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BEST PRACTICES

FOR INFILTRATION& INFLOW

SOLUTIONS

THE CASE FOR

EDDY CURRENT

DRIVES

LNG ON THE GO

JANUARY 2014PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

THE POWER OF eENHANCED EFFICIENCY FROM

BELL & GOSSETT'S E-1510

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CONTENTS JANUARY 2014

4 Industry News

10 Trade Show Prof ile

Case Studies 12 Increase Productivity,

Improve QualityMinnesota manufacturer fabricates wide range of material handling products

16 Grinder Pumps for Sewer Renewal A new best practice for solving infiltration and inflow issues

Water & WastewaterSolutions

20 Repair or Rethink...

Maintenance Solutions 24 Pump Selection Is Just a Click Away

VSX's multi-platform software, Spaix 4, gives voice to easier pump sales

Pump Solutions 28 Iron Scale Is No Match for KZN PumpBJM Pumps provide solution for rail spike manufacturer

30 The Power of EPart 1 of a 3-part series

Efficiency Islands: What are they? How do they result in operating benefits?

Dewatering Solutions 34 Preserving the Mary Rose

NOV Mono plays an important role in restoring historic artifact

Motor Solutions 36 Eff iciency Def iciency

A modern myth surrounding eddy current drives

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Power Generation

Solutions 40 Time to LNGo

TM

!Dresser-Rand's first small-scale liquefied natural gas plant has successful start

Processing Solutions 44 Ahead of All the Angles

New Primo 200E an advancement in pelletizing machinery

Valves & Controls

Solutions 48 Simple Setup the Key to SafetyThe first SIL-certified transmitter designed solely for safety system applications

Sealing Solutions 50 Raising Protection Standards

to New Heights

52 Modern Pumping

Products Featured Product Release: FRANKLIN ELECTRIC C1 Series Clean Water Cistern Pumps

Pumping Trends 56 The Communication Problem in

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

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JAMIE WILLETT Circulation [email protected]

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

RANDY MOON Account Executive

DERRICK MURPHY Account Executive

Terry BellDrives and Motion Solution EngineerBaldor Electric Company

Heinz P. Bloch, P.E.Consulting Engineer,

Process Machinery Consulting

Robert G. HavrinDirector of Technology,Centrisys Corporation

Michael ManciniConsultant and Trainer,Mancini Consulting Services

John M. RoachEngineering Manager

for New Product Development,Trebor International, Inc.:

A Uni t of IDEX

Lisa RoeBusiness Development Manager,Wastewater Pumps Xylem Inc.: Flygt

Greg TowsleyDirector of Regulatory andTechnical Affairs, Grundfos

Trey Walters, P.E.President, Applie d Flow Technolo gy

EDITORIAL ADVISORY BOARD

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INDUSTRY news

ASHRAE SEEKS PRESENTATIONS

FOR DEVELOPING ECONOMIES CONFERENCE

Presentations are being sought for a conference focusedon the design, construction, and operation of buildings indeveloping economies. Organized by ASHRAE along with thePhilippines Chapter, the Efficient, High Performance Buildingsfor Developing Economies Conference will take place April 24

through 25, 2014, in Manila, Philippines. It is co-sponsored bythe Air-Conditioning, Heating, and Refrigeration Institute (AHRI)and endorsed by the International Association of Plumbing andMechanical Officials (IAPMO).

Call for presenter proposals are due January 31, 2014. A400-word abstract addressing a specific topic and speakerbackground information are required. Presentations of casestudies, preferably with actual performance data, are of mostinterest. Notifications will be issued in February 2014.

The conference addresses the challenges developing countriesface in sustainable construction, such as rapidly growing energydemand, population density and urbanization, and focuses onaspects relating to design, construction and operation of highperformance buildings, including the HVAC&R industry’s role in

meeting this objective.The conference seeks to bring people from diverse cultures

and climates together to share building design approaches thatare responsive to local needs, says Ashish Rakheja, conferenceco-chair. A key motivation behind the conference is to uti lizetraditional construction practices. “The papers and presentationwill provide examples of how to apply the latest technology toachieve cost effective solutions to support high performancebuildings in developing economies.”

Papers are sought on the following themes: design criteriafor developing countries (hot and humid climates, thermalcomfort preferences and cultural expectations, impact ofthermal design criteria on energy use and occupant well-being), indoor air quality (impacts of outdoor air quality issues,potential application of natural ventilation), energy ef ficiency(indoor environmental quality constraints on energy efficiency,

reductions in emissions of global warming gases through use ofrenewable energy, energy impacts associated with water use),standards and government regulations (green building programsin developing countries, energy efficiency standards, indoorair quality and comfort regulations), refrigeration (refrigerants:limitations and opportunities, applications, e.g. improved foodpreservation), and rural communities (water use, lack of energyinfrastructure, combustion using low-grade fuels).

In addition, presentations based on papers and invitedspeakers from around the world will focus on the most criticalchallenges facing developing economy countries.

ALL-FLO INTRODUCES NEW PRODUCT LINE

All-Flo Pump Company is launching a new line of air operated

diaphragm pumps that will raise the bar on efficiency standardsacross the industry. The new line of innovative, stainless steeland aluminum pumps rolled out in December. For use in a widevariety of chemical and fluid transfer applications, the newair operated diaphragm pump line offers an extended set ofimproved features over legacy products.

Most notably, the newly designed All-Flo pump boasts a new,high-efficiency, air valve, built with fewer parts, making it themost air efficient pump in the industry.

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INDUSTRY news

“After initial testing, we can confidently say that our newline will be the industry’s most efficient air-operated diaphragmpump line available,” says Paul McGarry, All-Flo sales andmarketing manager for North America. “For customers runningour 2-inch pump, they could realize greater than 50 percentsavings in annual operating costs.”

This significant cost-savings comes at a good time for

customers. According to the Bureau of Labor Statistics, the priceof electricity hit a record high for the month of October, makingOctober the eleventh straight month when the average price ofelectricity hit or matched the record level for that month.

“With Americans now paying 42 percent more for electricitythan they did a decade ago, reducing operating costs for thecustomer was at the forefront of our minds when we designedour new line,” says McGarry. “Our team of experts spent atremendous amount of time engineering this new pump toensure it led to significant savings for our customers.”

INTERGRAPH LAUNCHES

INTERGRAPH GEOSPATIAL 2014

Intergraph® has launched Intergraph Geospatial 2014, a

comprehensive portfolio of industry-leading technologies.Building upon the foundation introduced in 2013, this releaseprovides enhanced analytical tools, mobile support andtremendous cost savings associated with managing big data.

With an ongoing focus on a fully united, modern anddynamic product portfolio, this powerful release synchronizesthe technologies across all Intergraph product lines, broadeningthe reach and availability for fully integrated solutions for allusers of geospatial information.

“As today’s organizations require the most dynamicgeospatial solutions for driving enhanced decision-making,we are excited to share this release, introducing new mobility,analytics and big data management tools,” says Mladen Stojic,president, Hexagon Geospatial. “We are also continuing todevelop creative and intuitive interfaces, smarter workflowsand automated technologies that support the entire geospatial

information lifecycle, transforming multi-source content intodynamic and actionable information.”“Many organizations must quickly understand and make

sense of massive volumes of geospatial data. In addition,there is a growing need to integrate mobile and analytics intothe cloud. Thoroughly understanding these requirements, wecontinually evolve our products to best meet these needs,further unleashing the power of geospatial data management fororganizational effectiveness,” adds Stojic.

HARTZELL AIR MOVEMENT OPENS OKLAHOMA

SALES REPRESENTATIVE OFFICE

Hartzell Air Movement is pleased to announce that AiretechCorporation is now their new sales rep office in Oklahoma.

Airetech Corporation has been in business since 1985. Thesales rep office currently sells products into commercial andindustrial markets. Their knowledge in selling dampers andlouvers will help create an easy transition into selling Hartzellindustrial fans. Principal of Airetech Corporation, Chad Smithstates, “We are excited about the addition of Hartzell to ourproduct line because it allows us to provide a complete solutionto our customers in the heavy commercial and industrialmarkets.”

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INDUSTRY news

Oklahoma provides both commercial and industrial marketsfor Airetech Corporation, specifically in the petrochemicaland wastewater industries. Chuck Abramson, director of salesat Hartzell Air Movement explains, “Airetech is a good fit forselling the Hartzell product line because of their knowledge andhistory of the ventilation applications in Oklahoma. They havea strong sales team, dedicated to providing quality solutions for

their customers.”Hartzell Air Movement is a leading manufacturer of industrialair moving solutions to a variety of markets throughout theworld. The company manufactures in Ohio, Indiana, andSingapore. Hartzell has been in business since 1875.

HAYWARD FLOW CONTROLEXPANDS CANADIAN PRESENCEHayward Flow Control announces the expansion of itsoperations and presence in Canada. Effective January 2014,Hayward Flow Control will be operating from the HaywardCanada facility, located in Oakville, Ontario. The 200,000square-foot warehouse and office facility currently houses theHayward Canada Residential and Commercial Divisions. This

facility will now also headquarter the following Flow Controlactivities for Canada: Customer Service, Technical Service,Valve Automation Services, Full-Line Product Warehousing, andSales and Marketing Support. The increased presence will allowHayward to expand its product offering and distribution for theCanadian market. Additionally, to further improve our industry-leading customer service support, Hayward Flow Control willnow feature bi-lingual (English and French) Customer ServiceRepresentatives located in the Oakville facility.

POSITIVE TRENDS CONTINUEFOR EQUIPMENT LEASINGThe Equipment Leasing and Finance Association’s (ELFA)Monthly Leasing and Finance Index (MLFI-25), which reportseconomic activity from twenty-five companies representinga cross section of the $827 billion equipment finance sector,showed their overall new business volume for November

2013 was $6.6 billion, up 3 percent from new businessvolume in the previous year. Month-over-month, newbusiness volume was down 13 percent from October. Year todate, cumulative new business volume increased 5 percentcompared to 2012.

Receivables over thirty days were at 1.8 percent, up slightlyfrom 1.5 percent in the previous month. Delinquenciesdeclined from 2 percent in the same period in 2012.Charge-offs declined to once again match the all-time lowof 0.3 percent from 0.4 percent the previous month. Creditapprovals totaled 76.5 percent in November, a slight decreasefrom 77.6 percent the previous month. Forty-seven percentof participating organizations reported submitting moretransactions for approval during October, a level more in line

with previous months’ activity after a spike to 82 percentlast month. Finally, total headcount for equipment financecompanies was up 1.4 percent year over year.

Separately, the Equipment Leasing and FinanceFoundation's Monthly Confidence Index (MCI-EFI) forDecember 2013 is 55.8, a decrease from the Novemberindex of 56.9, reflecting industry concerns over uncertaintyregarding capital expenditures (capex) and competitivemarket pressures in 2014, among other issues. ■

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The Gasket Fabricators Associationstrives to help its membersbe innovative, profitable, and

successful by aligning them with fellowprofessionals who can support and servetheir business needs. In addition toregular and significant member forums,the GFA also sponsors the bi-annualGasketing/Converting Expo, which hasquickly become a “must attend” industryevent with large numbers of suppliersand attendees. It’s an easy and cost-effective way to meet the best currentand potential customers—and learn thelatest technologies and great ideas.

Held this March in Orlando, Florida,the Gasket/Converting Expo ‘14 is aunique and valuable opportunity forfabricators and suppliers alike to developand strengthen profitable relationships.Presented by the GFA and co-sponsored

by the Fluid Sealing Association(FSA), the International Association ofDiecutting and Diemaking (IADD), andthe International Sealing DistributionAssociation (ISD), the Gasket/ConvertingExpo ‘14 is the place to get answers,ideas, and opinions to help attendeesstay ahead of the curve.

NEW FORMAT

FOR BREAKOUT SESSIONS

In an effort to bring the latest technicaland industry information to attendees,the Gasketing/Converting Expo ‘14 will

presented by

GASKETING/

CONVERTINGEXPO 2014Answers thatare ahead of the curve


TRADE SHOW prof ile

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JANUARY 2014 | 11www.modernpumpingtoday.com

feature a series of targeted sessions on topics that directly impactthe gasketing and converting industries. Industry leaders willexplore and lead in-depth discussions on topics such as:

• Adhesives• Innovation• Innovation in equipment•

Innovation in materials• Key performance measurement metrics• Social media

Attendees will not want to miss this opportunity to receivetimely and relevant industry information that may help themsolve a problem or develop their next big idea.

Previous Gasketing/Converting Expos typically had two largetechnical sessions, but at the Expo ‘14, these will be replacedwith multiple smaller breakouts sessions that will be heldthroughout the day while the exhibit hall is open. Sessions for theupcoming Expo include: “Innovation” led by 3M, “Innovation ofEquipment” led by Associated Pacific Machine Corp., “Innovationof Materials” led by Teadit N.A. and Canada Rubber Group, and

“Adhesives” led by Adchem Corp. and Adhesive Applications.Non-technical sessions will be available as well.

HOTSPOT FOR INNOVATION

A wide array of exhibitors from manufacturing, materialhandling, tooling, converting equipment, and quality inspectionservices help make the Gasket/Converting Expo ‘14 the place tobe for professionals looking to solve a problem or develop thenext big idea. Attendees already familiar with the easy access tointelligence, research, and the latest technologies through theGFA’s technical webinars and expert presenters will find the samehigh-level expertise available at this year’s event in Orlando.

GO MOBILE

For the first time, attendees will be able to use a mobile appto find their way and keep their schedules for the Gasketing/ Converting Expo. With the GFA’s focus to stay ahead of the curvewhen it comes to the use of technology, this app will certainlyhelp with that goal. The app will be available for all attendees todownload, and will have a number of features to help attendeesget the most out of the Expo.

NETWORKING IN A RELAXED ATMOSPHERE

Professional networking is serious business at the Gasket/ Converting Expo ‘14, but it doesn’t have to be a somber affair.Several hosted events during the exposition allow attendees andguests to relax and discuss the trending topics of the industry in a

casual, low-pressure atmosphere. The GFA has reserved poolsidemeeting areas on Thursday afternoon exclusively for attendees ofthe Gasketing/Converting Expo. The area will serve as a meetingplace for attendees who are not planning to partake in otheractivities to gather and network informally. Reserved tenniscourts are also available, welcoming players of all skill levels.

The Gasketing/Converting Expo features a cost-effectivetabletop display format that allows suppliers to haveunprecedented exposure to gasket fabricators and converterswithout having to arrange for elaborate displays and logistics.Attendees enjoy a unique and valuable chance to meet with bothnew and existing suppliers. You do not want to miss this one-of-a-kind opportunity to network and conduct business with gasketindustry professionals. ■

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CASE Studies

When aMinnesota-based

manufacturer wantedto fabricate anexpansive array ofmaterial handlingproducts—includingscrew conveyors,screw feeders, andbucket elevators fortheir global clientbase yet also expandits own capabilitiesas a job shop for theirlocal customers, theyturned to Jet Edge tofind the right tools forthe job.

Laser-cut partsoften prove tooexpensive to bepractical investments,but today’s waterjetsare proving they arepowerful enough for

metal cutting and alsoprecise enough for softer materials. Also, although waterjetcutting is a process many manufacturers are familiar with fromcontracted or outsourced jobs, Jet Edge has been making thesetools affordable for a range of industries to bring on-site, wherethey can find greater productivity in their shops as well asgreater quality in their parts.

IT PAYS TO PAY

ATTENTION

Anderson-CraneCompany, a worldleading materialhandling equipmentmanufacturer, hasinstalled a Jet Edgewaterjet cutting systemat its fabricationfacility in Litchfield,Minnesota. With itsnew waterjet system,Anderson-Craneis now capable ofcutting complexfinished-quality partsfrom virtually anymaterial. Anderson-Crane Companymanufactures a widevariety of materialhandling equipment,including screwconveyors, screwfeeders, and bucket

elevators, specializingin custom projects. Anderson-Crane conveyors are used aroundthe world to move everything from chocolate to taconite. Thecompany also fabricates hoppers, bins, and gates.

In addition to manufacturing its own products, Anderson-Crane operates as a local job shop, building structuralequipment for local businesses and molds for the plastics

Nancy Lauseng is the marketing manager for Jet Edge, a global designer and manufacturer of waterjet systems forprecision cutting, surface preparation and coating removal. For more information about Jet Edge, visit www.jetedge.com,or call 800.JET.EDGE (538.3343) or 763.497.8700. For more information about Anderson-Crane Company, visit

www.screw-conveyor.com or call 800.314.2747 or 612.359.3535.

About The Author

By Nancy Lauseng, Jet Edge

Increase

Productivity,

Improve QualityMinnesota manufacturer fabricates wide range

of material handling products

Anderson-Crane’s Jet Edge Mid Rail Gantry waterj et system feature s an 8 foot by 13 foot (2.4 meters by 4meters) work envelope and SigmaNEST® Companion CAD/CAM nesting software to maximize material usage.It is powered by a 60,000 psi, 50 horsepower Jet Edge iP60-50 waterjet intensier pump. The system featuresan eco-friendly Ebbco closed-loop water ltration and chillingsystem that prolongs waterjet component life andreduces water consumption and sewage fees by recycling water. (Photo courtesy Anderson-Crane Company)

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industry. It also offers metal repair services. Founded in 1950 asan offshoot of its Minneapolis-based sister company Anderson-Crane Rubber Company, Anderson-Crane Company has beensteadily growing its fabrication facility and capabilities formore than sixty years.

Company spokesman Rob Crane attributes his company’sgrowth and customer loyalty to its commitment to qualityand its expertise in manufacturing custom material handlingequipment.

“Anderson-Crane has become recognized as a leader inquality in the material handling business, delivering productswith a very high attention to detail and finish,” Crane says.“We have decades-long customers that include Fortune 500companies and major multi-nationals. We pay very closeattention to our products’ fit and finish, assuring all dimensionsare precise and weldments are cleaned. Customers call onus when they have a special conveyor design that can’t befound in a catalog. We treat our customers’ projects as unique

#304 stainless steel screw conveyor trough flanges and round inlet and dischargeflanges. They are all ¼ inch (6.35 millimeter) thick. (Photo courtesy Anderson-CraneCompany)

These parts are now always cut on the waterjet, and go straight from the waterjet tableto the welding production line with no cleanup in between required. (Photo cour tesy

Anderson-Crane Company)

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CASE Studies

equipment that deserves close attentionto detail and quality.”

PRECISION MATTERSThis meticulous attention to qualityis what compelled Anderson-Craneto install a precision waterjet cutting

system, Crane notes. Before installingits water jet, the company had been

cutting parts on a CNC plasma machineand outsourcing work to waterjet shops.

“Due to our high demand forquality, we have spent a lot of timecleaning parts that come off our plasmamachine,” Crane recalls. “We decidedto buy a waterjet because of its clean

cut; our goal is to reduce rework andpart cleaning time. We wanted a

system that cut parts with little or noedge cleanup required. A laser provedtoo costly and a waterjet allowed us tocut metal (our main working material),but also softer material such as gasket.We had been outsourcing waterjetcutting and were always satisfied with

the edge quality and easy assemblyof its finished parts. With the waterjetwe’re able to move from raw materialto finished parts in as little time aspossible while improving our products’quality and precision.”

Anderson-Crane’s new waterjetcutting capabilities will help thecompany maintain its competitive edge,Crane adds.

“Manufacturers in the materialhandling industry do not focus onthe same level of quality as we do,”he says. “Adding a waterjet to our

fabrication process set the quality bareven higher. Our goal is to minimizethe time it takes to go from raw materialto assembly. As we implement this,we’re striving to consistently deliver aproduct with outstanding quality. We’resetting Anderson-Crane even furtherapart in an industry where quality andworkmanship are often afterthoughts.”

A UNIQUE BENEFITIn addition to improving its ownproducts, Anderson-Crane also plans togrow its job shop business by offeringwaterjet cutting services. It plans to cutprimarily mild and stainless steel andoccasionally rubber gasket and UHMW.

Anderson-Crane’s Jet Edge Mid RailGantry waterjet system features an 8foot by 13 foot (2.4 meters by 4 meters)work envelope and SigmaNEST® Companion CAD/CAM nestingsoftware to maximize material usage.It is powered by a 60,000 psi, 50horsepower Jet Edge iP60-50 waterjetintensifier pump. The system featuresan eco-friendly Ebbco closed-loop

water filtration and chilling system thatprolongs waterjet component life andreduces water consumption and sewagefees by recycling water.

Anderson-Crane decided to buy itswaterjet specifically from Jet Edge for avariety of reasons, Crane notes.

“Jet Edge’s proximity to our shop is aunique benefit,” he says. “Being closeto the manufacturer for support andtraining is important to us. We alsowanted a dual gantry des ign, whichwe see as a more robust design thancantilever models offered by otherwaterjet firms.” ■

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CASE Studies

Low pressure sewer systemsusing semi-positivedisplacement grinder pumps

have been employed extensivelyto provide central sewer serviceto areas where gravity sewercould not be installed andto provide a solution for therenewal of failed gravity systems.

A low pressure sewer systemconsists of a network of smalldiameter pressure pipes andindividual pumping units thatconvey wastewater directly toa treatment facility or centralsewer. Developed more thanforty years ago, low pressuresewer systems have a large bodyof well documented experiencesthat show dependable operation,long term reliability, and lowerlife-cycle and social costs whencompared to gravity sewers.

The primary component of alow pressure sewer system is a

grinder pump station installedat each individual property inthe system. The grinder pumpstation collects the wastewater,grinds the solids into smallparticles, and discharges it tothe pressurized pipe network.

Because the system is closed andpressurized, the grinder pump iscapable of transporting sewageover two miles, dependingon the topography and othersystem parameters. The pumpunit is generally smaller than ahousehold washing machine.Because it does not rely ongravity flow, the system providesmore options and flexibility forsiting.

Several manufacturers offergrinder pumps for low pressuresewer systems with a semi-positive specifically designedfor household wastewaterapplications in low pressuresewer systems.

In addition to allowing forthe passage of the ground solidswithout clogging, the geometryof a semi-positive displacementpump produces a nearly verticalpump curve. The flow from the

pump is generally constant,and is somewhat independentof the pressure in the system.In practical terms, the pumpcharacteristics means that,unlike a system using centrifugalpumps, when a semi-positive

Keith McHale, P.E., is a professional engineer with more than twenty years of experience in wastewater collection and treatment,including gravity and pressure sewer design, and infiltration and inflow (I/I) evaluations. Keith is the I/I project manager forEnvironment One Corporation. He holds a BS in civil engineering from the University of Massachusetts at Amherst and is amember of WEF and NEWEA. For more information about E/One products, call 518.346.6161, email [email protected], or visit

www.eone.com/sewer.

About The Author

By Keith McHale,

Environment One Corporation (E/One)

G rinder Pumps for

Sewer RenewalA new best practice for solving

infiltration and inflow issues

The model DH071 grinder pump station from E/One Sewer Systems,a popular model for single-family homes.

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displacement pump is activated, itwill deliver essentially the same flowrate, no matter where the operatingpoint is within the allowable range ofoperating pressure.

The choice of the semi-positivedisplacement principle was made with

input from the ASCE Staff and SteeringCommittee more than forty years agobased on these irrefutable hydraulicfundamentals. The development ofthe wastewater pump began withno vested interest in any particulartechnology, so the developers werefree to start from the “ground floor”and devise a unique class of pump,tailored in every respect to the specificneeds of pressure sewer systems.

In evaluating the equipment foruse in pressure sewer systems, thedesigning engineer should begin with

two main choices: first, select thepump characteristic (H–Q curve),either centrifugal or semi-positivedisplacement; second, select theequipment manufacturer based onadditional pump characteristics,including:

• Performance features• Reliability and track record in the

“field”• Ease of installation• Serviceability• Preventive maintenance

requirements• Real estimates of operating and

maintenance costs• Initial cost• Life-cycle cost

LOW PRESSURE FOR SEWER

RENEWAL

Most central sewer systems installedin the past use gravity as the movingforce to transport wastewater totreatment facilities. Most systems,however, cannot convey the

wastewater solely by gravity. Gravitysewers may not always be the bestchoice of a new or rehabilitatedcentral collection system because ofterrain, soil type, groundwater, andother factors. Excessively hilly or flatterrain requires deep excavationsand large pump stations. Lowpressure sewers using semi-positivedisplacement grinder pumps can bea cost effective solution to sewerrenewal.

Over time, gravity sewers fail. Rootintrusion, pipe cracks, joint failures,

and other deficiencies allow excessivegroundwater and stormwater to enterthe system. Referred to as infiltrationand inflow (I/I), this excessive flowhas detrimental environmentaland economic effects on theoverall operation of the wastewatercollection and treatment system.The excess flows, or essentiallyclean groundwater and rain water,can quickly overload the collectionsystem capacity, resulting in sanitarysewer overflows (SSOs), backups ofraw sewage into basements, and highoperating costs and equipment weardue the transport of the excessiveflows.

Limiting the amount of I/I insewer systems through infrastructure

renewal measures provides manyeconomic, social, environmental, andpublic health benefits. Renewal ofthe collection system infrastructureincludes options to return thesystem to an acceptable level ofperformance. Repair, rehabilitation,

and replacement are a progression ofthe activities employed to address andrenew failing infrastructure. Sewerreplacement is an extensive approachto infrastructure renewal. Replacementinvolves the complete abandonmentof the existing sewer pipe andthe installation of a new pipeline.Unlike replacement with a gravitycollection system (replace in kind) thereplacement of a failed gravity sewerwith a low pressure sewer systemusing semi-positive displacementgrinder pumps can be viable and cost

effective option.Using small diameter pressurized

pipe buried just below the frontline,a low pressure sewer system canbe installed with low impactexcavation techniques or with

Grinder pumps are typically installed outside of each home onthe pressure sewer system. Only the access lid and alarm panelare visible to the homeowner.

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CASE Studies

trenchless directional drilling methods.Additionally, a low pressure systemeliminates essentially all excessiveflows over the entire service life of thenew system. Repair and rehabilitationmethods used in sewer renewal canachieve limited I/I reduction. Because

the wastewater in low pressure sewersystems is pumped under pressure

through flexible sewer pipe, manholesare not required to change thedirection or alignment of the mainlinesewers. This eliminates the needto maintain and rehabilitate theseancillary structures.

Low pressure sewer systems used

to replace failed gravity sewers canprovide a complete sewer renewal with

fewer disturbances to the communityand have minimal environmentalimpact. Based on more than fortyyears of project comparisons, typicalcapital costs for low pressure sewersystems repeatedly range from 40 to80 percent lower than gravity systems.

This low capital cost advantage i senhanced by the lower social costsincluding less business disruption,traffic disruption, damage to adjacentsurfaces, structures, and utilities, andnoise and dust pollution, low pressuresewers provide.

CASE STUDY: ELWOOD, KANSASElwood, Kansas, sits in the northeastcorner of the state, just across theMissouri River from the city of St. Joseph, Missouri. It’s a residentialand light commercial town built onalluvial sand soils deposited overthousands of years. The gravity sewersystem was barely functional becauseof the groundwater infiltration in thedeeply dug system, 15 to 20 feet (4.6to 6 meters) in some places. Nine liftstations kept groundwater out of thesystem. Manholes and sections of mainwere constantly sinking.

The town suffered a devastating floodin 1993. Following an unusually largesnowpack over the winter, wet weathercontinued throughout the spring,

saturating soil and elevating riversand streams well into the summer.Storms dumped heavy rainfall acrossKansas—amounts achieving 75- to300-year frequencies produced recordflooding on the upper Mississippi andlower Missouri rivers. Levees protectingElwood were breached, and theentire town was washed out. The soft,sandy soil became a porous, shiftinghydrography that destroyed manystructural foundations and the gravitysewer system.

The Federal Emergency ManagementAgency (FEMA) helped Elwood dig

Gravity sewer main in need of repair.

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out and patch up its severelycompromised sewer. Withfunding from FEMA, the entiresystem was videotaped andshown to be nearly beyondrepair. At this point, planswere laid to rebuild with a

more sensible solution for thisvulnerable area.Instead of installing another

gravity sewer system, the citydecided to use LPS. Other townsnearby had used the system withgreat success. The flat topographyand soil type further made thecase against a gravity system. Thenew sewer system was installedin two phases. The first phase,installed in 2004, consisted of245 grinder pump stations. Thesecond phase, completed in

2008, added another 139 grinderpump stations.

The gravity system had requiredextreme depths to maintain adowngrade. This, in turn, createdgroundwater inflow problems thatled to mains collapsing, manholessinking and sections of roadwayssinking. A constant repair requirement

accompanied the system and was aconstant strain on the Public WorksDepartment budget. With nine liftstations pumping groundwater inflow

around the clock, a breakdown ofa single station had a catastrophiceffect, as the entire system thenbacked up.

Due to this constant operation,Elwood’s lift stations wore outquickly. Between the electricity

to run the lift stations and therepairs, the old gravity systemwas literally sending moneydown the drain. With the pressuresewer system, the grinderpumps run for shorter durationand the closed system doesn’tallow groundwater infiltration,eliminating collapses ofroadways, mains, or manholes.

CONCLUSION

As existing infrastructure inthe United States ages, many

communities are replacing theirgravity sewer systems with lowpressure systems. A grinderpump- driven LPS is a viable andcost-effective alternative to I/I

challenges. The right pump and a well-designed system mean elimination of I/Iresulting in lower operating costs, anda satisfied and secure customer base. ■

Grinder pump station installed outside of a home.

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Moundsville, West Virginiais a small city locatedalong the Ohio River. It

is home to sites like Prabhupada’sPalace of Gold and the retired WestVirginia State Penitentiary. Like anyother U.S. city, Moundsville is alsohome to a wastewater treatmentplant that actively supports thecommunity’s sewage treatment

needs. The plant mainly goesunnoticed—a sign that it is doingits job well.

However, problems do ariseand when they do, Moundsville—like many cities—must address

them with one eye on performanceand the other on their budget. Whenthe Moundsville Wastewater TreatmentPlant in West Virginia chose not to fix abroken blower unit, but rather to correctan outdated approach, the result was asavings of $50,000 to $60,000 a year inenergy costs.

IDENTIFYING

WHAT’S REALLY

BROKEN

When theMoundsvilleWastewaterTreatment Plantexperienced a blowerfailure, they naturallyassumed they shouldrepair the failed unitto keep their system design intact. At

the time, two 75 horsepower centrifugalblowers fed air to the plant’s fouraeration tanks and a third centrifugalblower unit served as a backup.

However, plant personnel quicklydecided to place the repair on

hold pending an evaluation of tankconditions. The plant had beenexperiencing a problem with pin floc intheir activated sludge operation, whichindicated a problem with dissolvedoxygen (DO) levels in the tank. Thestudies that followed revealed theDO levels varied from about 0.5 parts

per million to around 6.0 parts per

million in a day. These results indicatedthe microorganisms that break downorganic waste were dying in anaerobiczones at times during the day. At othertimes the DO levels were too high,meaning energy was being wasted.


WATER & WASTEWATER solutions

Stephen Horne is the U.S. product manager for Kaeser’s Omega Blower line, and has over ten years experience with thedesign and function of blower systems in wastewater aeration applications. Stephen has also served as Kaeser’s in-houseengineer for machine modifications and system design. He is a primary blower product and application instructor in Kaeser’sFactory Certified Training program. For more information on Kaeser’s solutions for wastewater treatment facilities and other

blower applications, visit www.kaeser.com/omega .

About The Author

Repair or Rethink . . .

WASTEWATER GLOSSARY

When too many solids collect in the wastewatersystem, the result is frequently pin floc —a

darker, gritty sludge particle that can hampereffective wastewater treatment.

By Stephen Horne,

Kaeser Compressors, Inc.

Kaeser blowers’ wide turn-down range and surge-freecharacteristics made them theright choice for Moundville’stank aeration problem.

Kaeser blowers’ wide turn-down range and surge-freecharacteristics made them theright choice for Moundville’stank aeration problem.

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INSTALLING THE NEW SOLUTION

Next, Moundsville staff back calculatedthe air requirements for the individualtanks. Their calculations supported anew solution: installing a DO sensor, a50 horsepower positive displacementblower, and a variable frequency drivein line to the secondary aeration tanks.The proposed air system was carefullydesigned to respond to real-timeconditions in the aeration tanks.

The DO sensor would constantlymonitor oxygen levels in the tanks andoutput a control signal varying between4-20 mA. The signal would then besent to the variable frequency drive.Finally, the drive would control the

speed of the blower by changing thefrequency of the motor power supply.This new air system called for qualitycomponents, including a Danfossvariable frequency drive and a Kaeserpositive displacement blower.

Plant personnel chose Kaeserbecause of the wide turn-down rangeand surge-free characteristics. Further,the blower’s power is almost directlyproportional to the speed in constantpressure applications such as tankaeration. After the selection of the newequipment, plant personnel put the planin place. Staff programmed the drive to

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WATER & WASTEWATER solutions

maintain a DO level of 2.2 parts permillion and a minimum of 40 percentblower speed.

SEEING THE RESULTS

After just four days of automaticallycontrolled DO levels, the pin floc issue

was gone. What’s more, the Kaeserblower and the Danfoss drive weresaving a lot of energy by operating athigh efficiencies and not producingexcess air. In just the first year, theMoundsville Wastewater TreatmentPlant saved about $24,000 in powercosts. Plant personnel went on toperform additional DO studies in thetwo remaining aeration tanks. Theydiscovered the levels were too high,indicating energy was being wasted.This time the plant installed a Kaeser100 horsepower positive displacement

blower with a Danfoss variablefrequency drive and two DO sensorsto control airflow to the two first-stagetanks.

The two original centrifugal blowersin working condition did not go towaste, but were incorporated into thesystem as backup units to provide 100percent redundancy. Moundsville’s

new system is saving approximately$50,000 to $60,000 per year in energycosts, plus they have much better

control of the effluent quality—a bigfeat for a treatment plant in a smallcity. ■

Moundsville Wastewater Treatment Plant personnel performed multiple dissolved oxygen (DO) studies in the aerationtanks. They discovered elevated DO levels, indicating inefficient energy use.

http://greatsouthernpump.com/http://naglepumps.com/http://gusher.com/

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MAINTENANCE solutions

Successfully maintaining a pumpsystem takes countless man-hoursand sizeable investment capital.

However, one of the most critical stepsin ensuring a pump operates at peak

efficiency and performance—pumpselection—can now be as easy as theclick of a button. Now entering itssecond decade, VSX–Vogel Softwareis launching the latest version ofits well established pump selectionsoftware: Spaix. The software hasbeen successfully used by nationaland international customers forseveral years. The new multi-platformconcept consisting of desktop-, web-and mobile-version is unique on themarket, giving pump users another toolin their quest to match the right pumpfor the right job.

HOW DOES SPAIX 4 PUMPS

WORK?

Spaix 4 Pumps is based on acompletely new technology which hasbeen tailored specifically to meet thedemands of the modern IT landscape.Above all, aspects such as internetsecurity and flexible authorizationmodels played a major role. Inaddition, the new Version 4 offersexisting customers as well as new

clients many interesting possibilities tofurther optimize their pump selectionand configuration processes and toadapt to current market conditions.

The user-specific product data thatis stored in the database program islinked practically with predefinedselection parameters and calculation

methods. As a result, pumps matchingthe specifications are displayed for theuser. For selecting the right pump theusers are offered different access pointssimilar to the previous versions, suchas hydraulic selection or the productselection browser.

HYDRAULIC SELECTION AND

PRODUCT CONFIGURATIONThe hydraulic selection enables thesizing and configuration of pumps asper predefined operating conditions,such as area of application, fluid, flowrate, and head. The Spaix 4 productrange supports the selection of severaloperating points for the first time, even

for different fluids. The sizing can bedone as a single pump or as a parallelor series connection of several pumps.In addition, the definitions of limits andsearch guidelines have been simplified,as these can now be compared directlywith the product features of individualcomponents. Specifically predefinedinput templates also make sizing

special pump systems easier—forexample, pressure booster systems,borehole pumps, or process pumps—without the template being overloadedwith entry fields for simple systems.

The product configuration supportsthe user in selecting available optionsand is done in several steps, whereby

Christin Kubon is a management assistant for VSX–Vogel Software, who specializes in software and Internet solutions forthe fluid handling industry and develops applications for sizing, selecting, configuring, and selling engineered systems and

components like pumps, valves, and pipes. For more information, visit www.vsx.net.

About The Author

By Christin Kubon, VSX–Vogel Software

Spaix 4 Pumps is a high-performance application for the computer-supported selection and configuration ofcentrifugal pumps. In addition, the s oftware provides valuable support throughout the entire sales process.

VSX’s multi-platform software, Spaix 4, gives voice to easier pump sales

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the program independently checkswhether the selected pump fulfillsall the entered criteria. The pumpperformance curves are convertedautomatically to the relevant operatingconditions by the software. For high-viscous Newtonian fluids the method

according to the latest standards of theHydraulic Institute (HI) from 2010 isused amongst others.

The program supports all commonprocedures for adjusting the duty point(impeller trimming, speed adjustment,throttling and many others). Theperformance curve optimizationprocedures can also be used formulti-stage pumps. The new featurehere is that for the performance curveoptimization using affinity laws variousmethods for depreciating the efficiencyare available.

SIZING OF SPECIAL PUMP TYPES

AND COMPONENTS

Spaix 4 Pumps has been considerablyexpanded and improved for theefficient sizing and dimensioning ofspecial pump systems. The softwareoffers the user a multitude ofcomponents, which can be used for theconfiguration process—for example,materials, shaft sealing, bearing frame,and coupling protection.

Specifically to highlight here are theconsideration of motor performancecurves, magnet coupling sizing, thetreatment of frequency converters aswell as the sizing of borehole pumps.The sizing of booster sets according toDIN 1988 is also newly integrated. Forelectronically controlled circulatingpumps, as are widely used in heatingtechnology, there is a calculationmodule that calculates the controlcurves from the constant speedcurves. As well as various technical

parameters, such as a power control,graphical aspects are also taken intoaccount.

FRICTION LOSS CALCULATION

MODULE SUPPORTS DUTY

POINT CALCULATION

With the optionally expandablefunctionality of pipe calculations

(additional Spaix PipeCalc module),the user also receives support indetermining the operating point. Onthe basis of defined parameters, theprogram determines the pressureloss for unbranched systems and thepump volume in accordance with

common international standards (forsewage and wastewater based on DIN

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MAINTENANCE solutions

EN 12056).The results areautomaticallyassumed for thepump selectionand calculationdata sheets are

integrated intothe currentproject.For pumpmanufacturers,it is noweven easier todefine typicalpipe systemswith the datamaintenanceprogram andconsiderablyspeed up the

recording of friction loss data by theselection program’s user.

OPTIMIZED PROJECT

MANAGEMENTAs part of the project management,quotes including detailed datasheetscan be compiled and supplied. Theprice calculator integrated into the

program can be flexibly adapted tothe requirements of any company.Prices are calculated as per theselected configuration including allcomponents and accessory parts andcan be displayed as an overall price oron the basis of single components.

Using dynamic product codes, theconfiguration is linked with the price

table and theitem numbers asapplicable. Asa result, clearidentifiers arecreated, whichare also used to

integrate externalprograms, suchas ERP systems.In order to beable to manageand supplythe prices fordifferent marketsSpaix works withuser group-specific pricegroups. Variouscurrencies aresupported and

it is also possible to convert usingthe currency exchange rate. With anadditional module it is possible todisplay the product availability throughenabling delivery times on the quote.

By using special interfaces projectdata can be transferred to externalprograms such as ERP and CRMsystems for further editing.

CHECKMATE.Our spring loaded check valvesare assembled to your exactneeds, ensuring absoluteprecision and reliability. Theywork like they should. That’swhat makes Check-All the onlychoice. Plus, most lead timesare less than one week.Count on the king.

Manufactured in West Des Moines, Iowa, USA•

515-224-2301•

www.checkall.comGet me a Check-All.

When it comes to checkvalves, Check-All is king.

S I N C E 1 9 5 8

Calculation of operating and life cycle costs: consideration of different load profi les, graphic and tabular display of the cost comparison.

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EXTENDED

USER

MANAGEMENT

AND

PERMISSIONS

The usermanagement can

be organizedwith even moredetail in Spaix 4Pumps. Programfunctions, pricegroups, andproduct rangescan be managedand releasedappropriatelyfor differentuser groups. Anexpanded userauthorization

system makes it possible toaccurately allocate rights to usergroups.

RELIABLE AND FLEXIBLE DATA

MAINTENANCE

The data maintenance programis a versatile piece of softwareto maintain the entire database

and influence the functions of theselection program. The personcreating the data decides whichparts of the program are availablefor which products and which users.The modular concept guarantees aminimum amount of data redundancyand displays different productstructures.

KEEP UP WITH

CURRENT

MARKET

CONDITIONS

In Spaix 4 Pumpsthe calculationof the energy

efficiencyindex (EEI) andthe minimumefficiency index(MEI) is integratedin accordancewith the currentEU guidelines.Through theongoing updatingof the guidelinescompanies canreact properly oncurrent and future

framework conditions in the economicenvironment.

In addition, Spaix 4 Pumps offers thecalculation of operating and life cyclecosts whereas various load profiles canbe taken into consideration dependingon the use. The cost comparison of thevarious solutions is shown clearly ingraphic and tabular format.

■

The database maintenance program is a multifaceted software to maintain the complete databaseand to influence the functionalities of the selection program.

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PUMP solutions

B JM Pumps pr ides it self onsupplying the right pump fortough jobs. In the following case

study, a KZN submersible pump was thechoice for a very difficult pumping job.

The customer is the railroad spikedivision of a 100-year-old, fourth-generation, family-owned company thatemploys about 100 people. Based inAlabama, the parent firm manufacturesand sells overhead crane rail systemsand railroad products; sells new andused locomotive parts; and rebuilds

used locomotives for sale to U.S. andinternational markets. The spike divisionis one of only two U.S. companies thatmanufacture railroad track spikes; itproduces an estimated 36,000 spikes perday during busy periods.

THE CHALLENGE

Through three shifts per day, sevendays a week, the company’s foundryturns carbon-steel bars into 5 / 8 inchby 6 inch (15.9 millimeters by 152.4millimeters) rail spikes, which it sells to

Class I, regional and short-line railroadsas well as to contractors and industrialcustomers throughout North America.The spikes are precision forged to meetrigorous standards in specificationsand quality. The company’s twomanufacturing lines must run reliablyat optimum speed and efficiency todependably meet customers’ demandsfor large orders, high inventories, andquick turnaround.

During production, as hot, forgedspikes come out of a furnace, they

Suzette Gibson is the marketing coordinator for BJM Pumps, LLC. Headquartered in Old Saybrook, Connecticut, BJM Pumpshas been serving the industry since 1983 by supplying quality pumps at a modest price. For more information, call 877.BJM.

PUMP (877.256.7867) or visit www.bjmpumps.com.

About The Author

By Suzette Gibson, BJM Pumps

BJM Pumps provide solutionfor rail spike manufacturer

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are flash cooled by a blast of water; iron scale falls offthe spikes and collects, along with the water, in a sumpbelow each production line. Once a week, a plant workerformerly climbed down into the sumps—each about thesize of a desk and seven to eight feet deep—and shoveledthe iron scale out by hand. Depending on productionvolumes, this job took between a half-day and a full day

of tough, dangerous labor. The cost of this labor andthe risk to employees’ safety were unacceptable to thecustomer, which sought a better solution.

THE

SOLUTION

BJM’s industrialdistributorin Alabamabelievedthat the bestsolutionwould be forthe facility to

pump ratherthan shovelout the sumps.The salesmansaw a potentialapplicationfor BJM’sKZN Seriesheavy-dutysubmersibleslurry pump.Manufacturedof abrasion-resistant, high-chrome ironand featuringa hardenedwear plate,impeller andagitator, theKZN is idealfor handlingslurries thatcontainespecially

heavy solids such as mill scale, sand, gravel, and coal.The customer agreed to try a 7 ½-horsepower KZN55 for

thirty days.Because the scale was so heavy, a foundry worker used

a 4-inch (101.6 millimeter) diameter hose to blast waterinto the sump; the water jet and the KZN pump’s agitatorworked together to fluidize the scale, creating a slurrythat could be pumped out of the sump as the pump wassteadily lowered to the bottom. The entire process tookabout ten minutes instead of a half-day or more; the KZNwas moved as needed from one sump to the other tohandle both production lines.

Following the trial, the customer purchased the KZN,it has been running without problem for more than threeyears—having eliminated a dangerous manual processand generated benefits for the customer in labor andinsurance cost savings, safety, and production uptime. ■

KZN Series

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PUMP solutions

Pump system efficiency isinterlocked along with othersystem components within HVAC

systems. Evidenced by movements

in ASHRAE Standard 90.1,1 systemefficiency has moved to the forefrontwhen designing HVAC systems. As partof this movement, the design of endsuction centrifugal pump products hasadvanced to enable improved systemefficiencies. This design approach yields

significant benefits to the designers andoperators of HVAC systems for buildingsand facilities. Primary among theseenhancements are improved eff iciency

ranges offered by the newest designs.These efficiency improvements arebest described as enhanced Eff iciencyIslands. This paper describes theEfficiency Islands and how, from asystem perspective, these enhancementscan address new system efficiencies or

lead to the retrofit and improvement ofexisting systems.

EFFICIENCY ISLANDS

Let’s begin by describing what ismeant by the term Efficiency Island .Figure 1 shows the Island (shadedred) with boundaries of the maximumimpeller diameter performance, theminimum diameter performance andthe iso-efficiency lines (81 percent and

Christopher S. Johnson is the global engineering manager for centrifugal pumps in Xylem Applied Water Systems in thecommercial building and HVAC business unit, while also supporting the other business units with crossover products. He hasheld leadership roles in sales, application engineering, product management, global sourcing, global product development, and

engineering.

About The Author

By Christopher S. Johnson, Xylem Applied Water Systems

Efficiency Islands: What are they? How do they result in operating benefits?

PART 1 OF A 3-PART SERIES

eThe Power of

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Product A4 x 5 - 9.51770 RPM

Efciency Island of 81%and Above

CAPACITY

T O T A L H E A D

HI POR Range:70% to 120% of BEP

CAPACITY

T O T A L H E A D

Product A4 x 5 - 9.51770 RPM

Flow Width: GPM Range

Efciency Depth:Sustained Efciencyat Reduced Impeller

Diameter

FLOW RATE, GPM

H E A T , F T

System Curve

Inner Valves Closed

Outer Valves Closed

above in the illustration). This envelope lookslike and is thus called an Efficiency Island.As seen in figure 1, there are many EfficiencyIslands which make up the performance curvefor a centrifugal pump. For the best operatingperformance, it is desired to have these Islandsbe as wide and as deep as possible. Figure 2

demonstrates what is meant by width (in termsof flow rate) and depth (in reduced impellerdiameter) of these Islands. Figure 1 alsoshows the ANSI/Hydraulic Institute Standards2 Preferred Operating Range (POR) which isdefined as the flow range from 70 to 120percent of BEP. This is the optimal range forcentrifugal pump operation.

HVAC systems have substantial loadvariations (flow rates) depending on the loadprofile. Coupled with the load variations arethe head variations, which are dependenton the physical size of the system andcomponents within the system. One system

head curve does not represent the truesystem resistance against which the pumpmust operate. Previous work has identifiedboth lower and upper system head curves asapplicable in heating and cooling systems.3,4 An example of the upper and lower systemhead curves and the control area is shownin figure 3. The area between the upper andlower system head curves is known as thecontrol area (blue region). Pump operation canoccur within this zone, not just at the upperand lower boundaries or on a single systemcurve within the boundary.

As figure 3 illustrates, operation in a narrowband of flow and pressure requirementssimply doesn’t happen in the majority of thesesystems. So to provide efficient systems theEfficiency Islands need to be wide, deep andwith high efficiency levels. Narrow flow widthfor iso-efficiencies and rapid drop in efficiencyas the impeller diameter is reduced, are notdesirable to achieve the most efficient systemoperation.

When considering operation with aconstant speed drive to meet the variationsof a typical load profile, one can readilysee that control valve throttling moves the

pump on its curve and dissipates significantenergy – wasted energy and added operationalcost. To handle normal load profiles, avariable speed drive is preferred to enableload variations to be achieved with overallimproved system efficiency. Newer designsemploying enhanced Efficiency Islands enablethe engineer or operator to improve the systemefficiency using either fixed or variable speedpump operation.

MODERN HVAC CENTRIFUGAL PUMPDESIGN OBJECTIVESModern designs should utilize the mostsophisticated and cutting edge computational

Figure 3

Control Area Map with System Head Curves

Figure 1

Figure 2

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PUMP solutions

fluid dynamics design tools availableto achieve improvement of efficiencyin three aspects:• Higher efficiency levels• Wider efficiency ranges (from a

flow rate perspective) at constantdiameters

•

Sustain higher efficiency levels asimpeller diameters are reduced.

COMPARATIVE RESULTS

To examine how a modern HVACcentrifugal pump design improvesefficient operation, flow and efficiencycan be viewed from a slightly differentperspective; that of efficiency versusflow rate as a percentage of BEP withparticular emphasis on the HydraulicInstitute Preferred Operating Range.

The following illustrations willcompare the results of a modern

design effort to several current endsuction products in the HVAC market.The majority of the new product sizesfollow this example. The illustrationscompare Product A (4 x 5 – 9.5)performance to Product B (4 x 5 - 9.5)and Product C (4 x 5 – 9.25) at 4pole 60 Hz speed (1800 RPM). Moreconventional efficiency comparisons

are also provided, as well as operatingcost analyses for several heating loadprofiles and design conditions.

MAXIMUM DIAMETER

EFFICIENCY COMPARISONS

This comparison of maximumdiameter efficiencies is done using a

percentage of BEP flow. The HydraulicInstitute (HI) recommends a PreferredOperating Range (designated POR) as70 to 120 percent of BEP flow rate.This ensures a consistent comparisonis made among pumps with somewhatdiffering BEP flow rates. A comparisonof the actual HI POR flow rates for

Product A Product B

FLOW RATE, % OF BEP

E F F I C I E N C Y , %

Figure 4

Eff iciency vs Flow Rate as % of BEP

Product A vs Product B

Maximum Impeller Diameter @ 1750 RPM

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each competitor at maximum andreduced diameter is also provided.Figure 4 illustrates the efficiencyadvantage for Product A in the HI PORband compared to Product B. At thesame percentage of BEP flow, ProductA has higher e fficiency. At the sameefficiency level, Product A offers awider flow rate range.

Figure 5 compares the maximumdiameter efficiency of Products A andC. At the same efficiency, the range ofBEP flow is greater for Product A thanProduct C. For example, the flow rangeof Product C at 83 percent efficiency isfrom 90 percent of BEP to 113 percent ofBEP. The flow range for Product A at 83percent is from 78 to 115 percent of BEP.

A LOOK AHEAD

Xylem has redesigned the completeline of its best-in-class Bell & Gossett®

1510 pump—now called the Seriese-1510 brand—and the single stageend suction centrifugal pumpslaunched at the 2014 Air-Conditioning,

Heating, Refrigerating Exposition (AHRExpo).In part 2 of this series, we’ll

compare efficiency at maximum andreduced diameter impellers while alsoexamining the traditional view of flowversus TDH. The enhanced EfficiencyIslands that result from these testsfurther illustrate the advantages foundwith the power of “e.” ■

NOTES

1. ASHRAE 90.1 – 2010 Energy Standard forBuildings

2. ANSI/Hydraulic Institute Standard 9.6.3 –2012, Guideline for Allowable OperatingRegion

3. Simplified Analysis of Flow in Closed LoopHydronic Systems, Bell & Gossett TechnicalBrochure TEH-802P, August 2001

4. Variable Primary Flow Systems, Bell &Gossett Technical Brochure TEH-910, 2010

FLOW RATE, % OF BEP

Product A Product C

E F F I C I E N C Y , %

Figure 5

Eff iciency vs Flow Rate as % of BEP

Product A vs Product C

Maximum Impeller Diameter @ 1750 RPM

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In 1545, off the south coast of England, an invadingfleet of French vessels entered the Solent Channel,approaching the awaiting forces of King Henry VIII

and his flagship, the Mary Rose. The Battle of Solent wasunderway soon thereafter, a short and indecisive footnote inmilitary history that nonetheless claimed a famous casualty.After she unloaded one side of cannons on the Frencharmada, the Mary Rose turned around and was caught in anupending gust of wind. Reports at the time claimed that, inthe chaos and fury of the firefight, the lower gunports wereleft open, allowing water to rush into the hull and drag theMary Rose and roughly 400 of her crew to the bottom of theSolent, where she lay until discovered by British journalistand amateur diver Alexander McKee in the 1960s. However,the process of reclaiming and preserving this piece ofhistory would take many more decades still, and onlyrecently has one chapter come to a close.

PLAYING A CRUCIAL ROLEWhen a number of Moyno™ pumps were switched offrecently, it marked the end of a twenty-year operation topreserve the remains of an historic Tudor warship, the MaryRose. The progressing cavity pumps from Moyno™ havebeen used to help spray the fragile timbers of the Mary Rosewith a mixture of water and wax—a crucial stage in the

preservation process that has now come to an end.The race to preserve the remains of Henry VIII’s flagship

began after she was recovered from the bottom of theSolent, where she had lain since sinking some 430 yearsearlier. Moyno’s association with the ship began in 1994,when pair of industrial progressing cavity pumps werechosen for duty/standby roles to help spray the hullcontinuously with a solution of Polyethylene Glycol (PEG)to stabilize its waterlogged timbers. The pumps provided

a continuous stream of PEG to 360 spray nozzles locatedaround the ship, and were supported by four smaller Moynopumps, which operated the heating and cooling circuits thatmaintained the PEG at an optimum spray temperature.

EPSILON PROGRESSING CAVITY PUMPSThe Epsilon range of industrial progressing cavity pumpscombines proven pump technology with a number ofinnovative features designed to benefit the end user.Moyno’s experience, combined with an effective program

of customer feedback, has resulted in a range that hascharacteristics of reliabil ity, efficiency, and low operatingcosts.

Available in a choice of cast iron or stainless steelmaterials, the Epsilon range possesses a bloc constructionthat has reduced overall dimensions and can offer benefitswhen space restrictions apply. Other significant features ofthe range are the incorporation of Moyno’s PowerDriveTM transmission. The PowerDrive has proved its worth in many

34 | JANUARY 2014

PreservingMary Rose

www.modernpumpingtoday.com

DEWATERING solutions

Yvette Jacobs is the global marketing manager for NOV Mono, a global leader in the design and development of the

progressing cavity pump. Brands include Chimineer, Mono, Moyno, and Tarby. For more information, visit www.moyno.com.

About The Author

By Yvette Jacobs, NOV Mono

NOV MONO PLAYS

AN IMPORTANT ROLE IN

RESTORING HISTORICAL ARTIFACT

the

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Moyno applications where it reduces cost by eliminatingthe need for a double universal joint. With no wearingparts, the PowerDrive offers greater lifetime cost savingsover conventional drive train designs and extends intervalsbetween routine maintenance. This high pressure pump isreliable and efficient when handling abrasive materials,high viscosity fluids, and high head applications.

Epsilon has been developed thanks to a combinationof careful research and many years of experience ofMoyno pumps operating in various industries. Reliability,efficiency, and value for money are critical to ourcustomers, but so is simplicity. When the opportunity to re-design a popular E-series pump range presented itself, NOVMono was determined to make the Epsilon even easier toinstall and maintain.

RELIABLE PERFORMANCE UNTIL THE JOB IS DONEAfter ten years of operation when maintenance wasrequired on a gearbox, the Moyno pumps were alsoinspected and found only to need one stator componentreplacing. The pumps then returned to operating at speedsof 279 revolutions per minute, circulating 528 gallons(2000 liters) per minute of PEG solution around the spraysystem. Six additional Moyno Industrial E range pumpswere later added to increase the capacity of the heatingand cooling circuits.

“The ship’s timbers had to be kept fully moistened at alltimes, so the pumps used had to be totally reliable if thetimbers were to be properly preserved,” comments seniorsales engineer Mike Burton. “This project really has shown

Performance Data

Differential Pressure - PSI

C a p a c i t y G P M

C a p a c i t y G P M

Differential Pressure - PSI

0 87 175 3500 58 87

991

727

550

427

348

250

163

97

44

0

1850

1277

925

616

414

315

253

218

156

113

63

50

26

15

7

0

ModelSize

K Build

E1BK

E1AK

E19K

E18K

E17K

E16K

E15K

E14K

E13K

ModelSize

Number of Stages

Single Two Four

E1E

E1D

E1C

E1B

E1A

E19

E18

E17

E16

E15

E14

E1X

E13

E12

E11

how Moyno pumps can provide consistently high levelsof performance year after year and simply go on giving

excellent service.”Until she sank in 1545, the Mary Rose was one of the

largest ships in the English Tudor fleet. She is now theonly sixteenth century warship on display anywhere in theworld, and forms the centerpiece of a new £27million ($44million US) museum that has been built at PortsmouthHistoric Dockyard. The new museum also holds manythousands of the 19,000 Tudor artifacts that wererecovered along with the vessel. ■

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MOTOR solutions

Eddy current drives,known alternatelyas magnetic

drives or eddy currentcouplings, have beena trusted and reliablemeans of controllingpump speed dating backto before World War II.They enjoyed a periodof widespread growth inthe municipal water andwastewater treatmentindustries during the twodecades beginning about1965. The Clean WaterAct of 1972 fueled theexpansion of wastewatertreatment processing andsupplied federal fundingto municipalities facing

new requirements forbetter levels of wastewater treatment. During this period,eddy current drives were routinely selected for variable speedpumping applications, such as raw water pumps, return- andwaste-activated sludge pumps , effluent pumps, filter pumps,and various pumping stations where response to demandmade variable speed the best choice for process and energyconsiderations.

THE CASE FOR EDDY

CURRENT DRIVES

An eddy current dr ivecontrols speed byregulating a DC excitationcoil on a magnetic rotor,rotating concentricallywith a steel drum, drivenat by the motor at fullspeed, as illustrated infigure 1.

The “slip” between theinput drum and the outputrotor produces a “sliploss”, proportional toslip speed and the drivenload. Thus, the efficiencyof the drive, plotted asa function of speed,illustrates an approximateone-to-one relationship,

as shown in figure 2.Because a common reason for choosing variable speed is

to reduce energy consumption, this efficiency performancemay leave engineers and specifiers wanting something better.When variable frequency drives were developed and beganto gain a foothold in the market, they boasted efficiency wellin the 90s, across the entire speed spectrum. This promise ofbetter efficiency fueled a shift in the market thought to justify

Gary Patterson is a water and wastewater specialist for Dynamatic® / Drive Source International, owner of the Dynamaticbrand of eddy current adjustable speed drives, brakes, and controls. For more information, call 800.548.2169 or visit

www.dynamatic.com .

About The Author

By Gary Patterson, Dynamatic® / Drive Source International

A modern myth surrounding

EfficiencyDeficiency

eddy current drives

Figure 1

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preference of VFDs, even to the point of removing existingeddy current drives to achieve better energy performance.

CORRECTING MISPERCEPTIONS

OF EDDY CURRENT DRIVES

However, a comparison of efficiency exaggerates thedifferences and ignores associated losses not considered

in the calculation of VFD efficiency. It’s more instructive toexamine the losses in a system, as this is a truer indication ofenergy consumption and associated electrical costs.

A variable speed pump behaves according to well-known “affinity laws,” such that the load bhp decreases inproportion to the speed reduction cubed. When applyingthe eddy current drive efficiency to a centrifugal pump load

Figure 2: Eddy current drive efficiency versus output speed Figure 3: Eddy current drive losses when appliedto a centrifugal pump

0%

100%

90%

80%

70%

60%

50%

40%

30%

20%

10% 100%20% 30% 40% 50% 60% 70% 80% 90%

10%

PERCENT SPEED

0%

100%

90%

80%

70%

60%

50%

40%

30%

20%

10% 100%20% 30% 40% 50% 60% 70% 80% 90%

10%

PERCENT SPEED

V a l v e

C l o

s e d

V a

l v e O p

e nECD Efciency

Pump Load

ECD Loss

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MOTOR solutions

curve, the associated losses prove to be much lower thanone might expect, as shown in figure 3.

Figure 3 also il lustrates an often-overlooked fact: Thepump only operates above the speed necessary to overcomestatic head and produce a useful f low. This is usually nolower than 75 percent of rated speed; in this example, 80percent. If we expand the X-axis to include only the speed

range from 80 percent and above, we can approximate theperformance from zero to full flow, as in figure 4.

Figure 4 now includes published VFD efficiency andassociated losses, in order to compare for those of eddycurrent drives. Note that while efficiency still appears tofavor VFDs, the actual loss comparison is quite close. Theeddy current drive actually exhibits less loss than the VFDabove 90 percent flow.

However, most VFD installations include losses notconsidered in the efficiency calculation.

• VFD input harmonic currents induce losses in feeders,transformers and harmonic mitigation devices oftennecessary for the safe operation of the VFD. These lossesare usually impossible to quantify accurately, but resultin marginally higher kilowatt-hour usage nonetheless.

• In a similar manner, the output waveform of a VFD isnot purely sinusoidal. This causes additional losses toappear in the motor, which must be supplied by thesystem. These losses are also very difficult to isolate andquantify, but are generally acknowledged to exist.

• Many VFD installations require air conditioning orpowered ventilation to provide adequate cooling to the

VFD itself, which is sensitive to ambient temperature,due to the electronic nature of the equipment. Inaddition to the extra cost for this cooling equipment,the cost of powering the air conditioning is substantial.A rule of thumb holds that each 1 kilowatt of heat loadrequires 3 kilowatts of power.

ACCURATE COMPARISON AGAINST VFD DRIVES

When these additional losses are considered, the eddycurrent drive solution is as good or better than the VFD, asshown in figure 5.

These results have been demonstrated in actualinstallations. Figure 6 shows actual field results comparingeddy current drives and VFDs on identical pumps in thesame application.

Figure 4: Eddy current drive and VFD performancevs. percent flow

Figure 5: Comparing unreported VFD losses

0%

100%

90%

80%

70%

60%

50%

40%

30%

20%

100%25% 50% 75%

10%

PERCENT FLOW

0%0%

100%

90%

80%

70%

60%

50%

40%

30%

20%

100%25% 50% 75%

10%

PERCENT FLOW

0%

ECD Efciency

Pump Load

ECD Loss

VFD Published

Efciency

VFD Published

Losses

VFD Real Losses

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Most such comparisonswill exhibit a crossoverpoint where the VFD powerconsumption will exceedthat of the eddy currentdrive. Experience has shownthat above such a crossover

speed, the eddy current driveuses less energy than theVFD. In the illustrated case,average speed of operation tobe about 90 percent. Underthis condition, the customerestimates saving $7000 peryear in electrical costs.

LONG-LASTING,RELIABLE OPERATIONEddy current drives areacknowledged to beunfailing workhorses in

pumping applications.Many installations remainin service after nearly fiftyyears of continuous duty.Many others would probablystill remain, had they notbeen replaced by VFDs, in amisguided quest for “betterefficiency.” ■Figure 6: Eddy Current vs. VFD KW Usage for 500 HP 880 RPM Motor

Savings - kW difference x hrs x kW hour rate

@90% Speed-Efciency Difference = VFD kw - Eddy Current kW = 410 - 390 = 20 kW (from chart)

Yearly Savings (50% Running time @ $.08 per kwh) = 4380 HRS x .08 x 20KW = $7008

% Speed

K W U s a

g e

200.0

250.0

300.0

350.0

400.0

450.0

500.0

550.0

600.0

60.00% 70.00% 80.00% 90.00% 100.00%

VFDEddy Current

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POWER GENERATION solutions

The market for liquefied natural gas, or LNG, is onthe rise. And with the increase in demand comes acorrelating increase in innovation. Dresser-Rand recently

designed, constructed, and commissioned its first small-scaleliquefied natural gas plant, a demonstration plant that hasreached a keymilestone with theinitial productionof LNG. Extendedperformance andendurance testing isunderway. Dresser-Rand is alreadystocking plants thatare ready to shiptoday.

EXCITEMENTOVER LNG"We are veryexcited about this

technology forsmall-scale LNGproduction, whichallows for verysmall stand-aloneplants that are portable and can be moved to support changingrequirements and needs,” says Dresser-Rand president andchief executive officer Vincent R. Volpe, Jr. “The standard

LNGoTM plants are sized to produce approximately 6000gallons [22,712.5 liters] of LNG per day. There is substantialDresser-Rand scope potential in this offering including ournewly introduced MOSTM reciprocating compressor, Guascor® engines, Enginuity® control systems, and project management

to integrate allof these andthe processcomponents intocompact, portablepackages.

"Ourdevelopmentprocess began inearnest less thanone year ago,”says Volpe. “In thistimeframe, ourorganization hastaken the processand designed,

built, andcommissioned anentire plant. Thisdevelopment cycletime to market is

amazingly short, and is a tribute to our internal processes, aswell as to the men and women of our development team, andour Painted Post Operations.”

Charles Ely is the general manage r of distributed LNG solutions at Dresser-Rand, among the largest suppliers of rotatingequipment solutions to the worldwide oil, ga s, petrochemical, and process industries. For more information, visitwww.lng.dresser-rand.com or call 800.372.2608.

About The Author

By Charles Ely, Dresser-Rand

Time to LNGo TM

!Dresser-Rand’s first small-scale

liquefied natural gas plant hassuccessful start

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PRODUCTION OPTIONS FOR

SALE OR LEASE

Building on interest of over ninetyqualified leads, Dresser-Rand has beentalking to potential clients for severalmonths for commercial operation.Depending upon the nature of theapplication, these leads are broadlyclassified as plants that would either befor sale or for lease.

In the "for sale" category, Dresser-Rand would provide the liquefactionprocess and, depending upon theplant configuration, potentially also

include the associated ancillarygas processing equipment, a powermodule and full turn-key installationand commissioning. In the "rental"or "lease" space, the Dresser-Rand isevaluating several options, includingpotential market channel partners, andexpects that, over the coming weeks,it will determine which approach isexpected to be the most needed by themarket.

FULL TURN-KEY INSTALLATION

For all users, Dresser-Rand canprovide full turn-key installation and

commissioning services, as well asroutine operations, monitoring, andmaintenance contracts, to ensureongoing reliable and availableoperations.

"Now that we have produced LNGwith our demonstration plant, we are

in the enviable position of imminentmarket launch,” Volpe adds. "Given the

short cycle times that we embeddedinto our production plans, we believethat an

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