Modern Pumping - 072014

modern
todAY
Providing SoLUtionS for the WorLdWide PUmP indUStrY
IMPROVING
EFFICIENCY
IN CITY-WIDE
SYSTEMS
JULY 2014
CalCulating
PiPing losses
for PumPing
oPtimal
lift station
PumPing
solutions
Designing
formeD
DiaPhragms
for Peak
PerformanCe
ContentS
4
10
JULY 2014
industry news
trade Show Profile
Case Studies
12 Water Quality insights through

real time data
The LiquIDTM improves efficiency in poultry processing
16 improving efficiency and effectiveness

Across the Board
Schneider Electric completes energy retrofits to city facilities in Kirksville, Missouri
Water & Wastewater

Solutions
12
20 electronic Water treatment reduces

fouling in reverse osmosis
24 CiP guidelines for filter membrane
System Cleaning
maintenance Solutions
28 Know Your Pump Base Plate

installation options
Part 3 of a 3-Part Series
Pump Solutions
38
30 A revolution in Pumping eff icieny

All-Flo's A200 pump reduces energy costs, improves performance
Part 4 in a 4-Part Series
34 Calculating Piping Losses and their

effect on Pumping
dewatering Solutions
38 optimal Pumping for the Pleasure Pier

Lift Station
BJM submersible shredder pumps provide a reliable solution for the "Coney Island of the South"
motor Solutions
40 fish friendly Pumps go direct drive

Cam Pumping Station replaces diesel for improved efficiency
40
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266
Power generation
Solutions
42 Wr525 eliminates falures in

feedwater Pumps
Non-galling, non-seizing material saves company four to five million dollars
Processing Solutions
44 vAf Solves high volume river intake

for Canadian Paper mills
valves & Controls

Solutions
46 Wireless Controls for Use

in hazardous Locations
russell haDDoCk COO/Publisher

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Jeff fletCher Associate Publisher
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ranDY armisteaD Associate Publisher
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J. CamPbell Editor
jay@modernpumpingtoday.com
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sCott gorDon Art Director
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Chris garmon General Manager
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linDeY sCott Circulation Manager
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Sealing Solutions
48 designing formed diaphragms

for optimum Performance and
manufacturability
52
@modPumpmag
modern Pumping
Products
Jamie willett Circulation Consultant

jamie@modernpumpingtoday.com
ingriD berkY Administrative Assistant
nanCY malone National Sales Manager
tonYa browning Account Executive
Curtis frost Account Executive
ranDY moon Account Executive
Featured Product Release: MEGGITT SENSING SYSTEMS MachineryMate MAC050 and MAC100
Pumping trends
56 the Cutting edge
Flygt's Lisa Riles looks at the challenge facing municipal wastewater and a different type of solution
editoriAL AdviSorY BoArd

Terry Bell
Drives and Motion Solution Engineer

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

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

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

Technical Affairs, Grundfos
Trey Walters, P.E.
President, Applied Flow Technology
www.highlandspublications.com
312 Lorna Square | Birmingham, Alabama 35216

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tim garmon
President
larrY DaughetY
Vice President
Dennis DaughetY
Vice President
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INDUSTRy news
XYLEM RELOCATES NORTH CAROLINA BRANCH
TO LARGER FACILITY
Xylem, a leading global water technology company focused on

addressing the world's most challenging water issues, announces
the relocation of its Garner, North Carolina, branch. This
Xylem branch features Godwin products and Flygt pumps for
construction and mining. This new location will feature a larger
office and shop with over 10,000 combined square feet, which
will better accommodate our staff and customer needs. The
location has a large yard for storage of additional inventory of
pumps, HDPE pipe, and accessories.
The branch is convenient to all major local highways. This
facility will serve as a regional hub located midway between our
southernmost branches and our headquarters in New Jersey. It
will provide an ideal location to stage equipment in response to
severe emergency weather events anywhere on the east coast.
"This new facility will allow us to continue to provide the high
level of service local customers expect when they call Xylem.
Our continued growth in Garner year after year needs a new
space for this continued growth and effort. We look forward to
even more efficient customer service that this new facility will
allow," says branch manager Dave Donahue.
Regional manager Jarrod Williamson adds, "Our goal is to
continue to offer the highest level of service to all our customers
in the Triangle area and surrounding eastern and central North
Carolina counties. We will host an open house at our new
location later this summer, but for now, we are officially open
for business and fully operational. Branch personnel will remain
the same."
4 | JULY 2014
YASKAWA ANNOUNCES
NEW WEBSITE
Yaskawa America, Inc. launches

the next generation website for
www.yaskawa.com. The goal for
this project was to provide a better
user experience by improving
navigation, enhancing the
search engine and offering more
comprehensive content about
Yaskawas people, products and solutions.
Feedback provided by users guided Yaskawas team to
implement new design elements that optimized functionality
and improved performance in each section. Highlights include
Focus on people and solutions while increasing product
visibility
Improved navigation for quick and easy access to
information
Utilizing dynamic content to provide the most up-to-date
accurate information
Redesigned partner section provides immediate exposure to
important news and announcements
Modified search tool and new model number search to find
product and support information for current and legacy
model numbers
Mobile-friendly website that will work on mobile devices
Ability to rate content and provide feedback throughout the
site
INDUSTRy news
RF SYSTEM LAB
WELCOMES NEW CLIENTS
RF System Lab, a world-wide leader

in remote visual inspection and
manufacturer of the VJ-Advance, is
proud to welcome new customers
in a multitude of industries. RF
System Labs customer list includes
companies from industries such as aviation, power generation,
oil and gas, chemical processing, manufacturing, and more.
One of RF System Labs newest customers in the Aviation and
Aerospace Maintenance industry is Rolls-Royce. Rolls-Royce,
the worlds second-largest maker of aircraft engines, was looking
for a tool to inspect the inside of casting cavities, integral parts
of the turbine engine. They required a borescope that was
both durable and flexible, which made the VJ-Advance video
borescope, with its 360 degree joystick-controlled articulating
distal tip and flexible insertion tube, the perfect fit.
Representing the oil and gas industry, Schlumberger is
another company among RF System Labs newest customers.
Schlumberger, the worlds largest oilfield services company,
required a low-cost, high-quality borescope to assist them in
providing maintenance services to the petroleum industry.
RF System Labs VJ-Advance, which is battery-operated and
completely portable, is an essential addition to their tool kit.
Another new VJ-Advance video borescope user is Nike, Inc.
Nike, one of the worlds largest suppliers of athletic shoes,
apparel, and a major manufacturer of sporting goods, purchased
the super-slim 2.8 millimeter VJ-Advance video borescope to
6 | JULY 2014
inspect the heads of their line of golf clubs using remote visual
inspection (RVI).
Additionally, RF System Lab is excited to have a major power
generation company, Mitsubishi Hitachi Power Systems, as a new
customer. Mitsubishi Hitachi Power Systems provides responsive
and proactive service solutions for power providers throughout
the Americas. They will be using the VJ-Advance video borescope
to assist them in those efforts.
NATIONAL PUMP COMPANY

ACQUIRES BAYOU CITY PUMP
National Pump Company, a wholly-owned subsidiary of The

Gorman-Rupp Company, acquired the business of Bayou City
Pump, Inc. (BCP). Founded in 1973, BCP is headquartered in
Pasadena (Houston), Texas and has a service facility in Baton
Rouge, Louisiana. BCP is a leading manufacturer of and service
provider for highly-reliable vertical turbine pumping systems
primarily for the inland and coastal marine liquid petroleum and
chemical transportation markets, both domestically and globally.
Jeffrey S. Gorman, president and CEO of the Gorman-Rupp
Company says, BCPs strong customer relationships and
long history will help expand sales in targeted niche markets
complementary to National Pump Companys significant and
growing vertical turbine products leadership position.
FRANKLIN ELECTRIC ANNOUNCES

ACQUISITION IN BRAZIL
Franklin Electric Co., Inc. announces that it has acquired Bombas

Leo S.A., based in Monte Azul Paulista, State of Sao Paulo,
INDUSTRy news
Brazil. Bombas Leo designs, manufactures, and distributes
submersible groundwater pumping equipment through
manufacturing facilities in Monte Azul Paulista, Teresina and a
distribution facility in Recife. In 2013 Bombas Leo net revenues
were approximately BRL 67 million or about US$ 30 million.
The company believes the transaction will be accretive
to 2014 Earnings per Share (EPS). Gregg Sengstack, Franklin
Electric chief executive officer, comments,
Brazil is one of the largest ground water pumping markets
in the world and a cornerstone of our developing markets
growth strategy. Over the years, the Franklin brand was
established in the country principally through the importation
of our submersible motors by pump companies. In 2008,
we acquired Motobombas Schneider, located in Joinville,
Brazil, a leading residential pumping systems company with
an extensive distribution network. Since acquisition, Franklin
(Schneider) Motobombas sales have doubled, and, this month,
we are opening a new factory and training center to support the
continued growth of this business.
Bombas Leo, established in 1964, and owned by the Plaza
family, is a leading supplier of groundwater pumps principally
used in agriculture, industrial and municipal applications. We
have maintained contact with the Plaza family over the years
and are pleased with their decision to sell their company to
Franklin Electric. The Bombas Leo acquisition will provide
additional submersible pump products, extending the Franklin
Electric product offering, expand our distribution reach
and further position Franklin Electric as a market leader in
groundwater pumping equipment in Latin America.
8 | JULY 2014
PROJECT WATER INJECTION PACKAGE

FOR FLOATING PRODUCTION FACILITY
Ruhrpumpen
recently sold a
Water Injection
package that
consists of quantity
(2) SCE 10X8X16
(booster pumps)
and quantity (2)
SM 6X13X10 (main
pumps). The 2.3
MW driver for the
SM pump operated by a variable
frequency drive.
The base plate, that also
will carry the lube oil system,
is designed as a three point
support version. This is a special
design for platforms and FPSOs
(floating production storage
and offloading). The three-point
support will protect the pump unit
from stresses due to the twisting of the ship.
The package will be placed on a special FPSO from Sevan
Marine, the Sevan Voyageur. This FPSO from Sevan is a special
design (different from the more common standard design of a
Modified Tank ship). The cylindrical design makes it vertical
modular and extremely stable.
TRADE SHOW profile
PumP and
Turbomachinery
SymPoSia 2014
The Future Launches from houston
uilt on a history of
success, the 43rd
Turbomachinery and
30th International Pump
Users Symposia is an event
professionals in the industrial
pump and rotary equipment
markets cant afford to miss.
This annual event features a
world-class technical program
combined with an international
exhibition complete with fullsize equipment and hundreds of
leading companies.
EDUCATION AT ITS CORE
The Texas A&M Turbomachinery

Laboratory sponsors the two
annual symposia, held in the
fall of each year, to promote
professional development,
technology transfer, peer
networking, and information
exchange among industry
professionals. These two
events are led by engineers
with vast experience in the
petrochemical, process,
chemical, utility, contractor,
and consulting fields, along
with manufacturers of rotating
equipment and fluid-handling equipment from around
the world.
Both symposia feature lectures, tutorials, case
studies, discussion groups, and short courses, as
well as exhibits of the latest services and full-sized
equipment. These international meetings emphasize
the technology and troubleshooting that users need in
today's challenging workplace.
BY USERS FOR USERS
The Pump and Turbomachinery Symposia continue to

be the only meeting organized by users for users. The
members of the Advisory Committee, who provide
10 | JULY 2014
overall guidance, are recognized leaders in the

rotating equipment and power generation community.
The Symposia provide an outstanding opportunity
for users concerned with maintenance, performance,
troubleshooting, operation, and purchase of rotating
equipment. The technical sessions provide an
opportunity for attendees to select lectures, tutorials,
discussion groups, and case studies that best meet
their personal and professional needs and interests.
Discussion groups highlight this user-focused
approach that truly elevates the Pump and
Turbomachinery Symposia experience. Peer-to-peer
interaction and networking opportunities abound
throughout the Symposia events. Topics for this years discussion

groups include
Vertical Pump Problems and Solutions
Couplings and Alignment
Monitoring Vibration and Other Critical Machine
Conditions
Subsea Pumps and Drivers
Centrifugal Pump Operation, Maintenance, and Reliability
Improving Mean Time Between Pump Failures
Monitoring Vibration and Other Critical Machine
Conditions
THE LATEST SOLUTIONS
BREAKING THE CYCLE OF PUMP REPAIRS
The Turbomachinery Laboratory provides continuing

education opportunities to users of industrial turbomachinery
and pumping systems at the annual International Pump Users
Symposium and Turbomachinery Symposium. The five short
courses provide attendees the best of both worlds in terms of
introducing important developments in the context of todays
industry, yet also offering detailed attention and clarity to
technical concerns.
Attendance at a Pump Symposium short course is sure
to provide new insight and greater depth of knowledge to
both newly minted and veteran engineers. Topics for this
years short courses include Demystifying Piping Plans and
Support Systems, Fundamentals of Centrifugal Pump and
System Interaction, Pump Cavitation: Physics, Prediction,
Control, Troubleshooting, Vibration Problems and Solutions
in Pumps and Turbomachinery, and the popular Pumps
101 aimed at engineers and technical professionals who
need a broad-based introduction to basic pump selection,
application, and operation.
One of the founding members of the board of the Pump and

Turbomachinery Symposia, Heinz P. Bloch, will present
the tutorial session Breaking the Cycle of Pump Repairs.
Achieving the lowest possible life cycle cost (LCC) or lowest
cost of ownership is an undisputed goal of most pump users
and the author knows, from fifty-two years of solid engineering
practice, that pump hydraulics and fluid sealing details have
received due attention over the years. However, bearing
protection and lubricant delivery components are now often
decades-old; many no longer reflect best available technology
and "lean and mean" has often morphed into "cheap and risky."
Bloch shows why a few truly reliability-focused users enjoy
pump MTBRs four time greater than others and why their perpump maintenance expenditures are often only one-fourth of
those forced upon their struggling competition. This tutorial
delineates at least ten little-known, but highly important, details
of major interest to pump users seeking to improve pump life
and minimize maintenance cost.
The exhibits feature products from many key companies

in the industry. Exhibiting companies normally send their
"first-team" players to these symposia; hence, you can get
knowledgeable help at the exhibit hall, in addition to seeing
major exhibits of equipment, designs, and accessories.
Prospective exhibitors at this years Symposia include
companies such as St. Marys Carbon, Hydro, Ludeca,
Cincinnati Gearing Systems, Graphite Metallizing Corp.,
Milton Roy, IMI Sensors, SDT Ultrasound, and many others.
SHORT COURSE OPTIONS
JULY 2014 | 11
CASE Studies
Water Quality Insights

through Real Time Data
The LiquiD improves efficiency in pouLTry processing
By ZAPS technologies, inc.
APS Technologies manufactures

automated, real-time water
quality monitoring equipment
in support of professionals involved
in water treatment, water analysis,
and environmental monitoring. The
engineers and scientists at ZAPS
have combined hybrid multispectral
analysis (HMA)an optical
methodology which requires no
reagents. The LiquID station, a
unique stand-alone instrument uses
HMA combined with state-of-theart data analysis software and webenabled information delivery to run
unattended 24/7 while producing
thousands of tests per day on flowing
water from raw wastewater to finished
drinking water, and water from rivers,
lakes and marine environments.
THE TECHNOLOGY
Hybrid Multispectral Analysis (HMA)

is a unique combination of advanced
optical, photonic, and statistical
technologies applied to the challenge
of providing synchronized high

frequency data for complex water
types.
Those raw signals are then
automatically processed into
actionable information by
sophisticated computer algorithms
in the LiquID, which identify
the presence and measure the
concentration of a broad array of
substances of interest in the sample
flow. This information is then delivered
to the LiquID stations secure user
interface or transmitted to a SCADA
system for analysis by authorized plant
personnel.
This type of information is required
to control treatment processes in
real time. HMA allows plants to
continuously adjust treatment based
on current and on-line historical
data to eliminate over and under
treatment, provide real time water
security, and facilitate compliance
with and more effective enforcement
of environmental laws.
THE ADVANTAGES
In this way, a continuous, highresolution historical data record for the

LiquID stations monitoring locationencompassing months or years of
minute-by-minute measurements is
created, covering each of the different
parameters that the LiquID station has
been programmed to monitor. Spike
anomalies and sudden process upsets,
as well as diurnal shifts in (for example)
influent composition and seasonal
trends in water quality, become easily
visible.
Because that information was
determined quickly and automatically
by HMA through the LiquID station
instead of by indirect inference,
time-consuming wet chemical bench
analysis or bacterial incubation
protocols, the timeliness, costeffectiveness, and integrity of the data
are improved.
And because the LiquID station
eliminates the need for manual
sampling transport and analysis of
for more information

ZAPS Technologies, Inc. is a producer of online, real-time, water quality monitoring equipment to aid professionals involved
in water treatment, water analysis, and environmental analysis. For more information, visit www.zapstechnologies.com.
12 | JULY 2014
THIS SecTIon SponSored by
www.RFSYSTEMLAB.US/MPT
Those facilities are hence at risk for

BOD shocks and process upsets should
an unexpected PPW load suddenly
present in the influent matrix. Note
also that PPW strength can spike
much higher than average levels if a
blood or offal spill occurs within the
processing plant and enters the plants
effluent stream, or when wastewater
from specific plant operations is

accumulated over an operating shift
and then batched out into the effluent.
CASE STUDY:
DETECTION OF POULTRY
PROCESSING EFFLUENT
A poultry-processing facility in
Corvallis, Oregon, produces corn dogs
water samples, it allows permit-holders

to focus their resources more directly
on protecting human health and the
integrity of watersheds and aquatic
ecosystems. It also facilitates better
process control by placing each data
point in the context of the active
process, thus ensuring compliance
with wastewater treatment regulations
and enabling more timely and effective
process management.
POULTRY PROCESSING
WASTEWATER
Poultry processing plants convert live

birds into packaged meat products for
commercial sale. Significant quantities
of water, about 7 gallons (26.5 liters)
per chicken (Northcutt and Jones,
2004) are typically used in processing
plants to wash the meat, remove and
transport offal, and for cleaning and
disinfection of process machinery.
Poultry processing wastewater
(PPW) contains uncollected blood,
solubilized fat, urine, and feces, and
exhibits levels of BOD, cBOD, TSS,
E.coli and nitrates that can be ten times
the strength of sanitary wastewater. As
such it can require treatment prior to
discharge, either by treatment facilities
on the premises of the processor or
by municipal wastewater treatment
facilities nearby.
JULY 2014 | 13
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CASE Studies
350
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Average Value
14 | JULY 2014
Single Date
Figure 1: Raw influent cBOD data for Nov. 15, 2013 compared with annual average.
from pre-processed chicken meat,

and discharges its effluent into the
wastewater collection network leading
to the local wastewater treatment
facility. Because the poultry processor
does not work with live birds, their
PPW stream contains no offal, feces or
feathers but does contain significant
amounts of meat juice from the
grinding and extrusion lines that make
the corn dogs.
The Corvallis, Oregon, Municipal
Wastewater Treatment Facility is
equipped with multiple LiquID
stations including one to monitor the
contents of the raw influent matrix and
another to monitor the Facilitys final
effluent. According to Dan Hanthorne,
the facilitys manager, process
operators who were studying the
readings from the influent monitoring
LiquID station in 2013 noted transient
increases in cBOD and TSS readings
with a repeat time of about two hours.
Each two-hourly surge in cBOD and
TSS stood out in the data as a distinct
event. For example, figure 1 shows
a single days worth of raw influent
cBOD data (in red) in which the twohour spiking pattern is particularly
apparent. The blue line is a year-long
average of one-day cBOD readings for
comparison. The vertical axis is cBOD
in mg/liter.
ROOT CAUSE
Armed with this data, the wastewater

treatment facility operators were
able to back-trace the cBOD and
TSS spikes to a processing facility.
Although the manufacturer had an
on-site pretreatment system which
was designed to remove high-strength
wastes from their effluent, that system
was being overwhelmed by pumped
purges of hot water from the plants
machinery cooling system which
occurred at two-hour intervals.
Eventually the pretreatment system
was damaged by the purges, with the
result being the release of extremely
high-strength waste into the public
sewer each time the cooling system
was purged. Repair of the pretreatment
system fixed the problem.
DISCUSSION
It is clear that a single composite

manual measurement of the influent
would not have captured these onceper-two-hour signals in the matrix.
Despite the fact that the effluent from
the poultry facility had a marked
effect on the wastewater treatment

process, the flow represented on
average less than 3 percent of the
total influent entering the Corvallis
WWTF. The cBOD signals extracted
from that influent stream by the
LiquID station became visually and
statistically resolvable due to the
datas reproducibility, large quantity,
and high quality.
This examples demonstrates just one
application of how access to real-time
continuous monitoring furnished by
the LiquID station allows treatment
plant operators to better understand

not only the processes occurring
within the plants they manage but
also processes that occur within
the entire sewage collection and
transport network. With the ability of
the LiquID station to monitor over 50
distinct parameters in applications
ranging from finished drinking water
to raw wastewater influent in fresh
or saltwater conditions there are
a number of applications that can
benefit from process optimization,
plant stabilization and cost savings.
JULY 2014 | 15
CASE Studies
Improving Efficiency
and Effectiveness
Across the Board
Schneider Electric completes energy retrofits
to city facilities in Kirksville, Missouri
By merrill markson
(source: City of Kirksville)

Schneider Electric can find hidden revenue in nearly any operating budget. It lies within the energy spend. By implementing
more efficient lighting, energy management systems, HVAC systems, water fixtures, boilers, chillers, cooling towers, and
more. Schneider Electric helps customers manage risk and capture every opportunity to generate more funds for capital
improvements. For more information, visit www.enable.schneider-electric.com.
16 | JULY 2014
chneider Electric, a
global specialist in energy
management, recently
announced the completion of
a facility improvement project
as part of an energy savings
performance contract (ESPC)
with the city of Kirksville,
Missouri. With more than $4.7
million in renovations, the
project is expected to provide
the city more than $340,000
in annual savings, allowing the
project to pay for itself within
a fifteen-year period. The
technological upgrades to the
city facilities will dramatically
improve energy efficiency,
while improvements to the
metering infrastructure will
provide essential upgrades to
billing and utility services of
city government.
Technological upgrades to
aging infrastructure will
provide more than $340,000
in annual savings.
RINGING IN THE NEW
The most significant project

component is the replacement
of the citys aging water
metering system. Schneider
Electric worked with the city
A 4-inch (101.6 millimeter) Badger meter. Seventeen 4-inch meters were changed
out to provide more accurate reading and billing to the surrounding counties they
serve (source: Pedal Valve).
This contract
allowed us
to show that
improvements in
efficiency and
effectiveness in
government are
important to us
as a community.
Mari
Macomber,
city manager,
Kirksville,
Missouri
JULY 2014 | 17
CASE Studies
and its utility building staff to transition more than 7000 new
residential and commercial meters. The city of Kirksville
historically had problems with water loss within the system;
the new meters will allow the city to limit rate increases and
make the billing process more accurate, which will directly
benefit city residents. To help ensure long-term accuracy,
Schneider Electric is also providing ongoing support via
a Revenue Protection Plan, in which monthly billing data
is being monitored to identify and report on alarming
trends, and help prioritize the citys water meter and water
distribution maintenance.
Additionally, Schneider Electric replaced the HVAC system
in Kirksville City Hall. This aging system was the biggest
energy and maintenance drain for the city, but prior to the
ESPC with Schneider Electric, the city lacked the budgetary
means to retrofit the outdated and failing equipment.
The installation of the new HVAC system, which includes
compressors, variable volume and temperature (VVT)
boxes and ducts, will solve the comfort, maintenance and
efficiency issues associated with the old system.
Our meters, because of their age, were

not only reading too high but too low.
The inaccuracies across the system
were extreme. Now, customers can
feel confident in the system and know
theyre being assessed for their actual
usage.
Mari Macomber, city manager,
Kirksville, Missouri
A BRIGHT FUTURE
Other project elements include comprehensive

renovations to the lighting systems across the citys
facilities, as well as retrofitted building automation
systems. In total, the more than $4.7 million in
improvements will deliver annual savings in excess of
$340,000. Schneider Electric worked with U.S. Bancorp
to provide a local financing source for a rate below two
percent over ten years.
Partnering with Schneider Electric on this project has
allowed the city to directly address its most pressing
energy efficiency problems, alleviating financial pressures
on the city and its residents by ensuring accurate readings
and elimination of lost revenues, says Mari Macomber,
city manager for Kirksville. We are now positioned to
continue to meet a city-wide goal of efficiency in our city
facilities and services.
The 6-inch (152.4 millimeter) meter installed at a food manufacturing plant. This
compound meter features two radio transmitters (source: Pedal Valve).
In today's economic climate, every citys

budget is so tight and staff members wear
multiple hats. When you can provide a
comprehensive upgrade, rate-payers
can have the confidence that theyre
receiving an accurate reading and the
city will know the final price of the project
the day they sign the contract.
Orion CE transmitters installed by
Schneider Electric. The transmitters enable
city personnel to drive by meters with a
laptop and the signal collects the meter
readings (source: Pedal Valve).
18 | JULY 2014
A number of 5/8-inch (15.86 millimeter)

Badger residential meters with Orion CE
transmitters were installed across the city.
Schneider Electric, in partnership with city
personnel, were able to change out 7230
meters in six months (source: Pedal Valve).
Jordan Lerner, regional director,

Schneider Electric
The main things that made this project

work so well was great, direct, open
communication. When we do these
projects, its important that both the
municipal and the technical teams
communicate effectively with one
another.
Schneider Electric
In addition to the physical improvements weve provided
for Kirksvilles facilities, we are proud of the economic
impact the ESPC will have on the city and its residents, says
Jordan Lerner, regional director, Schneider Electric. We
were glad to have the opportunity to help the city with these
important HVAC and water metering retrofits, which will
benefit the city of Kirksville for years to come.
A COMMITMENT TO GROWTH
In the past twenty years, Schneider Electric has

successfully implemented over 530 energy savings
performance contracts (ESPCs) across the nation and
helped clients around the world save close to one billion
dollars. ESPCs help publicly funded entities make capital
improvements over longer payback periods. Funded by
third-party financing, ESPCs offer many long-term benefits
such as improved facility efficiency, occupant comfort,
financial management and environmental protection.
Typically, new, more efficient equipment and upgraded
facility automation systems maximize energy efficiency
and generate utility savings.
100 percent of what we do is improve

efficiency and effectiveness. Kirksville
was a great partner.
Schneider Electric
JULY 2014 | 19
WATER & WASTEWATER solutions

ELECTRONIC WATER TREATMENT REDUCES FOULING IN
REVERSE
REVERSE OSMOSIS
OSMOSIS
By Jan de Baat doelman, Scalewatcher north America inc.
everse osmosis
(RO) is used
in processes
requiring highquality, purified
water, such in semiconductor processing
or biochemical
applications and
can be used to treat
boiler feed water,
industrial wastewater
or process water. A
water purification
technique, it reduces
the quantity of
dissolved solids
in solution. RO
uses waterline pressure together with energy consuming
pressurizing pumps that increase the required yield. It is
essentially a molecular squeezing process that causes water
molecules to separate from the contaminants. The separated
water molecules then pass through to the inside of the
membrane on to a
holding reservoir.
The contaminants
are washed from
the membrane and
removed.
One of the
major problems
of RO systems
is the fouling of
membranes which
can quickly become
clogged by hard
water scale resulting
in less membrane
space for the water
to pass through,
therefore leading to
more pressure being required to reach the necessary yield.
The consequences are higher energy use, an increase of the
cleaning frequency and a shorter life span of the membranes.
This will cause the membrane water treatment process to
become much more expensive.
About the Author

Jan de Baat Doelman is president of Scalewatcher North America Inc. The Scalewatcher is an environmentally friendly
alternative to chemical and mechanical descaling. Launched in the 1980s it has successfully treated hard water problems
for industrial manufacturers as well as water companies, oil producers, farmers, horticulturists, shipping companies,
shopping centers, school, universities and government establishments. For more information, call 610.932.6888, email
sales@scalewatcher.com, or visit www.scalewatcher.com.
20 | JULY 2014
REVERSE OSMOSIS MEMBRANE
A reverse osmosis membrane must

be freely permeable to water, highly
impermeable to solutes, and able to
withstand high operating pressures.
Ideally, it should also be resistant to
scaling and fouling by contaminants
in the feed water. Water hardness,
also known as limescale, is made up
of calcium and magnesium carbonates
and can be found in both city and
well and spring water sources. Hard
water (above 7 grains of hardness)
will shorten the life of the ROs
membrane. Limescale fouling occurs
when contaminants accumulate on
the membrane surface effectively
plugging the membrane. The results
of limescale build-up are a higher
pressure drop across the system. This
translates into higher operating costs
and eventually the need to clean or
replace the RO membranes.
calcium carbonate solubility, leading

to the formation of mineral scale
deposits.
In RO, the raw water and its
components pass through the
membrane filtering the pure
water. Therefore there is a steady
process of supersaturation and
precipitation of the water through the
membrane. Within this environment

electronic water conditions, such as
Scalewatcher is the ideal solution
for removing and preventing the
membranes being clogged with scale.
As electronic water treatment (EWT)
changes the shape of the molecules
from rough to smooth, they do not
form a matted structure and are
SCALING AND ELECTRONIC

WATER TREATMENT
Scaling refers to the precipitation and

deposition within the system and will
to some extent take place eventually
given the extremely fine pore size
of an RO membrane no matter how
effective the pre-treatment. However,
by having proper pre-treatment in
place, it is possible to minimize RO
downtime and maintenance costs.
It will maximize efficiency and
membrane life by minimizing fouling,
scaling and membrane degradation
while optimizing product flow.
Electronic water treatment (EWT)
is the ideal solution for preventing
limescale build-up in RO membranes.
A fit and forget technology it requires
no plumbing, chemicals or salt.
To explain the effect of electronic
scale removal it is first important to
understand the major factors that
cause scale.
SUPER SATURATION
Aqueous solutions can become

supersaturated, which means that
they contain higher concentrations of
dissolved solute than their equilibrium
concentration. Such solutions are not
stable and are easily triggered into
dropping back to saturation level,
forcing the dissolved compound to
precipitate. Even when a bulk solution
is less than fully saturated, scale
formation can occur spontaneously
due to localized super saturation, at
a surface for example with a drop in
JULY 2014 | 21

washed away thereby preventing the membranes from being
clogged which in turn reduces maintenance shutdown and
energy costs.
ELECTRONIC WATER
CONDITIONING
EWT is a non-invasive
system utilizing a solenoid
coil or coils wrapped
around the pipework to
be treated. A continuously
frequency changing
signal generator, within a
specified range, supplies
current to the coils. The
pulse shaped current
creates an induced
electric field, concentric
around the axis inside the
pipe. As a consequence
to this arrangement, any
charged particle or ion
moving within the field
experiences a so-called
Lorentz force generated by the interaction between charged
particles and magnetic and electric fields.
The treatment influences the initial nucleation, resulting
in crystals that do not "stick" together. Untreated water
builds up matted structures that continuously grow. This
treatment creates idiomorphic, scattered crystals, which do
22 | JULY 2014
not form matted structures. They have a rotundas shape,

which means that they have a larger volume in relation
to a smaller surface. This feature makes them sensitive to
water currents and they
are easily flushed out of
the pipeline. As no new
scale layers are formed,
the sheer force of the
water flow will gradually
remove existing layers
of scale. The ability to
adjust power, frequency
and coil configurations
of products like the
Scalewatcher on site
enables performance to
be optimized with no
downtime and no pipe
replacement.
CONCLUSION
Reverse osmosis
technology is presently
undergoing rapid growth
in the area of municipal and industrial wastewater reuse.
Control of membrane fouling due to scale and particles in
wastewater is a major expense in the design and operation
of these facilities. Installing a EWT system will save
companies and organizations downtime and maintenance
costs.
CIP Guidelines for Filter

Membrane System Cleaning
By thomas mcguckin, international Products Corporation
cross both water treatment and chemical

processing plants, keeping equipment clean is one
of the keys to achieving a manufacturers promised
efficiency standards and power outputs. However, plant
managers are sometimes reluctant to incur downtime
costs associated with regular cleaning and push the
envelope for a perceived short-term gain. The chemists
at International Products Corporation saw this problem
and have designed productssuch as Micro-90 , a
concentrated cleaning solution, and Micro AO7, a
concentrated citric acid cleanerthat offer benefits of
effective cleaning that can be included in a regularly
scheduled maintenance program and of quick application
when necessary conditions arise. Below is a ten-step list
for clean-in-place (CIP) guidelines for filter membrane
systems.
When one of the following conditions occur, a cleaning

should be done:
Flux rate decreases by 10 percent.
Trans-membrane pressure (TMP) increases by 10
percent.
Permeate water quality decreases by 10 percent.
Based on the membrane foulants, Micro-90, Micro
A07, or both may be required to clean and return the
conditions to their original values. See the list of foulants
below to determine which cleaner(s) is needed. If one
cleaner is all that is necessary to correct the condition,
then that is satisfactory. Sometimes, a pre-soak is useful.
In other systems, both an alkaline and acidic cleaner are
used for full cleaning.
Review the manufacturers membrane specifications

for operating conditions. For future cleaning, it will be
beneficial to make note of these specifications and have
them prepared for the next scheduled cleaning.
Alkaline cleaning: Prepare a 1 percent Micro-90 solution

in permeate-quality water. The volume of cleaning
solution should be sufficient to fill all pipes, hoses,
and pumps, as well as fill the membrane elements up
to 50 percent of their total volume. This will provide
low pressure and high flux for optimal cleaning. An
additional 10 percent volume of cleaning solution should
be prepared that will immediately be discarded after
the first pass through the system. This initial 10 percent
cleaning will remove the gross contaminants and allow
the subsequent steps to clean more effectively.
For extremely fouled membranes, an initial soak may be

required. This soak time could vary anywhere between
one to eight hours. (Both Micro-90 and Micro A07 are
effective yet mild cleaners; therefore, excessive exposure
time should not be a factor.)
To clean the system, allow a slow flow rate (20 percent

to 30 percent of the membrane manufacturers maximum
design rating) across the membranes. A slow rate impedes
the suspended foulants from refouling the membrane.
After several minutes, increase the flow rate incrementally
until the maximum rate is achieved.
Continue recirculating. One hour of recirculation is

normally sufficient to effectively clean the membranes.
Heating the cleaning solution will significantly improve
its detergency. Check the membrane specifications to
determine the maximum operating temperature.
About the Author

Thomas McGuckin is vice president of research and development for International Products Corporation and can be reached
at tmcguckin@ipcol.com. For more information or free samples for testing, call 609.386.8770, email mkt@ipcol.com, or visit
www.ipcol.com.
24 | JULY 2014
7
8
9
Rinse membranes with permeate-quality water until no cleaner

is detected. (Micro-90 and Micro A07 will foam when shaken.
Transfer a small volume of rinse water to a jar. Cap and shake. If no
foam sits on the surface after thirty seconds, rinsing is complete.)
10
Dual cleaning with alkaline and acidic cleaners:

If both cleaners are necessary, Micro-90 should
be used first. Micro-90s mild alkalinity swells
the membrane fibers, which allows Micro A07 to
penetrate deep within the membrane to remove
the remaining foulants. Complete steps 2 through
8 using a Micro-90 solution first. Rinse completely,
and follow steps 2 through 9 with Micro A07.
Throughout the cleaning process, continue monitoring all process

variables for any abnormalities (pressure change, temperature
change, pH drift, and so on).
The goal of filter membrane cleaning is to return

the flux rate as close to 100 percent of the original
as possible, as well as correct the other pressure
and water conditions.
Acidic cleaning: Prepare a 1 percent Micro A07 solution in

permeate-quality water. Follow steps 2 through 8 above.
Pre-Soak and Cleaner by Foulant Type
Foulant
Micro-90
Oil
Grease
Natural Organic Matter
Hard Water Soaps
Micro A07
Scale
Mineral Deposits
Metal Oxides
JULY 2014 | 25
MAINTENANCE solutions
Know Your Pump Base Plate

Installation Options
Part 3 of a 3-Part Series
By heinz P. Bloch,
Process machinery Consulting
figure 6
is shipped. However, before installing

a conventional base plate, the pump
and its driver must be removed from
the base plate and set aside. Leveling
screws are then used in conjunction
with laser-optic tools or a machinists
precision level. With the help of these
tools the base plate mounting pads are
brought into flat and parallel condition
side-to-side, end-to-end, and also
diagonally. This takes time and skill.
After installing an epoxy-filled base
plate
and leveling it, an epoxy grout
Removable alignment jacking tabs shown inserted in three of
cap should be placed on the foundation
four locations next to the two motor feet shown here (source:
Stay-Tru, Houston, Texas)
top. Some of this epoxy grout should
flow into the space between the
figure 7
foundation and the perimeter of the
monolithic base plate. There will be no
incentive to fill the entire space and the
area of support desired is calculated
ALIGNMENT JACKING
such that this epoxy grout is loaded to
PROVISIONS
perhaps 50 psi compressive pressure.
A best-practices specification will
As an example, a 72 by 24 inch (1830
include smart alignment jacking
by 610 millimeter) epoxy-filled base
provisions. Note figure 6, where the
plate would have a 192-inch (4880
purchaser specified an arrangement
millimeters) perimeter. Grout supporting
that allows insertion (and later removal)
a 4-inch (100 millimeter) width would
of alignment jacking tabs in the x and
constitute an area of approximately 800
y-directions next to each of the four
square inches. If the total weight of the
motor feet.
pump set is, say, 12,000 pounds, the
Portable jacking tabs, figure 6,
Epoxy pre-filled base plate fully manufactured by a specialty
company, shown ready for shipment (source: Stay-Tru,
pressure load would be 12,000 / 800 =
(inserted in a welded-on bracket)
Houston, Texas)
15 psiwell within 50 psi.
allow driver alignment moves to be
By its very nature, pre-filling a base
made. Thereafter, the jacking bolts are
plate will greatly reduce problems of entrained air creating voids.
backed-off and the entire tab is removed. In careless installations
However, because grout materials are highly viscous, proper
jack screws are sometimes left tightened against the motor feet.
placement of the epoxy is still important to prevent air pockets
In those instances, motor heat and thermal growth might force
from developing (see reference 5).
the feet into these bolts even more, which could cause the entire
Outsourcing base plate design, fabrication and pre-filling with
motor casing to distort (see reference 4). Note, therefore, that
epoxy grout has often been found economically attractive. Figure
backing-off jacking bolts should be one of many installation
7 shows it ready for shipment.
checklist items.
Conventional grouting methods for non-filled base plates, by
If epoxy-filled base plates are part of the package, pumps
their very nature, are labor and time intensive (see reference 3).
and drivers can indeed be mounted and aligned before the set
n the first two parts this series,
we looked at many of the ways in
which pumps can be mounted as
well as some of the Best-in-Class
users decisions as well as an important
exception to the general guidelines for
secure-in-place installation. In this final
installment, we will discuss the bestpractice specifications for alignment
jacking provisions and conclude with
an adaptable checklist for base plate
installation options and guidelines.
Of course, no installation checklist
can cover the entirety of pump users
experiences and specifications,
but some concerns remain worthy
of attention in the majority of
applications.
About the Author

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

methods helps to minimize some of the cost, but the last pour
still requires a full grout crew, skilled carpentry work, and good
logistics. To further minimize the costs associated with base plate
installations, a new field grouting method has been developed
for pre-grouted base plates. This new method (see reference 4)
utilizes a low viscosity high strength epoxy grout system that
greatly reduces foundation preparation, grout form construction,
crew size, and the amount of epoxy grout used for the final pour.
On pump sets with larger than 75 kW drivers, ascertain that

base plates are furnished with eight positioning screws per
casing, i.e. two screws (jacking bolts) per mounting pad.
a) These positioning screws could be located in removable
tabs (i.e., tabs slipped into a welded guide bracket) or
fixed tabs (i.e., tabs welded onto the base plate).
b) Pad heights must be such that at least 1/8 inch (3
millimeters) stainless steel shims can be placed under
driver feet.
WHAT WE HAVE LEARNED:

PARTIAL CHECKLIST OF FOUNDATION AND BASE PLATE
TOPICS
Conventional base plates must be installed and grouted on

foundation with pump and driver removed. Only then should
pump and driver be re-installed and leveled.
Use ultra-stiff, epoxy-filled formed steel base plates (StayTru

method or an approved equivalent) on new projects and on
optimizing existing facilities
a) Proceed by first inverting and preparing the base plate; use
recommended grit blasting and primer paint techniques
b) Fill with suitable epoxy grout to become a monolithic block
c) Allow to cure; after curing, turn over and machine all
mounting pads flat and co-planar within 0.0005 inch per
foot (0.04 millimeters per meter).
d) Next, install complete base plate on pump foundation.
Anchor and level it within the same accuracy.
e) At final installation, place epoxy grout between the top
of the foundation and the space beneath the monolithic
epoxy pre-filled base plate
On welded base plates, make sure that the welds are
continuous and free of cracks.
Full epoxy and/or epoxy pre-filled steel base plates can be

installed and grouted on a foundation with pump and driver
already aligned and bolted down on the base plate.
REFERENCES
1. Bloch, H. P., and A. R Budris. Pump Users Handbook: Life Extension, 4th
Edition (2013). Fairmont Press (ISBN 0-88173-720-8).
2. Bloch, H. P., and F. K. Geitner. Major Process Equipment Maintenance and
Repair, 2nd Edition. Gulf Publishing Company (ISBN 0-88415-663-X).
3. Bloch, H. P. Pump Wisdom: Problem Solving for Operators and Specialists
(2011). John Wiley & Sons (ISBN 978-1-118-04123-9).
4. Monroe, Todd R. and Kermit L. Palmer. Methods for the Design and Installation
of Epoxy Pre-filled Base Plates (1997 Marketing Bulletin). Stay-Tru Services,
Inc., Houston, Texas.
5. Barringer, Paul, and Todd Monroe. How to Justify Machinery Improvements
Using Reliability Engineering Principles, Proceedings of the Sixteenth
International Pump Users Symposium (1999). Turbomachinery Laboratory, Texas
A&M University, College Station, Texas.
JULY 2014 | 29
PUMP solutions
A Revolution in Pumping Efficiency

All-Flos A200 pump reduces energy costs, improves performance
ParT 4 in a 4-ParT SerieS
By Paul mcgarry, All-flo Pump Co.
ike any business decision,

choosing the right air-operated
double diaphragm pump (AODDP)
for your application requires careful
consideration. You wouldnt hire a new
plant manager without verifying the
candidates experience. The same goes
for AODDPs. Performing due diligence
is critical. Whether you need one pump
or a thousand pumps, you deserve
the best fit and performance for your
investment. You should research, ask
pointed questions, and expect honest,
evidence-based answers.
In this final installment of our fourpart series, were going to look at the
three important questions you should
ask pump manufacturers to make sure
you get the pump that provides the best
mix of performance, efficiency and
value for your needs.
air valve timing). After that, we talked

about how to compare and contrast
pump performance across the industry
by using data-driven evaluations to help
you cut energy costs and improve ROI.
Now, that were all caught up,
lets get the AODDP manufacturer
inquisition underway!
GRADE ON A CURVE
Question 1:
Can you provide
performance curves?
If the most efficient, cheapest pump

on the market doesnt reliably do
the job you ask it to do, whats
the point? At the end of the day,
performance is king. In our industry,
performance curves are essential
tools for determining and evaluating
performance. Any reputable pump
manufacturer should be able to
produce accurate performance curves
for you to review. Furthermore, they
should have curves that document
the performance of pumps with
diaphragms made from the materials
youre interested in (most commonly
PTFE, rubber and thermoplastics).
The ability to compare pumps
with diaphragms made from different
materials is critical because those
FIRST THINGS FIRST
For those of you joining our ongoing

series for the first time (and for
those of us who devote the bulk of
our memories to things like website
passwords and anniversary dates),
heres a quick look back at what we
covered in the previous three articles.
We started out covering the AODDP
basics: how they work, how to read
performance curves and how to
calculate pump operating costs. Then,
we moved into an overview of all the
ways that All-Flos A200 revolutionized
AODDP technology, performance and
efficiency (by reducing and optimizing
dead space on the liquid and air sides
of the diaphragms and improving main
Figure 8a: Performance curve measured using PTFE diaphragm.
About the Author

Paul McGarry is the All-Flo sales and marketing manager for North America. To learn more, visit www.all-flo.com, and
www.aoddpumpefficiency.com.
30 | JULY 2014
www.wATRY.com
Figure 8b: Performance curve measured using TPE diaphragm.
protocols that are used to test pumps,

re-test them, and then test them some
more. After each evaluation, pump
components are checked for quality
and reliability, setups are tweaked if
necessary, and overall performance
is fine tuned. Data from the tests
are used to generate performance
curves. These protocols are extremely
important to us, as manufacturers,
because we know that, at the end of
the day, if our AODDPs dont work
like they say they will, you will buy
them from someone else. (We place a
great deal of value on our reputations
and customer satisfaction.) These
protocols are important for you, as a
user, because they ensure quality and
accountability.
When you ask a manufacturer to
share its testing protocol, what youre
really asking is, How did you get the
information I see in your performance
curves? Because we put so much time
and effort into creating and executing
our protocols, they become sources of
pride that we are happy to share with
interested customers. Nothing builds
trust like transparency, and we always
want you to feel good about your
choice.
KICK THE TIRES, SO TO SPEAK
Figure 8c: Performance curve measured using rubber diaphragm.
diaphragms can impact overall

performance, air consumption and
key factors such as dry suction lift.
This difference is evident in the All-Flo
A200 performance curves included in
the figure 8 graphs. These performance
curves all belong to 2-inch AODDPs
that are identical in every way except
diaphragm materials. As you can
plainly see, the air consumption
and performance vary from pump
to pump, with PTFE diaphragms
claiming the most dramatic difference.
Pump performance directly impacts
efficiency, which, in turn, directly
impacts operating costs and ROI.
Of course, performance curves alone
probably wont dictate your selection.
Some materials are just better suited
for certain applications than others,
no matter what the curve says (think
caustic liquids versus water, and so

on). That being said, you are entitled
to all the data required to make an
informed decision.
Question 3:
Can I perform field tests
or provide equipment
such as air consumption
meters to verify your
efficiency claims?
DIG A LITTLE DEEPER
Question 2:
What is your testing
protocol?
A big part of an AODDP
manufacturers job is to make sure that
its pumps deliver the performance it
promises. To do this, companies such
as All-Flo develop rigid internal testing
In some ways, buying a new AODDP is

a lot like buying a new car. You listen
for the sweet sound of the engines
hum, catch a whiff of that exhilarating
new pump smellOK, maybe not.
However, just as the test drive is an
integral part of the car-buying process,
a figurative test drive can be just as
useful for AODDP purchases. Before
you sign on the dotted line, your
manufacturer should allow you to see
how the pump youre considering will
perform in your reality; to kick the tires
and take it for a spin.
JULY 2014 | 31
PUMP solutions
Field testing will help you evaluate a
pumps true performance and efficiency.
You can even set up multiple tests to
pit one manufacturers AODDP against
anothers. In lieu of field testing, if
a manufacturer stands behind its
published efficiency claims, it should
have no problem allowing you to supply
equipment such as air consumption
meters to verify its data. Supplying your
own equipment will guarantee that you
get a fair and accurate reading that you
can trust.
WRAPPING UP
In your business, AODDPs probably

dont share the spotlight with big-ticket
purchase items such as new oil rigs or the
million-dollar machines that corporate
marketing folks like to point out on
factory tours. But because choosing the
wrong pumps for your needs can cost
you hundreds of thousands of dollars a
year in unnecessary operating expenses
and unscheduled downtime, its worth
your time to make careful, well-informed
decisions. Always perform your due
diligence, hold pump manufacturers
accountable, and remember that the
value of a well-designed AODDP extends
well beyond its initial purchase price.
32 | JULY 2014
PUMP solutions
Calculating Piping
Losses and Their
Effect on Pumping
By david L. russell, global environmental operations, inc.
f you have been involved in

pumping, piping, and design,
you already know that there are
a number of formulas for calculating
losses. The two most common are the
Darcy or Darcy-Weisbach formulas
and the Hazen-Williams equations.
The first requires the designer to
know something about the internal
roughness of the pipe and that he or
she needs to calculate the Reynolds
Number (Re) to be able to determine
the appropriate friction factor for
computing losses. The Hazen-Williams
formula by comparison, tends to
simplify the computation by absorbing
a lot of the computational work into a
C factor used in the computations.
When the designer seeks to design

a piping system, he or she is really
interested in the head loss per length
of pipe or the total head losses on
the system. In order to get that using
the Hazen-Williams formulation,
the equation is manipulated into the
following:
Where k=1.318 for US customary

units, and k=0.849 for SI units. Where
D is the diameter of the pipe in inches,
Q is the flow rate in gallons per
minute. S is the head loss in the pipe
in terms of psi per foot of piping, and
Darcy-Weisbach Formula:
Laminar flow:
the equation below expresses the

same result where S is feet of head
loss per foot of pipe.
NOTE: The equation has been

modified to express head losses in
terms of feet of head per foot of pipe.
In metric terms the conversion factor
is 10.716
C is dependent upon materials
properties as in Table 1.
The designer is free to use any
value of C in calculating pipe friction
losses by the Hazen-Williams formula.
The selection of an appropriate factor
Hazen Williams Equation:

Applicable for numbers of Re above 4000 (fully turbulent
according to the Moody Diagram)
Velocity:
Turbulent flow:
Where k is a conversion factor equal to 1.318 for US gallons,

and 0.846 for SI units.
Where is the pipe roughness, is the friction factor, Dh
is the Hydraulic Diameter (for full pipes it is the inside
diameter).
Re is the hydraulic radius, and S is the slope of the energy

grade line or head loss per length of pipe. The units have to be
consistent.
About the Author

David L. Russell, P.E., is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., a
specialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projects
ranging from environmental process designs and hazardous wastes to water systems and wastewater treatment. He can be
reached at 770.923.4408 or by visiting www.globalenvironmental.biz.
34 | JULY 2014
www.wATRY.com
Table 1: Hazen-Williams Coefficients for Pipe Roughness

C Factor low
C Factor high
C1.85
Difference between High

and Low values of C1.85 in %
Asbestos-cement
140
140
9339.79
Cast iron new
130
130
8143.2
Cast iron 10 years
107
113
5680-6283
10.61%
Cast iron 20 years
89
100
4039.9-5011.9
24.1%
Cast iron 30 years
75
90
2943.5-4124.3
40.1%
Cast iron 40 years
64
83
2195- 3550.5
61.73%
Cement-Mortar Lined Ductile Iron Pipe
140
140
9339.8
Concrete
100
140
5011.9- 9339.8
86.35%
Copper
130
140
8143.2- 9339.8
14.7%
Steel
90
110
4124.3 5978.3
44.95%
Galvanized iron
120
120
7022.4
Polyethylene
140
140
9339.8
Polyvinyl chloride (PVC)
150
150
10611.3
Fiber-reinforced plastic (FRP)
150
150
10611.3
Material
in piping design can materially affect the calculated head

loss and flow through the pipe. A number of designers
routinely use a C=100 for all municipal installations, more
or less regardless of the type of pipe and its age. Given
that value, the extreme variation can be up to almost 90
percent in velocity and flow.
For calculation of piping losses using the DarcyWeisbach formula, the value of the friction factor is
the all-important selection criteria because it directly
determines the head losses in piping.
Where units are consistent in terms of feet and meters.
The friction factor f is determined from a Moody and the

pipe internal diameter are in meters, for English units,
the measurements are in feet. The Moody Chart uses
/D, the internal pipe roughness over the diameter at
various ranges of Re to compute the frictional losses in
the pipes. This is known as relative roughness. The relative
roughness in the diagram below, for fully turbulent flows
(right hand values on chart) vary between 0.00001 and
0.07, or a factor of approximately 7000 while the friction
factor varies over a range of 0.008 to 0.1, a factor of
12.5. Another way of looking at the data so that we are
comparing similar values is to look at the range of relative
roughness in various piping materials. The following table
shows the absolute value in millimeters for various piping
materials:
JULY 2014 | 35
PUMP solutions
Table 2: Calculation of Friction Factor and Relative Roughness /D Values for the Moody Diagram
Surface Material
Aluminum, Lead
Drawn Brass, Drawn Copper
Aluminum, Lead
Absolute Roughness
Coefficient
in mm
Ratio of maximum
to minimum value
In %
Calculated relative
roughness /D Using
4 pipe
Value of f for
fully turbulent
flow
Difference
in values
of f
0.001 0.002
200%
0.000 01 0.000 02
0.0085-0.01
17.6%
0.000 015
0.009
0.000 015
0.009
0.0015
0.001 0.002
200%
PVC, Plastic Pipes
0.0015
0.000 15
0.009
Fiberglass
0.005
0.000 15
0.009
Stainless steel
0.015
0.000 45 0.000 9
0.017-0.02
0.000 15
0.009
Steel commercial pipe
0.045 0.09
200%
Stretched steel
0.015
0.000 15
0.009
Weld steel
0.045
0.000 45
0.017
Galvanized steel
0.15
0.001 5
0.0023
17.6%
Rusted steel
0.15 4
266%
0.001 5 0.04
0.023-0.068
195%
Riveted steel
0.9 9
1000%
0.009 0.09
0.038-0.065
71.1%
New cast iron
0.25 0.8
320%
0.0025 0.008
0.0037-0.0088
83.8%
Source: Absolute Pipe Roughness, Engineering Design Encyclopedia (www.enggcyclopedia.com/2011/09/absolute-roughness).
36 | JULY 2014
www.wATRY.com
In order to get the following values for the influence of

The formula requires the calculation of the Reynolds Number
relative roughness on pipe friction in the above table, we made
(Re) which is
a couple of assumptions; 1) the flow was fully turbulent, 2) for
sake of argument, we divided the relative roughness by a factor
of 100 to simulate a 4-inch pipe (its actually 101millimeters)
but the values and the extreme range to get the f values from
the Moody Chart.
Where is the density, is the dynamic viscosity (kg/(m-s)),
A note of caution needs to be injected here. Not all Moody
and is the kinematic viscosity of the fluid (m2/s). This formula
Charts are the same! In preparing this article we first used
will model the Moody Diagram (NOTE: View the Excel
different Moody diagrams, and found that some of them have
program on modernpumpingtoday.com for ease of calculation).
f values which are different by 20 percent or more. There are
In conclusion, in the design of piping systems, frictional
many more consistent Moody Diagrams than irregular ones, so
head loss can be a significant factor. The Moody diagram
look over a few,
provides a more rational basis for design than the
and select carefully.
frequently used Hazen-Williams coefficients because
(NOTE: Most
it is dependent upon the pipe properties and internal
The Churchill Equation:
Moody diagrams
roughness rather than upon the designers judgment.
have the lower left
The Hazen-Williams formulations lead to understating
hand value for f
piping losses when compared to the Darcy-Weisbach
set at 0.008, and
formula.
the upper left hand
In the design of critical infrastructure systems the
value for f at 0.1,
understated head losses can lead to under-sizing
but some cut the
of the piping, higher losses, and lower flows that
lower value off at
are desired at the delivery point. In some of these
0.01.)
critical situations, such as fire flows, and municipal
S. W. Churchill,
pipelines, the deliverable quantity of liquid could be
developed an
significantly less than required, and sometimes that
Where Re is the Reynolds Number, /D is the
internal pipe roughness (see Churchill, S.W.,
equation which
can be life-threatening.
Friction Factor Equation Spans All Fluid Flow
models the Moody
In future articles we will look at the formulation of
Regimes, Chemical Engineering, Vol. 91, 1977).
a spreadsheet for calculation of head losses and for
chart over its entire
range.
minor losses.
JULY 2014 | 37
DEWATERING solutions
O ptimal p umping
fOr the p leasure p ier
l ift s tatiOn
BJM submersible
shredder pumps
provide a reliable
solution for the Coney
Island of the South
By Suzette gibson, BJm Pumps
he 1130 foot long Galveston Island Pleasure Pier was

built in 1943 featuring rides, an arcade, an aquarium,
a large ball room, named the Marine Ballroom, and, of
course, a fishing pier. The pier was meant as an entertainment
destination for troops and sailors stationed at nearby facilities
during World War II. It was called the Coney Island of the
South and drew multitudes of visitors who enjoyed the
exciting pier features and top name dance bands. It remained
a top regional draw for many years.
Each Model SK22

pump can handle
up to 240 gallons
(908.5 liters)
per minute of
wastewater at heads
up to 59 feet (18
meters).
About the Author

Suzette Gibson is the marketing coordinator for BJM Pumps, LLC. Headquartered in Old Saybrook, Connecticut, BJM Pumps
has 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.
38 | JULY 2014
But, in 1961, the pier was destroyed.

Hurricane Carla, ranks as one of the
most intense Category 5 hurricanes
In Texas history, barreled through
Galveston with wind gusts as high as
170 miles (280 kilometers) per hour.
The storm surge reached 10 feet (3
meters). Precipitation totals topped
16.49 inches (419 millimeters). To make
matters worse, a tornado moved across
Galveston Island, severely damaging
hundreds of structures buildings and
causing eight deaths.
In 1965, the Pleasure Pier was rebuilt
featuring the Flagship, an over-thewater hotel, anchoring the end of the
pier. It would last for forty plus years.
Unfortunately, it too was destroyed. This
time, the hurricanes name was Ike. In
2008, Hurricane Ike damaged the hotel
beyond repair. Ikes rising storm surge
spilled over the 17-foot (5.2 meters)
Galveston Seawall, which faces the
Gulf of Mexico. The landmark Flagship
Hotel, which sat on deep concrete
pylons, was seriously damaged. The
hotel's siding was peeled off by the
storm, venting top-floor guest suites to
the elements. The elevated ramp, which
permitting vehicles to access the hotel's
lower level, fell into the Gulf. Although
initially thought to be repairable, the
hotel was finally demolished in 2011.
As they say, the third time is the
charm. In May 2012, the Pleasure Pier
was reopened as an amusement park
featuring a 100 foot tall roller coaster, a
100 foot (30.5 meter) tall Ferris wheel,
plus fourteen other rides, carnival
games, souvenir shops and restaurants.
The developer of the new Pleasure
Pier is Landrys Inc., a Houston based
dining, entertainment, gaming and
hospitality company. It cost $60 million
to complete.
THE CHALLENGE
BJM Pumps SK22 shredder pump, with its hardened cast

iron rotating assemblies, stands up to rough handling
and pumping abrasive sandy water.
closures is unacceptable from both a

customer relations standpoint and a lost
revenue standpoint.
BJM Pumps Houston based
wastewater distributor, Pumps of
Houston was called upon to evaluate the
requirements and provide the optimum
pumping solution.
THE SOLUTION
Pumps of Houston recommended

installing six sanitary sewage lift stations
on the pier equipped to pump the peak
load of raw sewage back to shore to
be treated by the City of Galvestons
wastewater treatment system. Three of

the six lift stations have been outfitted
with a pair of BJM shredder pumps.
Each Model SK22 pump can handle up
to 240 gallons (908.5 liters) per minute
of wastewater at heads up to 59 feet (18
meters).
The SK22 manufactured by BJM
Pumps is extremely efficient at
shredding potential blockage causing
solids and moving the raw sewage
from the pier-based sewage lift station
to land-based treatment facility. These
electric submersible pumps use a
unique shredder action to pass large
solids. A Tungsten Carbide tipped
cutting impeller rotates against a spiral
shaped impeller plate to shred any
solids.
The 304 Stainless Steel motor
housing helps protect the pumps from
abrasion and premature wear caused
by the sandy, saltwater environment.
Competitive pumps with aluminum
motor housings would quickly erode
due to sand and corrode due to
saltwater. The motor is protected by
double mechanical seals and a lip seal
which helps prevent abrasives, such
as sand, from entering into the seal
chamber. Unlike competitive pumps
with soft resin or plastic components,
the SK22 line, with its hardened cast
iron rotating assemblies, stand up to
rough handling and pumping abrasive
sandy water.
The thousands of daily patrons
excited about soaring over the Gulf of
Mexico on the Iron Shark Rollercoaster
or touching the heavens on the 100
foot (30.5 meter) Ferris wheel, want
the assurance that sanitary facilities are
nearby and operating effectively. Pier
operators also appreciate the importance
of reliability when it comes to
maintaining their wastewater systems.
Pleasure Pier has an approximate

capacity of 7000 people. When you
have thousands of visitors, on a pier
jutting out into the Gulf of Mexico,
you had better have adequate rest
rooms available and operating at peak
performance. Raw sewage had to be
pumped from the pier based source to
shore and connected to the Galveston
city system.
On a busy hot day, the last thing Pier
operators want to worry about is raw
sewage clogging the system and wiping
away the delightful smells of grilled hot
dogs and cotton candy. Having to clear
the pier because of sanitary facility
JULY 2014 | 39
MOTOR solutions
Fish Friendly Pumps

Go Direct Drive
By Lucy ogden,
Bedford Pumps
Cam Pumping Station replaces

diesel for improved efficiency
edford Pumps, the UKs leading

manufacturer of large submersible
and conventional pumps for the
Land Drainage industry, has recently
installed and commissioned a direct
drive variant of their Fish Friendly pumps
for Cam Pumping Station in the South
Level Cambridgeshire Fens. Bedford
Pumps worked with consultants, Hannah
Reed, in upgrading Cam for Waterbeach
Level IDB to supply a new, fish friendly
solution for this land drainage station.
ASSESSING THE PUMPING STATION
The Fenland area is comprised of mainly

high grade agricultural land, much of
which is below sea level, considerably
below flood level, and therefore totally
dependent on pumped drainage. Cam
Pumping Station is one of three stations
within the district and part of a 7000 acre
(2857ha) pumped catchment, managed
by Waterbeach Level Internal Drainage
Board.
Diesel engine driving the old pumps at Cam Pumping Station.
Cam Pumping Station, located close
to the village of Streatham, discharges
are powered by electric motor through a gearbox with an
directly into the River Cam. The pumping station had been
external PTO facility. This offers the ability to drive the pump
operating with a combination of old diesel driven and one
by tractor in the event of a power failure. Each pumpset will
electric pump, but with a requirement for the pumps to
discharge roughly 300 gallons (1150 liters) per second at 18.37
be upgraded combined with new legislation requiring that
feet (5.6 meters) head.
measures be put into place to reduce eel mortality at pumping
In addition to the pumps, Bedford Pumps also supplied
stations, the decision was made to install two new pumps from
Siphon Breaker Valves and Sub Bellmouth Flow Splitters for the
Bedfords Fish Friendly range.
units. They also undertook the M & E works for the site, taking
out the old control panel and replacing it with a new Motor
INSTALLING THE NEW PUMPS
Control Center. This will operate both the new pumps and an
Bedford Pumps manufactured, installed and commissioned two
existing pump, which was retained as a stand-by.
DAF (Fish Friendly Direct Drive Axial Flow) pumps for Cam
Pumping Station through consultants Hannah Reed. The pumps
A COMPLETE SOLUTION
have been installed in a vertical suspended position with below
Bedford Pumps new range of Fish Friendly pumps are a
floor discharge, in a new sump on the existing site. The pumps
complete solution for eel regulation compliance. There need
About the Author

Lucy Ogden is the marketing manager for Bedford Pumps Ltd. For further information, email her at lucyo@bedfordpumps.
co.uk, call 01234.852071, or visit the Bedford Pumps website at www.bedfordpumps.co.uk.
40 | JULY 2014
Bedford Pumps new Fish Friendly pump being installed at Cam Cam Pumping Station.
Bedford Pumps fish friendly impeller.
be no changes to the civil structure, nor additional fish scare

tactics. Utilising a Fish Friendly pump will even improve
hydraulic efficiency with an 8 percent reduction in power
absorbed. Bedford Pumps Fish Friendly pumps cover from 105
to 2377 gallons (400 to 9000 liters) per second at 6.6 to 45.9
feet (2 to 14 meters) head. Fish Friendly pumpsets are available
as a submersible, mixed flow or direct drive variants.
Bedford Pumps Fish Friendly pumps have proven credentials
awarded from independent research consultants in the field
of water management, VisAdvies BV, following extensive
and stringent trials. The tests prove conclusively that Bedford
Pumps range of submersible and direct drive pumps are
fish and eel friendly with no direct mortality observed from

exposure to the pump, with the official report going so far as
to state that Bedford Pumps have manufactured the best fish
friendly pump on the market.
Bedford Pumps range of Fish Friendly pumps offer a
complete solution for Eel Regulation compliance. There
need be no changes to the civil structure, nor additional
fish scare tactics. A Fish Friendly pump can be retrofitted
in place of an existing pump and can be installed in a
variety of configurations. Utilising a Fish Friendly pump also
demonstrates a significant improvement in hydraulic efficiency
with up to 10 percent reduction in power absorbed.
JULY 2014 | 41
POWER GENERATION solutions
Wr525 eliminates failures

in feedwater pumps
By Alex Balvedi, greene, tweed
non-galling, non-seizing material saves company

four to five million dollars
ur
customer,
one of
the largest utilities
providers in the
United States,
came to us with a
challenge involving
one of their nuclear
generating stations.
Nuclear power
plants work by
harnessing the
thermal energy
released from the
nucleus of an atom
during nuclear
fission. Heat is
removed from the
reactor core by a
cooling system and
used to generate
steam, which drives
a steam turbine
connected to an
electrical generator.
Within this system,
our customer
was experiencing
frequent and costly
failures of their feedwater pumps.
The role of feedwater pumps is
to increase the pressure of water
coming from the condensate system,
forcing it into the steam generator or
the reactor.
CHALLENGE
At the nuclear generating station in

question, operations were routinely
shut down to perform maintenance
APPLICATION
and refuel the reactors with uranium.
Afterward, problems would be
encountered trying to re-start the
feedwater pumps. The cause of the
issue was temperature stratification,
which distorted the pump case in
relation to the shaft and resulted
in the loss of original running
clearances. With running clearances
no longer uniform, the breakdown
bushing and shaft sleeve would
Pump: Horizontal multistage

barrel type
Temperature: 375 degrees
Fahrenheit
(190 degrees Celsius)
Media: Treated hot water
Pressure: 400 psi (27 bar)
suction 1300 psi (90 bar)
discharge
About the Author

Alex Balvedi is the senior marketing specialist for Greene, Tweed. From a proven suite of elastomers and thermoplastics,
to innovative thermoplastic composites and integrated solution offerings, Greene, Tweed is a trusted partner for the most
advanced solutions on the market. For more information, visit www.gtweed.com.
42 | JULY 2014
Because of its unique

thermal expansion
properties, WR525 is
deal for use as impeller
wear rings, bushings,
and case wear rings.
IN BRIEF
contact each other and gall and

seize.
In total, there were seven
feedwater pumps at the nuclear
generating station. Each time
one failed, a team of five people
would spend seven to ten days
repairing the pump. During this
time the plant would be running
at reduced capacity, resulting in
a significant loss of revenue per
failure.
SOLUTION
Based on the failure

characteristics, Greene, Tweed
recommended switching to a
new bushing materialWR 525.
WR525 is a high-performance
thermoplastic composite.
With non-galling, non-seizing
properties, a low coefficient
of thermal expansion, and
exceptional thermal shock
resistance, it could better
withstand startup conditions than
the 410SS used at the time.
In engineering new WR 525
breakdown bushings, Greene,
Tweed was able to eliminate
the original toothed design.
Breakdown bushings reduce the
differential pressure caused by

variance in suction and discharge
in a pump. In the original design,
each labyrinth would act as a
successive pressure barrier, with
pressure dropping as media
advanced from groove to groove.
By upgrading to WR525, running
clearances could be tighter due
to the materials non-galling,
non-seizing properties. These
tighter clearances achieved the
same pressure reduction intended
by the hardened steel, labyrinth
design.
RESULTS
The new WR525 breakdown

bushings were installed in April
2010. Since then, none of the
pumps has experienced an
episode of galling, seizing, or
failure. In addition, one of the
feedwater pumps was examined
after eighteen months of service
and measured for bushing wear
it showed no wear. The result for
our customer is the elimination of
future galling and seizing, and a
recuperation of four to five million
dollars in lost power generation
revenue.
Challenge
A major US utilities provider
struggled with frequent failures of
its feedwater pumps at one of its
nuclear power generating stations
The failures were caused by
temperature stratification, which
would distort the pump case in
relation to the shaft
The breakdown bushing and shaft
sleeve would then contact each
other, causing galling, seizing,
and ultimately failure
Solution
Greene, Tweed recommended
upgrading to WR525, a nongalling, non-seizing thermoplastic
composite
Results
New WR525 breakdown bushings
were installed in April 2010,
and none of the pumps has
experienced a failure since then
In addition, after eighteen
months of service one pump was
examined for bushing wear; it
showed no wear
The result is a recuperation of
four to five million dollars in
power generation revenue which
would have been lost in the past
due to pump failures
JULY 2014 | 43
PROCESSING solutions
VAF Solves High Volume

River Intake for
Canadian Paper Mill
By Karen Williams
THE CHALLENGE: Provide a small

footprint, cost-effective filtration
system solution to replace an
outdated filter technology
AF Filtration
Systems, based in
Arvada, Colorado,
addressed the challenge of
providing a small footprint,
cost-effective filtration
solution to replace an
outdated filter system
head-on with Canadianbased Irving Tissue of Dieppe, New
Brunswick. An outdated carbon
steel filter system had outlived
its usefulness and was in need of
retrofitting and/or replacement.
Faced with an obsolescence of
existing parts, combined with
the need for a simpler and more
efficient design, the choice was
clear: it was time to replace. VAFs
patented V-1500, 316L stainless steel
filters with custom 316 stainless
steel manifold, provided the ideal
solution.
Teaming up with their Canadian
distributor, Newterra, VAF supplied
a state-of-the-art filtration package,
while Newterras controller group
brought their expertise to design a
custom PLC control package that
interfaced with the Irving Tissue
maintenance control system. Newterra also provides on-site training
and service to support the plant.
VAF V-1500s installed at Canadian-based Irving Tissue.
A SPECIAL DELIVERY
Its a first-rate system and looks

great, says Trevor Downey, project
manager for Irving Tissue. Delivered
At Irving Tissue, intake water

filtration increased from 700 to 2000
gallons (3028.33 to 7570.82 liters)
per minute with the newly installed
VAF system, and the flushing cycle
time of fifteen minutes was increased
to a forty-minute duration between
flushing cycles.
The VAF system also decreased
flush water usage over 100 percent
by upgrading to V-Series filter
technology
and installed in ten weeks,

the totally new stainless
steel system replaces
the old system. Using
American made, patented
mechanical barrier
screen filtration with a
flushing volume of less
than 1 percent of the total
flow, the new system substantially
reduced the flushing volume:
something the competition could not
provide.
With the updated system in
place, Irving Tissue also realized a
reduction in its ecological footprint.
Optimizing water usage, increasing
productivity, and identifying and
analyzing the cost-benefits of an
integrated system is what we do,
says VAF vice president Steve
Springer.
We chose VAF for our site for
several reasons, Downey continues.
It was the most effective system
solution with the least amount of
moving parts. And the follow-up
from VAF has been greatthey really
back up their product.
IMPORTANT QUESTIONS
Similar to Irving Tissue, VAF can help

decide when a system solution is a
viable option:
Is your current system more than
ten years old; even five years old?
How efficient and effective is
your current filtration?

For thirty years VAF Filtration Systems has been providing filtration solutions worldwide with a business model built on
simplicity, quality, and integrity. VAF filters qualify for LEED and ARRA fundingas all materials, manufacturing, and
assembly are done in the United States. For more information, call 303.425.4242, email sales@vafusa.com, or visit
www.vafusa.com.
44 | JULY 2014
Are your maintenance

costs out of line each
year?
Would you like to
deal with an American
manufacturer?
Can you afford not to
replace now rather
than later?
EFFICIENT
SOLUTIONS
Filters and filtration

systems over ten years
old may not be meeting
the level of filtration
required to achieve your
highest ROI. Furthermore,
the efficiency of newer
systems includes
continuous filtration and
near zero water waste.
Replacing a current
system rather than
configuring your existing
one may require less in
maintenance, electrical
costs, and with fewer
parts, less in added
training costs. Irving
Optimizing water usage, increasing

productivity, and identifying and analyzing
the cost-benefits of an integrated system is
what we do.
Steve Springer,
VAF vice president
VAF V-Series is a unique

and patented system:
No exterior shafts
or seals that are
potential body leak
points
Fewer moving parts
100 percent screen
cleaning without electric motors, gear boxes, limit
switches, pistons or complicated controls
All 316L stainless steel construction to withstand
harsher conditions
Tissue examined all of

these and chose VAF for a
cutting edge, state-of-the
art design.
VAFs unique and
advanced systems include
individual, manifolded,
and skid-mounted
automatic self-cleaning
filtration systems all
manufactured in the
United States. The VAF
V-Series filters can remove
suspended solids from
1500 to 10 micron; and
the cleaning cycle takes
less than fifteen seconds
with no interruption
of flow or the filtration
process. Instrumental in
providing various types of
pre-filtration, including,
but not limited to, RO,
UV, cartridge, membrane
and other micro-filtration
technologies, VAF
provides both individual
filters and pre-assembled
systems to meet any flow
demand.
JULY 2014 | 45
VALVES & CONTROLS solutions
By Lynn Bostrom, magnetek, inc.
ast month at the

2014 Global
Petroleum Show
located in Calgary,
Alberta, Canada,
Magnetek, Inc., a
leading provider of
digital power and
motion control systems,
introduced visitors
to a relatively small
box that can provide
a big sigh of relief for
operators in hazardous
locations. Magneteks
wireless controls,
including the Enrange
XLTX, MLTX, and
MLTX2 transmitters,
are compact, durable,
and reliable options
for operators who
need precise controls
in demanding and potentially perilous jobsites. Magneteks
innovative, cost-effective wireless controls complete with
plug-and-play hydraulic interface controls are designed to
meet customer specifications, reducing internal engineering
and manufacturing costs, improving time to market, and
enhancing equipment performance.
A VARIETY OF
CHOICES
Magnetek offers three

wireless controls
ideal for hazardous or
potentially explosive
locations. Enrange
XLTX, and MLTX2
transmitters are ATEX
and IECEx approved for
EX Zone 0, Zone 1, and
Zone 2 environments,
while the Enrange
MLTX is intended for
applications requiring
non-incendive
ratings to comply
with North American
requirements. The
flexibility of a wireless
control system allows
the user to operate
farther away from
a dangerous situation than wired alternatives. These
innovative wireless controls can be applied to equipment
used in oil and gas applications, petrochemical operations,
above ground mining, and more.
The XLTX offers the most options to configure a flexible
solution. A user can customize the XLTX with up to eight
About the Author

Lynn Bostrom is the director of marketing communications for Magnetek, Inc., a leading provider of digital power and
motion control systems used in mobile hydraulic, overhead material handling, elevator, and mining applications. For
more information about ATEX and IECEx certified transmitters or any of Magneteks advanced wireless controls, visit
www.magnetekmobilehydraulic.com.
46 | JULY 2014
levers, four joysticks, and a combination of toggles, selector

switches, and potentiometers to suit almost any application.
It is also available with proportional controls and custom
labels on transmitters per application. Its spare battery
compartment includes an extra battery to avoid downtime.
The MLTX2
provides users
an ergonomic,
lightweight choice for
hazardous locations.
Like the XLTX, it
also is available
with proportional
controls and custom
transmitter labels,
but provides choices
up to seven levers
and three joysticks,
making it an
appropriate choice
for many jobs. Users
looking for a costeffective option to
meet North American
requirements should
consider the MLTX,
which is a transmitter
for use in hazardous
locations requiring
ISA 12.12.01 Class I
and Class II, Division
2, Group A, B, C, D,
E, F and G.
CERTIFIED AND ACCEPTED AROUND THE GLOBE
We were pleased to be exhibiting our ATEX and IECEx

certified XLTX and MLTX2 transmitters, as these wireless
controls are now certified to control equipment used
worldwide in potentially hazardous applications such as
petrochemical operations
and above ground
mining, says Ben Stoller,
director of radio controls.
End user acceptance of
the stringent ATEX and
IECEx standards is typical
in North America and
worldwide.
ATEX compliance,
required by the European
Union, certifies that
Magnetek wireless
controls are safe to use
in potentially explosive
areas with flammable
gases or vapors. IECEx
equipment certification
signifies that Magneteks
wireless controls
conform to international
safety standards for
environments where
a potential exists for
explosions.
RUGGED DESIGN, INNOVATIVE TECHNOLOGY
The controllers tough nylon exterior is made to

withstand shock, and each controller includes military
grade auxiliary function switches. Access code system
provides peace-of-mind, as the system only operates
the intended equipment. Also, the Enrange XLTX, and
MLTX2 transmitters are designed to minimize power
consumption, providing one of the longest life batteries
in the industry todayand are available in unlicensed
433MHz RF.
EXPANDABLE TO MEET THE NEEDS IN THE FIELD
Transmitters can be combined with receivers for a

complete radio control system. Magneteks receivers
can be put into an explosion-proof enclosure, which
meets NEMA 7 or NEMA 9 standards for added safety.
The MHR Radio Controller integrates the components
of a radio receiver and hydraulic controller into a single
unit, reducing cost and freeing up valuable space. It
features an informative graphic display for viewing
and modifying system settings and machine functions
in the field. The CAN-2 Receiver option provides a
compact design that is rugged enough to handle outdoor
environments, and the quick response allows for precise
controls, without the latency found in other radio
controls systems. CAN-2 allows users to tap on to most
CAN-bus systems supporting a variety of CAN-protocols.
The CAN-2 has two digital Machine Stop outputs, and 2
CAN-bus ports.
JULY 2014 | 47
SEALING solutions
Designing Formed
Diaphragms for
Optimum Performance
and Manufacturability
By Christopher gallagher, gallagher fluid Seals
umps that utilize

a diaphragm for
their mechanical
force have been
used since the midnineteenth century, and
continue to be utilized
in modern pumping
applications because
of their simplicity and
effectiveness. Over 150
years of innovation
and technical advances
in both diaphragm
profiles and elastomeric
material sciences have
secured their continued
utilization across a
range of pumping
and reciprocating
applications. The
design and utilization
of diaphragms in
pumping applications
is a vast topic. Despite
this broad scope, at
Gallagher Fluid Seals,
application engineers
approach the design
figure 1
figure 2
Figure 1: Convoluted diaphragm
Figure 2: Dished diaphragm
About the Author

Christopher Gallagher is the marketing director at Gallagher Fluid Seals, a fifty-eight-year-old ISO certified distributor of fluid
seals in King of Prussia, Pennsylvania. For more information, call 800.822-4063 or visit www.gallagherseals.com.
48 | JULY 2014
figure 3
figure 4
Figure 3: Rolling diaphragm
Figure 4: Flat diaphragm
and manufacturing of
diaphragms through a
step-by-step process
that results in the best
diaphragm design, with
the most appropriate
material, constructed in
a manner that optimizes
manufacturability and cost.
Freudenberg-NOK Sealing
Technologies are invaluable
partners to Gallagher Fluid
Seals in this process, and
are amongst the foremost
experts on diaphragms in
the world.
An elastomeric diaphragm
is a versatile dynamic seal
that eliminates many of
the limitations of other
sealing methods. They do
not leak, offer little friction
and can be constructed for
low pressure sensitivity.
With proper material
consideration, diaphragms
can seal over a wide
temperature and pressure
range without maintenance
or lubrication.
JULY 2014 | 49
SEALING solutions
DIAPHRAGM DESIGN CHECKLIST
1. Environmental, Functional and
Material Considerations
What is the basic function of the
diaphragm? Is it acting as a regulator
with pressure from one side, or as a
pump with pressure from both sides?
Very important distinctions distinguish
diaphragms for control, switching,
accumulation or pumping applications.

What are the environmental conditions?
Specifically what temperature, humidity
and media is the diaphragm exposed to?
After establishing the functional
criteria, decisions can be made regarding
the material for the diaphragm elastomer
itself, as well as any reinforcing-fabric
layers that may be required to increase
the structural performance of the

diaphragm. These material considerations
must be based on the media being sealed
or pumped. Is it a passive material such
as air or water, or an aggressive material
such as a solvent or petrochemical?
Material selection typically requires
the expertise of the supplier. Specifying
the best choice of materials not only
ensures the longest possible life of
the diaphragm, but can often avoid
unnecessary costs by not overdesigning. The elastomer choice
is critical when considering the
environment in which the part will
operate, and will often override
manufacturability considerations.
Relevant elements include: chemical
contact, abrasive hardware or medium,
applied loads and health or federal
regulations.
What are the pressure requirements
and is does it ever deviate or reverse
from those? Depending on the PSI levels,
different secondary materials integrated
into the diaphragm are required.
Typically PSI under 5 does not require
fabric reinforcement, and between 5 and
10 it is application dependent. PSI above
10 almost exclusively requires fabric
reinforcement. What are the maximum
and minimum operating temperatures?
What is the duration at its maximum
temperature? Information surrounding
the cycle rate and pumping volume
dictate the construction and shape
elements that complete the design of the
diaphragm.
2. Construction and Shape Elements
A primary goal of the design process
is to consider the construction method
of the diaphragm at the earliest stage
possible. A layer of reinforcing material
molded to the elastomer, or a layer of
coating on one or both sides of the
diaphragm can clearly add significant
cost to the component. The decision
to use a coating on one or both sides
of the diaphragm is dependent on the
pressure, media, and stroke length of the
piston. It should be noted that the when
considering stroke length it is the relative
stroke length of the piston head to the
diameter of the diaphragm that matters,
not any specific stroke length value.
The elastomer forms a sealing barrier
between the system pressure and the
porous fabric, enabling the diaphragm to
convert pressure into a mechanical force.
Pressure or aggressive media on one
side should use a one side coated part,
and could use a two side coated part.
50 | JULY 2014
With pressure on two sides, a one side

coated part will always fail and must
use a two side coated part. A short to
medium stroke length will allow for
a one or two sided coat, but a longer
stroke length must use a one side
coated design because of the additional
flexibility required. The mating hardware
finish is another consideration in the
construction elements of a diaphragm in
that a rough surface will erode the fabric
reinforcement to the point of seal failure.
The specific geometric profile of the
diaphragm is application dependent,
but more often than not, the primary
consideration is stroke length. A short
stroke will allow for a flat or die
cut diaphragm, a low convoluted or
shallow draw profile. A medium stroke
will typically call for a shallow draw,
convoluted or drop center. A long stroke
requires a deep draw or top hat. Figures
1 through 4 are images and illustrations
of each profile (source: FNST 2009).
during the prototype phase. How will the

diaphragm device be assembled? Options
include a bolted piston and flange, a
riveted piston with a flange, spin crimp
or swage, or a sonic weld. Requisite
hardware is made from either injection
molded plastic, stamped or formed
metal, or a machined plastic or metal.
Additional hardware considerations
include the presence of return springs,
positive stops, the piston design, and
care over time of the diaphragm.
Each of these considerations eliminates
various design options, and the optimal
diaphragm design begins to emerge.
Final considerations include any unique
specifications or requirements such as
UL, or FDA compliance. While typically
material in nature, these certifications
can require extensive testing and
validation to attain, and as such can add
significant cost to the overall diaphragm
application.
3. Application Properties and Hardware

Considerations
Cycle rate and expected cycle life of
the diaphragm must be established.
These values are tested for confirmation
Bonded to the diaphragm during the

molding process, diaphragm inserts
provide enhanced connectivity,
facilitating the assembly process
and conserving costs. Benefits of the
DIAPHRAGM INSERTS
inserts include ease of assembly of

the diaphragm, built-in piston-area
support, reduction of SKUs, and a well
centered attachment point. Typical
metal insert materials include stainless
steel, aluminum and brass, and plastic
materials are typically either fiberglassfilled polyamide or PEEK.
PRODUCT DESIGN AND

VALIDATION
Engineers at Gallagher Fluid Seals and

our partners at Freudenberg-NOK Sealing
Technologies design every custom
diaphragm to your specifications, and
validate the design before manufacturing
begins. Virtual validation techniques,
specifically FEA capabilities, allow
for decreased manufacturing costs
and optimal design. These rigorous
procedures give the customer the
benefit of exact product design, shorter
development times with lower costs.
Testing capabilities to validate in-use
performance include: Hot endurance
testing, Hot steam, tensile strength,
cold liquid, hysteresis, bending fatigue
strength, permeation, as well as any
customer driven application testing
process.
JULY 2014 | 51
MODERN PUMPING products

meggitt SenSing
SYStemS
Featured Product Release
machinerymate mAC050
and mAC100 handheld ir
temperature meters
The handheld thermometers read temperatures

of hard to reach or moving machinery for a
variety of industrial applications. The MAC050
and MAC100 add to the MachineryMate line of
tools used to assist in machinery health. Using
laser sighting for accurate detection, the rugged
thermometers can measure up to 1832 degrees
Fahrenheit (1000 degrees Celsius). Also capable
of contact readings, the meters are supplied with
K-type thermocouples for applications where
emissivity is unknown. The high performance
MAC100 is capable of Bluetooth connectivity
for data streaming, analysis and trending, and
has user selectable emissivity. MAC meters are
an affordable and safe solution for obtaining
temperature data. Machine equipment conditions
can be quickly gauged, reducing unplanned
downtime and increasing efficiency. Meggitt
Sensing Systems offers a wide range of condition
monitoring products including vibration sensors
and meters, mounting accessories, cable
assemblies and enclosures.
For more information, visit www.wilcoxon.com
or e-mail machinerymate@meggitt.com.
g.i.e. inC.
Lug type Butterf ly valve

G.I.E. Inc.s plastic lined butterfly valve lug type features face-to-face dimensions as per
as per ANSI B16.10 150# Narrow / EN 558-2 Series 20 and is suitable for mounting on
ANSI B16.5 150# flanges This is in addition to testing as per API 598 / EN 12266-1 and
stem connection and integrated actuator mounting flange as per ISO 5211. Features
also include spring loaded stem seal, elastomeric backing for body liner, a three coat
epoxy external surface finish, and direct mounting of manual geared or pneumatic
actuator for automation. For more information, visit www.gieinc.com.
trAnSdUCerS direCt
tdePS electronic Pressure Switch

The new TDEPS electronic pressure switch designed by Transducers Direct is the first in
the industry with digital reliability, patented design and proprietary circuitry that creates
redundant sensing capability. The UL-approved, US-made switch eliminates all mechanical
components, wear parts and setpoint drift for ultimate reliability in shock and vibration
applications in mobile hydraulic equipment, injection molding machinery, rolling mills,
amusement park rides, timber processing equipment and similar applications. Unique
in design, the TDEPS uses a one-piece, precision-machined stainless steel diaphragm
and header. It provides ten times the life of a conventional diaphragm and eliminates
all springs, pushrods, micro switches and o-rings. All wetted parts are stainless steel.
The TDEPS senses pressure by using a time-to-digital converter (TDC) to measure the
duration of a capacitive discharge across the changing resistance in a Wheatstone bridge
atop the diaphragm. For more information, contact Mark McDaniel at 513.583.9491 or
mark_mcdaniel@transducersdirect.com.
52 | JULY 2014
diALight
duroSite and SafeSite Led flood Light

Specifically designed for the worlds harshest environments, Dialights LED Flood Lights feature
integrated power supplies based on topologies and design techniques developed over several years.
The easy to install Flood Lights are rated to operate in temperatures between -40 and 149 degrees
Fahrenheit (-40 and 65 degrees Celsius) and provide up to an impressive 20 kV surge protection.
The DuroSite and SafeSite LED Flood Light family is also on the DesignLights Consortiums Solid
State Lighting Fixtures Qualified Products List. Posting on the DLC list identifies the fixture as
eligible for valuable utility rebate programs at the discretion of participating DLC utility partners
and validates the High Bays exceptional energy efficiency and lighting efficacy. DLC sets efficiency
specifications for commercial LED lighting in categories not included in the U.S. Department of
Energys Energy Star program, with only thoroughly tested products making their list of qualified
products. By making this list, facilities who install Dialights LED Flood Light not only receive
fixtures with ten-year full performance warranties and high efficiency but may also qualify for many
state and utility energy efficient rebate programsmeaning a short payback period and substantial
total cost of ownership savings. For more information, visit www.dialight.com.
vAL-mAtiC
Xrf Scanner
With its continuous improvement initiative and ISO 9001 certification, Val-Matic Valve has
implemented a Positive Material Identification (PMI) process for Class rated components
containing special alloys. The process uses X-Ray Fluorescent Spectroscopy (XRF) technology
to identify the part alloy identification and elemental chemistry. Additionally, specially made
plating standards are used with the XRF analyzer to verify the thickness of chrome and nickel
plating thicknesses even when the substrate contains similar elements. For more information,
visit www.valmatic.com.
CAShCo, inC.
model B7 high-flow/
high-Sensitivity
Back Pressure
relief regulator
The introduction of a new
Model B7 High-Flow/HighSensitivity Back Pressure
Relief Regulator is proof once
again that Cashco Inc., listens
to customer requests. The new
B7 valve came about largely
as a result of requests for an
equivalent to our P7 HighFlow/High Sensitivity Pressure
Reducing Regulator, which
we introduced in 2005, says
Clint Rogers, general manager,
valve division, Cashco, Inc.
So we were able to go back
and look at the P7 unit and
utilize as many components
as possible, in effect, giving
our customers a back pressure
valve with the durability and
ease of operation with which
they were already comfortable and
confident. For more information, call
785.472.4461 or visit www.cashco.com.
eLeCtro-ChemiCAL deviCeS
fluoride monitoring System
Electronics manufacturing engineers and plant technicians in need of a

Fluoride measurement solution will find the new Fluoride Monitoring System
from Electro-Chemical Devices (ECD) provides a highly accurate turn-key
analyzer solution for semiconductor wastewater treatment processes. The
next-generation Fluoride Monitoring System from ECD is designed with
its new advanced dual-channel T80 Universal Transmitter and precision
S80 Intelligent pION Sensor for Fluoride and S80 Intelligent pH Sensor.
Together, they provide highly accurate and reliable measurement of Fluoride
for electronics industry manufacturing plant wastewater treatment. The T80
Transmitter provides dual-channel comparison of measurements or inputs,
which can improve the accuracy of Fluoride measurement. For example,
Fluoride ions are affected by changes in the pH of a solution. The correct
measurement of Fluoride levels is only possible if pH is also measured and
appropriate compensation algorithms are processed. The S80 pH Sensor and
the dual-channel T80 Transmitter easily handles these types of measurement
comparisons. For more information, contact Joe Bradley at 714.692.1333,
email sales@ecdi.com, or visit www.ecdi.com.
JULY 2014 | 53
MODERN PUMPING products

gemS SenSorS & ControLS
31eP/32eP Pressure transducer
Looking for a compact, explosion proof pressure transducer? Oil and gas equipment needs a pressure transducer
that is reliable and able to withstand extreme environmental and pressure conditions. Gems Sensors explosion
proof units offer an alternative to high priced, unreliable alternatives. The 31EP and 32EP feature all stainless
steel wetted parts, a broad selection of electrical and pressure connections and a wide choice of electrical
outputs. Our manufacturing process includes the latest automated equipment, producing consistent sensor
performance. The compact yet rugged construction of these units makes them ideal for installation where space
in a hazardous environment is at a premium. For more information, visit www.gemssensors.com.
reeLCrAft indUStrieS
Series rt, 5000, 7000, and 9000
Reelcraft Industries now offers a non-corrosive fluid path option on many of our
popular reels, including Series RT, 5000, 7000, and 9000. For approximately half
the price of stainless steel reels, these new reels feature non-corrosive fluid paths
designed for corrosive materials. These reels are rigid enough to withstand industrial
or commercial use applications such as agriculture, food service, chemical spraying,
fire and rescue, mining, and grounds keeping. With a special cleaning and lubrication
process, these reels may also be suitable for drinking water and breathing air. The
structural reinforcements reduce weight while maintaining structural integrity. The
fluid path is engineered to provide maximum corrosion resistance for a better value.
For more information, contact Bill Martin, national sales manager, at 260.248.8188,
800.444.3134, or visit www.reelcraft.com.
AmeriCAn StAndArd
Champion Pro toilet
and Sato hygienic toilet Pan
Buy a Champion and be a champion. Its that simple. For every Champion
toilet sold in the U.S. and Canada in 2014, American Standard will donate
one sanitary toilet pan to help save lives and improve the quality of life in
developing countries. American Standard engineers have invented the SaTo
(pronounced SAH-toh, derived from Safe Toilet), a cost effective hygienic
toilet pan that uses ingeniously simple mechanical and water seals to close
off pit latrines from the open air, thereby reducing disease transmission.
In 2013 alone, the Company distributed more than 500,000 SaTos to
families in Bangladesh, providing them with a safe sanitation solution.
Learn more about the American Standard Flush For Good campaign,
which aims to raise the standard of living for families experiencing lack
of safe water and sanitation facilities. Visit www.flushforgood.com. For
more information on the complete line of Champion PRO toilets, visit
www.americanstandard.com or call 800.442.1902.
teChCon SYStemS
tSr2000 Series Bench-top dispensing robots

Techcon Systems, a product group of OK International and a leading provider of fluid dispensing systems
and products, has introduced the new line of TSR2000 Series bench-top dispensing robots. The new robot
series is easy to program, simple to operate, and compatible with all valve types and controllers. The versatile
TSR2000 dispensing platforms deliver consistent, high performance dispensing results at an affordable price,
and are ideal for the following applications: dispense dots of solder paste, form-in-place gasket, filling,
potting, encapsulation, bonding and coating. Designed and configured specifically for fluid dispensing
applications, Techcon Systems robots provide total control over fluid placement, from beads, arcs and circles
to repeated timed dots. Programming is simple via teach pendant. From a general assembly manufacturer
looking to automate an existing dispensing application to an engineer designing a production process from
scratch, Techcon Systems dispensing robots offer unsurpassed value in automated precision fluid dispensing.
For more information, visit www.okinternational.com/techcon.
54 | JULY 2014
greYLine inStrUmentS
Stingray Portable open Channel flow Logger

Greyline's new portable Stingray 2.0 is a compact, battery-powered area-velocity flow
logger. It data logs level, velocity and water temperature readings for flow monitoring
through open channels, partially full sewer pipes and surcharged pipes. Use it for flow
surveys, I&I studies, stormwater, irrigation water and sewage. The Stingray 2.0 uses a
new and improved submerged, steel reinforced, PVC ultrasonic sensor to measure both
velocity and level in the channel. No calibration is required. It operates up to four years on
standard alkaline D-cell batteries. For more information, email info@greyline.com or visit
www.greyline.com/stingray20.htm.
AZteC BoLting ServiCeS inC.

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

Pgm Control valves
alves
Singer Valve, a leading manufacturer of
control valves has now added Single
Rolling Diaphragm (SRD) technology to the
106/206 PGM Valve Series. The 106/206
PGM Series Control Valves are designed
for particularly sensitive applications or
situations where valves are difficult to
access and maintain. They provide
an integral back up control and
the ability to signal should the
desired function move off limits. It
can also provide an independent
and very positive override. With
SRD technology the valve
becomes incredibly
steady throughout a
complete range of
flows and eradicates
the need of additional
low flow bypass valves.
The effective area of a
single rolling diaphragm
remains constant so the
bonnet is much smaller
and lighter than a flat
diaphragm version. A measured quantity into the
bonnet control chamber always gives the same
smooth movement of the inner valve through
the entire stroke. For more information, visit
www.singervalve.com.
SKf
Laser vibrometer mSL-7000

The new SKF Laser Vibrometer (MSL-7000 series) serves as an ideal
laser-based tool to measure vibration and structure-borne noise from
fans, electric motors, and pumps reliably without making contact
with their surfaces. This non-contact vibration sensor offers a compact
and robust solution to deliver optimal results on every measurement
surface, regardless of environmental conditions. The technology
benefits from a high-end contactless velocity proportional sensor and
is especially suitable to perform process-integrated, end of line
acoustic inspections of noise critical equipment for information
on manufacturing quality and compliance with a products acoustic
emission limits. The direct integration of the SKF Laser Vibrometer
into a production line ultimately can create a real-time quality control
system for products enabling pass/fail decisions on the basis of
structure-borne vibration. The vibrometer further supports flexible resetting of manufacturing batches and test set-ups. For more information,
call 800.440.4SKF or visit www.skf.com/lasersensor.
JULY 2014 | 55
PUMPING trends
T he C uTTing e dge
Flygts Lisa Riles looks at the challenges facing municipal wastewater and a different type of solution.
isa Riles is the marketing and business

development manager for the municipal
transport market for Flygt, a Xylem
brand. In her position, she is responsible
for a wide array of pumping equipment and
pumping solutions for municipal applications.
She sat down with Modern Pumping Today
to discuss the growing challenges that
municipalities are facing and how new
technologies can provide a solution.
Modern Pumping Today: What are the top issues you hear from
your customers in the municipal wastewater market?
Lisa Riles: With municipalities budgets being tight and many
times having fewer maintenance people to deal with problems
when they do occur, efficiency and reduced downtime
are critical. When they are trying to cut costs,
energy efficiency is the number one issue.
When it comes to pumping equipment,
clogging caused by modern trash or
ragging with disposable products is a
major concern for municipalities. Because
they have plants and lift stations that have
pumps that are clogging, then that requires
them to send people out to de-clog them.
They have constituents, people who live
in the area who dont want to deal with
the smellits a nuisance. Plus it costs
money to complete the de-clogging work,
meaning their rates will probably go up.
leading edges where they add on and add on. With each cycle
of the impeller, the ragging increases until it clogs the impeller.
Flygt N technology directly addresses that problem because the
hydraulic design of the impeller directs the rags through and
doesnt allow an opportunity for this material to collect and
then clog.
MPT: This is different than a conventional pump.
Lisa Riles: It sounds obvious, but one of the differences between
clean water and wastewater is that clean water is just that
clean. Therefore, a pump for clean water can have a hydra
design with smaller clearances yet maintain good efficiency
without concern of solids passing through causing clogs or
other problems. With wastewater pumps, however, theres
always a balancing act between designing a pump that can pass
solids but also achieve sustainable efficiency. Traditionally, the
approach was that you sacrifice efficiency in order to pass the
solid, but the Flygt N technology offers a solution with the
same efficiency while still being able to pass solids.
MPT: Is Flygt N technology the solution for all municipal
markets?
Lisa Riles: Thats only one piece of the

puzzle. We have the technology with
the pump to handle clogging and to
complement the pump we also have
solutions for monitoring and control
called SmartRun, which is part of our
Flygt Experior solutions. It incorporates
algorithms within the control that are
designed specifically for wastewater
MPT: Has this become a growing concern
functions like pipe scouring and sump
for municipalities?
cleaning in a lift station to keep it
cleaner and ensure the pumps are
Lisa Riles: We know its an issue. Turn on
Flygt N technologys impeller at the backswept
leading edge passes todays modern trash.
working properly and are not going to
your local newscast or review any industry
clog or have other issues.
statistics, and youll see that the problem
We also offer an Energy Minimize function where, every time
is getting worse and worse. Many municipal systems were
the pump comes on, the VFD is actually looking for how well
designed and installed to meet completely different demands
the pump did last time. For example, if its a 60 Hertz pump it
than the ones they find in their communities today. Its required
can reduce the speed until it finds that optimal point where that
new ideas and new approaches. We as a pump manufacturer
pump will minimize its energy usage. These are just some of the
have taken on the challenge of finding a solution for it.
things were working on to save users on both energy use and
For one thing, the popularity of disposablewhich many
maintenance costs.
people mistakenly assume as flushabletypes of cleaning
products in the market including baby wipes, antibacterial
MPT: Flygt will have a large presence at the upcoming WEFTEC
wipes, floormop covers is on the rise. This is a growing segment
event in New Orleans, but how else are you spreading the
of the consumer market and the wastewater industry has had to
news to your customers?
come up with an answer for it.
MPT: What solution can Flygt offer to the problem?
Lisa Riles: We offer a unique solutionFlygt N technology
that incorporates impellers with a backswept leading edge
that reduce clogs and are actually able to pass those types of
disposable productsthe wipes and mop cloths that lead to
ragging and clogsand maintain sustained high efficiency.
Traditional wastewater pumps, whether using a single-vane or
two-vane channel impeller, allow for rags to collect on the blunt
56 | JULY 2014
Lisa Riles: One way were trying to go out and see customers
is that Flygt is travelling the country in our Flygt Trailers. Inside
the trailers, we have our newest products and were talking
to installers and engineersboth offering both training and
product demonstrations. Were always going to have a presence
at the traditional trade shows, but we understand that not all
of our customers can make it so were hitting the road to meet
with them. They can see the displays and the solutions right
there where they live.

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modern

12 Water Quality insights through

16 improving efficiency and effectiveness

Water & Wastewater

20 electronic Water treatment reduces

28 Know Your Pump Base Plate

30 A revolution in Pumping eff icieny

34 Calculating Piping Losses and their

38 optimal Pumping for the Pleasure Pier

40 fish friendly Pumps go direct drive

P.O. Box 660197 | Birmingham, Alabama 35266

42 Wr525 eliminates falures in

44 vAf Solves high volume river intake

valves & Controls

46 Wireless Controls for Use

russell haDDoCk COO/Publisher

48 designing formed diaphragms

Jamie willett Circulation Consultant

56 the Cutting edge

editoriAL AdviSorY BoArd

Drives and Motion Solution Engineer

Heinz P. Bloch, P.E.

Consultant and Trainer,

Business Development Manager,

Director of Regulatory and

Trey Walters, P.E.

President, Applied Flow Technology

312 Lorna Square | Birmingham, Alabama 35216

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

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The Texas A&M Turbomachinery

BY USERS FOR USERS

The Pump and Turbomachinery Symposia continue to

overall guidance, are recognized leaders in the

throughout the Symposia events. Topics for this years discussion

THE LATEST SOLUTIONS

BREAKING THE CYCLE OF PUMP REPAIRS

The Turbomachinery Laboratory provides continuing

One of the founding members of the board of the Pump and

The exhibits feature products from many key companies

SHORT COURSE OPTIONS

Water Quality Insights

By ZAPS technologies, inc.

APS Technologies manufactures

Hybrid Multispectral Analysis (HMA)

of providing synchronized high

In this way, a continuous, highresolution historical data record for the

for more information

THIS SecTIon SponSored by

Those facilities are hence at risk for

from specific plant operations is

water samples, it allows permit-holders

Poultry processing plants convert live

THIS SecTIon SponSored by

from pre-processed chicken meat,