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PUMP SOURCEa guide for pump users

A supplement to Water & Wastes Digest

WWW.WWDmag.com SPRINg 2011

Drives | Bypassing | HousingsPower

PumP Station

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uSPRING 2011

05 Continuous Control Editorial letter 06 Efficient Delivery North Carolina water plant adopts peristaltic pumps to reach WaterSense goals 08 All Mixed Up Mixer technology unclogs lift station wet well pumps

10 Drives for Dives Swimming pool operator reduces energy consumption with variable-frequency drives

12 Smooth Operations Tips for working with wastewater turbines

14 Bypass on the Run Gravity delivery system improvement project calls for detailed pumping plan

16 Irrigation Water: A Steady Supply Adjustable-frequency drives power new pumping station

18 Product Highlights Pumping technologies

10

06

ON THE COVER: Pump Station Power See page 16 for more information. (Cover photo courtesy of Eaton Corp.)

A Supplement to Water & Wastes DigestPUMP SOURCE

14

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editorial letter

pumping requirements vary from application to application—that’s a no-brainer—but it is easy to overlook the fact that they also

f luctuate within each unique application. Many water and wastewater pump operators err

on the side of running systems at full throttle day in and day out to ensure adequate performance: a costly precaution considering the amount of unnecessary power delivered. It is no wonder the equipment has earned a reputation as a top-tier industry energy consumer.

Controlling pump motor speed in real time, ensuring that sufficient but not excessive power is delivered, is now a real energy- and cost-saving opportunity. The ability to adjust the speed of drives, for exam-ple, can yield a significant return on investment (primarily in the form of reduced power bills and energy rebates), sometimes in a matter of months. Such technology also helps minimize maintenance requirements and extends pump life by alleviating long-term mechanical and electri-cal stress. More precise f low control and pump noise reduction are other potential benefits.

Learn more about energy-wise pumping applications in this issue: A 180,000-gal swimming pool retrofit (see page 10) and a 4,000-plus-acre irrigation system success story (see page 16).

If you think energy-efficient technology might complement your water or wastewater pumping operations, crunch the numbers—taking into account pump size, load profile, friction and other such factors—to deter-mine whether a similar investment could be worthwhile.

Finally, some of you may recognize me as managing editor of Water & Wastes Digest and its supplements, Storm Water Solutions and Membrane Technology. I’ll be the new face of Pump Source—to be published twice this year—and along with the rest of the editorial team, look forward to delivering the pumps information you need to stay knowledgeable and competitive in today’s water and wastewater market. PS

Continuous Control

Caitlin Cunningham, managing [email protected]

PUMP SOURCE SPRING 2011

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application peristaltic pumps

Efficient Chemical Delivery

North Carolina water

plant adopts peristaltic

pumps to reach

WaterSense goals

By Gary Rose

Over the years, the U.S. Environmental Protection Agency (EPA) has offered vol-

untary partnership programs to address a wide variety of environmental issues by working collaboratively with companies, organizations and communities. There are now more than 13,000 groups par-ticipating in EPA Partnership Programs, according to the EPA website. One of the most highly recognized EPA pro-grams is WaterSense.

Launched in 2006, this is a partner-ship to save water and protect the future of our nation’s water supply by imple-menting water-efficient products, ser-vices and practices as specified by the EPA guidelines. Many local water utili-ties have joined the WaterSense part-nership as a way to promote high water standards throughout their communi-ties. There are only a select few water plants that are able to achieve the part-nership program’s highest level of standard: Level 4.

The Orange Water and Sewer Authority (OWASA), which operates the Jones Ferry Water Plant (JFWP) in Carrboro, N.C., is one utility company that is on the cusp of obtaining such a distinction. The Level 4 standard is based on several factors associated with

providing the cleanest water in the most efficient manner. One of these factors is the measurement of turbidity in the treated water.

Potassium Permanganate Precision

The JFWP, like many other facilities in this part of the country, faces a unique well water problem. The natural occurrence of high levels of oxide iron and magnesium creates a yellowing effect within the water, and this effect is reflected on turbidity readings as dirty water. OWASA’s objective is to eliminate the yellowish color by add-ing and maintaining the precise amount of potassium permanganate.

The JFWP had been using a dia-phragm pump for potassium perman-ganate dosing for the past several years. The recent technical advancements of peristaltic pumps, however, have proven to provide a more consistent flow rate than a diaphragm pump with less main-tenance for chemical feed applications. Within the last two years, the plant has converted most of its chemical feed applications to the Blue-White Industries Flex-Pro A3V peristaltic pump, replacing the existing diaphragm pumps.

The new pumps have been installed in three critical injection stages: low-pressure sodium hypochlorite, high-pressure sodium hypochlorite and low-pressure fluoride. The technology has delivered accurate and constant flow rates with virtually no downtime. The Flex-Pro A3 tube life on the fluoride injection is lasting 9,500 hours, running 24/7 at less than 15 psi. The tube life on the sodium hypochlorite flash mixer consisting of 10 pumps is lasting 7,000 to 7,500 hours, running 24/7 at less than 15 psi. The tube life on the sodium hypochlorite post mixer is lasting 1,500 to 1,700 hours, running 24/7 at a pres-sure of 80 psi.

JFWP’s plant manager decided to switch out the existing diaphragm pump on the potassium permanganate feed for a peristaltic pump. The feed rate of

The new pumps at JFWP maintain precise amounts of potassium permanganate.

84 gal per hour (gph), however, greatly exceeded the feed rates of the Flex-Pro A3. As a result, two other competing peristaltic pump companies offered to test their higher-output pumps in the application. After just eight days of test-ing, the tubes failed on both the com-peting peristaltic pumps, running 24/7 at less than 15 psi and pumping 84 gph. Meanwhile, Blue-White prepared to introduce its Flex-Pro A4 higher-output peristaltic pump.

Testing of this new product began on June 1, 2010, in the aforementioned appli-cation pumping potassium permangan-ate. The A4 peristaltic pump continues to pump with the same tube more than three months after the initial start. It appears that the new peristaltic pump is emulating the success of its predecessor pump.

Technology ComparisonThe key differences between the Flex-

Pro model and other competing models

are the roller assembly and the tube speci-fications. The former models offer a four-roller assembly, two guide rollers and two squeeze rollers. Other manufacturers offer a three-roller assembly. Each tube used with the Flex-Pro is made in accor-dance with Blue-White’s rigid specifica-tions. These are advantageous features that affect tube wear, as demonstrated in the JFWP application.

The A4 model offers the same ben-efits as the A3 model, with the excep-tion of the output capability. While the A3 pump is limited to 33 gph, the A4 pump has a range of up to 158 gph. Both pumps are rated at 125 psi and have a motor speed adjustment range of 2,500:1. Other significant similar features of the two models are: NEMA 4X enclosure (IP66), 30 ft of maxi-mum suction lift, continuous duty cycle, SCADA inputs, non-maintenance brushless motor, tube failure detec-tion system and the ability to inject at

maximum pressure in either direction (clockwise or counterclockwise).

Coordinating for EfficiencyJFWP’s use of these peristaltic pumps

has contributed greatly to its water quality enhancement by reliably and consistently delivering vital water treatment chemicals. This increased efficiency is a key attribute to the EPA’s WaterSense program. The future of U.S. water supplies will be bet-ter managed with coordinated efforts of companies and organizations such as Blue-White Industries and the OWASA. PS

Gary Rose is president of Rose Industrial Marketing Inc. and a representative of Blue-White Industries. Rose can be reached at [email protected] or 800.975.5469.

For more information, write in 1101 on this issue’s Reader Service Card or visit www.wwdmag.com/lm.cfm/ps041101.

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For more information on WaterSense, visit www.allianceforwaterefficiency.org.


application mixing

All Mixed UpMixer technology unclogs lift station wet well pumps

By Kris Drewry The Moon Township Municipal Water Pollution Control Plant in Pennsylvania faced a prob-

lem with its lift station wet well: Grease, rags, rubber material and almost any-thing else that could enter the sys-tem were clogging pumps and creating maintenance issues on a regular basis. Water Pollution Control Supervisor Ray Moorhead had to vacuum the wet well and send personnel into an environment that would make even the “Dirty Jobs” host cringe.

“I needed a solution that I could apply on the fly, without taking the well out of service,” Moorhead said. “The well is 65 ft by 65 ft by 30 ft deep and accumulated everything and anything that could mat together.”

Moorhead found the answer through a flier about Pulsed Hydraulics Inc. (PHI) and its low-tech approach to clogging problems. PHI representative George Pitcaim contacted Moorhead and explained that Moon Township could

resolve its predicament by tapping into one of its existing compressors and add-ing a control box, valve and the piping necessary to deliver an air burst.

“The PHI-300 will introduce a burst of compressed air at the base of the well, in a dead spot, and let simple phys-ics break up the cap,” Pitcaim said. “By repeating the burst at controlled intervals, it will keep the cap from reforming.”

Moorhead was looking for a simple solution and considered this approach promising. The investment was minimal, and the installation could be conducted quickly. The results have been better than expected.

“The initial application broke up the grease cap so fast that the pumps clogged again as they tried to digest the chunks of matter that had broken free. I would suggest that the well be cleaned before installation of the PHI-300,” Moorhead said. “But, since the installa-tion, the well is no longer an issue. The compressor is activated by a float, and

The plant’s new mixing technology works by allowing a burst of compressed air at the base of the well to break up the cap.

we haven’t seen any measurable increase in energy costs.”

Stagnant Water ApplicationMoorhead was pleased with the

results and conveyed his enthusiasm to Bert Rateau, superintendent of the Moon Township Water Authority. Rateau was faced with stratification in water storage tanks, which was creating all of the problems associated with stagnant water.

“We looked at numerous solutions and their costs,” Rateau said. “Pittsburgh doesn’t have an abundance of sunshine in the winter months, so a solar system didn’t seem practical. Other applications required extensive installation efforts, and cost was always a factor.”

In June 2010, Rateau installed a PHI-300 in a 1-million-gal vertical water storage tank, and the results were every-thing he wanted. First, Rateau learned from the Pennsylvania Department of Environmental Protection that construc-tion permits were not required, so his staff installed the equipment without contractor assistance. The water author-ity, therefore, realized substantial savings from the beginning.

“We tapped into an onsite compres-sor, connected the valve and control box, then we ran flex pipe to the top of the tank,” Rateau said. “We next connected a stainless pipe that joined to a ‘T’ at the bottom of the vessel. The forming plates were then anchored and the installation was complete.”

Temperature sensors indicate that the tank is mixing consistently while the compressor is operating 30 minutes on and 360 minutes off. The energy cost is estimated at about 50 cents per day.

“Moon Township has three more tanks that will get their PHI installation soon,” Rateau said. “We will have divers clean the tanks and inspect the interior. Once that is complete, the PHI-300 solution will service those tanks as well.” PS

Kris Drewry is president of Pulsed Hydraulics Inc. Drewry can be reached at [email protected] or 425.785.3225.


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The wet well at Moon Township frequently faced maintenance problems prior to implementation of mixing technology.


application energy efficiency

DriveS for DiveS

Swimming pool

operator reduces

energy consumption

with VFDs

By John Masters Even in the best of times, it is diffi-cult to operate a public swimming pool cost-effectively. But cash flow

is particularly important for nonprofit recreation centers like the Geneva Lakes Family YMCA in Lake Geneva, Wis.

“We have done many equipment, light-ing, heating and cooling upgrades to lower our energy costs,” said Joe Peyer, execu-tive director of the Geneva Lakes Family YMCA. “That’s why we were interested in how variable-frequency drives (VFDs) for our main pool pump and air handlers could save us more energy.”

Peyer faced an energy double-whammy due to the high cost of operating a single-speed pump for a 180,000-gal, 25-meter competition pool and two single-speed motors for the facility’s air handlers.

“Ever since we opened, those air handlers created extreme negative pres-sure in the building,” Peyer said. “That caused many problems. It was tough to open the doors in the pool area, and then they would slam shut, which was dangerous. I had to put special closures on the door to make sure kids’ fingers didn’t get caught. The negative pressure also caused backdrafting that affected our gas heaters and main boiler. We had nonstop service calls to deal with power vent issues on our gas-fired burners and constant sooting in the boiler.”

Optimal Flow Peyer looked to Tim Ruesch, regional

sales manager for Innovative Cost Solutions, Green Bay, Wis., for answers.

“The YMCA was using single-speed drives for the pool pump and the air handlers. We knew that by incorporating the Danfoss VLT AQUA Drive we could save the facility a substantial amount of

money,” Ruesch said.The first problem Ruesch addressed

was the energy being consumed by the pool’s always-on, constant-speed pump.

“The pump was consuming more than 15 kW around the clock,” Ruesch said. “But pumping full speed all the time wasn’t really necessary. Health requirements called for the total vol-ume of pool water to turn over every six hours while the pool is in operation, which translated in this case to 500 gpm [gal per minute]. To get that flow rate, they were using a 15-hp pump. But my research showed that a VFD could deliver the required volume with less horsepower and much lower kilowatts.”

The drive used has a variable-frequency design with integrated controls developed especially for water applications. In this case, Ruesch was counting on the drive’s flow compensation algorithm to vary flow to meet the pool’s flow requirements and thus optimize energy consumption. When the pool is in heavy use or the fil-ters need cleaning, the pump horsepower would be increased. During minimal usage or at night, the pump horsepower would be decreased.

Protective CoatingThe drive also brought another benefit

specific to swimming pool applications: Inside the drive housing, the printed cir-cuit boards are specially coated to with-stand the harsh affects of chlorine.

“I worked with Danfoss VLT units before,” Ruesch said. “Their compact design easily fits into tight installation spaces, which is great for a retrofit job like this one. Plus, the electronics are completely protected inside a rugged metal housing. The electronics are also

separated from the cooling air flow to protect against dust and debris. It is a very robust and intelligent design.”

ROITaking advantage of the drive’s con-

trol capabilities, Ruesch wired the unit to a digital flowmeter. When pool usage and filters required higher pressure, the flow compensation algorithm accelerated pump speed. It reduced speed, however, when the pool was closed.

As a result of the flow compensation and drive efficiency, the YMCA saw some impressive electricity savings. “Compared to our original 15-kWh pump, the drive runs at 8 kWh when the pool is occupied and 2 kWh when we are closed,” Peyer said. “Those energy savings come to about $3,500 per year.”

After the success of the first drive, Ruesch was eager to tackle the negative air pressure problem.

“They had this monster air han-dling unit to eliminate the chlorine smell,” said Ruesch, who has been involved with commercial pool

applications for 10 years. “I calculated the cfm needed for suf-

ficient air changes and found that once again a VFD was the answer.”

This time, Ruesch applied two Danfoss VLT HVAC drives—one rated for 15 hp, the other for 20 hp—built on a modular plug-and-play platform and dedicated to HVAC applications. The drives were easy to install. “In this case, no sensor wiring was necessary,” Ruesch said. “I just set the rpm for the fan to deliver the required cfm.”

“The instant [Ruesch] installed the two drives on the main air handler, we solved all of the negative air pres-sure issues, not to mention a reduction in white noise in the pool deck area,” Peyer said. “Since then, we have had no unplanned service calls.”

The energy savings also have been outstanding. One year after the air han-dler and pump drives were installed, they yielded a combined annual energy sav-ings of $10,000. That does not take into account incentives from the utility that added up to more than $3,000.

“With returns on investment like that, this type of drive retrofit applica-tion easily sees a payback in 12 to 18 months,” Ruesch said. “That fact is opening doors for more work in other aquatic facilities. We have a lot of indoor water parks, competition pools and rec-reations centers around here because of the long winters. These facilities usually operate as public or nonprofit businesses, so they can’t afford the high operating costs of misapplied, single-speed drives on pumps and air handlers. VFDs are a very attractive energy-saving solution.”

As for Peyer, he is enthusiastic about the drives. “They have been nothing short of fantastic for our facility and for our cash flow,” he said. PS

John Masters is vice president of sales, Water Group, Danfoss VLT Drives. Masters can be reached at salesinformation@ danfoss.com or 800.621.8806.


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technical feature

Smooth Operations

Tips for working with

wastewater turbines

By Brian Daschner

When turbines are new and working at peak performances, day-to-day work is much sim-

pler because repairing and replacing tur-bines is costly and takes time away from business as usual. Keep focus on the more important aspects of business by follow-ing these steps for smooth operations and extending the life span of turbines.

1. Initiate a regular monitoring schedule and stick to it.

Turbines begin to wear the minute they are started, so it is vital to check them reg-ularly. Record the flow and the pressure of a pump’s outflow the first day a new tur-bine is started to gauge its efficiency.

Aim for a monitoring schedule of •once every three months.The more abrasive the application •of the turbine, the more regularly it should be checked—as frequently as once a month. Depending on the application, a normal life span for turbines in a wastewater envi-ronment is three to 10 years.

2. Choose stainless steel over bronze whenever possible.

Bronze is a key component for both vertical and submersible turbines. All municipal systems must include

chemicals in their water systems to ensure proper safety, of which the most common is chlorine.

Chlorine attacks bronze and causes early failure, shortening the overall life of the equipment. Stainless steel is a better choice in high-chlorine concentrations, saltwater applications or where there is a low pH in the water because it is resistant to the negative effects of these chemicals.

3. Lost wax investment castings are superior to all other impeller castings.

Lost wax castings are injected into a stainless steel pattern, creating a perfect mold with each injection. This yields smoothness, and the smoother castings promote higher efficiency. Better effi-ciency means less horsepower, so energy is saved. Sand castings have core shifts, void areas and rough surfaces, which cause lower efficiencies and faster deterioration.

4. Strength and hardness are consid-ered two of the most important physical properties when choosing pump impeller material because they relate directly to the ability to withstand abrasion.

Follow these guidelines:Stainless steel impellers: Brinell •hardness range of 148 to 172;Bronze impellers: Brinell hardness •range of 60 to 159; Tensile strength for stainless steel: •80,000 to 135,000 psi; andTensile strength for bronze: •26,000 to 85,000 psi.

5. Abrasive wear, sand and water cause damage.

Abrasiveness and water are the two most significant factors that wear on tur-bines. Be on the lookout for tolerances opening up, which compromise stabil-ity and cause vibration that also can lead to system failure. In addition, working turbines create friction and that friction causes wear over time.

6. When changes occur in amperage, flow and pressure, it is time to reassess and consider turbine replacement.

A drop in turbine output is detri-mental to the overall system. Sometimes a system failure can mean that a part

Stainless steel equipment fares better in high-chlorine, saltwater and low-pH environments than that made of bronze.

needs to be replaced, not that the entire pump needs to be rebuilt.

7. When replacing a turbine, look for the following characteristics in the new equipment:

Quick replacement;•Availability of compatible parts for •easy replacement; High-quality materials, which pro-•duce the most efficient system; andAbrasive-resistant materials for •parts such as the shaft, bearings, bushings, impeller and bowl.

8. When replacing a turbine, dis-mantle from the top down.

Reassemble from the bottom up.9. During a turbine replacement, do

a check for:Any fractures or cracks in castings;•Damage in the column and •head; andAny cracked or broken parts that •need to be replaced.

10. Improper handling of the packing is the most frequent error made by non-professional installers.

It is highly recommended to use professional, quality installers for all jobs. Packing should be loose upon startup, not tight. There should be water spray, but not on the motor. Start slowly controlling the tightening of nuts evenly on startup for proper f low to the head drain, and divert the f low back into the pit. Finally, replace pack-ing when necessary.

11. Follow all safety instructions pro-vided by the manufacturer. For instance:

Switch pumps off before •any maintenance;Drain out all liquids before servicing;•Stand away from any moving parts •and take necessary precautions, such as wearing rubber gloves and using insulated tools, while servic-ing electrical motors; andKeep an up-to-date record of all •maintenance work.

12. Hiring qualified installation pro-fessionals prevents headaches.

They should check: Shaft alignment and coupling;•Faceplate leveling and rigidity;•Alignment to the discharge •piping; and

Proper setting of the rotating •assembly of the impellers.

Personnel involved in day-to-day wastewater operations and management who follow these tips will see a longer turbine life and better overall perfor-mance of the turbines they monitor. PS

Brian Daschner is president of Hydroflo Pumps. Daschner can be reached at [email protected] or 615.799.9662.


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application bypass system

Bypass on the Run

Gravity delivery system

improvement project

calls for detailed

pumping plan

By Kirsten Petersen Stroud To quote President Barack Obama’s State of the Union speech on Jan. 25, 2011: “Our infrastructure used

to be the best, but our lead has slipped… Our own engineers graded our nation’s infrastructure: They gave us a ‘D.’”

Cub Run Gravity Delivery System

The Upper Occoquan Sewer Authority, along with the Fairfax Water Authority and Fairfax Parks Authority, long recognized the validity of the presi-dent’s statement and hired contractor S.J. Louis Construction Co. to replace approximately 28,000 ft of main gravity sewer lines. This improvement addressed wastewater quality management needs relating to the acquisition, expansion and rehabilitation of deteriorating facili-ties and systems. During the removal and replacement process, the sewage still has to flow. Thompson Pump’s expertise was tapped to execute this 18-month project located in Centerville, Va., an upscale suburb of Washington, D.C.

Beginning in December 2009, Thompson Pump representatives Tucker Lamontagne and Rob Hayden of the local Baltimore-Washington branch began bypass for the first of 10 phases of the Cub Run gravity delivery system improvement project.

A River of ChallengesMultiple bypass pump systems had

to be utilized to temporarily divert cur-rent flows around the pipe section being replaced—all without stopping the nor-mal flow, thus ensuring continuation of sewage service during construction. To accomplish this, temporary pumps were installed upstream from the pipe being replaced and sewage was bypassed to a downstream section of the pipeline that was still active. To stop the regular flow of the pipeline, temporary plugs were installed in the line before the section that would be replaced, thus diverting the flow to the temporary pumps.

Though the overall goal is to replace more than five miles of pipe, the chal-lenges lie in the details. The main sewer line has multiple tie-ins from smaller lines, there are several large creeks and river crossings to navigate, and the over-all project is located in a floodplain. Additionally, the majority of the site is not accessible via traditional transporta-tion (e.g., a work truck). The contractor also had to complete a four-year job in less than two years.

“If we received more than 3 in. of rain within a few days, the site would flood and turn into deep mud,” Lamontagne said. “Floodwaters would cover the manholes.”

A Planner is a WinnerThompson Pump creatively attacked

these enormous challenges. Off-road vehi-cles, such as the John Deere 4x4 utility Gator, have provided key site transporta-tion. A Thompson light tower remains on site to ensure proper lighting during darker hours of operation.

Detailed preparation of equipment and manpower was required for quick response. Full-service preventative main-tenance is performed, and Thompson Pump is on site every day. With the help of the contractor, pumps have been placed as needed on higher-grade

Centerville, Va., ultimately hopes to replace more than 5 miles of pipe. Bypass systems diverted flows around pipe sections being replaced.

embankments—all without disturbing the surrounding environment. Stream crossings were constructed carefully so as not to impede the flow of the stream and its tributaries.

“Through multiple floodings and challenges, Thompson Pump has main-tained successful bypass operations with no interruptions,” Lamontagne said.

The overall project was divided into 10 core bypass phases. Each phase includes the main bypass, plus multiple lateral bypass tie-ins. Each phase has required varying pump quantities and sizes. All of them required multiple main bypass and lateral bypass pumps with redundant backup pumps for precaution and auxil-iary fuel tanks to assure long run times. Each backup pump is outfitted with an auto-dialer notification system that would provide Thompson Pump first notifica-tion of the pumps’ activities.

Thompson’s Enviroprime sewage pumps were employed with automatic liquid-level controls. The Enviroprime is a priming system that allows for auto-matic self-priming while providing the environmental advantage of preventing fluid blow-by (spillage) during priming and operation unlike other current tech-nologies. Additionally, Thompson Pump Arctic Knight technology was used to assure continuous pumping during tem-peratures as cold as -40˚F while eliminat-ing the traditional problems of operating pumps in cold climates (e.g., frozen liq-uids in the pump housing).

The bypass for each phase experienced an average of 15-ft suction lift. Levels of peak and low flows varied from 6,900 gal per minute (gpm) to 27,000 gpm for the main sections, and bypasses varied from 350 gpm up to 10,000 gpm for the lateral sections. Almost a mile of discharge pipe ran the length of the project.

Smooth ExecutionPhase I employed five Thompson 8-in.

units as primary pumps at the main trunk line. The three lateral lines were covered by two 6-in. pumps. Phases II through VI engaged four Enviroprime 18-in. primary pumps on the main lines and various sizes, including 4-, 6-, 8- and 12-in. units to handle the lateral tie-ins.

Currently on Phase VI, more than 20 pumps have allowed for coverage of the high peak flows, while simultaneously handling the lighter flows. Phases VII and VIII will be addressed by employing five Enviroprime 18-in. primary pumps and two pumps each for the four lateral tie-ins, for a total of 13 pumps. Phases IX and X will require a variable amount of pumps depending on the progress.

In addition to the diesel-driven pumps, Thompson fused and installed the entire initial system of 18-in. high-density polyethylene (HDPE) pipe. Dual discharge lines of HDPE were divided into sections of approximately 4,000 to 5,000 ft. The lateral HDPE pipes tied into the main 18-in. discharge HDPE lines via “T” sections.

“Innovative ideas and good planning have made these phases of the ongoing Cub Run project a success,” Lamontagne said. “The contractor has been so pleased with our pump capabilities and fuel effi-ciency [that] he’s already purchased three of our 18JSCJ Enviroprime sewage pumps for this and future projects.” PS

Kirsten Petersen Stroud is marketing manager for Thompson Pump. Petersen Stroud can be reached at [email protected] or 386.944.4145.


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Each of the project’s 10 core bypass phases includes a main bypass and multiple lateral bypass tie-ins.


application drives

Irrigation water: A Steady Supply

Adjustable-frequency

drives power new

pumping station

By Harry Broussard For generations, Benton County in southern Washington state has been fertile ground for agricul-

ture. In recent years, it has become one of the largest wine-producing regions in the country. The agricultural indus-try demands a regular supply of water. To accommodate current irrigation needs, the Benton Irrigation District (BID) constructed a new pumping sta-tion on the Yakima River in the first part of 2010.

Energy EfficiencyThe pumping station design included

six medium-voltage adjustable-frequency drives, ranging from 400 to 700 hp. BID relies on Eaton’s Ampgard SC 9000 drives, which utilize highly efficient variable-speed operation. Designed for applications requiring variable power output, the drives are able to optimize energy usage by matching consumption to actual power requirements. This way BID uses only the power it needs and

the drives can gradually accelerate the motor and pump, helping protect the assets and extend equipment life.

Optimizing the operating speed of large pumps and motors can generate substantial energy and cost savings, as well as minimize the wear and tear on valuable assets. Today’s drives can save water and wastewater customers more than 40% in annual energy consump-tion in typical medium-voltage appli-cations. The return on investment on medium-voltage drives can be calcu-lated in terms of months, not years.

Critical Needs With regional agriculture depen-

dent on harvest and temperatures reaching upward of 110°F in the sum-mer, a steady supply of water is crucial to BID. A dependable water supply is taken seriously: The BID foreman is on call 24 hours a day during the irriga-tion season to make sure the system is up and running.

The irrigation district’s new pump station employs six medium-voltage

adjustable-frequency drives.

Beyond selecting equipment with a history of reliable operation, rapid response and service was critical to the success of the project. Having field sup-port available within 150 miles proved to be extremely convenient to get the new pumping station up and running. The drives used by BID are engineered to improve uptime and reduce mean time to repair. The SC 9000’s modular roll-in/roll-out inverter makes it easy to access and service.

The electrical system was tested shortly after the pumping station began operating, when it sustained two power outages within a month. The foreman was able to get the system up and run-ning quickly and from his home.

Space SavingsThe original plan for the

electrical room included six medium- voltage variable-frequency drives inside, but due to lack of space, the design had the medium-voltage switches out-side. Using compact drives smaller than those originally specified allowed those switches to be moved inside. Considering the wide range of tem-perature—from 20°F in the winter to the summer high of 110°F—the move helped improve the equipment life and the reliability of the system.

Additionally, the drives are engi-neered to be mounted up against a range of equipment. They can connect the main power bus bar, which car-ries voltage and current, directly out of one unit and into the other. This yields an improved aesthetic and space sav-ings. In the BID installation, the drives were coupled directly with the switches, which was what allowed all of the gear to fit into the original room dimen-sions. Alternately, if the drives cannot be coupled directly with switches, a transition structure would be required to accommodate cables that would need to run from the drive to the switch.

Meeting District DemandsUltimately, the solution allows BID

to meet its irrigation demands and plan for the success of regional agricul-ture. It meets demand with solutions that are designed to minimize energy consumption and work reliably for years to come. PS

Harry Broussard is marketing manager for Eaton Corp. Broussard can be reached at [email protected].



Challenge: A Washington state irrigation

district needed to replace a dete-riorating open canal system. This included a reliable pump station at the Yakima River to supply water for 4,630 irrigable acres crucial to the local agricultural industry.

Solution: A new pumping station was

constructed above the river to accommodate for current and future irrigation needs with six Eaton Ampgard SC 9000 medium-voltage adjustable-frequency drives. Since the summer of 2010, the new pumping station has been bringing water to the acreage.

Conclusion: Energy-efficient adjustable-

frequency drives maintain a steady supply of power that meets the sys-tem demand (and no more) while reducing wear and tear on valuable motor and pump assets. The com-pact footprint of the drives allowed for efficient and effective use of elec-trical room space—key for a pump-ing station located on a rock bluff above the river.


PRODUCThighl ights

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Drives | Bypassing | Housings · 2016-04-14 · • SLURRY/ DIGESTER • MIX FLOW Flows available...

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Transcript of Drives | Bypassing | Housings · 2016-04-14 · • SLURRY/ DIGESTER • MIX FLOW Flows available...