Modern Pumping - 122014

MODERN
TODAY
PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY
DECEMBER 2014
ON TAP:
THE WORLDS BEST

MUNICIPAL
DRINKING WATER
THE AGE
OF PUMP
OPTIMIZATION
MEASURING
TRUE PUMP
PERFORMANCE
SHREDDING
WASTEWATER
DEBRIS
CONTENTS
4
10
DECEMBER 2014
Industry news
trade show ProfIle
Case studIes
12 Measuring the True Performance of Pumps in Operation

16 Shredder Pumps Installed at Historic Ellis Island
water & wastewater solutIons
20 Channel Monster Shreds Debris, Ragging
Monster grinder cuts $78,000 from energy costs in Santa Margarita Water District
20
22 The Village of Montpelier Improves Efficiency

with New Gas Chlorinator System
MaIntenanCe solutIons
26 Performance Evaluation for Rotary Vacuum Filters

EDG-trac Knife Advance System proves efficient and cost-effective
PuMP solutIons
28 The Age of Pump Optimization and the Impact on Sustainable Design
dewaterIng solutIons
32
32 Solid Foundation for Business District
TerraFirma's groundwater system supports 100 Saint Paul development
Motor solutIons
36 Intelligent Pumping Systems
Easier diagnostics, monitoring, and troubleshooting of PLCs with web-enabled user interfaces
Power generatIon
solutIons
40 Power Where It's Needed Most
Franklin's new solar pumping technology proves itself in Africa
46
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266
ProCessIng solutIons
@ModPumpMag
42 High-precision Ingredient Metering

for Spreadable Butter
JEFF FLETCHER Associate Publisher

jeff@modernpumpingtoday.com
Dairy giant Arla uses multiplex pumps with a broad adjustment range
RANDY ARMISTEAD Associate Publisher

randy@modernpumpingtoday.com
ValVes & Controls

solutIons
J. CAMPBELL Editor
jay@modernpumpingtoday.com
DONNA CAMPBELL Editorial Director
donna@modernpumpingtoday.com
46 Quality Meets Quantity
In the field and in the lab, YSI measurement tools offer detailed monitoring and control
LISA AVERY Assistant Art Director

lisa@modernpumpingtoday.com
sealIng solutIons
48 How to Cost-justify Bearing Housing Protector Seals

Key factors for reliability-focused process pump users
Part 4 in a 4-Part Series
52
SCOTT GORDON Art Director

scott@modernpumpingtoday.com
JAMIE WILLETT Circulation Consultant

INGRID BERKY Administrative Assistant
NANCY MALONE National Sales Manager
TONYA BROWNING Account Executive
Modern PuMPIng ProduCts

Featured Product Release: MEGGIT SENSING SYSTEMS REF2500 Handheld Shaker
JERRY DICHIARA Account Executive

RANDY MOON Account Executive
CINDEE STANDRIDGE Account Executive
PuMPIng trends
56 The Gift of Doing Good
Louis Allis president, Bruce Bailey, on corporate responsibility and the rewards of giving back
www.highlandspublications.com
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TIM GARMON
CEO/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
RUSSELL HADDOCK
COO/Publisher
CHRIS GARMON
General Manager
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

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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:
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INDUSTRY news
ARMSTRONG FLUID TECHNOLOGY RECEIVES
PRESTIGIOUS CUSTOMER VALUE AWARD
Armstrong Fluid Technology has been presented with a

prestigious Frost & Sullivan Best Practices Award in recognition
of world-class performance in business strategy, operations
and customer service. At a gala ceremony in Toronto on
December 2, 2014, members of the senior leadership team
were presented with the Customer Value Award in recognition
of the outstanding return on investment provided by Armstrong
solutions.
In particular, Frost & Sullivan highlighted Armstrongs
Design Envelope technology which redefines the traditional
economics of energy and sustainability to provide both
lowest installed cost and lowest lifetime cost. The Frost &
Sullivan Best Practices Awards recognize superior leadership,
technological innovation, customer service, and strategic
product development. Frost & Sullivan's industry analyst team
studies companies internationally, across a wide range of
industries. The performance of each company is benchmarked
and measured independently through primary interviews, and
secondary industry research that identifies best practices and
evaluates candidates using a 10-step process. Based on a 360
research methodology, the evaluation considers corporate
performance in seven key areas: Competitive Intensity;
Customer Dynamics; Industry Convergence; Disruptive
Technology; Global Mega Trends; New Business Models; and
Emerging Markets.
Earlier this year, Frost & Sullivan examined the business
practices of Armstrong Fluid Technology, along with major
4 | DECEMBER 2014
competitors in the UK and European markets and selected

Armstrong to receive the Customer Value Award.
U.S. WATER RECEIVES

THE CALIFORNIA
GAME CHANGER
COMPANY OF THE
YEAR AWARD
U.S. Water Services,

Inc., the leading national
provider of integrated
solutions for water
treatment, has received
the California Game
Changer Company of the
Year Award.
The honor was presented by the California Governors Office
of Business and Economic Development, Oliver Rosenbloom,
and accepted by U.S. Waters Alexandra Causey at the 100th
Annual Vanguard Awards Dinner on November 20 at Chico
State University.
In an effort to conserve freshwater resources, California
facilities are actively working to reduce water use 20 percent
by the year 2020. U.S. Water has been working with California
agriculture, medical centers and businesses throughout the
state using integrated solutions that combine chemical,
equipment, engineering, automation and service to help
facilities achieve this goal. The California Game Changer of the
Year Award recognizes individuals and companies who have
INDUSTRY news
made a significant statewide impact either economically or
regarding key issues within the State of California.
On receiving this award, U.S. Water founder and CEO Allan
Bly states, U.S. Water is proud to be recognized for our record
of achievement in the State of California. Our people and
integrated water solutions approach are working very effectively
to reduce water use and improve business and plant efficiency
not only in California, but throughout the United States.
HIDROSTAL LAUNCHES NEW WEBSITE

WITH PUMP FINDER FEATURE
Hidrostal Ltd, the UKs expert in pumps and pumping systems, is

pleased to announce the launch of its brand new website.
The site has been designed to offer an enhanced browsing
experience with clear functionality and navigation. Users
will find information on Hidrostals full range of products and
applications and be able to download the technical data and
case studies showing the pumps in operation.
In addition the site now includes the Pump Finder, a
dedicated pump selection programme which enables the
customer to select the right solution for their own application.
The client can select the duty from the full range graph and
then search by the type of pump required. The selection will
grant access to the full range of technical data including CAD
drawings, pump curves and installation arrangements. This will
enable the customers to make the preliminary selections for
their pump station designs instantaneously.
Neil Langdown, managing director of Hidrostal Ltd comments
The website, in particular the Pump Finder, has been developed
6 | DECEMBER 2014
in consultation with our customer base i.e. consultants,

contractors, end users and distribution partners we believe
that we have delivered on our promise to marry ease of use with
the provision of technical information
To view Hidrostals updated website, visit www.hidrostal.co.uk.
NEW WATER STOCK ADDED TO DIRECTORY

OF GLOBAL WATER STOCKS
Investorideas.com, (www.investorideas.com) global news source

covering leading sectors including water, issues the updated
water stocks directory for November. The Water Stocks Directory
lists publicly traded water companies listed on the TSX, TSX
Venture, OTC, NASDAQ, AMEX, NYSE, ASX, AIM and other
leading global Stock Exchanges.
Recently added to the directory is Mount Everest Mineral
Water Ltd. Mount Everest Mineral Water Ltd (BSE: MOUNTEVE.
BO) produces, sells, and distributes natural mineral water under
the HIMALAYAN brand name in India. Its customers include
hotels, airlines, embassies, etc. The company also sells its
products through retail outlets, malls, multiplexes, hypermarts,
and fine-dine restaurants. In addition, it exports its products
worldwide. The company was incorporated in 1991 and is based
in Mumbai, India. Mount Everest Mineral Water Limited is a
subsidiary of Tata Global Beverages Limited.
The stock directory features water stocks ranging from
desalination companies to bottled water stocks, to infrastructure,
water treatment and technology as well as other sub sectors.
The directory is in PDF format and features hyperlinks to
stocks symbol(s), company URLs and company's description.
INDUSTRY news
For investors following water stocks this is one of the most
comprehensive directories in the sector available.
PLASTICS MACHINERY SHIPMENTS

CONTINUED TO RISE IN Q3
Market demand for plastics machinery continued to grow in

the third quarter of 2014, according to statistics compiled
and reported by SPI: the Plastics Industry Trade Associations
Committee on Equipment Statistics (CES).
The market conditions that drive investment in new
industrial equipment have prevailed throughout all of 2014,
and I expect these conditions to persist in 2015. These are: low
interest rates, and the need for increased productivity in order
to meet rising aggregate demand," according to Bill Wood, the
plastics market economist who analyzes and reports on the
plastics machinery market sector for the CES.
Shipments of primary plastics equipment (injection molding,
extrusion and blow molding equipment) for reporting
companies totaled $301.4 million in Q3. This is 6 percent
higher than the revised shipments total of $284.3 million in
Q2 of this year, and is down only 2 percent compared with
the robust total from Q3 of 2013. For the year to date, the
total value of primary equipment shipments is up 6 percent
compared with last year.
A closer look at the CES data show that the shipments value
of injection molding machinery decreased 4 percent in Q3 of
2014 compared with the total from Q3 of 2013. For the year
to date, shipments of injection molding machinery are up 4
percent. The shipments value of single-screw extruders dropped
8 | DECEMBER 2014
14 percent in Q3 compared with last year. For the year to date,

single screw extruder shipments are down 6 percent. The value
of shipments of twin-screw extruders (which includes both corotating and counter-rotating machines) jumped 33 percent in
Q3. For the year to date, shipments of twin screw extruders are
up 35 percent. The shipments value of blow molding machines
advanced by an estimated 27 percent in Q3. For the year to
date, shipments of blow molding machinery are up an estimated
25 percent.
The CES also compiles data on the auxiliary equipment
segment (robotics, temperature control, materials handling, etc.)
of the plastics machinery industry. New bookings of auxiliary
equipment for reporting companies totaled a record-breaking
$108.2 million dollars in Q3. This represented a gain of 8
percent compared with the total from Q3 of 2013. For the year
to date, bookings of auxiliary equipment are up 12 percent.
The trend upward in the CES data on plastics machinery
shipments corresponds with the trends in the two major
data series compiled by the U.S. government that measure
activity levels in the industrial machinery sector. According
to the Bureau of Economic Analysis, business investment in
industrial equipment escalated by 16 percent (seasonallyadjusted, annualized rate) in Q3 when compared with Q3 of
2013, and for the year to date investment is up 13 percent. The
other important machinery market indicator, compiled by the
Census Bureau, showed that the total value of new orders of
industrial machinery jumped 47 percent in Q3 when compared
with the total from last year, and for the year to date industrial
machinery orders are up a stellar 34 percent.
TRADE SHOW profile
2015 AHR EXPO

The Worlds Largest HVACR Marketplace
s the largest and most comprehensive HVACR

event, the AHR Expo attracts tens of thousands
of attendees from all facets of the industry,
including contractors, engineers, dealers, distributors,
wholesalers, OEMs, architects, builders, industrial
plant operators, facility owners and managers, agents
and reps.
Since 1930, the AHR Expo has been the HVACR
professionals leading resource for new products, new
ideas and new services. Its a hands-on, interactive
event that showcases a wide spectrum of equipment,
systems and components. This unique industry forum
creates a dynamic learning environment unequaled in
size and scope by any other industry event.
LARGEST EDUCATION PROGRAM

IN SHOW HISTORY
The 2015 AHR Expo includes its largest number

of seminars, workshops, certification reviews/
exams and new product presentations in the events
history. Attendees will have a wealth of educational
opportunities to choose from as the leading
associations, publications and organizations serving
the HVACR marketplace have come together to
create the industrys most comprehensive educational
program.
Designed to give HVACR professionals the
information tools they need to improve their
businesses, perform their jobs more effectively and
stay abreast of new technology and trends driving the
industry, more than 120 educational sessions covering
a variety of topics will be offered during the worlds
largest HVACR trade show. These educational offerings
range from more than three-dozen free sessions, nearly
two-dozen paid courses, and over sixty exhibitor new
product presentations in the New Product

and Technology Theaters.
This shows line-up is our largest
ever and covers many key issues that
engineers, contractors, OEMs, facility
managers, manufacturers and other HVACR
professionals should know about to be
successful, said Clay Stevens, president
of International Exposition Company (IEC),
which produces and manages AHR Expo.
When you include all the new technologies
and solutions being featured by the nearly
2000 exhibiting companies on the Show
floor, AHR Expo truly is an unparalleled
learning environment.
AN EXCITING TIME
FOR THE INDUSTRY
Now is the time to meet face-to-face with

the leading figures in this growing industry.
According to a recent ASHRAE and AHR
Expo survey sent to more than 1000 HVACR
manufacturers worldwide, there is growing
optimism for improving economic prospects
in 2015. Based on survey results, 87 percent
of the respondents said their prospects for
business were either excellent (26 percent)
or good (61 percent) for the coming year.
Thirteen percent of the respondents felt
prospects were fair.
These results reflect a significant 8
percent jump over last years survey that
found 79 percent of respondents expected
the economy would be better in 2014 than
2013. It also represents a sizable 17 percent
increase in optimism over the previous years
survey when 70 percent of the respondents
thought 2013 would be better than 2012.
In keeping with this positive outlook
for next year, 96 percent of the HVACR
manufacturers believe 2015 sales will
continue to increase, with 47 percent
expecting sales increases of between 5
percent and 10 percent. Twenty nine percent
of respondents forecast sales increases more
than 10 percent, and 20 percent expect
increases of less than 5 percent. Only 3
percent expected sales to remain the same.
This represents a 6 percent jump over last
years forecast and an impressive 16 percent
increase over the 2013 survey.
DECEMBER 2014 | 11
CASE Studies
THE TRUE PERFORMANCE OF

PUMPS IN OPERATION
By Fabian Papa and Djordje Radulj, HydraTek & Associates
recent large-scale testing program was conducted

across Ontario in which the actual performance and
efficiency of water pumps was assessed and compared
against original manufacturer specifications. The results were
interesting and lifted the veil of uncertainty which often
surrounds such matters and exposed
opportunities where substantial
savings in energy efficiency were
available.
FIELD TESTING CRITICAL

TO UNDERSTANDING
PERFORMANCE
The vast majority of tests were

conducted using the innovative and
highly accurate Thermodynamic
Method which measures the thermal
energy gain in the pumped water,
among other parameters including
pressure and power supplied to
the pump motor, to compute pump
inefficiency directly. This method
was found to be highly, although
sometimes not universally, applicable
relative to its conventional method
counterpart which relies heavily on
flow measurements which can be
difficult to obtain with accuracy in
many practical settings.
The results:
operating point noting that, in practice, pumps often

operate outside of their range of peak efficiency.
The average wire-to-water efficiency was found to be 69.4
percent, meaning that more than 30 percent of the input
energy is lost due to pump, motor
and drive inefficiencies, with the
pump inefficiency making up the vast
majority of this loss.
SAVING MONEY THROUGH

OPERATIONAL CHANGES
With accurate and reliable knowledge

of the actual performance of pumps,
the information is available to support
changes in the way existing pumps are
operated, including their scheduling,
utilization and combinations. This
can be a very cost-effective way of
reducing energy costs with minimal
investment required and, based on the
results of the testing, there is ample
room to consider such operational
improvements with positive effect.
SAVING MONEY THROUGH

REFURBISHMENT
Tests conducted before and

after pump refurbishments show
Calibration of temperature probes for
encouraging results, with the recovery
Thermodynamic Method
of lost efficiencymeasured as the
9.3 percent average reduction
difference between peak manufacturer
between manufacturers original peak efficiency and
efficiency and peak field efficiency before refurbishment
actual peak efficiency; and
commonly in the range of 50 to 70 percent, depending on
specific circumstances. Thus, sufficient information is now
12.7 percent average reduction between manufacturers
available to construct credible business cases supporting the
original peak efficiency and actual efficiency at typical
refurbishment of pumps.
About The Authors

Fabian Papa and Djordje Radulj are with HydraTek & Associates, a consulting firm specializing in hydraulic and energy
investigations of fluid systems. They can be reached at 416.238.7681 or at f.papa@hydratek.com and d.radulj@hydratek.com.
For more information on HydraTeks Ontario-wide pump performance and efficiency testing project, or to request a full copy
of the final report, visit www.hydratek.com/opa.
12 | DECEMBER 2014
Efficiency (%)
Pumping Head (m)
Flow Rate (L/s)

Sample pump testing results comparing actual performance to original manufacturer specifications
DECEMBER 2014 | 13
CASE Studies
Utilization Rate (Fraction of Time Operated Annually)
ESTABLISHING TESTING SCHEDULES
Pump Motor Size (hp)
Pump Efficiency, (%)
Pump testing frequency guideline
Flow Rate (L/s)

Sample efficiency recovery from pump refurbishment
Calibration of temperature probes for

Thermodynamic Method
14 | DECEMBER 2014
It is quite common for managers to establish

routine schedules for asset management
activities (e.g., lubricant or bearing
replacement, component cleaning, etc.) based
on a uniform frequency such as every two
years, every five years, etc. When it comes
to pump testing for purposes of controlling
energy usage, it is sometimes more practical
to consider pumps on the basis of their energy
consumption, noting that the amount of energy
consumed by pumps increases with: (1) the
size of the pump and its motor; and (2) its
utilization rate. That is, a large pump that is
rarely used can easily consume less power
than a more modestly sized pump that is used
regularly. Testing and potentially refurbishing
a pump that is not used sufficiently consumes
financial resources without producing the
benefit sought (or return on investment).
To assist managers with this, a graphical
guideline for pump test frequency was
developed based on economic principles to
ensure a positive return on investment. Of
course, this is not meant to be interpreted
rigidly, and certainly other important factors
may cause some pumps to be tested more
frequently than the graphic would suggest,
such as the criticality of a pump to a systems
performance. One can easily envision a small
system supplied by pumps only (i.e., a closed
system) which, upon the failure of a pump,
may no longer be able to deliver any service.
Numerous other examples easily come to
mind as well. In these cases, more routine
testing of critical pumps will help to identify
early warning signs to avoid such crisis
situations. Amongst other useful times to test
pumps include immediately upon installation
to both verify initial performance relative to
design requirements, as well as to establish
an in-situ (rather than factory) baseline from
which trends can be drawn with results from
future tests.
Pump performance and efficiency testing services are readily available and highly informative.
CASE Studies
Shredder Pumps Installed

At Historic Ellis Island
By Mike Bjorkman, BJM Corp.
llis Island, in the

shadow of the
Statue of Liberty, is
one of America's most
popular historic sites. The
island is one of a number
of small, naturally
occurring islands in New
York Harbor. Over many
years, this islandwhich
for millions of people
represented the gateway
to the New Worldwas
enlarged from its original
3.3 acres to its current
27.5 acres by adding
landfill from ships ballast
and possibly excess earth
from the construction
of the New York City
subway system.
The island was not
always a point of entry
for immigrants or a
tourist destination. By
the time it was purchased
in the 1770s by Samuel
Ellis, it had served
as a hanging site for
pirates, a harbor fort, and
an ammunition and ordinance depot. The U.S. Government
purchased the island from New York State in 1808. Just before
the War of 1812 broke out a series of structures were erected
that served as a defense system for New York Harbor. Ellis
Island was approved as a site for fortifications and on it was
constructed a parapet of three tiers of circular guns.
ELLIS ISLAND
ESTABLISHED AS AN
IMMIGRATION
STATION
In January 1892 the

federal government took
over the processing of
immigrants from the
states and opened a new
immigration station on
Ellis Island. Over the next
sixty-two years more than
twelve million immigrants
were processed at the
site. Approximately
1.25 million of those
came in 1907 alone.
Consequently, carpenters
and masons were
constantly working to
enlarge and build new
hospitals, dormitories and
kitchens and the island's
facilities were rapidly
expanded between 1900
and 1915.
Immigration
decreased as the United
States entered World War
I and during this time the
island was taken over by the U.S. Navy and the Army Medical
Department. In 1920 Ellis Island reopened as an immigration
receiving station. However, after World War I immigrants applied
for visas at American consulates in their country of origin. After
1924 the only immigrants passing through Ellis Island were
those who had problems with their paperwork, war refugees
About The Author

Mike Bjorkman is vice president of BJM Corp. and has more than thirty years of experience in the pump industry. He serves
as director of marketing and IT for BJM Pumps, LLC and All Test Pro, LLC. Both companies are subsidiaries of BJM Corp.
BJM Pumps, established in 1983, supplies electrical submersible pumps to industrial and municipal markets throughout the
United States, Canada and South America. For more information, visit www.bjmpumps.com.
16 | DECEMBER 2014
and displaced people. In

Hurricane Sandy came
1954 the last detainee was
ashore. At that time, New
released and Ellis Island
Jersey-based Pump Express
officially closed.
Services had been providing
In 1965 President
maintenance to the island's
Lyndon Johnson declared
sewage ejector system for a
ABOUT PUMP EXPRESS SERVICES
Ellis Island part of the
couple of years.
Pump Express Services, in business for more than
Statue of Liberty National
According to Pump
35 years, is headquartered in Wallington, N.J., and
Monument. Between 1976
Express sales manager
provides pump and electric motor repair, rebuild,
and 1984 Ellis Island was
Fred Hettinger, in the two
maintenance and installation services to clients in
opened to the public on a
years before Sandy they
New York, New Jersey, Connecticut and surrounding
limited basis. In 1984 Ellis
were called to the island
areas. Visit www.pumpexpressservices.com for more
Island underwent a major
numerous times in response
information.
restorationthe largest
to high water alarms,
historic restoration in U.S.
clogging and ultimately a
history.
failed pump. "They had a
This was the historic
two-pump system and when
foundation upon which
one pump failed they let the
the modern infrastructure
system run on the other," he
of Ellis Island was built. In recent years the island has become
says. Then, the second pump failed "and they had nothing."
one of the most popular tourist destinations in the National
Hettinger explained that a significant problem was that the
Park Service. That means a lot of visitors and the need for well
old pumps were a simple ejector type and didn't break down
working infrastructure.
solids. Along with the sewage flow on the island there was
On October 28, 2012, Hurricane Sandy swept over Ellis
also a significant amount of debriswith synthetic fibers being
Island, Liberty Island, and much of the East Coast. The Ellis
particularly problematicthat routinely clogged the system.
Island Immigration Museum reopened on a limited basis one
In addition to the clogging problem, physically getting to the
year later, but repairs to the buildings and infrastructure would
pumps in order to service them was a lengthy and labor-intensive
continue for many months.
ordeal. "The old system required four techs and an entire day to
Although the damage to Ellis Island was extensive, the island's
service a clog. A man had to physically descend into the 30-foot
antiquated sewage system was fraught with problems long before
pit to detach and later reattach the pump," Hettinger says.
DECEMBER 2014 | 17
CASE Studies
Left with only minimal sewage disposal, and faced with a
grand reopening to the public targeted for July 4th, 2013, the
island's maintenance engineers reached out again to Pump
Express Servicesthis time for a more permanent solution.
BJM'S SK SERIES ELECTRIC SUBMERSIBLE SHREDDER

PUMPS GET SYSTEM BACK ON LINE
"We submitted a proposal to replace the old pump system

with a pair of 15 horsepower BJM shredders," Hettinger says.
"We've been using BJM shredders for four or five years now and
everything we've been able to throw at them they've been able
to handle."
In addition, Pump Express proposed replacing two 20-foot
(6.1 meter) sections of steel pipe, along with discharge and base
elbows, installing a more efficient rail system and resurfacing
ABOUT PUMP PRODUCTS

PumpProducts.com was a result of the
expansion of Pump Express Services
standards: proficiency, reliability and
knowledge. PumpProducts.com is an
online store that took advantage of
contemporary technology to serve, not
only the local community, but the entire
nation; Amalgamated with expert in-house
connoisseur application engineers, Pump
Products has become, not only a store, but
an environment with Product engineers that
have a plethora of knowledge accumulated
through both hands-on experience and
technical data from industrial leaders and
professionals. In addition, a knowledge base
of information is included for consumer
self education, because we believe a smart
consumer is our best consumer. Pump
Products is our solution to bring Pump
Express Services quality to the nation,
distanced only by a phone call or e-mail.
We are always prepared with expert
counseling to provide better solutions for the
industry, consumer, and the nation. For more
information, visit www.pumpproducts.com.
18 | DECEMBER 2014
the base of the sewage pit. Instead of four techs and an entire
day, the new system can be serviced by two techs in four hours.
The two new BJM shredders lent themselves well to this new
configuration.
If a customer is ordering a new pump it's likely because the
one they have has failed or is about to. Hettinger said that an
important additional benefit of ordering the BJM Pumps was
that the lead time for their delivery was about half of what it
would have been for new ejector pumps equivalent to the ones
that had failed. He said that was impressive considering "all
this stuff has to be built. A lot of times the parts still have to be
manufactured." The BJM pumps were delivered in about four
weeks. The estimated delivery time for the ejector pumps had
been ten weeks.
In April 2013 Pump Express installed a pair of 900-pound
(408.2 kilogram) BJM SK Series shredder pumps into the
revamped Ellis Island system. The pumps can handle 845
gallons (3198.7 liters) per minute of wastewater at heads of up
to 94 feet (28.7 meters).
The SK Series pumps were chosen specifically because
they are designed to shred solids before passing the liquid.
The shredder pumps leave solids slightly larger than if they
were passed through a grinder pump. The shredding action is
produced through use of a unique FangTM non-clog cutting
impeller with tungsten carbide vane tips against a high-chrome
"tooth shaped" diffuser plate. The cutting tips shred solids
against the pump suction plate, continuously ripping the solids
apart with 360-degree shredding action. The SK Series shredder
pump works on many objects that would clog an ordinary
pump.
Other quality features built into the SK Series pumps that
supported their recommendation for the Ellis Island installation
include the following.
The 304 stainless steel motor housing helps protect the

pumps from abrasion and premature wear caused by the
harsh saltwater environment.
The motor is protected by double mechanical seals. The
lower seal is made of silicon carbide/silicon carbide and
the upper seal is made of carbon/ceramic. In addition, a
lip seal has been installed above the impeller that helps
prevent abrasives, such as sand, from entering the seal
chamber.
Winding protection and NEMA Class F motor insulation
allow the motor temperature to rise to 230 degrees
Fahrenheit (110 degrees Celsius). An automatic switch
turns the pump motor off if the temperature and/or amp
draw gets too high. When the motor cools the switch will
automatically reset and the pump will restart.
A hardened cast iron exterior stands up to rough handling
and pumping of sandy water unlike pumps with soft resin
impellers or plastic exterior components. (Specifications
may differ between models.)
CONCLUSION
About six months after installation a team from Pump Express
went back to Ellis Island to make sure the new pumps were
performing as anticipated. "We're now going on a year and a
half and haven't had any issues," Hettinger says. That's a vast
improvement over the previous average of a visit every six
months. "I bet in the last eighteen months if we had had to go
out there three more times it would have cost them half of what
the upgrade cost them," he adds.
WATER & WASTEWATER solutions
Channel
Monster
Shreds Debris,
Ragging
Monster grinder cuts $78,000 from energy
costs in Santa Margarita Water District
By Kevin Bates, JWC Environmental
hen the Santa Margarita Water District (SMWD)

was formed in 1964 by a group of ranchers who
wanted a reliable water source for their cattle, the
district served more cows than people. Since then, the area
has grown to over 150,000 homes and businesses, and the
SMWD maintains over 1200 miles (1931 kilometers) of water
and sewer lines across a 62,674 acre service area. Keeping
up with both the water needs and sewage disposal of the
community has come with significant challenges, particularly
due to both the increase in influent and change in the makeup
and durability of the sewage running through the districts
reclaimed-water facility.
A VALUED WATER SOURCE
Built in 1977, the reclaimed water facility was initially

intended to provide water for landscape irrigation in the
district. During a typical twelve-month period today, the facility
brings in 680 million gallons (2.57 billion liters) of sewage and
sends out 620 million gallons (2.34 billion liters) of reclaimed
water. Originally, the facility relied on a mechanically-cleaned
bar screen to remove debris from the waste system.
Over time, safer, more reliable solutions came on the
market, and the bar screen was replaced by a CMD singledrum Channel Monster from JWC Environmental that would
shred debris before it reached the pumps, preventing clogs
or damage. Ron Johnson, facilities supervisor for the SMWD
facility, said pump clogging hadnt been an issue since the
Channel Monster was installeduntil two years ago, when
the composition of the influent became heavily loaded with
disposable wipes.
We have a bank of four VFD controlled pumps at the
facility, and typically we run an alternating cycle with two
pumps operating and then switching to ensure equal runtime
for all the pumps, Johnson says. This operating sequence with
About The Author

Kevin Bates is the global marketing director for JWC Environmental based in Costa Mesa, Californai. JWC Environmental
is a world leader in solids reduction and removal for the wastewater industry with its Muffin Monster grinders and Monster
screening, compaction and washing systems. Bates has more than twenty years of experience working with global industrial
leaders to solve challenging technical problems spanning a wide range of markets including wastewater, construction and
mining.
20 | DECEMBER 2014
the pumps modulating around 50 Hertz

kept up with plant flow requirements.
But starting in about 2012, the pumps
would begin to lose efficiency as the
wipes loading increased and we would
have to run all four pumps to maintain
plant production. Once they reached 60
Hertz we would need to shut down the
plant to derag the pumps.
of pumps, Johnson says. Plus, this is a

solution that will completely eliminate
the pump clogging problems we were
having for the long term.
A BRIGHTER FUTURE
Since the new Channel Monster drums

were installed, the district has had zero
pump-clogging issues at the facility, and
has returned to using two pumps at a

time instead of all four. Energy costs have
decreased $78,000 per year and manual
pump deragging has been eliminated.
While the cost savings and the
eliminated safety risks are quantifiable,
our choice to go with a new Channel
Monster, to me, is priceless, Johnson
says.
SHUTDOWN COSTS ADD UP
The deragging process started to become

necessary every two to six weeks,
requiring two operators for about two
hours each time to complete the task.
And due to some aging isolation valves
that leaked, the plant needed to be
entirely shut down during deragging,
Johnson says. These unplanned
shutdowns were costing the district an
acre-foot of reclaimed water production
per month, and the labor costs added up
to about $15,000 per year.
Beyond the mounting monetary
cost, the safety concerns were equally
troubling. The most efficient method of
removing rags is to pull them through
the inspection port as one large ball,
Johnson says. But this procedure,
besides being unpleasant, exposes a
worker to potential sticks from sharps in
the rag balls.
SEARCHING FOR A SOLUTION
Johnson began looking for a long-term

solution to the ragging problem, since
both the cost and safety concerns were
not sustainable for the district. We
considered changing out the current
pumps to a new set of chopper pumps,
but this option came with a $100,000
price tag and wasnt really going to solve
the problem, Johnson says. We still
needed to maintain our inlet Channel
Monster to take care of the larger debris
the pumps couldnt handle.
Johnson ultimately decided to upgrade
the facilitys Channel Monster to a new
perforated metal drum configuration.
The coil drums of the original Channel
Monster were designed to capture large
debris and push it into the grinders
cutter stack for size reduction. As
sewage has evolved and non-dispersible
wipes have become a major part of the
waste stream, the infrastructure to deal
with it has needed to change as well.
The perforated drum on the newest
generation of Channel Monsters was
designed to better capture the wipes and
rags that flow through traditional coil
drums. This upgrade cost significantly
less than purchasing a whole new set
DECEMBER 2014 | 21
The Village
of Montpelier
Improves Efficiency
with New Gas
Chlorinator System
By Keith Thompson, Chlorinators Incorporated
hen Bill Blakely,

the water treatment
superintendent of
the Village of Montpelier,
Ohio, commented that the
village had pretty good tasting
water, little did he know that
his opinion would be a bit of
an understatement. 2007 is
the third year that the village
has won the gold medal for
the Worlds Best Municipal
Drinking Water.
AWARD-WINNING WATER
neighboring town. The city

of Kent, Ohio, entered the
Berkeley Springs Water Tasting
Competition and won fifth
place, states Blakely, We
thought we had some pretty
good tasting water, so we
entered the contest, and out
of the last seven years, we
have won the gold medal three
times.
As a novelty, the Village of
Montpelier has even had their
water bottled and labeled.
This award was given by the

FINDING THE RIGHT
annual International Water
EQUIPMENT
Tasting Event in Berkeley
Mr. Blakely runs a very smooth
Springs, West Virginia. The
operation
at the Village of
Josh Fritsch, Chief Operator (left) and Bill Blakely, Water Treatment
Village of Montpelier also won
Montpeliers water treatment
Superintendent (right) share a toast with their very own drinking water.
the gold medal in 2003 and
plant. But the plant did have
2006.
challenges to overcome when it
Founded in 1845 as a railroad town, the Village of
came to water disinfection equipment.
Montpelier is located in Williams County in north western
Prior to 1994 we used a gas chlorinator brand that needed
Ohio. Although its population is only 4,300 this prestigious
continual work on their heads, says Blakely, they would
award has certainly helped to put Montpelier on the proverbial
constantly leak or stick and need replacement components.
map.
Factory repair was never offered at that company, so we
What inspired the village to enter the contest? Pretty
would tear into the unit and order the parts needed. Sometimes
good tasting water and a little friendly competition with a
the part we needed was backordered, Blakely says, then,
About The Author

Keith Thompson currently serves as president of the Gas Chlorine Education Committee, a non-profit corporation organized
on behalf of interested parties in the water treatment industry. He is also general manager of Chlorinators Incorporated, a
company in the water treatment industry that designs, manufactures, markets, and sells equipment for water disinfection
and purification throughout the world. For more information, call 772.288.4854, email regal@regalchlorinators.com, or visit
www.regalchlorinators.com.
22 | DECEMBER 2014
when the parts did come in, we had

the extra cost of labor time of having to
rebuild it ourselves. So, we always had
to have an extra head on the shelf.
BUILDING THE NEW FACILITY
The villages old water treatment

plant was built in 1939not suited
to todays standards. So, in 2005
the village undertook the project of
building a brand new water treatment
facility.
When we were looking to
replace the existing gas chlorinator
equipment, Blakely states, we
inquired information from area reps
and also talked with them at the
state AWWA [American Water Works
Association] convention. The Regal
Gas Chlorinator with the automatic
switchover feature and fewer moving
parts really caught our eye. Weve
never regretted the change, Blakely
adds.
Although the plant switched to the
Regal Gas Chlorinator in 1994, Blakely
states, When we built our new plant
in 2005 we made sure to specify
Regal. We didnt want anyone elses
chlorinator.
DAWN OF A NEW DAY
The Village of Montpelier, Ohio, has

never used anything other than gas
chlorine for water treatment.
I am familiar with sodium and
calcium hypochlorite because I operate
two other small water treatment
plantsone at Lake Seneca and the
other, a small housing subdivision just
outside of Bryan, Ohio, says Blakely.
Sodium was not practical for use at
the Village of Montpelier due to shorter
shelf life and waste of product due to
degradation.
I prefer gas over sodium or calcium
hypochlorite, Blakely states. With gas
there is no degradation. Its contained
and remains at 100 percent available
chlorine. Calcium hypochlorite starts at
65 percent, and sodium hypochlorite
starts at 12.5 percent, and then
diminishes with age.
I also have less exposure to
chlorine by using gas rather than
sodium or calcium hypochlorite. I get
exposed to more gas by opening a
container of calcium hypochlorite than
I do switching chlorine gas tanks, and I
dont ruin clothes like I do when using
sodium hypochlorite, Blakely states.
CALCULATING THE COST

PER POUND OF SODIUM
This formula assumes that after
degradation occurs, a constant
10 percent solution of sodium
hypochlorite remains. (But,
keep in mind that sodium
never remains constant.)
Price per gallon of sodium X
1.2 (which equals 1 pound of
gas) = price per pound.
1.5 lbs of calcium @ 65% = 1
lb. of CL2 gas
IN THIS CUSTOMERS
EXAMPLE:
$2.00 X 1.2 = $2.40 per
pound of sodium hypochlorite
In the Montpelier, Ohio, area
calcium hypochlorite costs
around $2.40/lb.
Montpelier pays 46 cents per
pound of chlorine gas.
DECEMBER 2014 | 23

THE COST OF SODIUM
Cost concerns were another reason why the

village does not use sodium.
Sodium and calcium hypochlorite are
also more expensive than gas. As far as Im
concerned, gas chlorine is the cheapest way to
go, says Blakely, We pay 46 cents per pound
for gas chlorine. Sodium hypochlorite costs
around $2 per gallon, and calcium hypochlorite
costs around $2.40 per pound. If you look at the
cost per pound per the form of chlorine, factor
in the degradation, gas is a lot cheaper.
2.5
1.5
THE FULL SET-UP
It is evident that gas chlorine is the Village of

Montpeliers choice disinfection product, and
they couldnt be more pleased with the brand
that they have chosen for the past fourteen
yearsRegal.
With the Regal Switchover unit, when one
tank goes empty it automatically switches to
the standby tank, and you never have a drop in
chlorine. It maintains a constant feed rate, says
Blakely.
I can be doing other things. We can get
to itchange the tankat our convenience,
according to Blakely, This is important because
we have a small staff, and we dont have time to
baby sit the chlorine tank when it is about to go
empty.
0.5
Montpeliers Regal System set-up includes switchover units, SmartValves and vacuum
monitors.
Regal flow pacing valve products have helped the village,

which uses ground water, eliminate the trials and errors of
the past.
The SmartValves we installed at the new plant work
super. Our system is flow proportional, so if I want to adjust
the gallons per minute from 1400 (5300 liters) in the summer
to 1000 (3785 liters) in the winter, I just dial back my wells,
and the Regal SmartValve will compensate automatically to
achieve the same dosage, states Blakely.
24 | DECEMBER 2014
Disinfection Costs
GAS CL2
$0.46/lb.
SODIUM
$2.40/lb.
CALCIUM
$2.40/lb.
IN SUMMARY
The Regal system has helped the Village of Montpelier

eliminate downtime, save money, and lessen laborall
essential elements in running a smooth water treatment
operation.
In the fourteen years that Ive been with the Village, Ive
sent one chlorinator head to the Regal factory, and I got it
back promptlyin seven days, states Blakely, but because
we were using the switchover units, we had no downtime.
Regal is a good fit for us. The less maintenance-intensive,
the better, says Blakely.
MAINTENANCE solutions
EDG-trac Knife
Advance System
proves efficient
and cost-effective
By Charles M. Harrigan III, TriStar Ltd.
ristar, Ltd. is a manufacturer of fabricated components

and equipment, including remanufactured filtration
systems. The Encoded Digital Guidance (EDG) system is
designed to improve filtration performance and reduce energy
costs. The EDG-trac Knife Advance system is an ancillary
system for a rotary vacuum drum filter (RVDF), which consists
of an advancing knife, single motor gear drive, and associated
controls. In the EDG-trac Knife Advance system, accumulated
solids are cut away from the filter drum surface much more
efficiently, while maintaining acceptable solids separation and
improving liquid throughput.
OPPORTUNITY AREAS
Remanufacturing is an important
means of extending the life of a
product and reducing environmental
impacts. It was anticipated that, when
compared to conventional systems, a
remanufactured filter system, which
incorporated the newly designed EDGtrac Knife Advance System, would use
less energy and water, produce a drier
sludge cake, and have a higher filtrate
throughput. NYSP2I assisted Tristar
with quantifying these improvements.
The goal of this project was to
evaluate Tristars EDG-trac Knife
Advance System at a manufacturing
facility and quantify energy reduction,
suspended solid removal efficiency,
and increased throughput for this
system as compared to a traditional
RVDF system.
WORK PERFORMED
NYSP2I performed a comparative

analysis of the two systems at a
chemical manufacturer who was replacing
two traditional RVDF systems with two
remanufactured systems built by Tristar. The performance
of the traditional operating RVDF system and Tristars
remanufactured EDG-trac system was measured using the

following key parameters: energy use, filtration rate, sludge
moisture content, and effluent quality (suspended solids).
RESULTS FROM THE FIELD
TriStar states that it will rebuild or remanufacture existing

RVDF units at its facility or retrofit the EDG-trac system to
an RVDF at a customers plant. The Tristar Edge-trac Knife
Advance System, as installed in a remanufactured rotary
vacuum drum filter, exhibited the improved performance
results as compared to a traditional RVDF system.
An independent field test at a leading chemical
manufacturer in Buffalo, New York, showed that the EDGtrac system increased filtration
throughput by 700 percent
on average and reduced
energy consumption
by 87 percent
Rebuilt 3x1
rotary vacuum
drum filter
upgraded with
EDG-trac Knife
Advance System
filtering candle
filter backwash.
About The Author

Charles M. Harrigan III is the sales and marketing director at TriStar Ltd. He can be reached at 716.873.0081 or via email
at charrigan@tristarltd.com. Established in 1985, TriStar Ltd. is a remanufacturer of filtration equipment including Rotary
Vacuum Drum Filters, Belt Filters, Vacuum Belt Filters, and Filter Presses. In addition, TriStar manufactures a proprietary line
of Hot Water Sets. For more information, visit www.tristarltd.com.
26 | DECEMBER 2014
EDG-TRAC AT A GLANCE
700 percent increase in water filtration throughput.
87.4 percent reduction in energy use, on a per gallon

filtered basis.
Comparable sludge moisture content and suspended

solids removal efficiencies.
Tristar is targeting the creation of five New York state

jobs to expand manufacturing of EDG-trac.
For additional information about the New York State

Pollution Prevention Institute at the Rochester Institute of
Technology, visit www.nysp2i.rit.edu.
To download a PDF file of EDG-trac literature and the
independent report, visit www.tristarltd.com/news.html.
on a per-gallon filtered basis. The

study was recently conducted by the
New York State Pollution Prevention
Institute (NYSP2I) at the Rochester
Institute of Technology (RIT). In the
study (consisting of two batch tests) the
performance of an existing RVDF was
measured. The entire filter was then
replaced with a remanufactured RVDF
and EDG-trac system from TriStar, and
the new filter was evaluated under the
same process conditions.
IMPROVED FILTRATION
PERFORMANCE, LOWER ENERGY
COSTS
Ideal solids penetration into a precoat filter is 2 to 5 thousandths of an

inch. The EDG-trac system removes
as little as 1.4 thousandths of an inch
per revolution at a drum speed as low
as 0.2 RPM. This extends pre-coat
life by not cutting away clean precoat while maintaining acceptable
solids separation and improving liquid
throughput, according to TriStar.
EDG-trac also features a highly
efficient, single-motor VFD to reduce
energy use and cost. A fully automated
PLC controls the advance speed, retract
speed, and drum speed, allowing
precise control and providing valuable
information to operators, the company
states. An automatic high-speed retract
mode reduces time between cycles and
allows the filter to be recycled and put
back online quickly.
TriStar says that the company can
remanufacture an entire RVDF including
EDG-trac at 60 to 70 percent the cost
of a new filter in eight to ten weeks. It
can also retrofit the EDG-trac system
to any installed RVDF. TriStar also
fabricates a wide range of process
equipment including pump skids, heat
exchanger skids, pre-coat systems,
frames, platforms, piping systems, and
other custom projects. The company
also provides welding services including
piping, valve ends, equipment repair,
sanitary piping, and stainless steel
tubing.
VERTICAL MACHINING:
SAFE AND EFFICIENT
WorkSLHFH P D[
LQ
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P D[
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THE NEW EMAG VL-MACHINES
Maximum Performance Guaranteed

+ Machining of chuck parts =
Standardised machine platform
+ Small footprint = Reduced oor

space cost
+ Integrated automation = No
additional cost
+ Simple workpiece conveyor
& interlinking = Flexibility and

lower automation costs
+ Short traverse distances =

Minimal idle time, high
performance
+ Operator friendly = Quick

set-up, change-over
+ Standardised parts strategy =

Low maintenance costs
+ High energy eciency =

Reduced energy cost
www.emag.com
info@emag.com
DECEMBER 2014 | 27
PUMP solutions
The Age of Pump

Optimization and
the Impact on
Sustainable Design
By Dave Carrier, QuantumFlo, Inc.
Forbes Regional Hospital,

Monroeville, Pennsylvania
e live in an age of energy

optimization. It seems the
world has finally rallied
around the idea that addressing wasted
energy in pumping applications
represents a huge financial gain to
owners and a substantial efficiency gain
to energy providers.
All you have to do is ask a motor
manufacturer and I am sure you will
get an impassioned response related to
governmental energy standards. In just
the past several years, we have gone

from EPACT to EISA Motor Efficiency
Standards and it now appears that this
is going to be refined yet again.
Its great that these regulations have
continued to push the envelope on
motor efficiency, but they never seem
to consider the application. Motors
do the work applied to them, but the
intelligence is in the control. It is the
sum of the parts acting as a system
that contributes to the overall savings
and energy efficiency of a piece of

equipment, not just the motors.
THE LAWS THAT DRIVE ENERGY

OPTIMIZATION
Our company builds many pressure

booster pump stations that regulate
constant output pressure control.
Output pressure is our process variable
(PV), the primary element we use to
maintain a constant feedback loop to
maintain pressure regardless of the flow
About The Author

Dave Carrier is president and CEO of QuantumFlo, Inc. With nearly 100 years combined industry experience, QuantumFlo
has promoted and expanded the new packaged system technologies to the pump systems market. For more information, visit
www.quantumflo.com.
28 | DECEMBER 2014
through the pump. We have chosen

to do this using electronic rather
than hydraulic control. Incredibly,
electronic (variable speed) pressure
control has only become the
preferred means of control within
the past ten to twelve years. Prior
to this, hydraulic control (pressure
regulating valves) was the chief
control standard.
As you look around at the current
industry, you will likely notice
the proliferation of variable speed
motor control from large process
applications to small fractional
horsepower circulators. It makes
sense to vary pump speed when you
are trying to control a multitude
of potential process variables from
flow to temperature, to differential
pressure and discharge pressure.
So why has variable speed control
become so ubiquitous? The simple
answer to this lies in the pump and
fan affinity laws. These physical laws
state the following:
1. A pump or fan increases or
decreases flow in proportion to
the speed of the motor.

decreases in pressure as the
square of the speed change.
decreases in energy as the cube
of the change in speed.
It is easy to see that, based on
these three laws, pumps and fans
can have the greatest potential
differential of energy based on a
change in the motor speed. The
best part of this is, only a small
change in speed yields a fortune in
energy reduction due to the cubic
relationship to pump speed. If
you perform this basic math, a 20
percent motor speed reduction (.80
x .80 x .80 = .512 or 51.2 percent
total energy) nearly cuts your power
in half.
Adding the VFD to this
application saves far more energy
than simply specifying an EISA
compliant motor. This requires
the engineer to apply the proper
components to get to the next level
of energy efficiency made possible
by the affinity laws.
Under LEED 2009, there are 100

possible base points distributed
across six credit categories:
Sustainable Sites
Water Efficiency
Energy and Atmosphere
Materials and Resources
Indoor Environmental Quality
Innovation in Design
Up to 10 additional points may be

earned: four additional points may
be received for Regional Priority
Credits, and six additional points for
Innovation in Design (which includes
exemplary performance credits for
existing credit categories).
Buildings can qualify for four

levels of LEED certification:
Certified: 4049 points
Silver: 5059 points
Gold: 6079 points
Platinum: 80 points and above *
* Information in these two areas was pulled

from the USGBC and LEEDUser websites.
(www.usgbc.org and www.leeduser.com)
DECEMBER 2014 | 29
PUMP solutions
THE IMPACT OF LEED
CERTIFICATION
We apply many of our products to the

world of commercial building trades.
Since the advent of sustainable design,
many standards have adopted these
green efforts. One effort to improve
sustainable design and provide
resources to these efforts is the U.S.
Green Building Council (USGBC).
USGBC has established a roadmap
toward sustainable design known as
Leadership in Energy and Environmental
Design (LEED).
LEED goes beyond the general
standards that apply to specific trades
within the building such as structural,
HVAC, civil, etc. and is an attempt
at looking at the total environmental
impact of the building. The USGBC
committee evaluates the total impact
of the structure, including its carbon
footprint, or greenhouse gas emissions.
When LEED accreditations are followed,
existing building emissions can be offset
by following the rules of sustainable
design such as a green roof, which
would provide plant life to offset CO2.
The overarching goal of these new
efforts is simple: save energy. Since most
30 | DECEMBER 2014
as it relates to total points available.

This area alone represents up to 19
total points, comprising nearly half
of your minimum qualification. You
cannot shoot for LEED Platinum without
considering the requirements of EAc1.
THE ADOPTION OF ANSI/

ASHRAE/IES STANDARD 90.1
Bank of America Plaza, Tampa, Florida
energy is saved by speed reduction, as

in the affinity laws, the primary purpose
of these standards is to search for every
opportunity to save energy, and thereby,
the environmental impact of that energy
consumption.
Consider the case of LEED credit
for new Construction and Energy
Optimization (NC-2009 EAc1). This
LEED credit deals with optimization of
energy loads within a building. Since
the booster system is one of many
VFD pump and fan loads within the
structure, you can see how substantial
an impact this could represent. In fact,
EAc1 is by far, the most important credit
within the LEED accreditation system
ANSI/ASHRAE/IES Standard 90.1 is

the worlds most adopted building
energy code, and yet many plumbing
consultants do not realize that it affects
booster pumps systems in a major way.
Constant speed pumps have been some
of the greatest energy vampires in the
commercial building space, sucking
energy from the source to do nothing
more than charge a water riser so
someone can walk up to a toilet and
flush it.
In the past, this flushing sound
signified the owners cash being sucked
from his wallet, as a pump that does not
change in speed uses 100 percent of its
full power all the time to make certain
that water is available at each fixture.
From an energy perspective, the booster
was the low hanging fruit of the energy
optimization movement, but 90.1 did
not stop at just the standard operational

savings. The committee wanted more.
The Standard also requires the
consultant to either move the variable
speed pressure control sensor to the
farthest point in the building, or employ
software logic to simulate the operation
of this remote control. What this does
is dial-out the piping friction between
the booster and the farthest point in the
system. By eliminating piping friction
from the control, the pump is allowed
to slow even more when the flow rate
doesnt always require this additional
friction loss. This is a concept that
comes from the HVAC industry, as
most of the pressure required by a
closed loop HVAC system is due to
piping friction loss. However, the
friction contribution of an open-loop
plumbing system is not as substantial.
Nevertheless, Standard 90.1 wants this
energy back.
VIRTUAL SIGNALING
There is a secondary option in lieu

of the remote set point whereby the
system could be controlled via virtual
signalingor logic in the programming
that simulates the effect of a remote
sensor. This is probably the simpler

way to accomplish the reduction in
speed without having to involve another
contractor besides the plumber; namely
an electrician to run the signal wires.
As a result, pump system companies
have recommended the use of virtual
signaling in lieu of the extra labor
and contractor disciplines. (For our
company, QuantumFlo, this algorithm
is called GreenFlo). This process
measures the flow across the pump and
changes the set point when the flow
rate is low and the additional pressure
is no longer required. The setting then
resets when flow is increased back to
the range requiring the extra boost. The
best part of using logic control versus
physically moving the sensor is that the
system can maintain its factory-tested
and pre-engineered status, which is the
primary reason the consultant specified
this pre-engineered device in the first
place.
INCREASED OPPORTUNITY
FOR BOOSTER SYSTEMS
Standard 90.1 (as written) was adopted

in October of 2011 and provided a
two-year window for states to comply,
so most U.S. consultants are already

required to design to it. However,
many plumbing and mechanical
engineers do not even realize that the
section regarding the use of VFDbased plumbing pumps even exists. It
was then adopted by the International
Energy Conservation Code (IECC) in
2012 making it the most prominently
implemented.
It does not seem typical to consider
that a booster system pressure would
actually change according to the flow
conditions, but as technology advances,
so does the opportunity to use it for the
betterment of our world. ANSI/ASHRAE/
IES Standard 90.1 is being used in these
new designs to assist the engineer in
this endeavor and the manufacturer
is also there to answer the call to
continually innovate and implement
these useful energy optimizers.
It is imperative that the engineering
community continue to learn and
engage with the community of
technology and manufacturing in order
to find these energy optimizers which,
when taken in total, can contribute
greatly to the energy consumption
footprint of these buildings.
DECEMBER 2014 | 31
DEWATERING solutions
Solid Foundation for Business District

TerraFirmas groundwater system supports 100 Saint Paul development
By Josh Peltier, TerraFirma Earth Technologies
TerraFirma Earth Technologies installed an innovative dewatering and ground water treatment system at 100 Saint Paul, a retail and office development in the rapidly expanding Cherry
Creek business district. The firm has made Denver a permanent home to a satellite office.
erraFirma Earth Technologies was selected by general

contractor GE Johnson to install a groundwater
control system and innovative groundwater collection
and treatment system designed by Terracon in the heavily
travelled Cherry Creek business district in Denver, Colorado.
TerraFirma, an elite groundwater control contractor, is the
newest arrival among top-tier players in Denvers burgeoning
construction sector. The firm has opened
a permanent satellite office in the
Denver Tech Center.
A SURPRISE ON THE JOBSITE
When ground was broken in February,

2014, neither GE Johnson, 100 Saint
Paul, LLC (owner), nor the geotechnical
consultant Terracon, could predict
unforeseen conditions that would require
on-the-spot installation of additional
dewatering features than were originally
designed. TerraFirma worked congruently
with the owner, general contractor, and
design consultants to come up with an
innovative, supplemental dewatering
system that averted delays and
minimized costs.
According to TerraFirmas David Giles,
the original design included widely
spaced deepwell dewatering wells meant to maximize

drawdown, while minimizing the rate of groundwater flow,
in an effort to prevent migration of potentially contaminated
groundwater from adjacent properties. The modified system
meant adding mini-vacuum wells directly adjacent to
the buildings elevator pits and a permanent dewatering
sump pit that TerraFirma was able to custom design on
the job, making for a unique hybrid of
dewatering methods to better suit the
actual soil and jobsite conditions.
TerraFirmas president David Giles
explains, Usually when we pump water
from the ground, we pipe it directly to
a storm sewer drain. However, there
was concern that this ground water
was contaminated from three sources:
chemicals from a dry cleaning business,
hydrocarbons from a previously
demolished fuel station, and dissolved
metals, which occur naturally in the
earth.
By isolating the supplemental
dewatering to just those few areas
needing it, we saved precious time
and reduced costs. Also, by limiting
supplemental dewatering efforts to just
Electrical submersible pumps were placed near the
bottom of each dewatering well.
those few areas, we reduced the required
About The Author

Josh Peltier and partners David Giles and Mike Giles founded TerraFirma Earth Technologies in 2004 with the mandate of
elevating the quality and professionalism of the dewatering industry. Headquartered in Houston, TerraFirma helps owners
and contractors throughout the United States maintain acceptable groundwater levels for both temporary projects and
permanent installations. Contact TerraFirmas Houston office at 281.720.1212, or the Denver office at 720.893.0556. For
more information, visit www.tfearth.com.
32 | DECEMBER 2014
Going deeper. TerraFirmas well modification in progress. Wells must be lowered as

excavation advances.
TerraFirma utilizes Holland's Rotary Lobe wellpoint pump for its mini-vacuum well
dewatering system. The traditional deepwell dewatering wells can be seen in the
background.
amount of groundwater to be pumped, thereby reducing

the risk of pulling in contaminants identified on adjacent
properties during the investigative phase of the project.
Brian Lawrenson, GE Johnsons superintendent, adds, The
project is situated in the heart of Cherry Creek, with very
little or no laydown. TerraFirma worked with us during the
logistical challenges we faced daily. Due to the complexity
of the site excavation and ever-changing conditions, GE
Johnson had TerraFirma install two areas of vacuum-well
assemblies to provide additional localized dewatering.
TerraFirma reacted quickly to these unforeseen conditions
and was able to minimize the impact to the construction

schedule.
A CLOSER LOOK
The final dewatering system included 11 extraction wells,

1 injection well, 42 mini-vacuum wells, 3 perimeter HDPE
groundwater discharge manifold lines, and a groundwater
treatment system. It was first time I have seen such a unique
groundwater collection and treatment system design in my
28 years in this business, says Giles. It was much easier
and less expensive to design and install this at the outset,
DECEMBER 2014 | 33
DEWATERING solutions
Completed installation of the PVC mini-vacuum well- assembly following drilling of the
borehole, utilizing track mounted Geoprobe hollow stem drilling rig.
Placement of the PVC dewatering well assembly following drilling of the bore hole with
the track mounted Watson drilling rig.
just to cover the possibility that it would

be needed. Had we not planned in
advance for the three possible discharge
routes and needed them, it would have
been expensive to do so later. Terracon
deserves credit for a really unique
design.
According to Giles, in the end
Terracons samplings were all within
limits, and the water didnt have to be
redirected away from the sewer. The
injection wells will remain in place
after completion of the construction and
incorporated into a separate, permanent
dewatering system.
EXPERTISE IN ACTION
David Cross of 100 Saint Paul, LLC, was

pleased with the result. TerraFirma
brought a high level of expertise and
extensive knowledge base to the table
when we hit the bottom of the hole.
They were instrumental in bringing
about a speedy resolution to unforeseen
subsurface conditions to the benefit of
the general contractor and the project
owner.
100 Saint Paul, a Class A office and
retail development, is scheduled for
tenant occupancy in the summer of
2015. As of November 18 th, the steel
34 | DECEMBER 2014
Safety meeting. TerraFirma provides ongoing training and certification for its crew members. All
safety initiatives are continuously reviewed and updated to keep employees proficient in new
safety policies and procedural methods. The firm calls this plan Target Zero, and its goal is to
achieve zero accidents and injuries during every dewatering project.
Unique, innovative groundwater collection lines allowed clean groundwater

to be directed to the city storm sewer drain, contaminated-treatable ground
water to an onsite groundwater treatment system, or contaminated, untreatable
groundwater to be re-injected back into the ground, to its original source.
structure rises to eight levels above grade over three below-grade

parking levels. TerraFirmas past deep excavation projects include
athletic stadiums, hospitals, high-rise facilities, transportation
facilities, airports, tunnels, power plants, dams, waterways, petrochemical plants, and municipal infrastructure sites such as pumping
stations, treatment plants, as well as sewer and gas pipelines.
DECEMBER 2014 | 35
MOTOR solutions
By Siva Kanesvaran, Schneider Electric
s pumping systems become increasingly intelligent,

smart devices are at the core of most solutions. The
smarts in the system may reside in many locations,
some examples includePLCs/PACs, an HMI or a VFD.
In the world of pumping, this has resulted in challenges
such as:
Pumps are frequently located in remote locations

requiring time and expense to address these needs
Access to proprietary software along with specific

knowledge of operating in these software environments.
Lack of local expertise to diagnose and troubleshoot
MANAGING TIME AND COSTS
The results have been added time and costs in terms of

operator training and in getting the right personnel with the
right software to be present at the controller. The widespread
About The Author

Siva Kanesvaran is a senior design application engineer for Schneider Electric. As a global specialist in energy management
with operations in more than one hundred countries, Schneider Electric offers integrated solutions across multiple market
segments, including leadership positions in utilities and infrastructure, industries and machines manufacturers, non-residential
buildings, data centers and networks and in residential. For more information, visit www.schneider-electric.com/us.
36 | DECEMBER 2014
The next generation of MachineStruxure from Schneider Electric is an intuitive solution for machine automation.
adaptation of Ethernet based technologies along with

a notable drop in the cost of implementing Ethernet in
controllers have enabled for web-based user interfaces to
be integrated directly into the PLCs and PACs. The result
is a means to connect to a PLC using a web browser and to
access customizable screens for configuration, diagnostic
and possibly even maintenance purposes.
Configuring a control system during start-up may require
observation of the status of communication links and control
variables. Some this data may not be published to the HMI
as it may not be needed in day to day operations. Including
more information on the HMI screen increases clutter and
complexity within the interface. The solution is to abstract
some of this data from the HMI and utilize some of the inbuilt Ethernet web server functions.
THE ROLE OF REMOTE MONITORING
In addition to configuration and parameterization,

remote monitoring possibilities are another a key value
enabled by intelligent pumping solutions. Lets use energy
management as a key example. While the first couple of
key actions revolve around enhancing the controls relative
to energy consumption, monitoring provides closed loop
feedback to ensure continuous system performance. Lack
of such feedback will likely result in a relapse in energy
performance.
The data available via the web server enables an effective
first level of support. To illustrate this, imagine a situation
where a PLC is not communicating with one of its controlled
variable frequency drives. Without any further details
besides the lack of communication, the root cause may be a
Energy Management Diagram

Energy Audit
& Measure
Passive Energy Efficiency
Active Energy Efficiency
Fix the basics
Optimize
through automation
& regulation
Monitor,
maintain,
improve
Low consumption devices,

insulation material, power
factor correction
HVAC control, lighting

control, variable
speed drives...
Meters installation,
monitoring services, EE
analysis software
DECEMBER 2014 | 37
MOTOR solutions
Energy Consumption
38 | DECEMBER 2014
Optimized usage
via automation
Efficient devices
and installation
Energy
Consumption
physical connection issue,

or an issue at the device
level. The monitoring of
the Ethernet link status as
well as the ability to ping
100%
the device via the web
server would indicate if a
good physical connection
is present which allows
for troubleshooting to
progress by process of
elimination. This helps
70%
reduce situations where
service personnel are
dispatched to a site only
to find the problem to
be caused by something
simple such as a
disconnected cable.
The web server also
includes a scope tool that
allows for PLC variables
to be compared and
monitored over a web
browser. This allows for specific parts of control logic or
a process to be monitored in real-time without having the
same specific parts published in the HMI of the system.
Further to standard web server functionality, pump and
pump systems manufacturers may choose to include custom
web pages that could contain specific dashboards on the
Lack of monitoring,
maintenance programs, regulation
and control systems
Monitoring & Maintenance
status of various parts of the system. These may have a

variety of uses for maintenance or service personnel and
end users.
The added benefit here is that end user or service
personnel are now working with a graphical environment
on a browser instead of a ladder diagram in the software
environment. Essentially this reduces

support costs and will increase
customer satisfaction at the end user
as they are empowered to perform
some of their own troubleshooting.
IMPROVED CUSTOMIZATION
How easy or hard are these pages

to create? Some systems require for
the custom pages to be defined from
scratch in HTML along with JavaScript
for example, while others utilize
screen development tools within the
PLC programming environments. The
screen development tools may include
drag and drop objects that can be
configured for a variety of functions
which reduces development time
significantly.
The concept of intelligent pumping
is frequently associated with system
performance measurements such
as energy consumption, and indeed
these solutions contribute heavily to
these goals. Combined with the added
benefits of monitoring, diagnostics and
troubleshooting via web enabled user
interfaces, intelligent pump control
solutions will continue to be a game
changer.
The Magelis line offers user-friendly interfaces for a variety of industrial needs.
DECEMBER 2014 | 39
POWER GENERATION solutions
POWER
Where Its Needed Most
Franklins new solar pumping technology

proves itself in Africa
By Jason Nees, Franklin Electric
hough the Kampani School and Clinic in the

Zimbabwes remote Tsholotsho District arent far from
the world famous Victoria Falls, it had been twenty
years since either had a reliable source of fresh drinking
water. Women and children walked an average of seven
miles a day to haul surface water by bucketand many of
the clinics patients suffered from water-borne diseases. That
all dramatically changed in 2013 when Franklin Electrics
Franklin Wells for the World Foundation (FWWF) installed
five wells in the region powered by Franklins innovative
new SubDrive SolarPAK pumping system. Now more than
12,000 peoplemany for the first time in their liveshave
easy access to clean water.
AN AREA OF NEED, THE POWER TO HELP
According to Franklin chairman Scott Trumbull, Five

thousand children a day die in Africa of water-borne
diseases. But that problem could be solved if they could
get to the aquifers 200 feet (60.96 meters) under their feet.
We established Franklin Wells for the World Foundation in
2009 to address that problem.
Since then, FWWF has installed wells in Kenya,
Sudan, Botswana, and Zimbabwe using Franklins proven
submersible pump systems powered by diesel generators.
With the introduction of the new SubDrive SolarPAK in
2012, Franklin saw an opportunity to make new FWWF
installations even more efficient and reliable.
With the SubDrive SolarPAK system there are no moving
parts other than the highly reliable pump that is 200 feet
(60.96 meters) underground, explains Trumbull, So it will
be a much longer lasting solution for those communities.
LIFE-SAVING TECHNOLOGY
Access to clean water is the driving purpose behind Franklin Electrics Franklin Wells for
the World Foundation.
In fact, SubDrive SolarPAK technology gives water pump

installers and users the option to use solar as the power
source on virtually any 4-inch (101.6 millimeter) well.
The rugged, high-output system is capable of a wide range
of applications, including irrigation systems, tank and
cistern filling, renewable energy projects and rural water
supply for villages, cottages and homesteads. Thanks to
the SolarPAKs variable frequency drive (VFD), the pump
produces water even on cloudy days or with minimal
sunlight.
For More Information

For more information on Franklin Wells for the World Foundation, visit www.fwwf.org, or contact Brooke Moore at 260.827.5395
or via email at bmoore@fele.com. For more information on Franklin Electric products, visit www.franklinwater.com or
www.franklin-electric.com/solar.
40 | DECEMBER 2014
Solar panels being installed.

The SubDrive SolarPAK system is designed to deliver higher flow rates than most existing
solar powered products.
Besides the Kampani School and clinic, FWWF also installed

new wells at the nearby Jabulani, Jakalasi, Mpindo and Zigo
schools. Because the SubDrive SolarPAK system is designed
to deliver higher flow rates than most existing solar powered
products, each one of the new Zimbabwe installations is able
to fill large, above-ground water tanks at the rate of 1320 to
2640 gallons (5000 to 10,000 liters) a day.
Each one of those will provide enough water for drinking,
bathing and garden irrigation, says FWWF director Attie
Jonker. For many of the people in the regionespecially
the childrenthats literally the difference between life and
death.
The nearest source of water for the school was a community

borehole about 0.9 miles (1.5 kilometers) away, and the entire
community of about 4000 people collect their water from
the same borehole. The borehole was equipped with a hand
pump, which was often broke down.
The Franklin Wells for the World Foundation drilled a well at
the school, equipped it with a Franklin Electric Solar Pumping
System, and erected two 1320 gallon (5000 liter) overhead
tanks, one for the school and one for the community.
A video of the applications by Franklin Wells for the
World in Africa narrated by Scott Trumbull, is available at
youtube.com/fecorporate.
FRANKLIN WELLS FOR THE WORLD FOUNDATION
In 2014, the Franklin Wells for the World Foundation also

completed a project in the Chibombo District of Zambia,
South Africa. The project consisted of water well installations
at five schools in the community.
Installation of Franklin Electric Solar Pumping System.
Mwanje Primary school was founded in 2000 by the

community after seeing an increase in the drop-out rates for
children in the community, especially among girls, due to the
long distance to the nearest school (Shimukuni Basic school is
located approximately 3.7 miles [6 kilometers] from Mwanje).
The community mobilized themselves and constructed
temporal structures and the school was run by community
members as volunteers.
DECEMBER 2014 | 41
PROCESSING solutions
High-precision
Ingredient
Metering for
Spreadable
Butter
DAIRY GIANT ARLA USES
MULTIPLEX PUMPS WITH A
BROAD ADJUSTMENT RANGE
By Jrg Sommer, Lewa
preadable butter is one of the primary products of the

Danish/Swedish dairy company Arla. At their facility
in Gtene Arla is producing the brand Bregott for
the domestic market in Sweden. To be able to reproduce
the specific characteristics of the different types exactly,
ingredients must be precisely metered. For ten years, the
production facility in Gtene has used pumps from Lewa
GmbH for this purpose, which are not only designed for
high discharge pressures but also have an accuracy of 1
percent, meeting the manufacturer's strict requirements.
From the different variants of the Ecoflow pumps, which are
also very suitable for the production of food items, Lewa was
able to configure a perfect solution for Arla in 2010.
TEAMING WITH ARLA
Water, rapeseed oil, and brinethose are the most

important, exclusively natural ingredients to give the butter
Arla produces in Gtene, Sweden its medley salty flavor and
its spreadable consistency. The mixing system for the plant
must meet the strictest of hygienic requirements andeven
more importantlymeter with high precision to ensure
consistent product quality. Since the Ecoflow pumps from the
About The Author

Jrg Sommer is the Ecoflow pumps product manager. Lewa GmbH was founded in 1952 as a family company by Herbert Ott
and Rudolf Schestag, and today is the world's leading manufacturer of metering and process diaphragm pumps as well as
complete metering systems for process technology. For more information, email lewa@lewa.de or visit www.lewa.com.
42 | DECEMBER 2014
Leonberg manufacturer Lewa stand out not only for the

fact that they are suitable for high discharge pressures,
but also because they ensure good reproducibility,
about thirty of them were installed in different plants,
including nine diaphragm pumps and one packed
plunger pump in the facility in Gtene.
ABOUT ARLA FOODS

Arla Foods is a Swedish/Danish dairy group
headquartered in Viby near Aarhus in Denmark. The
originally Swedish company was founded over 100
years ago. In spring 2000, the Arla group merged with
the Danish company MD Foods. The core markets of the
company are Denmark, Sweden, Finland, Great Britain,
Germany, and the Netherlands. After the merger with
Hansa Milch eG in Mecklenburg-Vorpommern and the
takeover of the Allguland cheesemakers in Bavaria in
2011 as well asshortly afterwardsthe merger with the
Milch-Union Hocheifel eG in Rheinland-Pfalz have put
Arla in the top three dairies in Germany.
Arla provides a broad product portfolio of wellknown brands, such as Apetina, Buko, Krgrden and
Castello as well as numerous trademarks for the partners
in the group. Their product line includes, among other
things, butter and dairy spreads, cheese, milk, and
dairy beverages, as well as lactose-free products. The
company is also the world's largest maker of organic
dairy products.
Among other things, the Ecoflow pumps used at Arla/Gtene are outstanding for
their low dead space as well as their smooth stainless steel surfaces (1.4571).
That makes the entire pump extremely well-suited for the food industry and for
CIP cleaning.
Arla has production facilities in thirteen countries and

sales subsidiaries in twenty more, employing 18,112
people as of the start of 2013. That makes the company
the fourth largest dairy company in the world. Its 2012
sales were about 8.460 billion Euros, with profit of
around 254 million Euros.
DECEMBER 2014 | 43
PROCESSING solutions
During a visit to the Arla plant in Gtene at the start of 2013, the responsible Lewa product manager Jrg Sommer (right), got an idea of
how the basic ingredients of water, rapeseed oil, and brine are processed to make spreadable butter. Bertil Holmstedt (left), technician,
and Klas Erikson, maintenance team leader at Arla Foods Gtene/Sweden, were quite satisfied: "These pumps not only satisfy the
strictest of hygienic demands, but also meter very precisely."
44 | DECEMBER 2014
In line with the

modular principle,
different drives were
combined, each with
two to six pump heads.
With the Ecoflow, up
to 1320.86 gallons (6
cubic meters) per hour
per pump head can be
conveyed. The discharge
pressure supported
can reach up to 500
bar. Depending on the
application, for Arlas
pumps the range is up to
about 264.17 gallons (1
cubic meter) per hour and
15 bar.
Since the entire
production facility runs
at a highly automated
level for both hygiene
and efficiency, the pumps
must be able to work
nearly maintenance-free,
so that the process chain
needs to be interrupted
as little as possible. "The
pumps are in operation
about twenty hours a
day, although not all at one time. And

they have to work at a reproducible
metering accuracy of 1 percent,
says Klas Erikson, maintenance team
leader at Arla Foods Gtene/Sweden.
"The strict requirements for precision
and robustness that our application
demands have been met by Ecoflow
pumps to our complete satisfaction."
All components that come into

contact with the medium are
designed to be suitable for foods.
When selecting the materials, Arla
paid particular attention to the fact
that the seals of the valves must
remain elastic even after years of
contact with the brine. Since salt
has a corrosive effect over time, the
decision was made to use Gylon,

a type of Teflon. The diaphragm
consists of pure PTFE, which is
compatible with biological tissues.
Due to the high energy efficiency, low
maintenance costs, and long service
lifetime of the sandwich diaphragms,
the system costs and lifetime costs
remain remarkably low.
DURABLE DIAPHRAGM
METERING PUMPS FOR
HYGIENIC APPLICATIONS
Thanks to the patented DPS

Diaphragm Protection System, also
used in the Ecoflow series, the
diaphragm needs no positioning and
the pumps can start reliably from any
operating condition. The result is a
high level of process reliability and
resilience. The special technology
permits an absolute suction pressure
of up to 0.1 bar. So they keep working
reliably even after operating errors
or in case of extreme operating
conditions, such as high suction
pressure or a closed suction line.
Moreover, the pumps also have the
advantage that the diaphragm can be
changed quickly and easily. Automatic
stroke adjustment and additional
frequency control of the motor permits
the large adjustment range of the
pumps be regulated reliably and the
entire process can be documented.
The concept is extremely well-suited
for the traceability of batches and the
high quality requirements in today's
food industry.
MULTILAYERED DESIGN
"Aside from the usual standards for

the food industry, we have also made
sure that the pumps can easily be
cleaned," adds Erikson. Due to its
minimal dead space and smooth
stainless steel surfaces (1.4571), the
entire pump is outstandingly wellsuited for the food industry and for
CIP cleaning. The hermetically sealed,
oscillating diaphragm pumps are
used, where high production quality
and precise recipe settings must
remain consistent over years. Due to
their operational reliability and the
high metering accuracy, the pump is
also used for toxic, environmentally
harmful, abrasive, viscous, sensitive,
and expensive fluids. The diaphragm
monitoringin combination with the
multilayered design of the sandwich
diaphragm structurereliably prevents
any contamination of the product.
DECEMBER 2014 | 45
VALVES & CONTROLS solutions
QUALITY
MEETS
QUANTITY
In the field and in the lab, YSI
measurement tools offer detailed
monitoring and control
By Peter Bornhorst
and Patrick Higgins,
Xylem Inc.
YSI IQ SensorNet
Orthophosphate Analyzer, which can be used as a standt the most recent WEFTEC trade exposition, YSI,
alone analyzer or in conjunction with other sensors in an
a Xylem brand, showcased their IQ SensorNet
IQ SensorNet continuous monitoring system. The P 700
continuous monitoring and control system, which
measures the amount of orthophosphate (also known as
featured in tandem with their Orthophosphate Analyzer as
soluble reactive phosphorus and commonly referred to as
well as a new line of UV-Vis UV Sensors to address water
phosphate) throughout the wastewater treatment process,
quality in the wastewater market.
and the continuous data it provides can help verify
The IQ SensorNet is a modular water quality system for
phosphate elimination and
a complete sensor network
improve operational efficiency.
ideal for an assortment of
Since phosphorus is the
installation needs. The system
nutrient in short supply in most
enables a wastewater treatment
plant to monitor every aspect
fresh waters, even a modest
of their processfrom preincrease in phosphorus can,
under the right conditions
sedimentation to the biological
set off a chain of undesirable
tanks to the effluent. A single
events in a stream, including
module can link up to twenty
sensors measuring different
accelerated plant growth or
parameters, from DO and pH
algae blooms, and the death
of certain fish, invertebrates,
to ammonium, turbidity, and
and other aquatic animals.
temperature.
The P 700 has proven to
Also featured at WEFTEC
YSI IQSN Orthophosphate
be an important tool for
this year was the P 700
For More Information

Xylems analytics businesses are leading manufacturers of premium field, portable, laboratory and online analytical
instruments used in water and wastewater, environmental, food and beverage, pharmaceutical and life science applications.
The companys meters, sensors, analyzers and related consumables are used daily by thousands of end users worldwide. To
learn more about YSI visit www.ysi.com. To also learn more about the complete range of analytics products from Xylem, visit
www.xylemanalytics.com.
46 | DECEMBER 2014
municipalities aiming to limit

options, is going to be
the discharge of phosphorus to
another valuable tool for
meet permit requirements and
laboratories that need
improve operations and costs
quality measurements
by cutting treatment chemical
of numerous parameter
volume.
concentrations. And now
The P 700 can run itself
with the TruLine ISEs,
continuously for up to eight
for customers measuring
months without needing a
ion concentrations in the
user calibration or a reagent
wastewater industry, our lab
change. And when networked
products portfolio is really
with other sensors in an IQ
stronger than ever.
YSI IQSN UV VIS Sensor
SensorNet system, data from
While the TruLab 1110
the P 700 displays in the
is ideal for routine pH/
network just like any other sensor.
mV lab measurements where a robust workhorse meter
The IQ SensorNet has been a valuable tool for
is required, the TruLab 1310 and 1310P (with printer)
wastewater facilities across the US, says Tim Grooms,
provides precise lab measurements and automatic
director of marketing for YSI, And when you link it up
Good Laboratory Practice (GLP) documentation, plus a
with the Orthophosphate Analyzer, you can really get a
USB interface for data transfer and backup. All TruLab
complete picture of the water quality process.
instruments offer auto-buffer recognition plus recalibration
Also, a new line of UV-Vis UV Spectrophotometer Probes
prompts. The TruLab 1320 and 1320P (with printer) are
from YSI, measuring numerous parameters as part of the
two-channel instruments with simultaneous measurement
IQ SensorNet system, were debuted at WEFTEC. The new
of pH, ISE orORP. The 1320 series logs calibration
sensors are rugged and have built-in ultrasonic cleaning
information for GLP compliance and has a USB interface
for lower maintenance requirements over the life of the
for data transfer and backup.
sensor. The new spectral sensors can measure a broad
In addition, YSI is also introducing the new TruLine ISE
spectrum (256 wavelengths for each measurement) for
electrodes for its TruLab product line.
increased accuracy, and can measure COD, BOD, TOC,
The wide variety of TruLine sensorsoffering fifteen
Nitrate/Nitrite, and TSS. Single wavelength sensors are
electrodes for sixteen different parametersare compact
also available for UVT-254 and NOx, and there are new
in design, available as glass or plastic probe bodies,
variations of FDO and ViSolid sensors for Class 1, Div 2
can be ordered with or without temperature and with a
rated zones (explosion proof).
refillable option.
To address the needs of the wastewater and laboratory
The new TruLine electrodes are proven, highly
markets, YSI also highlighted their TruLab instruments,
versatile laboratory electrodes for the most demanding
a complete line of lab instruments ideal for routine and
measurements. The glass electrodes include the
precise measurements of pH, mV, ISE, and temperature for
temperature sensor and can be ordered with a platinum or
water quality data. Compatible with the TruLab products
ground junction. Each pH electrode comes with individual
or for use with any instrument with a BNC connectorYSI
serial number and quality certificate.
will also launch the TruLine ion-selective electrodes (ISEs),
Together, the TruLab and the extended line of TruLine
a brand new line of ISE electrodes for the laboratory setting.
ISE electrodes provide laboratories across multiple
According to Grooms, We think our TruLab line, with
industries the ability to conduct easy, fast, and highly
its flexibility, stable measurements, and 15 new sensor
repeatable measurements.
YSI ISE Electrodes
DECEMBER 2014 | 47
SEALING solutions
How to Cost-justify
Bearing Housing PART
4 of 4
Protector Seals
Key factors for reliability-focused process pump users
By Heinz P. Bloch, Process Machinery Consulting
n this final part of the four-part

series, we will examine face-seal
options for bearing protection and
provide an example cost justification
tabulated for advanced bearing
housing protector seals. The reliability
advantages and easy cost justification
for bearing housing protector seals are
widely known, and in the installment,
we will provide examples taken from
Best-In-Class plants that will benefit
process pump users across a range of
applications.
6
7
11
FACE-TYPE BEARING PROTECTOR

SEALS AND APPLICATION
CRITERIA
10
There are a number of face-seal

options for bearing protection.
Face-type (or face-contacting) seals
use springs or, in figure 9, magnets
to apply the needed closing force.
Although they cost more than rotating
labyrinth seals, face-contacting seals
are often used in gearbox units. As
Figure 9: Dual-face magnetic seal and O-rings (2, 4, 6, 10), snap ring (11), rotating face (1), stationary faces (3),
to their capabilities, a manufacturer
stationary face holder (9), stationary magnets (8), magnet carrier (7), and outer body (5) (source: AESSEAL, Inc.,
of magnetic seals explains aerospace
Rotherham, UK, and Rockford, TN).
applications and case histories at
300 degrees Fahrenheit (149 degrees
Celsius) / 5 psi / 21,000 rpm; 392 degrees Fahrenheit (200
operation when the film and interface are being developed.
degrees Celsius) / 14.5 psia / 14,407 rpm; at temperatures
Once developed, the film helps control wear, reduces
frictional heat, and stops bounce, or chatter.
ranging from 65 to 350 degrees Fahrenheit (18 to 177
degrees Celsius) / 20 psi / 28,018 rpm, and many more.
Dual-face magnetic seals (figure 9) were first introduced
to process plants in the early 2000s. They have an excellent
When a hydrodynamic oil film is maintained between
the faces, the coefficient of friction can be less than 0.05.
performance record and hundreds of reliability-focused users
The coefficient is normally higher during early periods of
have contributed to an impressive reference list. Dual-face
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.
48 | DECEMBER 2014
magnetic seals are typically designed for shaft peripheral

velocities approaching 20 m/s, which is within the operating
speed of an estimated 99 percent of all centrifugal process
pumps. Large gear speed reducers and vertical shaft fan
drive shafts often use dual-face magnetic seals.
For maximum life, especially at high speeds, face loads
are usually kept low; about 15 psi is typical. Proper cooling
and / or lubrication must be provided to remove frictional
heat. Lubrication, of course, is present in the overwhelming
majority of oil-lubricated bearings in centrifugal pumps,
gear speed reducers, and other machines operating in
process plants. In the very few instances where bearing
lubrication would not reach the adjacent magnetic bearing
housing protector seal, it might be wise to question the
adequacy of bearing lubrication as well.
DUAL MAGNETIC SEAL EXPERIENCE
Dual magnetic seal experience is well documented.

Serious designers and manufacturers have, since 1971,
successfully adapted mechanical seal face technology to
bearing protector seals. Manufacturers observing proper
face materials and flatness criteria have prospered. Their
products have been of service to reliability-focused users.
Conversely, manufacturers who years ago tried to cut
corners by using lowest cost materials ran into difficulties
maintaining seal face flatness. Today, as never before, it is
important to seek out and buy products from knowledgeable
vendors.
Knowledgeable vendors are found after separating
sales talk from facts. We must ask how subassemblies or
components really work. We must look at the dimensions
and the design criteria. Above all, we should use common
sense. The old adage that more parts mean more failures
is flatly contradicted by the modern automobile. An
engine built in 2014 probably has more parts than an
entire automobile built in 1930. Also, a modern aircraft
navigational system requires more skill to maintain than
many an old compass. Which system would we choose
for a modern aircraft? Common sense clearly furnishes the
answer: We choose the complex system and employ an
experienced maintenance technician.
Modern industry can achieve optimum reliability
performance by manufacturing well-designed components
for users willing to capitalize on these designs. In reviewing
bearing protector seals, potential users must place sciencebased facts above marketing claims. A business-as-usual
approach whereby vendors handing out trinkets are given
preference over vendors who dispense technology is at odds
with reliability performance and best-practices goals.
Face-type seals can also be used in electric motors as long
as they are applied within their respective design envelopes.
The dual-face magnetic seal of figure 9 complies with ATEX,
the European testing authority for components operating
in explosive atmospheres. The European Health & Safety
Executive also tested and certified the safe sparking and
hazard-related performance of these dual-face magnetic
seals.
then allowed us to derive a rather direct cost justification

sheet for a refinery with 1380 installed process pumps. We
start with a logical sequence:
1.
Number of pumps installed
2.
Number of pumps that had experienced repairs in a 12-month period
3.
Mean-time-between-failure (MTBF) in
years (1380 / 250)
4.
Average cost of a pump repair, including all overhead costs (see reference 1)
5.
Roughly 50 percent of these repair

events involved bearing lubrication
issues
6.
Roughly 50 percent of lubrication issues are attributed to contamination
7.
Yearly cost of contamination on this

refinerys pumps (62 * $12,000)
$744,000
8.
Cost of a superior bearing protector

seal
$500
9.
First year cost of retrofitting bearing

protector seals (250 * $500)
$125,000
1380
250
5.5
$12,000
125
62
COST JUSTIFICATION CAN BE QUITE SIMPLE
Some users are in a position to interrogate their own plants

failure records to determine lube related failures. While
reluctant to publish their experience, consulting engineers
often receive informal feedback from such facilities. This
DECEMBER 2014 | 49
SEALING solutions
Because Best-In-Class refineries
report an 11-year MTBF, we can
assume that in the following year
62 pumps no longer fail every
5.5 years, but fail every 11 years.
On each of those 62 pumps, the
yearly cost of repairs is no longer
$2182 ($12,000/5.5), but $1091
($12,000/11). The yearly avoided
repair cost per pump is $1091; for 62

pumps we avoid a total of $67,642.
During the next year, the upgraded
250 pumps will have an MTBF of 11
years (achievable per references 1
and 8); the remaining 1130 will have
an MTBF of 5.5 years. Therefore, 205
(1130/5.5) of the larger group and 23
(250/11) of the smaller group need
repairs. The total needing repair in

year 2 is 228 (205+23). Compared
to year 1, there will be 22 (250-228)
avoided repairs in year 2. At $12,000
per incident, we will have saved
$264,000 (22 * $12,000), but will
spend $114,000 ($228 * 500) for
retrofitting bearing protector seals to
the 228 pumps undergoing repair in
year 2.
We would go through identical
iterations for the few next years and
could readily calculate the value
of failure avoidance through such
systematic retrofits.
CONSIDER THIS SUMMARY
Both reliability advantages and easy

cost justification for bearing housing
protector seals are widely known.
Numerous articles and at least twelve
books deal with the subject. However,
marketing-driven and often misleading
claims abound in a world where one
rarely gets to hear the full story.
Still, reliability-focused best-ofclass companies make it their goal to
investigate the merits of tradition and
the value of advancement. They draw
a number of conclusions:
1. Credit belongs to manufacturers
for entrepreneurship and for
designs that have rightly replaced
lip seals in many process plant
machinery applications.
2. Many old-style bearing housing
seals have serious limitations.
These limitations are rooted in the
laws of physics and the concepts
of lubrication and wear.
3. Reliability-focused users
examine both test data and the
construction features of costcompetitive products, both
old and new. To be relevant,
cost must be calculated on the
basis of full life cycles. The
reliability-focused buyers will
then draw their own, fact-based
conclusions.
4. Superior designs will (usually)
require better installation tools
than heavy hammers; also, no
process plant tolerating hammer
blows on bearings and seals will
be profitable in the long run.
5. In the hands of value-conscious
engineers and technicians,
50 | DECEMBER 2014
advanced rotating labyrinth seals

and dual-face magnetic seals have
saved process plants hundreds of
thousands of dollars.
Observing the work processes
and procedures at process plants
is as important as examining their
stipulated goals and aspirations. We
noted a strange paradox: Everyone
talks reliability but many only pay
lip service to the term. To be exact-many managers are driven by shortterm goals only. Similarly, some wage
personnel have voiced concern that
their jobs may be phased out when
there are fewer equipment failures, so
why cooperate? And while allowing
modern components in ones plant
may run counter to some instincts,
it doesnt run counter to logic and
experience.
Finally, there is ample evidence
that business-as-usual attitudes and
procurement decisions based on
advertising claims alone will not
yield best-in-class performance
(see reference 8). True reliability
professionals investigate first the
facts. They periodically update their
knowledge base and when they have
the facts, they freely share them
with anyone who is teachable. There
are even times when engineers and
technicians see the light before
a manager does. When that is the
case, consider making your points
based on evidence. It is the key to a
facilitys long-term productivity and
competitiveness.
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 978-1-118-04123-9.
REFERENCES
1. Bloch, H. P. and A.R. Budris, Pump
Users Handbook: Life Extension, 4th
Edition, Fairmont Press, Inc.: Lilburn,
GA (2013). ISBN 0-88173-720-8.
2. Adams, V., R., Barry Erickson,
Bill Needelman, and Michael
D. Smith, Proceedings of the
13th International Pump Users
Symposium, Texas A&M University,
Houston, TX (1996): 71-79.
3. Eschmann,P aul, Ludwig Hasbargen,
and Karl Weigand, Ball and Roller
Bearings, John Wiley & Sons, New
York, NY (1985): 183, ISBN 0-47126283-8.
4. Bloch, H. P.; Twelve Equipment
Reliability Enhancements with 10:1
Payback, NPRA Paper RMC-0582, Presented at NPRA Reliability
and Maintenance Conference, New
Orleans, May 2005.
DECEMBER 2014 | 51
MODERN PUMPING products

NET IRRIGATE
WireRat 4.0
Featured Product Release
MEGGITT
SENSING
SYSTEMS
REF2500
Handheld Shaker
The ReferenceMate portable
vibration reference quickly
and easily checks operation
and set-up of accelerometers
and velocity sensors in the
field. Ensure confidence in
the entire measurement chain
before beginning expensive
tests and calibration. The
highly competitive REF2500
promotes continuous cost savings
through affordability and steady
equipment performance.
Net Irrigate, a
manufacturer
of Wireless
Agricultural
Irrigation
Monitoring (WAIM)
technology, is
excited to announce
WireRat 4.0,
an update to its
WireRat technology
that offers pivot
owners new
benefits like the
ability to selftest the system and increased battery performance. Since its
release in 2011, WireRat technology has become the agriculture
industrys best selling alarm solution for copper theft on center
pivot irrigation systems and additional agriculture equipment.
WireRat technology offers farmers the ability to better protect
the valuable copper wire on their pivot irrigation systems and
other equipment by immediately sending alerts to your phone
when a span cable is cut. The technology works seamlessly with
all brands of center pivots and requires no external power. New
for the WireRat 4.0 is the ability to self-test by simulating span
cable cuts without causing any damage to your equipment.
Every month the system will auto-test the copper wire, ensuring
the alarm is not compromised during the off season. For more
information, visit www.netirrigate.com.
Key features of ReferenceMate:
1.
2.
3.
4.
Three user selectable

frequencies which work in
both peak and RMS mode
Easy front panel operation
Compatible with sensors
weighing up to 250 grams
(standard IEPE, triaxial,
velocity)
Extended battery life
For more information, visit the

ReferenceMate portable vibration
reference source product
page at www.wilcoxon.com/
referencemate.cfm.
52 | DECEMBER 2014
HDI INSTRUMENTS
Certified HDI 2000P

Mud/Standpipe Gauge System
HDI Instruments LLC, a leading provider of batterypowered, stand-alone gauge systems based in
Houston, Texas, today announces the
release of the Certified HDI 2000P
Mud/Standpipe Gauge System. The
electronic platform of the HDI
2000P is the same as the twentyyear, field proven HDI 2000B
Panel Gauge, known worldwide
for its accuracy, reliability, and
safety enhancing properties. In
addition to these field proven,
stand-alone Gauge Systems, HDI
also provides the HDI 9000 Choke
Console and the HDI 3200 Mud
Gas Separator Monitoring System
which incorporate a series of
Gauge Systems integrated for the
individual rigs needs. Contact HDI
at info@hdigauges.com regarding
inquiries for the 2000P or other
well control products.
BIONOMIC INDUSTRIES
Series 5000 Counter Current Packed Tower Scrubber

Bionomic Industries, Inc., an industry-leading manufacturer of proven air pollution abatement,
product, and heat recovery technologies, has announced availability of their latest concept, the
high efficiency Series 5000 Counter Current Packed Tower Scrubber with increased versatility. Series
5000 Packed Towers incorporate Bionomics maximum throughput Hi-Flow random or structured
packing, high efficiency mist eliminator designs, and a variety of clog resistant liquid distribution
systems match engineered to more precisely meet specific application requirements. An optional
dual packed bed arrangement enables removal of multiple contaminants using different scrubbing
reagents within the same unit. For more information, call 201.529.1094, email sales@bionomicind.
com, or visit www.bionomicind.com.
HAYWARD FLOW CONTROL
ECP Series Thermoplastic Quarter Turn Electric Actuator

Hayward Flow Control announces the addition to our industry leading line of Actuation and
Controls of the new ECP Series Thermoplastic Quarter Turn Electric Actuators. The ECP features a
GFPP (Glass Filled Polypropylene) housing that provides the actuator superior corrosion resistance
and performance in environments and atmospheres where most metal actuators cannot. The ECP
Series are available in several sizes for use with Hayward ball- and butterfly valves up through 6/
DN150. Available in torque ranges from 221 in/lbs / 25Nm to 796 in/lbs / 90Nm, all ECP actuators
feature a manual override, LED status light and Namur style mounting for solenoids and ISO5211
mounting base. The product line is available in 115/230V and 12/24V voltages, with digital
positioner and battery fail safe kits available as options. For more information, call 888.429.4635,
email hflow@haywardnet.com, or visit www.haywardflowcontrol.com.
DEZURIK, INC.
APCO ASU Combination Air Valve

The APCO ASU Combination Air Valve is an innovative new
concept in air valve technology. This single body combination
valve features a patented air release and air/vacuum mechanism
that is specifically designed to deal with media containing
grit, solids and grease. The unique design provides varied and
predictable air flow over a wide range of air release conditions.
A large diameter Air/Vacuum Disc provides high volume air
flow for rapid venting during pipeline filling and allows high
volumes of air to enter the pipeline during draining. During
normal pipeline flow conditions, the dual-range air release
design prevents air build up and resultant flow restrictions under
changing conditions and through the full flow range. For more
information, visit www.dezurik.com.
GROSCHOPP, INC.
Brushlesss DC Gearmotors
and Controls
Working to set the standard for quality in the fractional
horsepower motor industry, Groschopp, Inc. introduces a
highly reliable, robust, and economical Brushless DC Motor
and Control package. Groschopps family of brushless DC
motors and gearmotors have been tested for pairings with
the brushless DC control product line giving engineers
a brushless DC motor and control package designed for
optimal operation. Groschopps brushless DC motors are
highly efficient and provide high power density, all in a
compact design. The closed loop controls are designed
to deliver commutated power and variable speed control,
maintaining excellent speed regulation over a wide range
of loads. Compact, economical, and efficient, Groschopps
Brushless DC Motor and Control packages are ideal
where high torque, high speed, quiet operation, and low
maintenance are needed. For more information, call
800.829.4135 or visit www.groschopp.com.
DECEMBER 2014 | 53
MODERN PUMPING products

GTI PREDICTIVE TECHNOLOGY, INC.
VibeRMS LT
GTI Predictive Technology, Inc., creators of the iPad Vibration Analyzer, unveils
VibeRMS LTthe complete, affordable condition documentation solution for iPad.
Developed for the iPad, VibeRMS LT is a single channel vibration documentation tool. Users
can view live vibration data (velocity, acceleration, displacement) and create reports at
the site on the iPad. Reports include machine data, spectrum data, alerts and alarms, user
notes and integrated photos from the iPad. The Build Machine function includes templates
for common machine types (motors, pumps, fans) and the ability to combine machine
types to create machine train templates. Machine templates can also be built on-site using
a photograph of the machine. Measurement points are added by the user to complete
the template. VibeRMS takes advantage many of the functions included in the iPad like
camera functions, touch screen, and instant email of reports. For more information, email
info@gtipredictive.com or call 888.473.9675.
AUMA
AUMA Support App for Android

After the successful launch of the AUMA Support App for Apple devices earlier this year, the
electric actuator manufacturer now announces a new version of the app for Android devices.
Designed to make life easier in the field, the app gives engineers on-site rapid access to all
device-related documents, including technical data sheets, operation instructions, wiring
diagrams and inspection certificates. These documents are made available by simply scanning the
name plate of an AUMA actuator using a smartphone or tablet PC connected to the Internet. The
actuator is identified by means of a data matrix code on the name plate, and the actuator-specific
documents are displayed within a few seconds. Documents can be printed, forwarded via e-mail,
or saved on the mobile device. The AUMA Support App for mobile devices using the Android
operating system is available free of charge from the Google Play Store. The version for iOSbased devices is available from the Apple Store. For more information, visit www.auma.com.
CASHCO, INC.
PTR-1 Regulator
Theres a lot more to the new PTR-1 from Cashco Inc. than an identity based product
designation. Formerly known as the T1 valve when the product was acquired with the acquisition
of Kaye MacDonald in 1999, the PTR-1, which stands for Pressure Temperature Regulator, now
comes with all of the information a customer needs to match the regulator to the application.
That includes a technical bulletin, an IOM (installation, operation and maintenance) manual,
and assembly drawings for all line sizes and item numbers. The PTR-1 is similar to the recently
introduced ULR-1. However, in addition to the CA1 mounted on a DA4 pressure reducing
regulator, customers also purchases a Model 135 Low Temperature Probe, which is inserted into
the lines they want to control. If the pressure in the line gets too cold, the probe will open and
bleed the gas out of the cover dome of the DA4, thus shutting the DA4 off and protecting the
downstream apparatus. For more information, call 785.472.4461 or visit www.cashco.com.
SIPOS AKTORIK
SIPOS Seven
A new electric valve actuator range has been launched by SIPOS Aktorik. The SIPOS Seven series
features a number of breakthrough innovations to enhance the flexibility and functionality of
actuation technology. Pioneering advancements include large color display, simple joystick
control and USB interface. SIPOS Seven products include the Ecotron, Profitron and high
precision, HiMod. Full Color Display: SIPOS Sevens large, full color display is a first for
an electric actuator. Designed to be easy to read, all essential information is visible and is
configurable by the user in a variety of different languages. Simple animations provide step-bystep instructions for actuator set-up and operation, reducing the need for instruction manuals
on-site. For more information, visit www.siposseven.com.
54 | DECEMBER 2014
METALLIZED CARBON CORPORATION
Metcar Bearings for Dry Running at High Temperature

Metcar bearings are ideal for use in continuous dryers, high temperature conveyors, kiln
cars, and high temperature ventilation dampers. They are also a great choice for other
high temperature equipment, including continuous bakery ovens, screw conveyors,
valves, and paint dryers. Several Metcar Grades have received FDA approval for use in
contact with foods and pharmaceuticals. Metcar bearings for dry running can be provided
to customer prints or custom-designed for specific application dimensions and tolerances.
Standard pillow blocks and flange blocks with Metcar bearing inserts are available with
cast iron, stamped steel, or stamped stainless steel housings. Metcar high temperature
bearings are also available shrink-fitted into metal housings or metal retaining rings. For
more information, call 914.941.3738 or visit www.metcar.com.
YSI, A XYLEM BRAND
Pro10 and Pro1020 Handheld Meters

Expanding their handheld meter line, Xylems YSI brand has introduced
the YSI Pro10 and Pro1020 options. Both of these new handhelds are YSI
Pro basic meters for the wastewater market, are extremely versatile and
ruggedeven in the harshest environmentsand they will both measure
pH and ORP (redox). The Pro1020 will also measure Dissolve Oxygen
(DO) to broaden the handheld offering. For more information, visit
www.ysi.com/productsdetail.php?Pro1020-103.
HAMILTON CASTER
Colossus 200-Ton Toting Caster

Hamilton Caster is well known for making heavy duty
industrial castersand now, one of the biggest. Hamilton
recently designed and built four 100,000-pound capacity
casters for a federal contractor. Fully assembled, each caster
towers 52 inches above the factory floor and weighs more
than 8000 pounds. Together, they represent Hamiltons highest
payload capacity ever: 200 tons. Each Colossus caster was
designed with a spring-loaded suspension system to absorb
shock. The swivel construction consisted of 32-inch and
18-inch diameter raceways flame hardened to 55-60 HRC
with a total of (96) 1-1/2inch diameter bearing
balls. Each caster
also featured an eight
position swivel lock for
directional control, a
huge 7-inch diameter
oscillating axle
to accommodate
uneven surfaces,
and a footoperated braking
system. For more
information, call
800.733.7655 or visit
www.hamiltoncaster.com.
METTLER TOLEDO
GPro 500 TDL
Analyzer Series Extension
Compact, explosion-proof spectrophotometers with advanced

SpectraID signal processing are the hallmark of the
GPro 500s design. The analyzers ruggedness and small
footprint allow installation in the most difficult locations.
With the availability of reliable CO TDLs for installation in
combustion on fired heaters, package boilers and similar
power applications, users can now switch from oxygenonly, fixed-point control to combined oxygen and CO trim
control. This can significantly reduce fuel costs and NOx
emissions. Building upon the unique probe concept, new
process adaptions are available to enable the deployment
of Tunable Diode Laser (TDL) technology in measurement
locations never previously possible. Further, Mettler Toledo
now makes full use of the platform concept of the GPro 500
Series by introducing CO and moisture spectrometers that
are freely selectable with any suitable process adaption. For
more information on the GPro 500 TDL product line, visit
www.mt.com/tdl.
DECEMBER 2014 | 55
PUMPING trends
The Gift of Doing Good

Louis Allis president, Bruce Bailey, on corporate responsibility
and the rewards of giving back
ith over a century

of experience, Louis
Allis specializes in
manufacturing industrial electric
motors for some of the most
demanding applications in the world.
Also, under the direction of their
president and CEO, Bruce Bailey,
Louis Allis employees participate
in a variety of philanthropic and
charitable causes through a mix of
financial donations and service hours
every year. As the holiday season
approaches, Mr. Bailey took time
to share some of his thoughts on
giving in general and the specific
humanitarian crisis facing refugees
in the Syrian conflict. He can be
reached at bbailey@louisallis.com.
More information about Louis Allis,
their products, and their philanthropy
can be found at www.louisallis.com.
Modern Pumping Today: For people
unfamiliar with the details of the
Syrian refugees plight, what would
you most want them to understand?
Bruce Bailey: It is important to
understand the scale of the problem.
There are over 1.5 million Syrian
refugees in Lebanon alone, and 6.5
million displaced internally. This is a
protracted crisis, and refugees have
depleted savings and cannot afford
rent, food, heating fuel, and have
little access to education or health
care. The majority live in unfinished
buildings and informal tents and
hutsmany of which are in poor
repair and have poor drainage and,
thus, are susceptible to flooding and
the cold. This is the worst global
crisis of our age after the genocide in
Rwanda.
MPT: With wide-ranging experience
in the water and wastewater fields,
how can Louis Allis and similar
companies effect the most change
where their skills and expertise are
needed?
56 | DECEMBER 2014
Bruce Bailey: Unless you see the

need first hand its hard to wrap your
mind around just how bad the refugee
crisis really is. You cannot imagine
living in a tent with three feet of snow
on the ground, no running water,
no bathrooms, and dirt for floors.
Tents are susceptible to flooding and
leakage, and settlements have poor
drainage and wastewater disposal
options.
Also, hundreds of thousands of
children were left without education
for the last three years, and the ones
who still have parents spend their
days either begging or hanging around
in the camps vulnerable to terrorists
recruitment. Funding to improve
shelters specially nowwhen winter
is approachingwould be most
effective. The number one request
coming from adult refugees is funding
to expand educational efforts. We
currently are working toward a school
for three hundred children and with
plans to expand to two thousand.
MPT: Where do you see the role of
giving back for people in your
industry? What are some ways you
integrate this within your corporate
culture?
Bruce Bailey: There is no greater joy
to be found in this life than helping
the orphans, widows, and people
living in utter poverty. As the saying
goes, it is truly better to give than to
receive.
We see giving back as our social
responsibility. Its not really a choice
for us its who we are. But by the
grace of God, any one of us could
have easily been born into one of
these countries like Syria, Iraq, and
Iran where people are in dire need.
We have been blessed with as many
resources in this country compared to
the rest of the world. There are huge
needs in the refugee camps for fresh
water and waste disposal. We have
the solutions, so all we have to do is
deploy assets.
PRESSURE & FLOW
The right amount of water pressure and flow is critical to protecting pipes,
preventing loss of prime and avoiding dead head conditions.
Thats why you need the iQPump1000 from
Yaskawa. The most intelligent pump controller
available gives you complete control of your
irrigation needs for water land management
resulting in lower installation costs, simpler
operations and greater energy savings. The iQPump1000 can be easily
integrated into any pump station, or retrofitted into an existing system.
When the right amount of pressure and flow is critical, call Yaskawa.
Get personal with Yaskawa.

Call Scott Mathews today.
1-847-887-7144
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
2015 Yaskawa America Inc.
For more info:

http://Ez.com/yai709

Modern Pumping - 122014

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Modern Pumping - 122014

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MODERN

THE WORLDS BEST

12 Measuring the True Performance of Pumps in Operation

water & wastewater solutIons

20 Channel Monster Shreds Debris, Ragging

22 The Village of Montpelier Improves Efficiency

26 Performance Evaluation for Rotary Vacuum Filters

28 The Age of Pump Optimization and the Impact on Sustainable Design

32 Solid Foundation for Business District

TerraFirma's groundwater system supports 100 Saint Paul development

36 Intelligent Pumping Systems

40 Power Where It's Needed Most

Franklin's new solar pumping technology proves itself in Africa

P.O. Box 660197 | Birmingham, Alabama 35266

42 High-precision Ingredient Metering

JEFF FLETCHER Associate Publisher

RANDY ARMISTEAD Associate Publisher

ValVes & Controls

46 Quality Meets Quantity

LISA AVERY Assistant Art Director

48 How to Cost-justify Bearing Housing Protector Seals

SCOTT GORDON Art Director

JAMIE WILLETT Circulation Consultant

Modern PuMPIng ProduCts

JERRY DICHIARA Account Executive

56 The Gift of Doing Good

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

Armstrong Fluid Technology has been presented with a

competitors in the UK and European markets and selected

U.S. WATER RECEIVES

U.S. Water Services,

HIDROSTAL LAUNCHES NEW WEBSITE

Hidrostal Ltd, the UKs expert in pumps and pumping systems, is

in consultation with our customer base i.e. consultants,

NEW WATER STOCK ADDED TO DIRECTORY

Investorideas.com, (www.investorideas.com) global news source

PLASTICS MACHINERY SHIPMENTS

Market demand for plastics machinery continued to grow in

14 percent in Q3 compared with last year. For the year to date,

TRADE SHOW profile

2015 AHR EXPO

s the largest and most comprehensive HVACR

LARGEST EDUCATION PROGRAM

The 2015 AHR Expo includes its largest number

product presentations in the New Product

Now is the time to meet face-to-face with

THE TRUE PERFORMANCE OF

recent large-scale testing program was conducted

FIELD TESTING CRITICAL

The vast majority of tests were

operating point noting that, in practice, pumps often

SAVING MONEY THROUGH

With accurate and reliable knowledge

SAVING MONEY THROUGH

Tests conducted before and