCTOBER 2014
Matching PuMPs
to the Right
aPPlication
electRonic WateR
tReatMent in
action
PuMPtuRbo and
WeFtec RecaP
COnTEnTS
4
10
OCTOBER 2014
Industry news
trade show ProfIle
Case studIes
12 Thinking Globally and Acting Locally to Preserve a Natural Wonder

Septic tank replacement using a low pressure sewer system (LPS)
Part 2 in a 3-Part Series
16 Pump Station Upgrade Reduces Operating Costs Using

20
Modern Technology
Low-Profile Chambers Solve Athletic Field Site Constraints
20
water & wastewater solutIons
22 Recycling Earth's Rapidly Shrinking Resource
A basic primer on how food and beverage plants can reuse water effectively and efficiently
26 Electronic Water Treatment
An alternative solution to removing beerstone and limescale
MaIntenanCe solutIons
30 Improving Cooling Tower Filtration
The Southern Hemisphere's largest entertainment complex reduces maintenance and treatment costs
34 The Evolution of Lubrication Technology
26
Why and where to use the Pulsarlube automatic single point lubricator
PuMP solutIons
38 Right Pumps and Right Maintenance Are a Must

Two case studies illustrate the importance of matching pumps to applications
dewaterIng solutIons
40 Reliability Needed in Treatment Facility
Motor solutIons
42 Maximum Results from Mini Drive
WEG Electric's CFW100 Mini Drive puts power at users' fingertips
38
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266
Power generatIon
solutIons
@ModPumpMag
44 Highly Accurate Sensor for Thermal Power Stations

Low maintenance dissolved oxygen sensor monitors boiler feed water
ProCessIng solutIons
46 Precision Fluid Control for Food and Beverage

Ingredient Additions
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
ValVes & Controls

solutIons
scott goRdon Art Director

scott@modernpumpingtoday.com
chRis gaRMon General Manager
chris@modernpumpingtoday.com
48 The Next Wave of Radiant
lindeY scott Circulation Manager

lindey@highlandspublications.com
New solutions for radiant heating and cooling applications
JaMie Willett Circulation Consultant
sealIng solutIons
ingRid beRkY Administrative Assistant
50 How to Cost-justify Bearing Housing Protector Seals

Key factors for reliability-focused process pump users
54
Russell haddock COO/Publisher

russell@modernpumpingtoday.com
nancY Malone National Sales Manager

tonYa bRoWning Account Executive
JeRRY dichiaRa Account Executive
Modern PuMPIng ProduCts
RandY Moon Account Executive
Featured Product Release: WATRY INDUSTRIES Permanent Mold Castings
PuMPIng trends
56 Predictable Power On the Go
www.highlandspublications.com
Atlas Copco's Jlio Tom on the growing market for reliable, portable power sources
312 Lorna Square | Birmingham, Alabama 35216

T: 866.251.1777 | F: 205.824.9796
tiM gaRMon
President
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
laRRY daughetY
Vice President
dennis daughetY
Vice President
Lisa Riles
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
No part of this publication may be reproduced or transmitted in any form or by any

means, electronic or mechanical, including photocopy, recording, or any information
storage-and-retrieval system without permission in writing from the publisher. The
views expressed by those not on the staff of Modern Pumping Today, or who are
not specifically employed by Highlands Publications, Inc., are purely their own. All
Industry News material has either been submitted by the subject company or pulled
directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
jay@modernpumpingtoday.com.
For address changes, please contact Lindey Scott:
lindey@highlandspublications.com
INDUSTRy news
KSB RECOGNIZED IN 2014 CITATION OF EXCELLENCE
KSB, the world's most experienced supplier of pumps and
mixers, was awarded by WEF the Best Design in the 2014
Citation of Excellence in Advertising Awards. KSB was
formally recognized at WEFTEC on September 30, 2014 at
the New Orleans Convention Center. Advertisements up
for consideration were judged by a committee comprised
of members of the Water Environment Federation (WEF)
Manufacturers and Representatives Committee and publishers
in the field.
The winning advertisement promotes KSB's end-to-end
water management solutions, which address all stages of the
water cycle from water extraction to sewage treatment. The
message resonated with the WEF, a not-for-profit technical
organization that brings together scientists, engineers,
academics, and other professionals with the mission of
leveraging knowledge to support clean and safe water
worldwide. Additionally, the advertisement highlights how
KSB's know-how and extensive product range enable users to
meet water supply and treatment requirements.
The design of the advertisement reflects KSB's mission:
applying over a century of experience in water management
to create simple solutions that ensure top performance,
longest wear life, and reduced total cost of ownership for any
water application.
CHLORINATORS INC. CELEBRATE FORTY YEARS
Chlorinators Incorporated is celebrating forty years serving

the water quality industry. With the design of the first direct-
4 | OCTOBER 2014
cylinder mounted all-vacuum gas chlorinator in 1960, a

new company was formed in 1975 releasing another safer
and more efficient product design. In 2015 Chlorinators
Incorporated is commemorating forty years of service to the
water and wastewater industries.
Since that time, the Regal brand is known both nationally
and internationally. The company designs a variety of
products for water processing serving both municipal and
industrial water and wastewater treatment in many industries.
The Regal brand product lines serve a variety of industries
including fruit and vegetable washing, poultry, dairy and
other livestock drinking water, meat, poultry and seafood
processing, drip irrigation, nurseries, municipal and industrial
water and wastewater treatment facilities.
MAINTENANCE AND RELIABILITY SEMINARS OPEN

FOR REGISTRATION
All-Test Pro, LLC is partnering with UE Systems, Allied

Reliability Group, CTC, and Ludeca to offer two one-day
complimentary maintenance and reliability seminars in
November. Seating is limited so early registrants will receive
preferred status.
Increasing uptime and decreasing the cost of operation is
possible when a comprehensive predictive and preventive
maintenance program is implemented. Attending this free
seminar will allow participants to learn from the best in the
industry how an electric motor testing program, vibration
analysis, and ultrasound testing can combine to reduce
downtime and increase profitability.
INDUSTRy news
The Greenville, South Carolina, seminar is November 12
and the Durham, North Carolina, seminar is November 13.
Those interested in attending should call 864.284.0111 or
919.286.0774.
INTEGRA TECHNOLOGIES OPENS

NEW TEXAS RENTAL OFFICE
Integra Technologies is expanding its rental coverage and is

excited to announce the opening of a new rentals location in
Nederland, Texas. The office was officially opened this August
and is INTEGRAs second location in Texas. Located off of
Memorial North Frwy, the facility supplies tooling for bolted
joints. Tensioners, Hydraulic and Pneumatic Torque Wrenches
and Nutsplitters are available for rent as well as specialty
services such as Qucikflange, H.I.T.S. utilizing the Aqua
Plug, and LeakSeek. This location supports Beaumont,
Lake Charles, Port Arthur and the surrounding areas. The
site functions as a fully equipped workshop and office
with a focus on safety as the number one goal. INTEGRA
Technologies is dedicated to developing innovative answers
to the industrys most critical challenges and providing quick
responses to customers needs on time, every time.
AWARD IN PROGRESSING CAVITY PUMPS

FOR OIL AND GAS GOES TO NETZSCH
For the second time since 2011, Netzsch will be presented

with a highly appreciated, best practices award by Frost &
Sullivan, the U.S.-based growth partnership company. In
its motivation statement, Frost & Sullivan explains that the
6 | OCTOBER 2014
2014 Global Product Leadership Award in Progressing Cavity

Pumps for Oil and Gas was issued by evaluating total client
experience and strategy implementation excellence using a
scorecard, including ten benchmark criteria for both product
leadership and management culture, which has set Netzsch
clearly apart from the other companies in the field.
Frost & Sullivan recognizes that the dynamics within the
oil and gas industry are constantly changing. Innovativeness,
uniqueness, customer values and matching the needs of
the end customers are the key ingredients for success in
this highly competitive market. To gain market share, pump
manufacturers must introduce new and better technology
to replace existing inefficient technology in the oil and gas
industry. Vision alignment, operational efficiency, and positive
company culture will nurture the existing talent within the
company to manufacture high-performance, high-quality,
and reliable products. Netzsch has been in the progressive
cavity pumps market for more than sixty years, and Frost &
Sullivan finds that close partnerships with end users have
given Netzsch the knowledge of various processes, which led
it to design a suitable product that meets all of the end-user
requirements, as well as in upstream as mid- and downstream
applications.
Oil and gas is a critical process industry, as it cannot afford
downtime. Hence, the reliability and quality of a pump play
important roles in ensuring that the process is problem-free.
Frost & Sullivan analysis confirms that Netzsch offers products
that are highly reliable and dependable. Moreover, Netzsch
uses advanced testing facilities to ascertain that all pumps
INDUSTRy news
perform satisfactorily before they are installed on site. Unlike
other manufacturers, Netzsch has a dedicated consulting
team, technical team, and spare-parts team that make sure
the best customized solution is built and delivered on time
for each application. In addition, Netzschs service and
maintenance contracts are proactive, rather than reactive.
Netzsch has global presence with an extensive distributor
network in all of the major regions. This enables Netzsch to
provide around-the-clock services and ensure that downtime
is minimized. Netzschs technicians document every aspect
regarding its customers and the products to make sure
the products are serviced on time. This shows Netzschs
commitment to reliability and quality.
Frost & Sullivan notes that NETZSCH has continuously
developed innovative technologies that aid end users with
their current challenges. This close look at the customers
requirements and the benefits that really count for their
application has made and kept NETZSCH the world market
leader for progressing cavity pumps over the years. Together
with joint venture partner Heishin in Japan, they hold 28
percent of the global market share.
RACO ANNOUNCES CATALYST UPDATE, NOW

SUPPORTS TWO COMMUNICATION PROTOCOLS
RACO Manufacturing and Engineering Co., a leading

provider of remote monitoring, reporting and control devices,
now offers EtherNet/IPTM and Modbus TCP protocols for
Catalystan integrated system for data and event logging,
alarm notification and status checking.
8 | OCTOBER 2014
With the optional EtherNet/IP and Modbus TCP protocols,

Catalyst can easily interface and integrate with more system
designsincluding PLCs, SCADA systems and other devices.
These communication protocols are just two of RACOs
latest product updates.
RACO is committed to continuous product improvements
to meet our customers growing needs, says James Brown,
vice president of sales and marketing for RACO. Catalyst is
a flexible, single-package solution to provide the peace of
mind, stability and confidence our clients require.
RACOs Catalyst is an integrated data logging and
alarm notification system that offers immediate access
for extensive data and event logging. Catalyst is reliable
and adaptable with two-way connectivity and constant
communication via landline, pager, cellular phone or fax.
Easy programming and upgradeability, even remotely, allows
for efficient monitoring, reporting and control function.
ENGINEERING WEBINAR: DESIGNING

BETTER CENTRIFUGAL WATER PUMPS
CD-adapco is offering a free online seminar on October

30 for companies interested in using simulation to design
pumps that perform to specification not only at the
Best Efficiency Point (BEP), but also under wide-ranging
operating conditions. Such companies know that their
customers will not always operate their pumps at the
BEP, so the more robust they can make their designs,
the better. Details on participation can be found at
www.cd-adapco.com.
TRADE SHOW profile
A Look Back at
PumpTurbo and WEFTEC
From increased efficiency standards to wastewater repurposing, innovation pushes the pump industry
or industrial pump
manufacturers and their
related markets, the past
few years have represented a
shift from old ways of thinking
and an embrace of new
technologies, applications,
and designs. The downturn in
the domestic and international
economies during the first
part of the decade provided
an incentive for pump users
to seek out more efficient
operating standardsand
brought with them a rise in
after-market and maintenance
services.
However, as the economy
improves, risk is no longer a
four-letter word among those
working in the industrial pump
and rotary equipment markets.
Nowhere is this commitment
to forward-thinking and
innovative solutions better
on display than the recent
Pump and Turbo Symposia and
WEFTEC events from this past
fall.
addressing their readiness in

the remainder of 2014 and
into 2015. With no decrease in
pump users demand for power
expected, many OEMs see
these new regulations as an
opportunity to introduce more
efficient equipment and new
designs of existing models.
WASTEWATER WONT
GO TO WASTE
A similar emphasis on
innovation continued into
the annual WEFTEC trade
show, held this year in New
Orleans. Not only is there a
shared quest for improved
efficiency standards, but
todays water and wastewater
industry is currently creating
Experienced pump users shared insights with tomorrows professionals at Texas
opportunities for itself
A&Ms Pump and Turbo Symposia.
in power generation and
chemical processing as well.
One wastewater expert in
attendance noted that, using
current industry standards,
the potential contribution to
the domestic power grid via
gas extraction from industrial
PUMP USERS LOOK
wastewater is three to four
times the cost to filter and
TO THE FUTURE
remove it. Furthermore,
The recently concluded 43rd
many experts project that
Turbomachinery and 30th
the majority of industrial
Pump Symposia welcomed the
most attendees in its history
wastewater processing plants
will be energy neutralor
over 6000and provided
even energy positivewithin
pump professionals with
the next five years.
hours of in-depth, field-tested
The expansive WEFTEC
solutions that can leave the
lecture hall in Houston and
exhibit floor featured new
WEFTEC 2014 showcased the industrys push toward innovative solutions as plants
products highlighting the
make a difference in plants
move from water treatment to reuse and repurpose.
around the world. Outside of
industrys urgent demand
the seminars and on the exhibit
for innovationfrom both
floor, attendees benefitted from the Symposias traditionally
large and smaller manufacturers. In the next decade, water
welcoming environment as lecturers and students mixed with
reuse and water repurpose will be the norm for wastewater
OEM representatives to share ideas and experiences.
processing rather than the exception, which means OEMs and
A common topic of discussion was the implementation of
equipment users will be working together to implement new
the Environmental Protection Agencys (EPA) Tier 4 emission
designs and new treatment processes that make the most of
standards and how manufacturers and operators will be
these opportunities.
10 | OCTOBER 2014
CASE Studies
Thinking Globally and Acting Locally

to Preserve a Natural Wonder
Septic tank replacement using a low pressure sewer system (LPS)
Part 2 of 3
By Wayne Ackart, Town of Jerusalem (new york),
and Clark A. henry and michael Crowley, Environment One
he transition from independent

septic systems to a centralized
low-pressure sewer (LPS)
collection system has economic,
environmental and altruistic advantages
to communities like the
Town of Jerusalem, New
York.
A decade after
the installation was
complete, the Town of
Jerusalem and E/One
decided to embark on a
unique study: Parts Two
and Three of this article
provide a ten-year
(2003-2013) review
of Operation and
Maintenance (O&M)
data and a hydraulic
performance analysis
comparing expected
design flows to
quantitatively measured
flows for the 265-unit
septic tank replacement
project.
Three key conclusions
regarding this LPS are
evident from the data:
the system is reliable
and cost-effective,
hydraulically flexible
and improves quality
of life.
FINDING THE RIGHT

MEASUREMENTS
Perhaps the self-evaluation could

predict future performance by revisiting
the past. "In business, the idea of
measuring what you are doing, picking

the measurements that count like
customer satisfaction and performance
you thrive on that," Bill Gates once
said.
Figure 1: Service calls and the MTBSC for the ten-year period under analysis.
About The Author

Wayne Ackart, P.E. is town engineer for the Town of Jerusalem. Clark A. Henry is director of engineering at Environment One.
He can be reached at chenry@eone.com. Michael Crowley is LPS system designer at Environment One. For more information
on Environment One Corporations full line of grinder pumps and LPS solutions, visit www.eone.com or call 518.346.6161.
12 | OCTOBER 2014
Operation and maintenance

records and invoices from the Town
of Jerusalem files were analyzed
for the period from January 2003
through December 2013. Office
and maintenance personnel
were interviewed regarding their
experiences with the project.
The project team of Clough,
Harbour & Associates LLP (CHA);
Siewert Equipment Company; the
Town of Jerusalem; Environment
One Corporation (E/One); and local
plumbing company Dean Roberts
Plumbing and Heating established a
procedure for addressing service calls
and system maintenance. All parties
were factory trained and certified by
E/One field service personnel.
the grinder pump station, installed a

replacement pump, transported the
pump requiring service back to their
service shop, repaired it and readied it
for return to use.
Service records show a Standard
Repair was often performed consisting
of pump stator, pressure switch and
start contactor replacement.
RELIABILITY AND MEAN TIME

BETWEEN SERVICE CALLS
Mean time between service calls

(MTBSC) was calculated to be
approximately twenty-eight years.
During the 10-year period, 165 calls
were recorded on 274 pumps.
Only 70 of the 274 pumps on the
project experienced a service call.
The New York Association

of Consulting Engineers
gave its 2003 Silver Medal
Engineering Excellence
Award to Clough, Harbour
& Associates for the Town
of Jerusalem Low-Pressure
Sewer System Design.
It noted the "Survey,
design, and construction
services for 29,000 linear
feet of low-pressure sewers
and associated grinder
pump stations. A significant
portion of the sewer was
installed using directionaldrilling techniques in order
to minimize disturbance in
this lakeside sewer district."
Simple removal and installation of

the pump for service is inherent to the
design of the E/One grinder pump. The
stations components are accessible by
removing just three bolts on the access
lid. Homeowners experience minimum
downtime and a maintenance crew
can repair and test the damaged core
in the shop.
Service calls were initially routed
to Town of Jerusalem maintenance
personnel. An initial field assessment
was performed. If the pump required
repair, Dean Roberts Plumbing
and Heating was contacted. A
representative removed the pump from
OCTOBER 2014 | 13
CASE Studies
However, 27 of
these 70 pumps
experienced two or
more service calls.
These repeat calls
accounted for 71
of the 127 calls or
56-percent of the
calls.
The root causes
of these calls
were traced to the
following and were
quickly corrected.
Many were attributed
to excessive disposal
of cooking grease
into the wastewater
stream by several
homeowners and
root penetration and
obstruction of the
inlet line between
homes and grinder
pump stations.
A spike in
service calls was
experienced in 2011
due to a prolonged
power outage.
14 | OCTOBER 2014
Figure 2: Annual maintenance cost per pump for the ten-year period under analysis.
Power was out for an extended

period of time and homeowners
inadvertently continued to use water.
This resulted in several flooded
stations and a variety of flood related
call outs.
OPERATION & MAINTENANCE

(O&M) COSTS
Figure 2 and the interviews reveal

several observations: During the tenyear period, the O&M cost per pump
was approximately $37 per pump
per year (excluding power). This is
consistent with many other E/One LPS
installations which typically report
O&M costs ranging from $30 to $50
per pump per year.
Initial O&M costs were very low
from 2003 through early 2005 due to
the focus the project team placed on
installation training and inspection of
installations.
Costs increased in 2005 due to
a significant number of relatively
expensive pump motor repairs.
This problem was traced to a
manufacturers defect in a push-torun switch used on the grinder pump
alarm panel.
The switch was prone to shorting
out in the closed position. This caused
the grinder pump to run continuously
resulting in excessive wear on the
entire pump. Occasionally the pump
motor would become damaged
due to excessive heat and require
replacement.
The practice of typically performing
a standard repair on pumps
mentioned in the maintenance
procedure section above contributes
to slightly elevated O&M costs. This
practice may lead to the replacement
of components that still have several
years of useful life remaining.
However, since all pumps are
owned by the Town of Jerusalem, it
is understandable that they would
invest in upgrading a pump when
the opportunity presents itself. This
practice slightly increases the O&M
cost per pump per year. However, it
also lengthens the MTBSC at minimal
cost.
A LOOK AHEAD:
Part Three of this article provides a tenyear (2003-2013) review of hydraulic

performance analysis comparing
expected design flows to quantitatively
measured flows for the 265-unit septic
tank replacement project.
OCTOBER 2014 | 15
CASE Studies
Pump Station Upgrade

Reduces Operating
Costs Using Modern
Technology
By Steven london
arrenton, Oregon, is located in Clatsop County

on the northwestern tip of the state. A small
coastal community with a population of about
5000 people, Warrenton is bordered by the Pacific
Ocean on the west and the Columbia River on the north.
Originally platted in 1889, the city was incorporated
under the laws of Oregon in 1899.
By 2012, Warrentons SW Alder pump station was
rapidly reaching the end of its life. In fact, it had even
become more cost effective to run a diesel backup pump
at the station as opposed to refurbishing the existing dry
mounted pumps. The station was originally equipped with
10 horsepower pumps designed to generate 400 gallons
(1514.16 liters) per minute at 34-foot (10.36 meter) total
dynamic head feeding into a shared force main. But the
pumps had difficulty meeting this requirement and often
wound up running against shut off head at the primary
pump station. This situation is known as deadheading,
which occurs when the discharge of a pump is closed.
Typically, the pump goes to its maximum shut-off head
and fluid is recirculated within the pump, which can
result in overheating and subsequent damage.
During a high rain event, significant inflow and
infiltration could cause the overburdened SW Alder
station to operate continually for eight to ten hours,
deadheading for most of that time. This was a significant
issue as the potential for an overflow event made every
storm front a cause of concern for maintenance staff. In
addition, the long-term deadheading affected the lifespan
of the existing pumps significantly. Another factor in the
operation of the SW Alder plant was a large food-oilgrease component that entered the station, which at the
time necessitated multiple weekly cleanings. The running
costs based on power and maintenance records along
with cost allocation for staff time at the site averaged
$21,898 annually.
Figure1: TOP Basin secured at bottom of wetwell.
Figure 2: TOP basin sealed in place, forms new bottom of well.
About The Author

Flygt, a Xylem brand, is a world leader in the design and manufacture of dry and submersible pumps, mixers and related
intelligent controls systems. Under the Flygt banner, customers have access to a complete range of products and solutions for
moving water, wastewater, and advanced monitoring and control equipment to optimize their use. For more information on
Flygt and its parent company, visit www.xyleminc.com.
16 | OCTOBER 2014
Figure 3: Rail system permits Flygt pumps to be easily mounted in position.
The city decided to refurbish the wet well and controls

in 2013. An RFP was issued requiring suppliers to meet
minimum material standards and operational conditions for
the pump and variable-frequency drive duplex operation. As
the specification allowed for innovation above the minimum
standards, the Portland branch of Xylem Water Solutions
submitted Flygts Experior Pump System package of two
NP3127 10 horsepower submersible pumps, which include
N impellers and SmartRun controls.
The Experior Pump System combines N technology,
premium efficiency motors, and intelligent controls to
Figure 4: Flygt's small adaptive N-pumps
maximize reliability and efficient operation. The N impellers

are self-cleaning, which improves their efficiency and
lowers power usage. SmartRun controls provide the benefits
of variable speed pumping, optimized to achieve energy
savings and maximum cleaning within wastewater pumping
stations.
This pump-impeller-controls combination maximized
power and cleaning savings for the city. This submission
was the successful low bid$32,803 for equipmentand
met all of the citys criteria. Importantly, the city received
a non-conforming bid using traditional materials of
OCTOBER 2014 | 17
CASE Studies
construction that was $665 lower than
Flygts conforming offer. This gives a
good baseline for the cost difference
between traditional design and newer
materials along with the more modern
approach to controls.
Upon review of the project with Jim
Rankin of JB Rankin Engineering, the
citys engineer for this project, it was
18 | OCTOBER 2014
decided that a Flygt TOP 150 preengineered fiberglass insert should

be installed in the existing pump
station to control grease and solids
in the wet well. The TOP 150 insert
is a factory built fiberglass insert
for existing concrete pump stations
designed to pump wastewater or storm
water in municipal sewage systems,
in commercial facilities, and other

applications where the removal of
solids and scum is a priority.
Custom installation brackets would
also be used to suspend the insert
off the floor in the existing eight-foot
diameter wet well to avoid having to
remove the original benching. Initial
engineers estimate for installation of
standard equipment without the TOP
insert was $80,000. It compared well
to the chosen contractors actual bid
of $79,032. This made the inclusion
of the TOP 150 insert a no-cost option
and provided the station with a selfcleaning bottom design.
As shown by the bid process, the
difference between a traditional
approach and using more modern
design and materials has been
negligible, impacting the cost of the
station upgrade very little. However,
the positive effects of a modern design
using newer materials have been
dramatic in terms of reliability, power
savings, breakdown and emergency
operation concerns, cleaning, and the
necessity to stock spare parts.
City staff has been able to reduce
pump station cleaning to either
monthly or bi-monthly routines
without the need to add degreaser,
which was previously required prior
to the upgrade. Power consumption
has been reduced by 27.82 percent
with vastly shorter run times (pumps
operating near or against shut off use
less power in operation over a longer
running time), making damage due
to operating near shut off a thing of
the past. In the first year the station
will have cost $6,290.00 in operating
expenses, saving the city $15,607
from the original pre-rebuild operating
costs.
Based on the power and
maintenance history, it is estimated
that a rebuild using the traditional
methodology would have cost the
city $14,832 to operate annually;
the modern design and materials
saved $8542 savings when compared
to the more traditional approach.
Naturally, as the station is still within
the warranty period, the absence of
breakdown costs associated with the
old station also needs to be taken into
account for comparative analysis.
To provide a suitable baseline
for ongoing pump and control
maintenance, the Xylem Gold
TotalCare program can be utilized,
which offers three TotalCare Options
gold, silver and

bronze. Gold
provides bi-annual
service visits and
100 percent part
replacement costs
on parts and labor
on the installed
pumps. This allows
the city to base
its operating costs
on a fixed number
for the upkeep of
the pumps with no
additional surprises.
Based on one-yearold pumps and an
allowance of $500
per year to cover
additional electrical
components, the
cost to maintain the
Figure 5: Flygt pump control panel.
pumps in operational
condition would be
$2612 with a three-year contract.
By implementing the program, the city could adjust its
annual budgeted operational cost to $8,902. This would
provide a realistic saving to the citys operating budget of
$12,996 per year or a total operating cost reduction of an
impressive 59.35 percent.
SW Alder pump
station used to
be considered a
moderate to high
maintenance
station with ageing
infrastructure,
reliability issues
and peak loading
concerns. It is now
a model of what
can be achieved
by utilizing a
modern approach
to refurbishment.
The city can
effectively redirect
almost $13,000
(compared to an
estimated $4450
using traditional
materials and
designs) annually
towards other asset
management requirements as well as enjoy greater reliability
in operation, which will further reduce additional overtime
expenditures. In addition, with significant reduction
in electrical power used, the city is able to meet the
communitys current energy consumption and environmental
impact expectations.
Dont surrender
to wipes!
The buildup of wipes and other debris in sewage is the enemy.
Fight back with a powerful and energy-efficient Muffin Monster
grinder in your pump station. With over 40,000 installations and
over 200 different grinders and fine screens, JWC will help you
eliminate clogging and finally win the war on wipes.
New Monsters. New Solutions. No More Wipes.
Sign-up for Wipes Alert Newsletter at NoMoreWipes.com
Muffin Monster
& Channel Monster
sewage grinders
OCTOBER 2014 | 19
CASE Studies
Low-Profile Chambers
Solve Athletic Field
Site Constraints
By CulTEC Technical Staff
he public school district in

Hingham, Massachusetts,
is comprised of six schools,
including Hingham High School, which
aims to graduate students with the
academic, civic, social and personal
skills necessary to become productive,
responsible members of a democratic
and ever-changing global society. With
the support and involvement of the
community, Hingham engages students
in a challenging, well-balanced
educational program complemented by
co-curricular activities.
As part of the co-curricular activity
offerings, the school touts a number of
athletic teams, including football, boys
and girls soccer, track and field, cross
country, softball and baseball. In an
effort to upgrade the athletic facilities,
Hingham High Schools traditional

grass fields were reconstructed and
replaced with synthetic turf fields. The
permitting process for the renovation
took place in late 2012 and early 2013,
and the actual construction ran from
June through August 2013.
GETTING THE LAY OF THE LAND
Hingham High Schools new turf

fields, which include lights for night
games and an additional parking
area, will primarily be utilized by the
schools football and soccer programs.
Part of the process for designing and
installing the new fields included the
design of a new subsurface stormwater
management system. Engineers at
Gale Associates collaborated with
contractors from R.A.D. Sports to
design and install a subsurface system

that would effectively provide retention
and detention to the site.
During the initial planning phase,
engineers were faced with a couple
of challenges. A seasonal high-water
table was an initial design constraint.
In Massachusetts, sites without proper
clearance from the water table require
additional storage to provide detention,
and infiltration cannot be included as
part of a model during a larger storm
event.
When designing the system, we
had to be mindful of the high water
table, as well as a 100-year flood
elevation area, which is situated just
outside the site, says Peter Spanos,
Gale Associates engineer. We were
able to use CULTECs StormGenie
for more information

CULTECS technical staff offers free design assistance including preliminary calculations and job-specific CAD details.
For more information about CULTEC stormwater management chambers and other products, call 203.775.4416 or visit
www.cultec.com.
20 | OCTOBER 2014
drawing program and the HydroCAD

Stormwater Modeling System to easily
generate an accurate system layout
and design. Using these tools we
dramatically cut down our design
time and determined that CULTECs
Contactor 100HD chamber was ideal
for this project because of its low
profile.
A HEAVY-DUTY SOLUTION
CULTECs Contactor 100HD heavyduty subsurface plastic chambers

were chosen for the job as they
maximized the storage capacity while
maintaining a low profile. Distributed
by John Hoadley and Sons, Inc.
from Rockland, Massachusetts, the
Contactor 100HD is one of CULTECs
lowest profile chambers with of height
12.5 inches (318 millimeters). The
chamber holds 112 gallons (422.7
liters) and stores a minimum of 28.81
cubic feet (0.82 cubic meters) of
storage per unit when surrounded with
stone. The chambers have repeating
support panels to add strength and
features the patented side portal to
allow for internal lateral manifolding
of the system. A small chamberthe
HVLV SFCx2 Feed Connector
is inserted into the side portal of
the Contactor 100HD to create
the internal manifold. The internal
manifold eliminates the need for
an external custom pipe and fitting
header system, which would take
up additional space and is costly to
fabricate.
Because of its low profile, the
Contactor 100HD is ideal for projects
with restrictive depth parameters
caused by high water tables, ledge,
etc. In addition, CULTEC has an even
lower profile unit, the Contactor Field
Drain C-4 which is only 8.5 inches
(216 millimeters) high for applications
with extreme depth restrictions.
chambers and is located beneath the

fields and parking lot. The system also
utilizes CULTECs Separator Row and
deep sump catch basins, which flow
into the Separator Row, as a method
of double-duty pre-treatment. The
Separator Row acts as a water quality
row preventing suspended solids
from intruding into the chamber bed
and stone. It captures any silt or fine
particles prior to runoff overflowing
into the rest of the basin and sump. To
help maintain the stormwater system,
any debris can be pushed toward the
catch basin and sump using a water
jet, and vacuumed out.
Deep sump catch basins are storm
drain inlets that typically include
a grate or curb inlet and a sump
to capture trash, debris, and other
sediment, oil and grease. Stormwater
runoff enters the catch basin via an
inlet pipe located at the top of the
basin. The basin outlet pipe is located
below the inlet and can be equipped
with a hood (i.e., an inverted pipe).
Floatables such as trash, oil and grease
are trapped on the permanent pool of
water, while coarse sediment settles to
the bottom of the basin sump.
ON THE STARTING LINE
The entire installation process went

even faster than we had imagined
which was great because the fields
and parking area had to be complete
by the start of the school year, says
Rob Delmonico, President of R.A.D.
Sports.
Everyone was working on a
really tight schedule, he adds, so
the constant support from CULTEC
representatives helped keep this a very
seamless operation. Students have
been using the new turf fields since
the start of the fall 2013 school year.
HOW IT WORKS
Four separate beds were arranged

within the site to comply with the
local Conservation Commissions
requirement that the system also treat
the runoff from the new parking area.
The existing lot did not previously
utilize any type of formal treatment
runoff simply flowed off the site onto
the grass athletic fields. This often
compromised the fields playability
and made maintenance difficult.
The new system consists of nearly
950 CULTEC Contactor 100HD
OCTOBER 2014 | 21
WATER & WASTEWATER solutions
Recycling Earths
Rapidly Shrinking
Resource
A basic primer on how food and beverage plants
can reuse water effectively and efficiently
Part 3 in a 3-Part series
By nate maguire, greg Claffey, and Keel Robinson, Xylem
n the parts 1 and 2 of this series, we examined the benefits

of reusing wastewater and the biological and disinfection
processes available to plants who pursue treatment options
for a specific need. However, treating water is only the first
step to ensuring wastewater is recycled and reused efficiently
and effectively within a plant because the transportation and
storage of water reuse is also important. In this installment,
well take a detailed look at the choices and options that make
a water reuse system a desirable option for plants, including
the essential keys to consider when moving from planning to
implementation.
ENSURING EFFICIENT AND EFFECTIVE

WASTEWATER REUSE
Treatment and pumping systems are primary energy consumers

within a water or wastewater loop. Sizing the system
and selecting the right equipment to meet specific reuse
requirements are critical to maximizing energy savings over the
life of the equipment.
Pumps serve two purposes in a reuse system: transporting and
pressure boosting. Water needs to be moved from one location
to another for treatment, storage purposes, or for use. Pressure
boosting is required for some treatment technologies, including
reverse osmosis (RO), where specific pressures are required to
move water through a membrane. Many reuse applications,

such as irrigation and equipment washing, also require boosting
capabilities.
SELECTING THE RIGHT PUMP
The pump and piping selection can have a considerable impact

on the energy consumed over the course of the systems life.
Pumps should be selected to operate at their Best Efficiency
Point (BEP) and the plumbing should be engineered to minimize
friction loss. A leader in global water technology, Xylem,
estimates that a water reuse system using improperly sized
piping and pumps can increase energy consumption by 200 to
300 percent.
IMPLEMENTING A WATER REUSE SYSTEM
Define Objectives: When deciding what type of water

reuse system is needed in a facility, a plant must define its
objectives both from sustainability and cost perspectives.
Select Applications: Next, plant owners and/or operators
should define the applications for which the water will be
used. It is best to start with high-volume reuse applications
that have lower water quality requirements, therefore
requiring less treatment, such as landscape irrigation.
About The Authors

Nate Maguire is the Americas business unit director, industry, and agriculture for Xylem's applied water systems business
unit; Greg Claffey is Xylems director of treatment sales, North America; and Keel Robinson is Xylems North America
reuse marketing and business development manager. Xylems well-known global brands provide world-class products,
comprehensive solutions, and unmatched applications expertise in more than 150 countries. To implement a water reuse
system in your facility, visit www.xyleminc.com/food.
22 | OCTOBER 2014
Pump Selection framework
1
2
Determine the flow rate, or the volume of fluid

that must pass through the pump per unit of time.
By following the steps below and working

with a trusted water technology partner, a
food and beverage plant can substantially
improve its energy efficiency in water reuse.
FOR A TRANSPORT APPLICATION:
FOR A BOOSTING APPLICATION:
Determine the static head and friction loss for

the piping system. Be sure to minimize friction
loss when designing the plumbing layout.
Determine pressure requirement and friction loss

for the piping system.
Static head: The height of a column of water that would be produced at a given pressure. The calculation
represents the internal energy of a fluid due to the pressure exerted on it from the pump.
Friction loss: The loss of energy (reduction of static head) that occurs in the pipe due to viscous effects
generated by size and surface of it. Narrow pipes, corners and valves that impede flow create friction loss.
3
4
Determine the water makeup

and comparability.
Check the density of the water.

Check chemical compatibility, such as pH levels.
Find the flow curves and Best Efficiency Point (BEP).

Select the pump.
Choose the Net Positive Suction Head (NPSH) or the

suction head value at a specific flow point that is
required to keep the pump out of cavitation.
When making the final decision, include the
following in your list for consideration:
When purchasing new equipment or

updating existing systems, it is essential to
contact a water solutions expert who can
ensure proper selection for the facility.
Certifications (Underwriters Laboratories (UL), CE

Marking, NSF-61 for potable water)
Environmental conditions, which are needed to
determine the correct motor enclosure.
Voltage requirements.
Variable speed options and controllers.
By following this approach, the facility will achieve the

greatest return on investment, as higher levels of treatment
drive costs up.
Determine Treatment Levels: Finally, determine the
treatment levels required for the selected applications
by measuring current wastewater quality to establish
a baseline, and then compare that to the quality level
required for the selected applications. This gap in water
quality will determine the treatment intensity.
SUSTAINABILITY
With increased reports of drought in the news, water

reuse is at the forefront of how businesses can expand
sustainability efforts and help ensure the available water
supply. Beyond water shortage, there is also greater focus
on social responsibility and water stewardship. In part,
due to public indices such as the Dow Jones Sustainability
Index, companies are investing more heavily in their
sustainability efforts than ever before and are better
managing their water use.
OCTOBER 2014 | 23

HEALTH AND SAFETY
Another driver of water reuse is health

and safety mandates. Food and beverage
operations must comply with the Food
and Drug Administration (FDA), as well
as the EPA and other relevant regulatory
bodies. These standards put in place
by these organizations to regulate
wastewater quality vary, but apply in
some form to all plants, regardless of

size. For example, in 2012, the EPA
released a document outlining state and
federal water reuse guidelines for all
industries, including food and beverage
processing (see reference 4).
Any company that operates in a
foreign country should also be aware
of international regulatory bodies and
standards. Reuse mandates vary from

country to country, but many businesses
are looking to the U.S. and Europe as
examples of countries implementing
regulations that could impact them.
THE TAKEAWAY
There are five key takeaways regarding

water reuse in food and beverage
facilities.
1. Water scarcity is a serious challenge:
While the earths population
continues to increase, readily
useable water supply is decreasing.
Many businesses, regardless of size,
are using water reuse to help fill this
gap.
2. Water reuse solutions mitigate
business risk: Reuse systems enable
companies to become less reliant on
source water from aquifers and local
municipalities, thereby lowering
their risk of supply disruption and
future water tariff increases.
3. Multiple treatment options are
available for specific needs: There
are a variety of conventional and
advanced treatment processes that
can be configured for each facility
and tailored to be fit-for-purpose
depending on the application.
4. Choosing the right equipment results
in long-term benefits: A plants total
water and wastewater costs are
significant and will continue to rise
due to the factors described in this
white paper. Employing the correct
reuse technologies can result in
both hard and soft savings for your
organization, including reduction
in supply risk and benefits to the
environment.
5. Collect the necessary information to
start the process: Now that youve
decided to start reusing water, the
first step is to define your objectives.
Consider both your financial and
environmental goals.
REFERENCES
1. Shiklomanov, Igor. World Fresh Water Resources.
Water in Crisis: A Guide to the Worlds Fresh
Water Resources.Ed. Peter H. Gleick. 1993. Print.
2. The Water Resources Group. Background, Impact
and the Way Forward. Rep. 26 Jan. 2012. 16. Web.
3. EMD Millipore. Filtration Basics. Millipore
Membranes and Filtration. Web.
4. United States. Environmental Protection Agency.
2012 Guidelines for Water Reuse. Sept. 2012.
Web.
5. The Coca-Cola Company. 2012/2013 GRI Report
Water Stewardship. Rep. Web.
24 | OCTOBER 2014
Electronic
Water
Treatment
An alternative solution
to removing beerstone
and limescale
By Jan de Baat doelman,
Scalewatcher north America inc.
eer contains 90 percent water, and it is the most

important ingredient in determining its flavor. Water
contains calcium and is the most important mineral to
the brewing process. The levels of calcium in local water have
determined the type of beer produced. The different types of
beer whether a light lager or a porter are for the most part due
to the water profiles of the areas that made the styles famous.
Calcium is by far the most influential mineral in the brewing
process. It reacts with phosphates, forming precipitates that
involve the release of hydrogen ions and in turn lowers the
pH of the mash. Calcium is the principal mineral of hardness,
which increases mash acidity and inverts malt phosphate. It
stimulates enzyme activity and improves protein digestion.
Calcium also extracts the fine bittering principles of the hop.
However, although calcium is the most important ingredient
in brewing beer it also has a negative effect on brewing
equipment as it creates beerstone and limescale.
BEERSTONE
Beerstone is calcium oxalate that appears in mash kegs,

boiling kegs, tanks and lines. The precipitate is largely due
to the reaction between alkaline cleaners (caustic), hard
water minerals (calcium and magnesium) and protein. If not
completely removed in the cleaning process, beerstone leaves
an unhygienic surface that can harbor microorganisms. An

unhygienic surface will infect the beer. Beerstone can cause
off flavors or shorten the shelf life of beer. In the worst case
scenario, undesirable organisms can ruin an entire batch of
beer, costing time and money to replace.
LIMESCALE
Although calcium is an essential ingredient in beer production

it also creates limescale, which has a negative effect on heat
exchangers, reverse osmosis (RO), pipes and vessels used
in the brewing industry. Over time, limescale will gradually
build up, progressively reducing the efficiency of heat transfer
of equipment, blocking water lines and increasing fuel costs.
Deposits are an insulating layer on heat transfer surfaces. It
About The Author

Jan de Baat Doelman is president of Scalewatcher North America Inc. The Scalewatcher is an environmentally friendly
alternative to chemical and mechanical descaling. Launched in the 1980s it has successfully treated hard water problems
for industrial manufacturers as well as water companies, oil producers, farmers, horticulturists, shipping companies,
shopping centers, school, universities and government establishments. For more information, call 610.932.6888, email
sales@scalewatcher.com, or visit www.scalewatcher.com.
26 | OCTOBER 2014
is estimated that 40
percent more energy is
needed to heat water in
a system fouled with
inch (6.35 millimeters)
of limescale. This leads
to more power being
consumed or to the
installation of heavier
duty, more expensive
heat exchangers to
compensate.
Although beerstone is
primarily derived from
calcium oxalate and
limescale from calcium
carbonate, both are
caused through precipitation and scaling
which are mostly caused through the
heating of water solutions. Within
this environment Electronic water
conditioners, such as Scalewatcher,
are the ideal solution for removing and
preventing the RO membranes being
clogged with scale. As Electronic water
treatment (EWT) changes the shape of
the molecules from rough to smooth,
they do not form a matted structure and
are washed away thereby preventing the
membranes from being clogged which in
less than fully saturated,

scale formation can
occur spontaneously
due to localized super
saturation, at a surface
for example.
pH EFFECT ON
SCALE FORMATION
turn reduces maintenance shutdown and

energy costs.
SUPER SATURATION
Aqueous solutions can become

supersaturated, which means that
they contain higher concentrations of
dissolved solute than their equilibrium
concentration. Such solutions are not
stable and are easily triggered into
dropping back to saturation level,
forcing the dissolved compound to
precipitate. Even when a bulk solution is
The pH of the solution

is directly related to its
acid content (typically
carbonic acid). The
higher the acid content,
the lower the pH
value. The solubility of
calcium carbonate is
directly affected by the pH of the water.
If the pH of the water is decreased,
more calcium carbonate solid can be
dissolved. Conversely, if the pH of
the water rises, it will force calcium
carbonate out of solution and hence
scale deposits will form.
TEMPERATURE EFFECT ON SCALE

FORMATION
Gases in general, and specifically

carbon dioxide, are less soluble in
water at high temperatures. There is an
OCTOBER 2014 | 27

equilibrium between CO2 (the gas) and
H 2CO3 (carbonic acid) in water, which
depends very much on temperature.
With the rising temperature, H2CO3
decomposes andwith Ca-ions in the
solutionCaCO 3-crystals are formed
from the solution. As less carbonic
acid is there, the pH increases (i.e.
from 7.5 to 8).
PRESSURE EFFECTS ON SCALE

FORMATION
Carbon dioxide and gases in general

are more soluble under higher
pressure. Therefore, as the pressure
drops, carbon dioxide gas will be
forced out of solution, lowering the
carbonic acid concentration. The rise
in pH is associated with a drop in
mODErN pumpING TODAy
INTErAcTIvE
DIGITAL EDITION
LOOk
fOr ThE
PLAY
VIDEO
buttOns
No need to wait! Get industry newsfirst!

Interactive DIGITAL EDITION features video content
as well as active links to key suppliers and industry
leadersall with one, easy click
In-depth, comprehensive articles written by respected,
working members of the pump community
Dynamic, informative illustrations and exciting photography
describe innovations happening now in the pumping world
Subscribe Today!
Modern
TodAY
Follow us on:
fOr ADvErTISING OppOrTuNITIES, ruSSELL hADDOck:

russell@modernpumpingtoday.com 205.824.9793 X 115
28 | OCTOBER 2014
calcium carbonate solubility, leading

to the formation of mineral scale
deposits.
ELECTRONIC WATER
CONDITIONING
EWT is a non-invasive system utilizing

a solenoid coil or coils wrapped
around the pipework to be treated.
A continuously frequency changing
signal generator, within a specified
range, supplies current to the coils.
The pulse shaped current creates an
induced electric field, concentric
around the axis inside the pipe. As
a consequence to this arrangement,
any charged particle or ion moving
within the field experiences a socalled Lorentz force generated by the
interaction between charged particles
and magnetic and electric fields.
The treatment influences the initial
nucleation, resulting in crystals that
do not "stick" together. Untreated
water builds up matted structures that
continuously grow. This treatment
creates idiomorphic, scattered crystals,
which do not form matted structures.
They have a rotundas shape, which
means that they have a larger volume
in relation to a smaller surface. This
feature makes them sensitive to water
(beer) currents and they are easily
flushed out of the pipeline. As no new
scale layers are formed, the sheer
force of the water flow will gradually
remove existing layers of scale. The
ability to adjust power, frequency
and coil configurations of products
like the Scalewatcher on site enables
performance to be optimized with no
downtime and no pipe replacement.
Recent laboratory research has
shown that EWT fields are effective
in suppressing biofilm development
and removing biofilm if it is already
present. The research also found a
clear relationship between developing
bacterial colonies and pipe material,
plastic material being the worst. As
combined biofilms/scale-structures
are often found together and support
each other, removal has to deal with
both elements. The laboratory testing
showed that EWT does not only have
an impact on biofilms, but also softens
the scale. So it is gradually broken up
thus removing the support structure for
the biofilms. The technology gradually
breaks down the combined scale/
biofilms-structure and its components,
which are progressively flushed away
by the water (beer) flow.
MAINTENANCE solutions
Improving Cooling Tower Filtration

The Southern Hemispheres largest entertainment complex reduces maintenance and treatment costs
Part 2 of 2
By glenn dobbs, vAf filtration Systems, and Roy mcdougall,

hydrochem Water Treatment Systems
he following case study describes

one end-users experience with
multiple filtration technologies
and their inherent advantages and
disadvantages in their cooling tower
systems. In part 1, we examined deep
bed and sand media systems. In this
months conclusion, we take a closer
look at centrifugal sand separators,
piston operated self-cleaning screen
filters, and finallywhat is becoming
the technology of choice for cooling
tower filtration applications
automatic self-cleaning screen filters.
CENTRIFUGAL SAND
SEPARATORS
A recent expansion with the

installation of a new chiller plant
included eight additional common
cooling towers with 26,417.2 gallons
(100,000 liters) total system volume.
These were originally fitted with
two large centrifugal separators. The
separators operated for several years
and were found to leave the basins
with at least 1.18 to 3.94 inches (30
to 100 millimeters) of silt and organic
matter build-up across the cooling
tower basin floors between the cooling
tower cleans that were conducted
every two months.
The chiller VSDs were again
affected by unfiltered debris in the
system with strainers blocking up and
causing overheating issues. The VSDs
themselves required annual chemical
cleaning to remove fouling that had
built up stopping effective heat transfer.
The centrifugal separators were
replaced with two VAF V-500 filters
which are effectively maintaining the
cooling tower basins in a clean state.
Figure 3: The Centrifugal Sand Separator Installation
Centrifugal sand separators are

primarily selected based on the
fact that this technology is the least
expensive. By definition, centrifugal
sand separators (or hydrocyclones)
are not filters since filtration is
defined as "the process whereby a
fluid passes through a surface or
depth media". They are "separators"
in that they utilize centrifugal forces
by spinning the water to separate
heavier particulate from water. Based
on separator manufacturers published
statistics, centrifugal "sand" separators
only remove particles that have a
specific gravity significantly greater
than water and are larger than 70

microns. Any particles that are organic
or lighter than water, or any particles
smaller than 70 microns which
remains as sedimentation, will not be
removed. It has been clearly stated
within ASHRAE publications, that
centrifugal separation technologies
are not appropriate for cooling tower
filtration. ASHRAE and the EPA have
both stated that the organic particulate
such as algae, combined with the
sedimentation that remains in the
cooling tower basin after centrifugal
separation provide an ideal habitat for
bacterial growth such as Legionella
About The Authors

Glenn Dobbs is president of VAF Filtration Systems, Arvada, Colorado, and has developed the company into providing stateof-the-art self-cleaning screen filtration products worldwide removing suspended solids down to 10 micron. Roy McDougall
is senior projects manager for Hydrochem of Australia and has provided cooling tower treatment services including filtration
for more than thirty years. For more information, visit www.vafusa.com.
30 | OCTOBER 2014
THIS SecTIon SponSored by

(see references 2
and 3). ASHRAE states
that "filtration", not
separation, is the method
by which the very small
and low density organic
particles found in cooling
towers are removed (see
reference 3).
Centrifugal separators
are cleaned either by
purging the particle
collection chamber or by
allowing a continuous
small flow from the
collection chamber
to a drain. Centrifugal
separators are often a
part of other filtration
systems that more reliably
remove smaller and lighter
particles. In those cases,
the separator removes the
larger and heavier particles
while the filters remove the
remaining particulate that
pass through the separator.
www.est-aegis.com
Figure 4: Typical Centrifugal Sand Separator
PISTON OPERATED
SELF-CLEANING
SCREEN FILTER
The original cooling

water plant comprises
ten cooling towers in a
common single basin
system of 31,700.6 gallons
(120,000 liters) total system volume.
These were initially fitted with five
piston operated self-cleaning screen
filters. These were operated for a
number of years but found to not
maintain the cooling tower basins in a
sufficiently clean state, with frequent
issues of filter failures and excessive
backflushing occurring. Also, the filter
bodies were constructed of mild steel
and had corroded from the cooling
towers water treatment chemicals.
The filters were eventually switched
off as they failed and were deemed not
worth repairing.
The piston filters have been replaced
with five stainless steel VAF V-250
filters which are maintaining the
cooling towers in a clean state and
will never corrode.
Another hotel complex cooling plant
comprises of one main system of three
common dual cell cooling towers of
7925.16 gallons (30,000 liters) total
system volume. These were fitted with
one piston operated self-cleaning
screen filter system. The filter suffered
Figure 5: The Piston Operated Screen Filter Installation
frequent uncontrolled backflushing

and blockages. The very large amounts
of water for backflushing caused
the cooling tower system to lose the
majority of chemical treatment and
in warmer months had caused the
cooling towers to run dry as the makeup supply could not deal with both
the evaporation and backflush. When
this happened maintenance staff had
to re-fill the towers with a hose, but
not before it had caused temperature
issues throughout the hotel.
The piston filter was replaced
with one VAF V-500 filter system.
The cooling towers are now being
maintained in a clean state with
minimal water consumption.
Piston operated self-cleaning screen
filters have been around for more
than fifty years and were originally
founded for low pressure irrigation
applications. There are several types
of self-cleaning screen filters that
only differ in the mechanism used to
clean the screens. Piston operated
self-cleaning screen filters utilize a
suction nozzle system

that is common on most
automatic self-cleaning
screen filters. In a piston
operated self-cleaning
screen filter, the nozzles
are rotated over the
screen filtering element
using a water motor with
line pressure, and then
the nozzles are moved
along the screen length
with a piston. Since the
rotational movement of
the nozzles is not directly
related to the longitudinal
movement of the nozzles
along the screen, piston
operated self-cleaning
screen filters have the
inherent problem of not
always cleaning the entire
screen area.
This problem reduces the
piston filter's capacity to
keep up with the dirt load
it is filtering which results
in higher flush waste and
hence excessive chemical
losses. Also, the hydraulic
controls for a piston filter
are relatively complex and
are inherently problematic,
as they can easily empty
a cooling tower basin
should the unit fail in the
open position. Piston operated screen
filters are also known as "hydraulic"
filters and are the lowest cost option
for an automatic self-cleaning screen
technology.
SUMMARY
After installing the newer patented

V-Series automatic self-cleaning
screen filters, the end-user is very
satisfied with the improvement
in their cooling tower systems
cleanliness. This has resulted in a
reduction of cooling tower cleaning
frequency from six times per year
to the minimum Australian standard
requirements of two times per year.
This reduction in cleaning frequency
resulted in substantial savings in
maintenance costs. By replacing the
older technologies with VAF's V-Series
automatic screen filters, the end-user
has seen the benefits of improved heat
transfer efficiency, less chemical usage
and improved chemical treatment
effectiveness for bacterial and
corrosion control.
OCTOBER 2014 | 31
1. Cover
2. Body
3. Coarse Screen
4. Fine Screen
5. Collector
6. Suction Nozzle
7. Hydraulic Motor 10. Piston

8. Flushing Chamber 11. Pressure Gauge
9. Flushing Valve
12. Controller
Figure 6: Typical Piston Operated Self-Cleaning Screen Filter
Figure 8: VAF's Model V-250 Filter Installation
Automatic self-cleaning screen filters are becoming

the technology of choice for cooling tower filtration
applications. The primary reason is that the screen filtering
element acts as a barrier removing ALL particulate (both
organic and inorganic) down to the micron rating of the
screen. VAF's V-Series self-cleaning screen filters remove
all particulate down to 10 micron in size from the water
the first time the water passes through the screen. Sediment
and algae are retained on the screen for a very short time so
there is no contribution to bacterial growth on the screen.
This technology uses only a few liters of water during
each flushing cycle resulting in the least flush waste in the
industry.
Automatic self-cleaning screen technologies provide
uninterrupted screen filtration during the screen cleaning
process, thereby requiring only a single filter for continuous
filtration. The new patented V-Series filters installed for this
end-user differ from the Piston Operated screen filters in
that the rotation of the nozzles is provided by a water motor
32 | OCTOBER 2014
Figure 7: Typical Piston Type Hydraulic Filter Controls
Figure 9: VAF Patented V-Series Self-Cleaning Screen Filter Technology
using system line pressure, and it rotates on a screw such

that 100 percent of the screen filtering element is cleaned
bi-directionally at least four times with each cleaning cycle.
This results in a very thorough cleaning of the screen, very
low volume of flush waste and minimal loss of chemicals.
With the lower flush volume required to clean the screen,
it is much easier to show that none of the flush water is
wasted since it is only a small portion of the cooling towers'
blowdown requirements (see reference 4).
REFERENCES
1. Systems and Equipment Handbook (2000), ASHRAE.
2. Legionella: Human Health Criteria Document (1999), Office of
Science and Technology / Office of Water, United States Environmental
Protection Agency.
3. Meyer, W. Craig. Controlling Legionella in Cooling Towers, ASHRAE:
Woodland Hills, Calif. 2000.
4. Dobbs, Glenn and Roy McDougall. The ROR of Cooling Tower
Filtration. 2010.
The Evolution of
Lubrication Technology
Why and where to use the Pulsarlube automatic single point lubricator
By Bill Zavala, Pulsarlube uSA, inc.
hen it comes
to bearings,
grease is often
the lubricant of choice.
However, over or undergreasing can cause
overheating, lubricant
deterioration, and eventual
bearing wear or failure.
To help ensure proper
lubrication, the Pulsarlube
automatic lubricant
dispensing system can be
used to manage a precise
amount of grease applied
to specific lubrication
points.
Condition of bearing before trial
Condition of bearing after trial
M250 and M125 Pulsarlube

automatic lubricators
Personnel avoiding hardto-reach or dangerous

places
Shutting down
equipment to safely
access bearings
Mixing incompatible
greases
Adding too much or too
little grease.
FOUR HISTORICAL
LUBRICATION
METHODS
Prior to the introduction

of automatic lubrication
devices, it was necessary to
shut down some machinery
SINGLE POINT
in order to lubricate it.
AUTOMATIC
Today, however, automatic
LUBRICATORS
lubrication devices reduce
Pulsarlube single point
this downtime. Single
automatic lubricators,
point automatic lubricators
which are used in a variety
are an important element
of applications such as
of a lubrication program
lubrication of bearings,
and help improve greasefans, chains, electric
related maintenance
motors, slides and guidepractices by replacing
With automated maintenance in place
ways, are among the
manual greasing and, in
types of automated grease
some cases, more costly
dispensing systems available in todays industry. They help
central lubrication systems. Because of this, automatic
reduce operating costs and maximize equipment life by
lubricators can be an inexpensive way to maximize a
providing a precise and controlled supply of lubricant
plants maintenance resources.
to lubrication points. The Pulsarlube product reduces
Historically, there have been four key lubrication
downtime caused by inadequate bearing lubrication,
methods used in a manufacturing environment:
thus contributing to the uninterrupted operation of plant
equipment and improved productivity and profitability.
1. Run to failure, which is the operation of machines
As part of an overall lubrication program, automatic
until breakdown. Equipment is subsequently torn
lubricators play a key role because without them, it
down, repaired, lubricated and then rebuilt. This
is difficult to implement an easy and cost-effective
method is costly and inefficient. Not surprisingly, this
maintenance plan. Without a maintenance schedule in
operation cycle was more common in the past then it
place at your plant, problems can arise from:
is today.
Without automated
maintenance in place
About The Author

Bill Zavala is vice-president of international sales for Pulsarlube USA, Inc. He can be reached at bill@pulsarlube.com.
For additional information, visit www.pulsarlubeusa.com.
34 | OCTOBER 2014
BENEFITS OF AN
AUTOMATIC LUBRICATOR
The Pulsarlube M unit delivers a powerful 280
psi average operating pressure, but is capable of
delivering 1160 psi if necessary, through the use
of its vertical positive displacement pump, motor/
gear set, and microprocessor control system. This
is one of the key reasons why the Pulsarlube M
unit can lubricate up to 8 points, thereby offering
our customers tremendous savings, compared to
lubricators that can only lubricate a single point.
Immediate and Exact Lubrication: Exact,
Reliable, lubrication through Microprocessor
chip controlled technology.
LCD Display: You can obtain all info. at a
glance on LCD about the status of your lube
point i.e. Low battery, too much back pressure,
# of days before empty, how many days on
empty etc.
Lock Out Mode: Only lubricator in the world
with automatic digital lock out mode to prevent
accidental or unauthorized keyed entry.
Cost Efficiency: Can lubricate up to 8 points
(20 feet per point).
Increased Uptime and Profitability: Less
downtime and loss of production. According
to studies done by renowned lubrication
experts around the world, the Pulsarlube M
unit reduces bearing failure by more than 85
percent compared to manual lubrication.
www.est-aegis.com
2. Oil bath and splash, which is either the submergence
of all system gears and bearings in an oil sump or
the splashing of components with rotating gears. This
enclosed system is cost effective in the short term.
However, contaminants that may get trapped inside the
system will decrease the life of the oil and ultimately
cause increased maintenance costs.
3. Central lubrication systems, which store lubricant in
a reservoir and then continuously pump it to critical
equipment components through a complicated system.
Although these systems are important for some particular
manufacturing purposes, they are not effective for
most applications. Central lubrication systems are also
expensive to assemble and install.
4. Single point automatic lubricators, like those
manufactured by Pulsarlube, which are designed to
dispense lubricant consistently and precisely through a
powerful positive displacement pump for up to one to
two years depending on the application. It also has the
capacity to lubricate up to 8 lube points at a maximum
of 20 feet (6.1 meters) per point, this in turn allows for
the lubrication of hard to reach/hazardous areas. The
Pulsarlube product is a simple, accurate, and costeffective method for most applications.
Originally, automatic lubricators simply enabled a facility
to operate machinery and lubricate bearings simultaneously.
Today, single point automatic lubricators are widely accepted
in the modern manufacturing world and have an expanded
Reduced Maintenance Costs: Significant

savings in repair and spare part costs due to
fewer parts needed and thereby lowering your
labor costs as well.
Increased Equipment Life: Increases your
equipment life by up to 85 percent.
Reduced Lubrication Consumption: Up to 70
percent savings in lubricant costs due to the
accurate timing and dosing of lubricant.
Fixed Cost Savings: Additional savings in fixed
costs since less lubrication personnel is needed.
OCTOBER 2014 | 35
role to improve overall
maintenance practices,
reduce costs, increase
efficiency, and promote
plant safety.
RESISTANCE TO
CHANGE
Even though there is

value in implementing
automatic lubricators,
there is still some
resistance in
manufacturing circles
due to the initial
investment required.
Ultimately, lubrication
related bearing wear and
equipment failure will be
a much larger expense.
Companies that invest
in automatic lubricators
to improve preventative
maintenance will benefit
financially in the long
term.
Some companies
prefer to stick with tried
and true lubrication
methods and often
36 | OCTOBER 2014
Pulsarlube M250 on cooling towers
www.est-aegis.com
times prefer manual application

of the lubricant. This method
requires maintenance personnel to
monitor the plant, interact with the
machinery through the use of grease
guns and other manual lubricators
and document the procedure in a
report. In these cases, companies
may be uncomfortable relinquishing
a humans responsibility to a
mechanical device.
RELIABILITY IN CRITICAL
APPLICATIONS
If a plant is concerned about the

reliability of automatic lubricators,
we encourage them to test our
lubricating device in less critical
applications. Plants can easily
conduct a phase progression on
equipment that is probably not
being lubricated regularly and has
perhaps failed, such as fan bearings
on a roof, or pump bearings in a
basement. This machinery may not be
as critical to the plants production
line as other pieces of equipment.
Due to the difficulty in accessing
these bearings, they may have gone
an extended period of time without
proper lubrication. A plant will gain a
better understanding of the Pulsarlube
automatic lubricators reliability and
role in proper grease application
through initial testing in less critical
areas.
As part of a lubrication
management program, the Pulsarlube
automatic lubricator can help a
plant ensure that its machinery is
receiving proper lubrication, in the
right place, at the right time, and in
the correct amount. This helps plant
efficiency by minimizing the amount
of grease being used and maximizing
maintenance resource time. Instead
of assigning staff with the preventive
maintenance task of greasing
bearings, the plant can benefit
through more active involvement with
predictive maintenance work such
as oil analysis, thermography, and
vibration analysis.
SUMMARY
The innovative Pulsarlube automatic

single point lubricator can be
an important component to a
successful lubrication program. It
is a cost effective way to reduce
bearing failure, minimize equipment
downtime and contribute to a plants
continuous operational success.
OCTOBER 2014 | 37
PUMP solutions
Right Pumps and Right

Maintenance Are a Must
Two case studies illustrate the importance
of matching pumps to applications
By Art Savage, landia, inc.
lleged hygiene failings discovered in the poultry industry thanks to

an investigative report in The Guardian newspaper have seen three
of the United Kingdoms leading supermarkets launch emergency
investigations into their chicken supplies and have also brought pump
specification and pump maintenance firmly into the spotlight.
Landia, whose non-clogging chopper pumps are installed at numerous
poultry processors, abattoirs, farms, and biogas plants, says that the
shocking evidence shows just how quickly standards can deteriorate
when pumps fail. Therefore, operators need to ensure their pumps
are properly matched to their applications and are responsive to
maintenance needs.
Riccardo DeCarli, mechanic at Stafford WPCF, carrying out routine

maintenance on a Landia mixer.
PLANNING IS CRITICAL
We dont yet live in a world of course where pumps never break down,
but any well-run abattoir will be acutely aware of the sometimes dire
consequences of wastewater backing upand will have already have a
preventative maintenance program in place, says Landias Paul Davies.
With some larger abattoirs running lines at a rate of almost 200 birds
per minute, or well over 10,000 per hour, downtime can be disastrous,
Davies adds. In too many places the production line is being pushed
to absolute breaking point in order to meet the deadlines of their
supermarket customers, but all the same, a decent sturdy chopper pump
that doesnt allow solids to clog it up, backed by a regular servicing, can
make a world of difference.
Landia pumps working and production on time
THE CONSEQUENCES OF PUMP FAILURE
At one factory, The Guardian discovered offal piled up during a pump system failure, with
breakdowns leading to high-risk materialfeathers, guts, and offalpiling up for hours.
Another breakdown led to the water in scald tanks at the same site not being cleaned
for three days, so that around 250,000 birds passed through dirty water after slaughter.
During The Guardians five-month investigation, workers also witnessed a breakdown
(which they said are repeated events) where it was the pump feeding the flume of water
that is supposed to carry feathers away from the plucking machines.
The evidence prompted Tesco, Sainsburys, and Marks & Spencerthree of the United
Kingdoms largest supermarket chainsto launch emergency investigations into their
chicken suppliers.
The concern centers on the campylobacter bacteria, which at the last count was present
in two-thirds of British fresh chicken sold in the United Kingdom. Although the bug is
killed by thorough cooking, around 280,000 people in the United Kingdom are currently
made ill each year by it and 100 people are thought to die. Contamination rates are
known to have increased in the past decade.
Pump system failure
About The Author

Art Savage is regional sales manager for Landia, Inc. For more information Landias range of applications, call 919.466.0603,
email info@landiainc.com, or visit www.landiainc.com.
38 | OCTOBER 2014
OPTIMAL PUMP PERFORMANCE

EXPANDS OPPORTUNITY
However, careful pump selection and

routine maintenance are not limitations
on a pumps usefar from it. In
fact, when pumps are maintained to
performance standards, creative options
are available for pump users seeking
innovative solutions. For example, a
water pollution control facility (WPCF)
in Connecticut is benefitting from
reduced downtime, thanks to pumps,
mixers, and significant back-up service
from Landia.
Treated wastewater from Stafford

WPCF is discharged into the
Willimantic River. The collection
system, which has over 2000 hookups, encompasses approximately
22 miles (35.4 kilometers) of the
town and utilizes four pumping
stations. Covering 58 square miles
(150.2 square kilometers), Stafford is
the third largest town (land area) in

Connecticut.
In addition to the equipment at
Stafford WPCF, Landia has well over
2000 pumps and mixers installed in
activated sludge processes across the
United States, many of which have
been in continuous operation for more
than twenty years.
PUMP AND MIXER

TEAMWORK PAYS OFF
Serving over 11,000 residents, the

facility at Stafford, Connecticut,
underwent an upgrade in January 2011,
when six 1.8 horsepower Landia mixers
were installed in the anoxic tanks as
part of a new activated sludge process.
Three 2.4 horsepower Axial flow pumps,
designed and manufactured by Landia,
were also introduced for the aeration
basins, from where they return nitrified
mixed liquor back to the anoxic tanks
for denitrification.
In an effort to improve their
maintenance program and equipment
service life, plant personnel at Stafford
contacted Landia for assistance.
When we made Landia aware of our
need to reduce maintenance costs, they
responded in a very timely manner,
reports Rick Hartenstein, chief operator
at the WPCF. Some companies are only
interested in helping when they have
secured a service contract, but Landia
sent one of their skilled engineers to
show our maintenance staff how to best
look after the pumps and mixers for
our benefit, which in turn means we
provide a better service to the people
of Stafford. Since then, weve become
more efficient, had no downtime, saved
money and had no hassle. It is refreshing
to work with a company who has such
high standards for customer care.
POSITIVE RESULTS
FROM PROPER MAINTENANCE
Kenneth E. Jacobs Jr., the Landia service

manager who visited the WPCF, adds,
It was a pleasure working with the
team at Stafford. We looked at best
practice servicing methods, including
mechanical seals, electrical testing, oil
changes and replacement of oil sealing
rings to enhance the performance and
longevity of the pumps and mixers at the
facility.
OCTOBER 2014 | 39
DEWATERING solutions
Reliability Needed
in Treatment Facility
Self-priming filter backwash end suction pumps offer high efficiency solution
By Andy Wilson, hidrostal ltd.
A PERFECT FIT
ocated just south

of the Englands
second largest city
of Birmingham, the small
town of Redditch is not
without its own municipal
concernsespecially when
it concerns improving the
reliability and efficiency
of their local wastewater
system. One key concern
was upgrading the suction
lift application, but officials
also desired to maintain
some of the existing
infrastructure. They found
their solution in Hidrostals
self-priming filter backwash
end suction pumps.
LOOKING FOR AN
ANSWER
In the summer of 2012

Hidrostal supplied and
installed a static priming
tank system to feed two
new 11 kilowatt Hidrostal
end suction pumps.
The new system
was required to
replace existing but
unreliable selfpriming pumps
installed on a suction
lift application at
Redditch wastewater
treatment facility.
The application was
to feed the sand filter
backwash process.
Original installation
PROJECT AT A GLANCE:
SELF-PRIMING FILTER BACKWASH PUMPS
Customer: Severn Trent Water
Value: 15,500.00 (~$24,700 US)
Type: Supply and Install
Equipment Installed: Two Pumps and Static Priming Tank
Hidrostal were selected

because the solution
proposed utilized a lot of
the existing equipment
such as pump house,
pipework, plinths, and
control panel. This
simple but clever solution
represented a good value
engineered and upgraded
solution with a good low
risk CDM compliance.
The static priming
tank system is built
around the Hidrostal
Screw Centrifugal Pump,
renowned for its high
efficiency and low NPSH
capabilities, an optimum
centrifugal pump for
suction lift applications.
In fact the improved
efficiency meant the new
Hidrostal pumps were able
to reduce the installed
kilowatt size. One 11
kilowatt Hidrostal pump
was capable of
pumping more
than two of the
originally installed
18.5 kilowatt selfpriming pumps.
Due to the higher
efficiency of the
Hidrostal system
duty/standby was
now possible,
compared to the
About The Author

Andy Wilson is the business development manager at Hidrostal Ltd. With over thirty years of experience and having deployed
thousands of pumping systems, Hidrostal fully understands the needs and technical requirements of todays pump users. For
more information, email sales@hidrostal.co.uk or visit www.hidrostal.co.uk.
40 | OCTOBER 2014
All working fine with no

issues. I am very pleased with
the improved reliability and
performance.
John Ratheram, Redditch
service delivery manager
original duty/assist/standby layout. The static

priming tank was installed into the position of
the original middle assist pump, even making
use of its concrete plinth.
On this installation Hidrostal supplied
and installed two identical end suction
bearing frame pumps of model E06UMMN3R+EFM1X-M160 fitted with 11
kilowatt, 4-pole, WEG, WIMES High
Efficiency motors. The two pumps were
installed alongside a suitable sized and
fabricated static priming tank to generate a
suction lift of 7.5 feet (2.3 meters).
New Hidrostal installation
IMPROVED PERFORMANCE
AND SAFETY
The installation now only required a single suction pipe

from the wet well to the static priming tank. This in turn
provided a new suction connection to the new pumps. Two
of the original suction lines were removed from the pump
station layout, improving access. The discharge pipework
was maintained apart from the pipework in the redundant
pump position. This was removed and blanked off, again
improving access.
The Hidrostal above ground solution was compared to
a number of submersible wet well proposals. The above
ground solution was selected because it negated the
risks of entering and lifting around the wet well, for both
the installation and on-going maintenance requirements
associated with submersible pumps.
LONG-TERM SOLUTIONS
Since commissioning in June 2012, the customer is very

satisfied with the solution and system performance. Also, a
follow up in April 2013 and later in October 2013 saw John
Ratheram, service delivery manager for Redditch area report
that the installed pumps continued to meet their needs and
were operating successfully without incident.
Finally the long standing self-priming issue had been
solved at this part of the works. The original 13.2 gallons
(50 liters) per second pump duty, delivered from a pair of
unreliable duty/assist self-priming pumps, is now being
handled by a single and reliable Hidrostal duty pump
with an output of 15.3 gallons (58 liters) per second.
The Hidrostal solution was the simplest, safest, and most
reliable solution proposed for the Redditch problem.
OCTOBER 2014 | 41
MOTOR solutions
Maximum Results
fro
Mini Drive
WEG Electrics CFW100 Mini Drive puts power at users fingertips

By gerardo Elias, WEg Electric Corporation
quipment manufacturers seeking to give induction

motors a selectable scalar (V/F) or voltage vector
control (VVW) now have a new solution at their
fingertips. The CFW100 Mini Drive recently introduced
by WEG Electric Corporation is the smallest volume
variable speed drive (VSD) in the market, but it provides
the power OEMs are looking for as well as HMI and plug
and play philosophy, with easy and fast installation and
operation. The CFW100 is a single-phase variable speed
drive developed for simple applications ranging from 0.18

kilowatts to 0.75 kilowatts (0.25 to 1 horsepower).
COMPACT, ROBUST AND FLEXIBLE
The WEG CFW100 Mini Drive has power ranges of

1/4 , 1/3 , 3/4 and 1 horsepower at 230 VAC with singlephase in and 1.5A, 2.6A and 4.2A three-phase output
current. Its simplicity and flexibility are unsurpassed
with design features such as built-in HMI, DIN rail
About The Author

Gerardo Elias is the marketing manager, North and Central America, for WEG Electric Corporation and can be reached at
678.249.2022. Founded in 1961, WEG has grown into a global solutions provider of electric-electronic technologies and
equipment and is the largest industrial electric motor manufacturer in the Americas and one of the largest manufacturers of
electric motors in the world. For more information, visit www.weg.net.
42 | OCTOBER 2014
mounting, detachable fan for easy

maintenance and plug-in modules for
communication and I/O options. All
this in a size no larger than a typical
panel contactor.
Programing is easy with the built
in keypad that monitors two different
parameters at the same time along
with operation status, alarms and
faults. A remote keypad CFW100HMIR connected through a USB
cable or remote serial connection
for longer distances is also available.
The CFW100 works with WEGs
Superdrive G2 programing control
software, available free from the WEG
Electric website.
THE QUALITY ADVANTAGE
For a small compact package, the

CFW100 is extremely robust allowing
it to accept an overload of 150
percent for one minute, every six
minutes in a 122 degrees Fahrenheit
(50 degrees Celsius) ambient. This
capability eliminates the need for
the machine designer to oversize the
variable frequency drive.
Along with all these features

you also receive WEG quality
advantages. Each CFW100 is tested
under load at the factory, has
protection against ground fault, short
circuit and over temperature and all
are manufactured with conformal
coated circuit boards classified
as 3C2 per IEC specification
60721-3-3.
FEATURE-RICH IN A SMALL
PACKAGE
WEG Electrics CFW100 Mini Drive

offers many features in a small
package. The CFW100 is a singlephase variable speed drive designed
with OEMs and end users in mind.
It is the smallest variable frequency
drive with HMI on the market and
is designed to handle 150 percent
overload for sixty seconds at 122
degrees Fahrenheit (50 degrees
Celsius) ambient temperature rating.
A full complement of plug-in
communication and I/O modules
are available to meet most machine
designers application requirements.
A flash memory module is available
to upload and transfer the drive
parameters and programmable logic
controller program to other CFW100
drives. Powered by internal batteries,
the flash memory module has the
capacity for over five thousand
operations and can be used without
applying power to the variable
frequency drive. The module saves
drive parameters and the PLC code
directly from the Soft PLC feature. The
CFW100 can interface using a USB
connection, Bluetooth, or infrared
wireless.
The built-in programmable logic
controller enables the variable
frequency drive to do much more
than just turn a motor. Programing
flexibility combined with network
and I/O options make the CFW100
the most powerful drive of its size
available. This built-in programmable
logic controller often eliminates the
need for an external programmable
logic controller, which reduces cost
and optimizes space.
OCTOBER 2014 | 43
POWER GENERATION solutions
HigHly A ccurAte S enSor for

t HermAl Power S tAtionS
Low Maintenance Dissolved Oxygen Sensor Monitors Boiler Feed Water
By Joe Bradley, Electro-Chemical devices
ngineers responsible for maintaining boiler operations

will find the new Model DO90 Trace DO2 Sensor
from Electro-Chemical Devices (ECD) is designed for
the continuous and highly accurate measurement of trace
levels of dissolved oxygen, helping to maintain oxygen-free
boiler feed water and reducing corrosion.
EFFECTIVE MONITORING
ECDs Model DO90 Trace Dissolved Oxygen Sensor offers

reliable and effective monitoring of boiler feed water.
Oxygen should only be present in trace quantities in
boiler feed water, as excessive concentrations of oxygen
can result in corrosion damage to the components of the
About The Author

Joe Bradley is director of technical services for Electro-Chemical Devices (ECD), a manufacturer of liquid analytical process
instrumentation. Founded in 1977, ECD has built its industry leading reputation by providing quality products, developing
technical innovations, and providing responsive, knowledgeable service. For more information, call 800.729.1333, email
sales@ecdi.com, or visit www.ecdi.com.
44 | OCTOBER 2014
FEATURES AND BENEFITS
Large measurement range

Galvanic, Lead Silver measurement
Long maintenance interval
Easy calibration
Digital signal
The Triton DO90 is designed for the continuous

measurement of trace levels of dissolved oxygen
in aqueous systems. The primary application of the
Triton DO90 is in the monitoring of boiler feed
water.
BENEFITS
0.001 to 20.00 milligrams per liter

Long term stability
Drift < 1 percent per month
Air calibration only, no zero calibration needed
Noise free signal, calibration stored in the
sensor
The Model DO90 Trace DO2 Sensor offers a large measurement range, reliable and
effective monitoring, and easy installation.
from the flow cell. The measurement chamber is optimized

for fast response and all wetted parts are 316L stainless
steel. The DO90 sensor is also compatible with ECDs T80
Analyzer, which also works with the full range of Model
S80 Sensors.
LARGE MEASURING RANGE,

LITTLE MAINTENANCE
steam cycle. Boiler feed water is thermally and chemically

degassed to achieve oxygen-free water, a state which must
be maintained throughout the steam cycle.
The DO90 Sensor offers a large measurement range, from

0.001 to 20.00 milligrams per liter. Long-term stability
means that drift is less than 1 percent per month. Needing
virtually no maintenance, the DO90 sensor has an easily
replaceable electrode cartridge, eliminating the need for
messy electrolyte/membrane replacement kits.
The Model DO90 Trace DO2 Sensor is available as
separate components, sensor, fittings, flow cell, Model T80
Transmitter or as a complete panel mounted system. The
panel mount system is a complete plumb-and-play device.
The system is also available as a complete kit, less the
panel, for mounting to an existing water panel. Installation
of the flow cell is also easy, using either the clamp style
holders for wall mount or the two 10 x 32 threaded ports
on the backside of the flow cell for panel mounting.
RELIABLE AND EASY TO USE
QUICK INSTALL
Photo credit: Ram-R2R 2014
The Model DO90 Trace DO2 Sensor is a lead-silver

galvanic sensor with a durable PFA Teflon membrane. As
a digital sensor, all of the signal conditioning, calibration
and diagnostic functions are performed inside the sensor.
Its signal is noise-free and it features zero calibration and
air calibration.
The Model DO90 flow cell has been specially designed
for use with the Model DO90 Sensor. The orientations of
the inlet and outlet sample lines automatically purge air
To install the Model DO90 Trace DO2 Sensor, simply

screw the holder into the wall or onto a panel and connect
input and output sample lines to the inch (6 millimeter)
tube fittings This design allows easy removal of the sensor
from the flow cell for air calibration. The orientation of the
inlet and outlet sample lines automatically purges air from
the flow cell when the sensor is returned to service. The
measurement chamber is optimized for fast response and
all welded parts are 316L stainless steel.
OCTOBER 2014 | 45
PROCESSING solutions
Precision Fluid control

For Food and Beverage
ingredient additions
By herb Warner, fluid metering, inc.
ood and beverage processing plant operators looking

to add vitamins, colors, flavors, fragrances, enzymes,
and preservatives into their processes have a new
option available in the benefits from Fluid Metering, Inc.s
(FMIs) valveless piston technology. Valveless metering
pumps provide precision
dispensing of additives
for food processing
applicationsoften in
concentrated form, FMI
pumps precision of 0.5
percent ensures product
consistency, while
eliminating waste of
expensive ingredients.
ELIMINATING
VALVES, IMPROVING
PRECISION
SYNCHRONOUS ROTATION AND RECIPROCATION
The valveless function is accomplished by the synchronous

rotation and reciprocation of the ceramic piston within a
precisely mated ceramic liner. The reciprocation action of
the piston, similar to a standard piston pump, accomplishes
the pumping function.
However, thats where
the similarity ends.
The piston also rotates,
alternately aligning a
flat at the end with the
inlet and outlet ports of
the pump. When the flat
is aligned with the inlet
port, fluid can be drawn
into the pump. When
the flat is aligned with
the outlet port, fluid can
exit the pump. Only one
port is open at any time
and at no point are both
ports interconnected.
This effectively functions
as, and replaces,
conventional check
valves.
FMIs patented valveless

CeramPump pumping
principle utilizes one
moving part, a sapphirehard ceramic piston, to
perform all fluid control
functions, eliminating
valves typically present
in other low volume
A COMPLETE
metering technologies.
PACKAGE
Elimination of valves,
The Industrial Variable
as well as having
Speed Metering Pumps
The IVSP Industrial Variable Speed Metering Pump provides precision dispensing of additives for
dimensionally stable
variable stroke rate pump
food processing applications.
ceramic internals, results
system for industrial
in a pump that will
process applications
provide millions of maintenance-free dispenses without the
uses a high torque 3 phase variable speed drive, which is
need for recalibration.
ideal for handling a broad range of fluid viscosities. The
The IVSP Industrial Variable Speed Metering Pump is ideal
complete metering system consists of a valveless pump head
for viscous fluids. It has a rugged horsepower variable
module, a high torque drive module, and a control module.
speed drive motor and available with sanitary quickThe pump head is integrally mounted to the drive and the
disconnect fittings. Speed is controlled via a DIN mountable
control module is connected to the drive via a 4 conductor
controller for both manual and electronic speed control.
cable.
About The Author

Herb Warner is the marketing manager for Fluid Metering, Inc. For more information call 800.223.3388 or 516.922.6050, fax
516.624.8261, email pumps@fmipump.com, or visit www.fmipump.com.
46 | OCTOBER 2014
TECHNICAL DATA
Controller:
Input 115 VAC, 1,
50/60 Hz.
Output: 230 VAC, 3,
50/60 Hz
Features:
Local keypad control
Multifunction Control I/O

connector
115V, 50/60Hz, 1-Phase
from 1 horsepower
NEMA 4X Option for Harsh
Environments
Motor:
Variable Speed, 1800 RPM
max
230 VAC, 3, 50/60 Hz.
The control module has a 3 digit LED

display corresponding to frequency - 2
Hz (60 rpm) minimum, 60 Hz (1800
rpm) maximum. Motor speed can be
adjusted either manually using the
convenient front panel membrane
switches, or electronically using a 0-20
mA, 4-20 mA, or 0-10VDC input signal.
Additional control functions include
start, stop, acceleration, forward, and
reverse. Flow rate is determined by the
combination of drive speed, piston size,
and pump head displacement.
PISTON
CODE
MAX FLOW
(mL/min)
MAX FLOW
(gph)
RH00
45
0.71
RH0
90
1.4
Q0
144
2.2
RH1
180
2.8
Q1
576
9.1
Q2
1296
20.4
Q3
2304
35.9
Table 1: Maximum flow rate for each piston size based on

maximum displacement at 1800 revolutions per minute.
For over fifty-five years FMI pumps

have been used food and pharmaceutical
processing; medical, analytical and
laboratory instrumentation; industrial
process, water and wastewater treatment,
environmental monitoring, and much
more.
OCTOBER 2014 | 47
VALVES & CONTROLS solutions
The Next Wave of Radiant

New solutions for radiant heating and cooling applications
By mark hudoba, uponor
hydronic radiant
system consists
of warm or cool
water flowing through
flexible PEX tubing
embedded in the floor
or in radiant panels.
Radiant systems use
the structure and
surfaces of an area
to transfer energy.
In radiant heating
applications, the
energy moves away
from the heated surface
toward the cooler area;
for radiant cooling,
the energy moves
towards the cooled
surface from the
warmer area. Radiant
heating and cooling
applications are among
the most efficient and
technologically sound
atmospheric systems
used in commercial
structures todayas
well see with a closer
look at two new
components.
The new stainless-steel manifold from Uponor is available in 1 and 1- inch (25.4 to 31.75 millimeter) sizes and offers 2 through 8, 10, and 12
loop configurations for residential and commercial radiant heating and cooling applications.
COST-EFFECTIVE AND DURABLE

STAINLESS-STEEL MANIFOLD
For residential and commercial radiant

heating and cooling applications, a
stainless-steel manifold offers a flexible
and durable solution that also makes
economic sense in the short and long
term. The stainless-steel manifold is
a new addition to Uponors radiant
manifold line and was designed to be a
customer-focused, cost-effective, preassembled metal alternative.
Tony Radcliff, vice president of

marking, offerings, and engineering
at Uponor, adds, Now professionals
can choose from our comprehensive
offering of stainless-steel, engineered
polymer (EP) or TruFLOW brass
manifolds to meet any radiant
application need.
Pre-assembled right out of the box,
the manifold provides contractors
with faster installs and also offers
greater material cost savingsin line
with Uponors history of plumbing,
fire safety, radiant heating/cooling,

hydronic distribution piping, and preinsulated piping systems for residential
and commercial applications
Made of corrosion-resistant stainless
steel, the manifold is available in 1 and
1- inch (25.4 to 31.75 millimeter)
sizes in 2 through 8, 10, and 12 loop
configurations. It features integrated
flow meters for easy system balancing,
full-port ball valves with temperature
gauges, and balancing and isolation
valves for complete loop isolation.
About The Author

Mark Hudoba is the director of heating and cooling for Uponor. For homeowners, installers, architects, engineers, builders,
developers, building owners and consultants, Uponor is your professional partner for PEX plumbing, radiant heating/cooling,
hydronic distribution, pre-insulated pipe and fire sprinkler systems for residential and commercial structures worldwide. For
more information, visit www.uponor-usa.com.
48 | OCTOBER 2014
PEX-A PIPE SUPPORT FOR

COMMERCIAL APPLICATIONS
Also available is the PEX-a Pipe

Support in sizes up to 3- inches (88.9
millimeters) for suspended piping
applications in commercial plumbing
and hydronic distribution piping
systems.
Uponor PEX-a Pipe Support is
a galvanized steel channel that
provides continuous support of PEX
in suspended piping applications,
enabling hanger spacing similar to that
of copper or steel pipe. The product is
available in 9-foot (2.74 meter) lengths
for PEX pipe sizes ranging from to
3- inches (12.7 to 88.9 millimeters)
and comes with nylon-coated,
stainless-steel strapping to secure the
pipe to the support.
We are continuing to see an
impressive growth in commercial PEX
piping systems for both plumbing
and hydronic distribution piping
applications, says Radcliff. Offering
our PEX-a Pipe Support in larger
sizes allows professionals a wider
range of offerings to incorporate PEX
systems into more of their commercial
projects.
PEX-a Pipe Support is a galvanized steel channel that provides continuous support of PEX in suspended piping
applications, enabling hanger spacing similar to that of copper or steel pipe.
BENEFITS OF RADIANT HEATING

AND COOLING
Combined low-temperature heating and

high-temperature cooling integrated
with the use of alternative energy
sources make radiant the ultimate in
low-energy building solutions. Because
water has 3500 times more energytransport capacity than air, radiant is
also fast becoming the energy-efficient
alternative to forced-air systems. Radiant
also helps building professionals acquire
LEED (or Leadership in Energy and
Environmental Designan incentive
programmed backed by the U.S. Green

Building Council) for New Construction
(LEED-NC) points in environment and
atmosphere, indoor environmental
quality, and innovation in design.
For more than forty years, Uponor
has been committed to improving and
implementing radiant heating and
cooling systems throughout commercial
application. The first to bring radiant
heating to North America, Uponor
continues to provide improvements to
hydronic radiant system design and
application.
OCTOBER 2014 | 49
SEALING solutions
How to Cost-justify
Bearing Housing PART
2 of 4
Protector Seals
Key factors for reliability-focused process pump users
By heinz P. Bloch, Process machinery Consulting
n the first of this four-part article,

we pointed out the importance of
keeping contaminants away from
lube oil in pump bearing housings. We
mentioned that well-designed modern
bearing housing protector seals can
provide substantial ingress reductions.
However, the reliability-focused user
must consider the level of protection
offered by a particular bearing housing
seal. Not all bearing housing protector
seals function the same way. As this
series continues, we will examine
how rotating labyrinth seals work and
ask several questions of interest to the
reliability-focused professional. Also,
well take a closer look at both industry
standards and user standards for motors,
applications for steam turbines, and
application criteria for face-type bearing
protector seals. In the end, we hope to
show that by understanding the different
demands of these applications, cost
justification can be quite simple.
ROTATING LABYRINTH SEALS:

HOW THEY WORK AND HOW
THEY DIFFER
It can be shown that in machinery such

as the literally millions of centrifugal
process pumps operating today,
modern bearing housing seals make
much economic sense. Findings of
rapid payback and quantifiable failure
reductions with bearing isolators are
supported both by user industry statistics.
For decades, lip seals have been out
of compliance with the minimum
requirements stated in the widely

accepted API-610 industry standard for
centrifugal pumps (see reference 6).
Indeed, most rotating labyrinth seals are
a good choice for fluid machine bearing
protection and will often outperform lip
seals by wide margins.
It must be realized, however, that
there are many types, configurations
or versions of rotating labyrinth seals.
Different configurations will allow
anything from a truly minimal amount of
breathing and virtually zero leakage, to
a rather significant amount of breathing
and worrisome leakage. The amounts
of breathing and leakage depend very
much on the design and construction
features of a given style or brand; these
features must be compared against
the configuration and/or construction
features of another make, style, or brand.
A number of parameters are observed
and compared by reliability and valuefocused observers. Before deciding to
buy, a value-focused observer often
requests test data and cross-sectional
views. Together, these data will disclose
the operating principles of different
versions of bearing protector seals
(figure 2). Reliability professionals
are not asking for the disclosure of
proprietary manufacturing drawings;
however, they want to see and
understand exactly what it is they are
purchasing. (Note that figure 2 is a
generic depiction only.)
Reliability professionals are most
productive when they manage to
work with dependable vendors who,

in essence, become their technology
providers. Competent vendors and
manufacturers display a cooperative
attitude which then facilitates rigorous
product comparisons. Although brief,
a detailed review of their relevant
drawings, references or patent
applications will often prove revealing.
For instance, some rotating labyrinth
designs and configurations (such
as figures 2a and 2b) are decidedly
not field-repairable, while other
manufacturers have thoughtfully
designed in-place repairability
into rotating labyrinth seals. Certain
advanced designs incorporate both
axially sliding and radially nonwearing O-rings; note that both O-rings
in figure 2c are field-replaceable
Observe where the O-ring might
be located in a relatively elementary
seal, shown as a simplified or generic
example in figure 2a. Here, the O-ring
is located between rotating and
stationary components. It must move
radially in or out of a very closetolerance groove. Tight manufacturing
tolerances are needed in bearing
protector seals whose effectiveness
depends on sliding motion of a
dynamic (or moving) O-ring against the
edges of a sharp abrupt groove (figure
2a). In contrast, visualize another,
more modern, design that incorporates
a dynamic O-ring making contact with
a relatively large area (see figures 2c
and 5).
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.
50 | OCTOBER 2014
Figure 2: Three different generic versions of bearing housing seals. Styles with contact between O-ring and sharp edged grooves (2a) are vulnerable,
especially so if rotors incorporate low clamping forces. Some styles have high drag force between the rotor and the stationary component (2b). Advanced
styles with dynamic O-rings (2c) make contact with a large and contoured surface (2c). They exert low pressure and have optimally low drag forces.
AREA OF CONTACT
AND NEED FOR LIFT-OFF
Available area of contact is important

in bearing protector seals. An O-ring
contacting a very small area will
show the effects of force divided by
a small area (figure 3). A sharp edge
has a small area. The pressure (equal
to force divided by area of contact)
will be much lower as the force acts
on a large area than if that same force

were to contact a sharp edge. A tiny
amount of lubricant must be present to
counteract wear, but that tiny amount
is far more likely to stick to a large
surface at low pressure than to a much
smaller surface at high pressure.
It certainly was (and remains) the
original design purpose for O-rings
to seal against an applied fluid
pressure. In most conventional O-ring

applications, fluid pressure forces
the O-ring against contacting groove
surfaces and the elastomer forms a
stationary seal. In hydraulic cylinders,
the O-ring is often inserted in a
closely dimensioned groove in the
piston. When the piston is stroked, the
O-ring is said to become a dynamic
O-ring. Because the hydraulic
OCTOBER 2014 | 51
SEALING solutions
fluid provides sufficient
lubrication between O-ring
periphery and cylinder
bore, reasonably long life is
usually attained.
In some rotating labyrinth
seal designsthe ones
similar to figure 3the
O-ring is expected to lift
off radially when the shaft
is rotating. But, the same
O-ring is also expected to
seal the small gap between
rotating and stationary
component whenever the
shaft stops turning. Will it do
that?
Figure 3: O-rings in contact with sharp edges are prone to wear excessively. Sometimes, slivers of the elastomer get into a bearing housing.
QUESTIONS OF
INTEREST
move radially outwards and

disengage it from the primary
shut-off valve. This then
allows the primary shut-off
valve to move away from
the stationary ring and the
Will an O-ring lift off as
resulting micro-gap allows
anticipated?
the bearing housing to
As the O-ring lifts off,
breathe. As the equipment
is it likely to make
stops, the energizing member
contact with sharp
again takes up its idle
edges of neighboring
position and axially moves
components?
the primary shut-off valve to
Are all relevant
provide a static seal with the
components likely to
stator.
stay in place, or will the
The O-ring serving as a
rotor walk down on the
shut-off valve is made from a
Figure 4: O-rings in contact with large surfaces show polishing, not wearing.
shaft?
wear-resistant material with
Is a product fielda low coefficient of friction.
repairable, and what is its reliability record?
Tests showed that this simple, yet effective, arrangement
Does the bearing protector seal manufacturer have test
prevents moisture droplets from being sucked back into the
data relating to the wear life or leakage behavior of the
oil during cycles of bearing chamber breathing.
product?
A second moisture ingress abatement feature of the seal
shown in figures 2c and 5 acts as a multi-tiered terrace-like
True non-contacting designs will allow an interchange
pathway system. It consists of a staggered path between the
between ambient and housing-internal air. Fortunately, the
counter-rotating members; each pathway includes a series of
contamination-inducing interchange of air can be minimized
orifice-like outlets. The pathway system creates a cascading
by thoughtful engineering and by incorporating a multi-stage
effect and extensive testing confirmed that water intrusion
or multi-tiered design. Such a field-repairable design, figure
is virtually non-existent. This earned figure 5 the high IP66
5, can exclude contaminants more effectively than certain
Ingress Protection rating.
simpler, traditional, rotating groove designs.
A LOOK AHEAD
The field-repairable and compound cartridge rotating
labyrinth seal design of figure 5 offers some rather unique
Parts 3 and 4 will highlight ratings and standards. They will
also show bearing housing protector seals for small steam
features. Its manufacturer can provide test data and Weibull
turbines and an example cost justification tabulated for
plots that indicate attractive life expectancies and virtual
advanced bearing housing protector seals.
freedom from leakage.
Examine how figure 5 actually works: Two O-rings clamp
the rotor to the equipment shaft. With the equipment in the
REFERENCES
non-running condition, an O-ring (energizing member)
1. Bloch, H. P. and A.R. Budris, Pump Users Handbook: Life Extension,
applies a radial load on a portion of the periphery of another
4th Edition, Fairmont Press, Inc.: Lilburn, GA (2013). ISBN 0-88173720-8.
O-ring, one with a considerably larger cross-sectional
diameter. This second O-ring serves as the primary shut2. Adams, V., R., Barry Erickson, Bill Needelman, and Michael D. Smith,
Proceedings of the 13th International Pump Users Symposium, Texas
off valve. When the equipment is operating, the energizing
A&M University, Houston, TX (1996): 71-79.
O-ring is subjected to centrifugal forces that cause it to
Before making a product
selection, several questions
are of interest to the
reliability-focused:
52 | OCTOBER 2014
3. Eschmann,P aul, Ludwig

Hasbargen, and Karl
Weigand, Ball and Roller
Bearings, John Wiley & Sons,
New York, NY (1985): 183,
ISBN 0-471-26283-8.
Water Spray/Moisture
Shaft
Housing
2nd Outlet
1st Outlet
Figure 5: Multi-tiered arrangement, tortuous path and expulsion orifices of modern, field-repairable rotating labyrinth seal
(source: AESSEAL, Inc., Rotherham, UK, and Rockford, TN).
4. Bloch, H. P.; Twelve

Equipment Reliability
Enhancements with 10:1
Payback, NPRA Paper RMC05-82, Presented at NPRA
Reliability and Maintenance
Conference, New Orleans,
May 2005
5. SKF Catalog 140-170, August
1988: 40 (Figure 17).
6. API-610, Standard for
Refinery-Type Centrifugal
Pumps, 8th and later
Editions, The American
Petroleum Institute,
Washington, DC.
7. Derrick, R, W. Martiny, and
W. McDonald, Pulp-Coated
Motors: The Effect on Motor
Life, Engineering Conference
Book, TAPPI, Technology
Park: Atlanta, GA (1986).
8. Bloch, H. P., Pump Wisdom:
Problem Solving for
Operators and Specialists,
John Wiley & Sons: Hoboken,
NJ (2011). ISBN 978-1-11804123-9.
OCTOBER 2014 | 53
MODERN PUMPING products

WATRy induSTRiES
Permanent mold Castings
Watry Industries is one of the most automated high-tech,

permanent mold foundries in the industry. Capabilities
extend far beyond your typical permanent mold foundry.
Watry is capable of pouring castings from a few ounces to
over 100 pounds with or without cores. We routinely pour
in a wide range of alloys including 319, 355, 356, 357
and 443. Another advantage of Watry is the fully staffed
engineering department
using 3D CAD modeling,
Magmasoft Solidification
simulation software and
real time digital X-ray to
ensure quality parts are
made from the start of the
Featured Product Release
project. We are registered
to ISO 9001 however can
comply to almost any
quality standard. Watry
also offers a wide range of Vertical and Horizontal CNCs
to fit your needs going from the very small up to 800
millimeters. With our In house powder coating, heat treat
and assembly we can reduce lead-times and inventory
required using another source. As your single source for
permanent mold castings, machining and powder coating
we can also reduce your transportation costs and eliminate
headaches that arise in dealing with subcontractors.
For more information, visit www.watry.com.
SJE-RhOmBuS
CE Approved Electromechanical
Control Panels Series Emd
SJE-Rhombuss CE approved Electromechanical Control Panels series EMD designed for
international applications control one or two submersible single phase or three phase
electric pumps in water and wastewater applications. The panels are provided with a
thermal overload protection relay incorporated in an IP 55 weatherproof cabinet. The
EMD control panels operate pumps based on signals provided from liquid level floats
or pressure switches. Four models are available; EMD1S, EMD1T, EMD2S, EMD2T
and accommodate single phase voltage (240VAC) or three phase (400VAC) voltage
50Hz or 60Hz applications. For more information, email sje@sjerhombus.com, call
218.847.1317, or visit www.sjerhombus.com.
AumA
EWg Electronic Position Transmitter
A new electronic position transmitter designed to simplify end position adjustments for actuators
has been developed by AUMA. The EWG is compatible with its predecessor, the RWG, which
ensures rapid replacements and retrofits. Advantages provided by the EWG include continuous
recording of the valves current position, and transmission as an analogue 0 20 mA or 4 20 mA
signal to the control system. Inverse operation is also possible. End position adjustment is simple
and straightforward, as tools are not required. Valve position detection is contactless and avoids
wear. Should a power failure occur, the EWG reliably recognises the current valve position, even if
the device has been operated via the handwheel during the outage period. Once power supply is
restored, a position signal is issued immediately, without the need for renewed setting or reference
operation, and battery back-up is not required. For more information, visit www.auma.com.
54 | OCTOBER 2014
ARmSTROng fluid TEChnOlOgy

Astro Wet-Rotor Circulator
Armstrong Fluid Technology has announced the expansion of its Astro wet-rotor circulator
offering with the introduction of the Astro 2 Series. Featuring four new sizes, the Astro 2 Series
now offers flange-to-flange and bolt-to-bolt compatibility with 100 percent of competing
models in terms of performance. Designed for fast and convenient installation and years of
trouble-free operation, the new models also address a broader range of applications. Key
features include: three field-selectable operating speeds, double the head and triple the
flow, a plug-in terminal strip to save time on installation, e-coating on the inside of the cast
iron volutes to provide enhanced corrosion protection, pre-installed high-flow check valve
and availability in cast iron, stainless steel and lead-free bronze. For more information, visit
www.armstrongfluidtechnology.com.
KB ElECTROniCS, inC.
AC digital drive KBWK-23d
KB Electronics, Inc. of Coral Springs, Florida, a manufacturer of AC drives and DC drives

from fractional through 5 horsepower, introduces a new AC digital drive to their current
product line. The new KBWK-23D operates with either a 115 or 230V AC line, is housed in
a NEMA 1 / IP 20 enclosure, and features a digital display with LED status indicators. This
drive is rated for 3-phase induction motors to horsepower. Common Sense Programming
(CSP) is included, which organizes parameters into easy to understand intuitive groups.
The UL approved proprietary current limit software provides motor overload protection,
prevents motor burnout, and eliminates nuisance tripping. The KBWK drive offers energy
savings using only the power the application requires. GFCI software allows the drive
to operate with Ground Fault Circuit Interruption circuit breakers or outlets. For more
information, visit www.kbelectronics.com.
AZTEC BOlTing
SERviCES inC.
Electric Tensioner Pump

Aztec Bolting Services Inc., a leading provider
of bolting tools to the natural gas, oil,
petrochemical, and wind energy industries
for the past twenty-five years, announces its
latest tool, a new generation electric tensioner
pump designed for critical bolting applications,
specifically in the wind and power generation
industries. This pump is taking
tensioning to a new era, says
Larry Garza, owner of Aztec
Bolting Services Inc. The
tool has a unique footprint;
it is 65 percent smaller than
anything on the market.
Portability and compact
design are key in our industry
and this tool has them both.
Other key design features
include the fast pressure-up
and retract and a hi-tech,
calibrated digital gauge,
multi-functional intrinsically
safe remote control, and
certified one point lift.
For more information,
call 800.233.8675 or visit
www.aztecbolting.com.
XylEm
godwin dri-Prime nC350 Pump

The Godwin Dri-Prime NC350 is the largest pump in the
NC line, a powerful pump offering flows to 6,530 GPM and
discharge heads to 160 feet. The higher flow capabilities are
ideal for wastewater applications where other pumps could clog
or fail. The NC350 features patented Flygt N-technology with an
innovative self-cleaning impeller for non-clog performance. NC
series pumps are engineered to deliver sustained high efficiency,
lower energy and fuel costs, and reduced unplanned downtime.
This makes the NC350 a best-in-class portable pump suitable
for both sewage and clean water applications. The NC350
can be customized with a diesel engine or electric motor. It
is also available as a Critically Silenced unit or as a Godwin
DBS for pump station backup. For more information, visit
www.godwinpumps.com.
OCTOBER 2014 | 55
PUMPING trends
Atlas Copcos Jlio Tom on the growing

market for reliable, portable power sources
lio Tom is the divisional product

marketing manager of generators
for Atlas Copco, a world-leading
provider of compressors, vacuum
solutions and air treatment systems,
construction and mining equipment,
power tools, and assembly systems.
He spoke with Modern Pumping
Today about the groups recent
release of its redesigned QAS 60
portable generator, a new option for
on-site power demands.
Modern Pumping Today:
The transportation
and overhead costs
for generators can be
prohibitively expensive
for some equipment users.
How have Atlas Copcos
rental options made
generators more attractive
for these clients?
Jlio Tom: Transportation
is one of the five key
benefits of our QAS range
within our Predictable
Power core valueand
indeed a key design
driver during all product
development. Rental
operations are by definition
a frequent movement
activity for equipment and all aspects of handling needs to be
considering: size, weight, lifting, safety, and robustness.
All in all, for generators, a good design considers the standard
dimensions of a truck in order to accommodate the maximum
number of units, lifting strength and central point of gravity, and
a very solid and wider base frame. At the end all this results in
lower transportation, repair, and handling costs which are an
important part on keeping overhead costs under control, with
limited surprises. This is in fact a very important topic.
MPT: What were some of the concerns you were hearing
regarding transportation efficiency that led to the redesign of
the QAS 60 generator?
56 | OCTOBER 2014
Jlio Tom: The QAS 60 used to be in the same box as QAS 80

and QAS 100 and following our Predictable Power design
guidelines we decided to invest in the redesign based on a
smaller box and footprint. The outcome is a unit that can be
transported transversal on a truck lorry allowing up to 12 units
on a 45-foot truck lorryso lower costs and better operation!
MPT: How does its performance compare to earlier models?
Is it suitable for hazardous conditions?
Jlio Tom: We kept exactly the same engine and alternator
as before. This means the same power and similar cooling
performance, which is a difficult and remarkable engineering
achievement. On other
side we lost a bit on
noise, but it is still very
much within a reasonable
range (LWA90), and on
fuel autonomy due to
size constraints but still
ensuring a minimum of
one shift (8h) at full load.
Also, the QAS 60
designs fall in the
versatility of the QAS
range and very well
appreciated by rental
sector. It is ready to
operate in the most diverse
applications and critical
areas.
MPT: Improved monitoring
and efficiency are key attributes generator users are looking
for. What are some of the options available for the QAS 60?
Jlio Tom: Thats correct. We took the opportunity to include
the new Qc1103 controller that replaces the old Qc1002.
This is the first model to change and it will be followed by the
complete QAS range in Europe.
The new Qc1103 is able to monitor and log the current in all
three phases allowing a better monitoring not only on current,
voltage and frequency but also on active and reactive power.
A full option list is available for the new QAS 60. AMF
controller (Qc2003), battery charger, coolant heater, dual
frequency, dual voltage, larger fuel tank (24h), external tank
connections (3 way valve), on-road undercarriage, refinery
package, customized colors.

Modern Pumping - 102014

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Modern Pumping - 102014

Uploaded by

Copyright:

Available Formats

mOdERn

PUMP STATION UPGRADE

Reduces oPeRating costs

12 Thinking Globally and Acting Locally to Preserve a Natural Wonder

16 Pump Station Upgrade Reduces Operating Costs Using

water & wastewater solutIons

22 Recycling Earth's Rapidly Shrinking Resource

26 Electronic Water Treatment

An alternative solution to removing beerstone and limescale

30 Improving Cooling Tower Filtration

34 The Evolution of Lubrication Technology

38 Right Pumps and Right Maintenance Are a Must

40 Reliability Needed in Treatment Facility

42 Maximum Results from Mini Drive

WEG Electric's CFW100 Mini Drive puts power at users' fingertips

P.O. Box 660197 | Birmingham, Alabama 35266

44 Highly Accurate Sensor for Thermal Power Stations

46 Precision Fluid Control for Food and Beverage

JeFF FletcheR Associate Publisher

ValVes & Controls

scott goRdon Art Director

48 The Next Wave of Radiant

lindeY scott Circulation Manager

New solutions for radiant heating and cooling applications

JaMie Willett Circulation Consultant

ingRid beRkY Administrative Assistant

50 How to Cost-justify Bearing Housing Protector Seals

Russell haddock COO/Publisher

nancY Malone National Sales Manager

Modern PuMPIng ProduCts

RandY Moon Account Executive

Featured Product Release: WATRY INDUSTRIES Permanent Mold Castings

56 Predictable Power On the Go

312 Lorna Square | Birmingham, Alabama 35216

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

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

CHLORINATORS INC. CELEBRATE FORTY YEARS

Chlorinators Incorporated is celebrating forty years serving

cylinder mounted all-vacuum gas chlorinator in 1960, a

MAINTENANCE AND RELIABILITY SEMINARS OPEN

All-Test Pro, LLC is partnering with UE Systems, Allied

INTEGRA TECHNOLOGIES OPENS

Integra Technologies is expanding its rental coverage and is

AWARD IN PROGRESSING CAVITY PUMPS

For the second time since 2011, Netzsch will be presented

2014 Global Product Leadership Award in Progressing Cavity

RACO ANNOUNCES CATALYST UPDATE, NOW

RACO Manufacturing and Engineering Co., a leading

With the optional EtherNet/IP and Modbus TCP protocols,

ENGINEERING WEBINAR: DESIGNING

CD-adapco is offering a free online seminar on October

TRADE SHOW profile

addressing their readiness in

Thinking Globally and Acting Locally

he transition from independent

FINDING THE RIGHT

Perhaps the self-evaluation could