M AY 2 0 19

SYSTEMS
PUMPSANDSYSTEMS.COM

The Leading Resource for Pump Users Worldwide

Worldwide
Infrastructure
Woes
Investing in clean
water as aging
equipment fails.

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TROUBLESHOOTING
QUIZ

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Circle 106 on card.

2 FROM THE EDITOR

T he American Water Works Association

(AWWA) conference is June 9-12 in
Denver, so Pumps & Systems has devoted this
EDITORIAL
EDITOR-IN-CHIEF: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
EDITOR: Jennifer King
edition to clean water. In past issues we have
jdking@cahabamedia.com • 205-278-2826
discussed water scarcity and bringing clean
PRODUCTION MANAGER: Amy Cash
water to nations that need greater access to acash@cahabamedia.com • 205-314-8274
it. In this issue, we talk infrastructure. MANAGING EDITOR: Drew Champlin
Failing infrastructure is one of the most dchamplin@cahabamedia.com • 205-314-8264
serious domestic problems facing countries CONTRIBUTING EDITORS: Lev Nelik,
Pumps & Systems’ Drew Champlin (right) Dominik Fry, Jim Elsey, William Livoti
around the world and those in the industry
interviewed Mike Rowe at ABB’s Customer CREATIVE SERVICES
work hard to keep things up and running. World event in Houston.
Investment dollars may be available for DIGITAL PROJECT MANAGER &
SENIOR ART DIRECTOR: Greg Ragsdale
projects in the next couple of years, so there is reason for some optimism. ART DIRECTOR: Elizabeth Chick
Our team has been on the road the last few months and has more travel plans WEB DEVELOPER: Greg Caudle
through the end of the year. At the recent ABB Customer World, Managing Editor Drew EMAIL OPERATIONS & STRATEGY MANAGER:
Champlin had the chance to meet and talk with Mike Rowe. Rowe is known for his work Melissa Weems
on the show “Dirty Jobs,” but also for his support of skills training. CIRCULATION
Dealing with the skills gap is a challenge to plants around the world. Rowe AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
encourages young people to go into the trades, and has set up scholarships to help them lmasaoay@cahabamedia.com • 205-278-2840
do it. We are very excited to bring you his comments. Watch for that interview in our ADVERTISING
upcoming July issue, where we are focusing on workforce development and training. NATIONAL SALES MANAGER:
Early last month, Drew also attended Valve Industry Knowledge Forum, which was Derrell Moody
held in our own backyard in Birmingham, Alabama. dmoody@pump-zone.com • 205-345-0784
The first week of this month, Editor Jennifer King is attending the Offshore SENIOR ACCOUNT EXECUTIVES:
Technology Conference (OTC) in Houston. We are seeing that interest in oil and gas, Mary-Kathryn Baker
especially fracking, is picking up. Experts say it will never be as high as it was a few mkbaker@pump-zone.com • 205-345-6036
years ago, but investors are looking for places to drill and according to the Baker Mark Goins
mgoins@pump-zone.com • 205-345-6414
Hughes weekly rig count, more rigs are operating in the United States virtually
Garrick Stone
every week. gstone@pump-zone.com • 205-212-9406
Jennifer will come back from OTC with even more insight into market activity. And SALES DEVELOPMENT REP:
that is why we try to go to as many events and meetings as possible. It helps us keep Gannon Greene
up with what is happening in the world of pumps so we can bring you that information ggreene@pump-zone.com • 205-278-2876
every month. CLIENT SERVICES COORDINATOR:
If you ever have a story to share or an event to tell us about, please email Carra Barnes
pumpeditors@cahabamedia.com. cbarnes@pump-zone.com • 205-561-2600
As always, thank you for reading!

PUBLISHER: Walter B. Evans Jr.

Editor-in-Chief, Alecia Archibald VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri Jackson
aarchibald@cahabamedia.com
CONTROLLER: Brandon Whittemore

P.O. Box 530067

Birmingham, AL 35253
EDITORIAL & PRODUCTION
Pumps & Systems 1900 28th Avenue South, Suite 200
is a member of the following organizations: Birmingham, AL 35209
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue S., Suite 200, Birmingham, AL 35209. Periodicals 205-212-9402
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and ADVERTISING SALES
possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and 1806 6th Street, Suite 200
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2019 Cahaba Media Group, Inc. No part of this publication may be reproduced
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertise- Tuscaloosa, AL 35401
ments, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descrip- 205-345-0784
tions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media
Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine.
SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media
Group, Inc., permission by an irrevocable license (with the right to license to third parties) to edit, reproduce, distribute, publish and adapt your submission
in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will
not be returned. Volume 27, Issue 5.

May 2019 | Pumps & Systems

 Comprehensive
& Cost-Effective
A word from HCP Pumps partner, Pacific Southwest Industries

Pacific Southwest Industries, located in the heart of Southern California, has been
a leader in engineered pumping solutions and pump distribution since the 80s.
Our approach is to provide comprehensive pumping solutions from conception
to startup. We take pride in our attention to details while offering a cost-effective
pumping solution. We selected HCP Pumps America to partner with us in our design
specifications for commercial/industrial and residential applications. HCP caught
our attention with a full line of single-phase pumps for our residential clients’ needs,
but we find ourselves utilizing many more pumps from their three-phase lines for The Pacific Southwest Industries team
industrial/commercial applications.
Contact PSI info@psipumps.com
Service is a cornerstone to Pacific Southwest Industries success and our partnership 800-358-9095
with HCP is crucial. The entire team at HCP Pumps works hard to provide us with psipumps.com
the inventory and quick responses that allow us to do the same for our clients.
With an expanding line of submersible pumps and a growing need for pump systems
in our market, we can see ourselves forging a long and prosperous relationship with
our friends at HCP Pumps.

Circle 104 on card.

Pumps & products to fit your needs.

We serve residential, commercial, industrial, and municipal industries. Our products can be used in almost any
applications from lift stations and water treatment plants to water features and dewatering. Furthermore, we
have a national network of distributors like Pacific Southwest Industries to address your needs.

Contact us at sales@hcppumpsofamerica.com or 251-943-8080 to learn more about our products.

HCP Pumps America, Inc. • 1723 industrial Pkwy, Foley, AL 36535 • hcppumpsofamerica.com
4
This issue MAY
Volume 27 • Number 5

COVER
SERIES CLEAN WATER COLUMNS
26 CLEAN WATER AROUND PUMPING PRESCRIPTIONS
THE WORLD 12 By Lev Nelik, Ph.D., P.E.
By Pumps & Systems Staff Pumping Machinery LLC
Water statistics from Proper Gauge Positioning
around the world.
PUMP SYSTEM STANDARDS
28 THE STATE OF EUROPEAN 44 14 By William Livoti
DRINKING WATER
Senior Engineer
By Thomas Angle
General Scope Document:
Swiss Flow Solutions & 38 PRODUCING CLEAN WATER Project Strategy
Julien Chalet FOR ISOLATED STEEL MILL
PROFLUID COOLING TOWERS PUMP SYSTEM IMPROVEMENT
European Union member states By Bryan Brister
attempt to address standardization Voltea 16 By Dominik Fry, P.E.
differences for ensuring safety and Engineered Software, Inc.
Technology purifies the only feasible
access for its citizens. System Troubleshooting Quiz:
water source for mill.
Can You Identify the Problem?
41 PUMP EFFICIENCY, DOE COMMON PUMPING MISTAKES
32 REQUIREMENTS FOR 2020
By Reece Robinson 20 By Jim Elsey
Grundfos Summit Pump Inc.
Make sure your pumps are Why Cavitation Occurs &
compliant with this new energy Ways to Treat it
conservation standard.

44 INSTRUMENTATION IN CLEAN
WATER TREATMENT
2 FROM THE EDITOR
& DISTRIBUTION
By Jack Roushey 8 NEWS
Siemens Process Instrumentation
How ultrasonic level controllers can
68 ADVERTISERS INDEX
result in cost and energy savings.
68 PUMP USERS MARKETPLACE
32 TAKING ON THE INSTALLATION
OF 5 RAW WATER PUMPS 72 PUMP MARKET ANALYSIS
By Chuck Smith
Sulzer
Keeping up with the demand
for clean water from this rapidly
growing population proved a 38
complex challenge.

34 HOW TO PROTECT WATER

IN COMMERCIAL BUILDING
INFRASTRUCTURE
By James Peterson
Crystal IS
Legionella is a risk when designing
water systems.

May 2019 | Pumps & Systems

 LAY WASTE
TO WASTE.

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solutions for solids and solutions.
Our innovative, dependable pumps and mixers provide
guaranteed performance in the toughest applications.
Learn more about our unmatched reliability. Contact us
today to see why our versatile pumps and systems are
perfect for your next project.

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Circle 105 on card.

6
This issue MAY
OTHER
REPORTS DEPARTMENTS
22 VARIABLE SPEED PUMPS
PROVIDE LONG-TERM 59 HI PUMP FAQS
HVAC PLAN Fluid Handling in Commercial
By Steven Lane
Armstrong Fluid Technology
22 Building Pumps & Uniform Flow
Requirements
By Hydraulic Institute
Solution allows property managers to
monitor data continuously. 54 DESIGNING PIPING SYSTEMS &
PUMPS CONCURRENTLY 62 SEALING SENSE
By Stephanie Villars API 622: Valve Packing for
24 SMART PUMPS FOR Applied Flow Technology Fugitive Emissions
COMMERCIAL BUILDINGS
Maintain a high system efficiency By Mark Freeman, FSA Member,
By Bob “Hot Rod” Rohr
with varying demand. EGC Enterprises, Inc.
Caleffi
ECM technology curbs excessive and 64 FLOW METERS
under pumping. 56 CHOOSE THE RIGHT FIRE PUMP
By Steven Brown Accurate Flow Measurement:
Steven Brown & Associates, Inc.
Critical for Water System Pumps
46 HOW A MUNICIPALITY By Chris Sizemore
SAVED $1.7M IN Learn about the advantages and
Badger Meter
WASTED WATER disadvantages of different pumps
used for stationary fire protection.
By Michael Kanellos
OSIsoft
Case studies show how detecting
leaks saves resources from going
down the drain.

49 DESIGN FOR THERMOPLASTIC

DOUBLE-CONTAINMENT
PIPING SYSTEMS
By Rodney Van
Asahi/America Inc.
Consider chemicals, temperature,
pressure, expansion and more.
EDITORIAL ADVISORY BOARD
THOMAS L. ANGLE, P.E., MSC,
Geschaeftsleiter (CEO), Swiss Flow
Solutions GmbH
AXEL BOKIBA, Vice President of
Project Management, Pulsafeeder
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
KEVIN CLARK, VP, Fluke Accelix
JACK CREAMER, Market Segment
Manager – Pumping Equipment,
Square D by Schneider Electric
BOB DOMKOWSKI, Business
Development Manager – Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA – Flygt
49
JIM DRAGO, Principal Applications
Engineer, Garlock Sealing
Technologies
WALT ERNDT, Vice President of
Business Development, Pump and
Process Equipment, Inc.
JOE EVANS, Ph.D., Customer &
Employee Education, PumpTech, Inc.
GEORGE HARRIS, President & CEO,
Hydro
ROB LAIRD, Engineering Manager,
Sulzer
LARRY LEWIS, President, Vanton
Pump and Equipment Corp.
WILLIAM LIVOTI, Senior Pump
System Engineer
TODD LOUDIN, President/CEO
North American Operations,
Flowrox Inc.
JOHN MALINOWSKI, Industrial
Motor Consultant
MICHAEL MICHAUD, Executive
Director, Hydraulic Institute
WILLIAM E. NEIS, P.E., President,
Northeast Industrial Sales
LEV NELIK, Ph.D., P.E., APICS,
International Center for Pumps
Research and Development, Israel
HENRY PECK, CEO, Geiger
Pump & Equipment Company
MICHELE SHAUGHNESSY,
Vice President Marketing & Sales,
PSG Dover
SCOTT SORENSEN, Oil & Gas
Automation Consultant & Market
Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump
Association (SWPA)
JERRY TURNER, Founder/Senior
Advisor, Pioneer Pump
DOUG VOLDEN, Global Engineering
Director, John Crane
CHRIS WILDER, CEO, SEPCO
JAMES WONG, Associate Product
Manager – Bearing Isolator, Garlock
Sealing Technologies

May 2019 | Pumps & Systems

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Circle 109 on card.

8 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
YUVBIR SINGH, SUEZ
PARIS – SUEZ announced the appointment of Yuvbir
Singh as CEO of the Water Technologies & Solutions
(WTS) division. He started on April 8, succeeding
Heiner Markhoff.
A graduate of the University of Pune with a
bachelor’s degree in engineering in electronics,
Singh joined General Electric (GE) in 1995, holding Yuvbir
Singh
various engineering, sales and marketing roles.
Between 2004 and 2015, he worked for GE Water, where he ultimately
led the engineered systems team. In 2015, Singh was promoted to vice
president of the global locomotive business for GE Transportation, and
as the vice president of equipment in 2018.
After leading the GE Water and now Water Technologies & Solutions
business for 10 years, Markhoff made the decision to step down as
CEO, effective March 30. Markhoff will continue to work with SUEZ in an
advisory capacity. suez.com
CODY MACK, CALEFFI
MILWAUKEE, Wisc. – Caleffi North America, Inc.
announced the promotion of Cody Mack to training
and education manager. Mack, working with
Caleffi U.S. and Canadian manufacturers’
representative networks, will conduct product and
application training for contractors, designers
and other influencers.
Cody
Prior to Mack’s five years at Caleffi, he installed Mack
and serviced HVAC and plumbing systems
throughout southern Wisconsin. caleffi.com
GARY PATTERSON, DSI/DYNAMATIC
MILWAUKEE, Wisc. – Drive Source International (DSI)
announced that Gary Patterson has been named
municipal market manager. Patterson started his
career at Drive Source International in 2012, as the
regional sales engineer for a portion of the Midwest.
Patterson then became the technical specialist of
the newly formed DSI/Dynamatic’s pumps, fan and Gary
Patterson
compressor group.
Patterson holds a Bachelor of Science in electrical engineering
from Michigan Technological University, where he specialized in
rotating equipment and electrical power generation, transmission and
distribution. dynamatic.com
MERGERS & ACQUISITIONS
Hunt Valve  Acquires Montreal Bronze                       March 21
Emerson  Acquires KNet Software      April 4
May 2019 | Pumps & Systems
MIKE YARUSSI, MUNRO
GRAND JUNCTION, Colo. – Munro, a manufacturer
of pumps, pump controls and pump stations for the
turf irrigation market, has named Mike Yarussi as
its new regional account manager for the Eastern
United States. Yarussi will work with the company’s
network of professional distributors, as well as
with irrigation specifiers, landscape architects, Mike
and landscape contractors, to provide support and Yarussi
further market presence.
Yarussi brings more than 30 years of experience in the irrigation
and golf industries to his new position. Yarussi is a certified irrigation
designer (CID) and a certified golf irrigation designer (CGIA), and holds
both an undergraduate degree and MBA from Liberty University.
munropump.com
MICHAEL SCHULZ, ARMSTRONG FLUID TECHNOLOGY
TORONTO – As part of its expansion in Europe, Armstrong Fluid
Technology GmbH introduces Michael Schulz as the sales director for
Continental Europe.
As sales director for Continental Europe, Schulz is a strategic leader
within Armstrong Fluid Technology’s sales team. He will manage the
new European sales teams in Germany, Hungary and France.
He joined Armstrong Fluid Technology recently after more than a
decade with a Danish pump manufacturer, where he was employed in
a senior sales management role with responsibility for the wholesale
business in Germany. armstrongfluidtechnology.com
MARTIJN BERGINK, FRAMO
BERGEN, Norway – Martijn Bergink has been named CEO of Framo,
succeeding Sameer Kalra. Kalra is the new head of the Alfa Laval Marine
Division and a member of the Alfa Laval Group management.
As CEO of Framo and president of business unit pumping systems,
Bergink will be based out of Bergen. He is a chemical engineer and
holds a degree in chemistry. He began working for Alfa Laval in the
Netherlands in 1998 and most recently held the position of president of
the business unit boiler and gas systems. framo.com
CHRIS DOWNEY & SHANE WRIGHT,
FRANKLIN ELECTRIC
Fort Wayne, Ind. – Franklin Electric
named Chris Downey as its new
territory manager for the north
central region and Shane Wright as
its new territory manager for the
southeast region. Most recently,
Downey worked as sales director
Chris
Downey
Shane
Wright
for Hydroflo Pumps, USA, and has
previously gained experience in positions at American Marsh Pumps.
Wright also worked as an inside sales representative as well as
director of sales and marketing for American Marsh. Most recently,
Wright worked as a national distribution manager for Ruhrpumpen.
franklinengineered.com
 9

EVENTS
OTC
May 6-9
NRG Park
Houston, Texas
2019.otcnet.org

AWWA
June 9-12
Colorado Convention Center
Denver, Colorado
events.awwa.org

NFPA
June 17-20
Henry B. Gonzalez Convention Center
San Antonio, Texas
nfpa.org

EASA
June 30-July 2
Mandalay Bay Convention Center
Las Vegas, Nevada
easa.com

Turbomachinery &
Pump Symposia
Sept. 10-12
George R. Brown Convention Center
Houston, Texas
tps.tamu.edu

WEFTEC
Sept. 21-25
McCormick Place
Chicago, Illinois
weftec.org

Pack Expo
Sept. 23-25
Las Vegas Convention Center
Las Vegas, Nevada
packexpolasvegas.com.

Chem Show With

Wiith more distribution channel access than ever to brands you can trust – lilike
ike
Oct. 22-24 Pioneer Pump®® andd FPS® – along
l w with onsite expert service,
i choose Franklin
kl n Electric
Javits Center when you arrive at your next water pumping crossroads.
New York, New York
chemshow.com Identify your local Franklin Electric sales representative at
Circle 112 on card.

franklinengineered.com/contact/locate-salesperson
ADIPEC
Nov. 11-14
Abu Dhabi National Exhibition Centre
Adnec, Abu Dhabi
adipec.com

pumpsandsystems.com | May 2019

10 NEWS

AROUND THE INDUSTRY

Grundfos Earns Top
Frost & Sullivan Award
LONDON – Grundfos won the award for
Company of the Year in the global water and
wastewater pumps market at the annual
awards show of consultancy company Frost
& Sullivan held in London.
In the award report, Frost & Sullivan cited
superior offerings of sustainable solutions
and commitment toward a customer-centric
service, coupled with market foresight and
innovation-driven growth.
“Grundfos was among the first companies
to introduce an off-grid water supply
solution with its solar-powered pumping
system in 1982,” said Fredrick Royan, vice
president at Frost & Sullivan.
“More recently, Grundfos introduced the
borehole pump for submerged applications
and became the first pump manufacturing
company to integrate software into
its products to support bidirectional
communication between the hardware and
its operators.
To have a news item considered, please send the information to Drew Champlin, dchamplin@cahabamedia.com.
“By pioneering this technology, Grundfos
avoided commoditization and outperformed
the competition.”
Marianne K. Knudsen, group vice
president, water utility, accepted the award
at the banquet at Royal Garden Hotel in
London. grundfos.com
ABB Signs Global Frame
Agreement with BP
HOUSTON, Texas – BP appointed ABB as one
of its global main contractors (MEC) for the
provision of engineering, procurement and
construction of electrical equipment for BP
Upstream Major Capital Projects.
The new agreement reflects a strategic
collaboration between ABB and BP, with
ABB committed to delivering innovation,
substantial savings, improved scheduling
and lower risk as a valued long-term partner.
ABB’s global MEC frame agreement is
effective for an initial term of five years.
As a global MEC partner, ABB can
assume full responsibility for the design
and engineering, procurement and
supply, project management, installation,
commissioning and on-time startup for
overall electrical systems on BP projects that
may be awarded to ABB under this global
frame agreement. abb.com
Quadrant Announces
Official Name Change
READING, Pa. – Quadrant is now officially
Mitsubishi Chemical Advanced Materials,
effective April 1.
Advanced Materials represents the
company’s capabilities and will allow the
company to continue its existence as a
group under the umbrella of their parent
company, Mitsubishi Chemical Corporation.
Product brands will remain unaffected and
continue to be used to distribute Mitsubishi
Chemical Advanced Materials products
under the same specifications into customer
channels. plasticperspectives.com

Preview: AWWA/ACE Preview: NFPA

June 9-12 Exhibition Hours June 17-20 Exhibition Hours
Colorado Convention Monday, June 10 Gonzalez Convention Monday, June 17
Center 10 a.m. – 5 p.m. Center 3 p.m. – 6 p.m.
Denver, Colorado Tuesday, June 11 San Antonio, Texas Tuesday, June 18
10 a.m. – 6 p.m. 11 a.m. – 3 p.m.
Wednesday, June 12 Wednesday, June 19
10 a.m. – 2 p.m. 11 a.m. – 3 p.m.
T he American Water Works
Association’s Annual
Conference and Exhibition
T he 2019 NFPA Conference
& Expo brings to life the
products and services needed
(ACE19) in Denver will be the place to learn, connect and be to meet and maintain compliance with prevailing codes
inspired to solve global water challenges. and standards in the design, construction and operation of
“Innovating the Future of Water” returns as this year’s buildings and facilities of every kind.
conference theme, with new technologies and water sector The NFPA Technical Meeting, also known as “Tech Session,”
innovations highlighted throughout the conference. is an important element in the standards development
This year’s professional programs include sessions focused process, ensuring that consensus is achieved on proposed
on asset management, utility risk and resilience, and water changes to NFPA standards prior to standards council review.
quality challenges. During this meeting, supporters and opponents of certified
Technological advances, new materials, designs and motions voice their opinions and qualified NFPA members
products will be on display at the expo. Participants will be vote on proposed changes.
able to conduct face-to-face discussions in the exhibit hall, This year’s technical meeting is scheduled to begin at 8 a.m.
and learn about utility trends and solutions. on June 20.
Visit events.awwa.org for registration information and NFPA will also offer more than 120 technical sessions
more about ACE19. during the show. Visit nfpa.org for more show information.

May 2019 | Pumps & Systems

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Circle 110 on card.
12 PUMPING PRESCRIPTIONS

By Lev Nelik, Ph.D., P.E.

Pumping Machinery LLC, P&S Editorial Advisory Board

Proper Gauge Positioning

This reader’s response to Dr. Nelik is I ran the pump we were testing the angle at which the water enters the
from Global Pump Engineering Manager through a full performance test, and the impeller, this also affects the suction
Ben Lindstrom difference was, of course, most visible at gauge reading. Due to the increased

B
high flow rates. velocity head of a rotating water column,
arry Erickson’s response to your At about 3,000 gallons per minute compared to a nonrotating column
article (March 2019 Pumps & (gpm) through this 8-inch discharge of water moving through the pipe at
Systems) was well written. He pipe section, we found the gauge reading the same flow rate, the static suction
notes that in many cases, gauges are at the discharge of the pump (before pressure reading can be artificially low.
not located on the pump flanges. This the check valve, and before accounting This is, of course, a manifestation of
is significant, and not just because of for the gauge height relative to pump Bernoulli’s equation.
the relation this has to the velocity head centerline) to be 88.5 pounds per square The prerotation, and its negative
correction (and height correction as inch (psi), and after the aforementioned impact on pump performance, can be
applicable). When the gauges are away assembly of fittings, valves, and pipe, minimized by adding a flow straightener
from the pump, friction loss in the pipe, we measured 72 psi. That is a 23 percent at the suction of the pump (many pumps
fittings and valves between the gauge drop in discharge pressure: 16.5 psi have a small one cast in).
can have a substantial impact on the (38 feet since the pumpage was water) However, in my experience, it is still
pressure readings, and thus, any flow rate of head loss that was unaccounted for visible in many cases when you measure
estimations or performance evaluations. as a result of the gauge location along the suction pressure right at the suction
I encountered this with a user who the pipe. Additionally, the gauge on the flange of the pump. Measuring farther
was testing a pump for performance pipe was also a couple of feet below the away from the suction of the pump,
monitoring purposes. The user was centerline of the pump, and this was especially when a flow straightener is
having trouble matching the published not accounted for on the customer’s test installed, will reduce prerotation gauge
performance curve. results, resulting in further error. error to a minimum.
When I visited the facility, I found Prerotation or preswirl is an unrelated We typically cannot directly measure
that they were measuring discharge error that can be typically seen at low what this prerotation is, but it can be
pressure not at the discharge of the flow rates at the suction of a centrifugal estimated during a performance test.
pump, but after a check valve, two pump. This is the liquid column in Since the friction loss—and other
90-degree elbows, a tee fitting (which the the suction pipe spiraling in the same dynamic losses—in the suction pipe can
flow was directed at a 90-degree angle direction as the impeller rotation. be approximated to change by the square
through), and a total of about 10 feet of Aside from the effects this has on of the flow rate, we can plot the measured
pipe and hose. pump performance due to the change in suction gauge reading at each flow rate
against the square of the flow rate.
The resulting plot should be a
straight line, with the line at zero flow
In my experience, it is still visible in many terminating at the value of the static
suction head. However, if you have
cases when you measure the suction pressure right prerotation, you will see the suction
at the suction flange of the pump. Measuring pressure decrease more than expected
at low and zero flow rates. You can
farther away from the suction of the pump, safely correct the suction gauge
especially when a flow straightener is installed, will readings at low flow to match the
expected values.
reduce prerotation gauge error to a minimum. It is worth noting that the effects
of this prerotation on gauge readings

May 2019 | Pumps & Systems

 13

are, in my experience, measurable

but typically small when a pump
has even a small flow straightener
installed. Without one, prerotation can Flowrox Heavy Duty Pinch Valves
have a large impact on shutoff head
performance of a pump.
For demanding shut-off & control applications
Finally, this prerotation or pre-swirl
is not to be confused with the suction
swirl you address in your December 2013
Ideal for applications involving abrasive/corrosive slurries,
article in Pumps & Systems. That
powders or coarse substances.
is a similar phenomenon that results
in a different gauge error and with a
slightly different solution regarding
Benefits of superior Flowrox valves:
gauge correction. ● Free flow
● Wear-resistant
Regards, ● Reliable operation
Ben Lindstrom ● Self-cleaning
Engineering Manager, Global Pump
● Bubble tight shut off
Dr. Nelik’s Comment:
Thank you so much, Ben. Another good Typical applications:
example of the importance of paying ● Grinding/screening ● Thickening
attention to details! Your observation ● Hydrocyclone & magnetic separation ● Filtration
regarding the effect of prerotation in ● Flotation ● Tailings
the inlet on a pump head (making a
pump curve “droop” near shutoff ) is an
excellent point. Need slurry knife gate valves? Flowrox has those too,
As well documented by A.J. Stepanoff ideal for flow isolation in most demanding conditions.
in his “Pump Bible,” inlet prerotation
is not caused by the shear effect on
fluid by the rotating impeller blade,
but indeed by the inlet approach
piping conditions—and, as you noted,
correcting these inlet issues can also
manifest in correcting the pump head
curve shape.

Dr. Nelik (aka “Dr. Pump”) is president

of Pumping Machinery LLC, an
Atlanta-based firm specializing in
pump consulting, training, equipment
troubleshooting and pump repairs.
Circle 111 on card.

Dr. Nelik has 30 years of experience in

pumps and pumping equipment. He
may be reached at drpump@pump-
CE 197
magazine.com. For more information, SIN ASK FOR MORE: www.flowrox.com
Follow us:
7

visit pumpingmachinery.com/pump_ 880-356-9797

school/pump_school.htm.
M
FL

OW
R O X.C
O sales-us@flowrox.com

pumpsandsystems.com | May 2019

14 PUMP SYSTEM STANDARDS

By William Livoti
Senior Engineer

General Scope Document: Sample Project Strategy

Statement
Project Strategy The project team will use a pumping system
specialist from XYZ engineering. XYZ
consulting will support the project leader and

T
team in developing a flow model (using state-of-
his month, we will discuss the-art flow modeling software) of the system
the fifth component of the in question to determine the most efficient,
general scope document: reliable pump package that will ensure the
project strategy. upgraded system will meet current and future
requirements as defined by the project leader
and team members.
Components of a
General Scope Document
1. purpose and justification
of the project Details
2. scope description
The project team has also determined that they
3. high-level project requirements
do not have the in-house resources to perform
4. project boundaries
this work and (as a team) have identified and
5. project strategy agreed on a specific engineering firm with the
6. project deliverables necessary skill sets that the team members feel
7. acceptance criteria (owner) is necessary to ensure the success of the pump
8. project constraints or system upgrade. The team also clearly stated
9. project assumptions that the flow model must be performed using
10. cost estimates state-of-the-art flow modeling software and
11. cost-benefit analysis that the pump upgrade must meet current and
future requirements (as defined by the team).
As you can see, details begin to emerge in the
As we move through each portion of the general general scope document—details that may or
scope document, specific details begin to emerge. may not have been identified had the project
Project strategy outlines in detail how the project team leader not had the input of those with a vested
(remember this is a team effort) will execute the project. interest in the system in question.
Next month, we will address project
Obviously, strategy may vary depending on the size
deliverables and more details.
of the project. For example, a simple pump upgrade
will require significantly less detail than a major plant
expansion. You still need to do your homework, and all
parties with vested interest in the project must
be involved. William Livoti is retired after more than 40 years
What does a typical project strategy statement look in the pump industry. Livoti is a member of the
like? Let us explore a simple pump upgrade project as Pumps & Systems Editorial Advisory Board. He
an example. may be reached at wlivoti@outlook.com.

May 2019 | Pumps & Systems

EXPERIENCE, EXPERTISE AND
A STAINLESS REPUTATION
Count on Ashcroft to ensure you have
the right materials to resist corrosion
Corrosion is a nasty business.
It can damage your instruments,
sometimes to the point of cata-
strophic failure. Acids, chemicals
or even water can aggressively
attack incompatible metals. The
good news is that you can avoid
this costly problem by choosing
the correct instrument right from
the start.
Ashcroft offers a wide variety
of pressure gauges, switches,
transducers, transmitters and
accessories with stainless steel
wetted parts that are specifically
Circle 103 on card.
designed to stand-up to harsh
pressure media. Are you measur-
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Understanding your application
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instruments is what we do every
day. Please contact us by calling
203-385-0635 or through our
website at:
www.ashcroft.com/contact_us.
tel: 203-378-8281
www.ashcroft.com/contact_us
www.ashcroft.com
16 PUMP SYSTEM IMPROVEMENT

By Dominik Fry, P.E.

Engineered Software, Inc.

System
Troubleshooting
Quiz: Can You
Identify
the Problem?

S
ystem troubleshooting can be
a difficult process for the most
experienced professionals.
Securing the necessary data to support
your conclusions can be even more
challenging. Before getting started, you
will need to know how the system was
designed, how it is supposed to operate,
and where on the curve your pumps
are operating, among other factors. In
this article, I will walk you through a
system that is operating correctly and
two problem scenarios that are often
encountered with this system. I will also
explain some common pitfalls—and tips
on how to avoid them.
When it comes to gathering data on a
system, building services are among the
hardest. Most of the piping system may
be hidden behind equipment or built into
the physical structure, such as the walls
and ceiling, and instrumentation is often
few and far between.
For example, one engineer recently
visited a mechanical room where more Image 1 (top). System under normal operation
than half of the pressure gauges on the Image 2 (middle). System with initial issue
Image 3 (bottom). System with expansion issue (Images courtesy of the author)
pumps were broken or outside of their
rated range. In this type of situation, it
is important to never speculate on how but the needle is slightly past 80, do not component will impact the hydraulic
well they were calibrated, and when attempt to calculate pressure because you performance of the entire system.
comparing these systems, you may have passed the instrument’s range and Because of this, we must be able to
have to get a little creative. Do not get any readings will be unreliable. What you understand the symptoms, and then
discouraged, and do not attempt to take will know, however, is that there is a fault focus on the root cause of the problem.
exact measurements in this instance (but somewhere in the system causing it to To start, we need to know what is
you can still receive general data). operate outside of its design parameters. considered normal. If the system has
For instance, if the pressure gauge only As all components of a piping system been operational for some time, then the
goes to 80 pounds per square inch (psi), are interconnected, a problem with one systems operator should have a decent

May 2019 | Pumps & Systems

ARSENIC
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Circle 102 on card.

18 PUMP SYSTEM IMPROVEMENT

understanding of what normal is for their system. However, it

is always helpful, whether you have worked with the pumping
system before or are new, to build a flow model to give you a
better understanding of what is going on and what normal
should be. For this example, we will say that the pressure, flow,
level and valve position readings in Image 1 are the normal
steady-state operating conditions for this system.

Normal Operation
• The supply tank is open to atmosphere and its level is
maintained at 10 feet.
• The supply pump has a suction pressure of 15 pounds
per square inch gauge (psig) and a discharge pressure of
80.5 psig.
• The heat exchanger has an inlet pressure of 67 psig and an
outlet pressure of 57 psig, for a total differential pressure
of 10 pounds per square inch differential (psid) at 1,000
gallons per minute (gpm).
• The flow control valve is 85 percent open with 1,000 gpm
flowing through it.
• The product tank is pressurized to 25 psig and has a level of
15 feet.

After being placed into operation, the system began to

experience a variety of issues. One operational note is that
the flow rate from the product tank is reduced to maintain the
tank level, which limits the flow rate for the entire system.
While this is an issue, it is not the main system problem.
Take a minute, and compare Image 1 with Image 2. See if you
can identify what is causing the system issue in Image 2.
A good first step is to look at how everything compares to the
normal system operation. Here is a quick summary of how the
operation differs.
• supply tank level: OK
• pump suction pressure: OK
• pump discharge pressure: higher than normal
• pump dP: higher than normal
• HX inlet pressure: higher than normal
• HX outlet pressure: lower than normal
• HX dP: higher than normal
• FCV: open farther than normal
• system flow rate: less than normal
• product tank level and pressure: OK
Circle 115 on card.

What is abnormal, and what could cause it? It would be

understandable to look at the pump first, as the discharge
pressure and the differential pressure are higher. This indicates
the pump is producing more head, but this is expected because
it is running farther back on the pump curve at the lower flow
rate. The heat exchanger inlet pressure is also slightly higher,
but this is due to higher pump discharge pressure.

May 2019 | Pumps & Systems

 19

The total pressure drop across the heat exchanger is 18 psi at

940 gpm. Under normal operating conditions, it should be 10
psi—an even higher flow rate. This would indicate that the heat
exchanger has been plugged up, and thanks to this flow model
we have solved the mystery of this system’s main problem.
Let’s take a look at another system example. The system in
Image 3 was built with a system expansion in mind, but they
ran into issues during implementation. A trial run was done to
determine the maximum flow rate possible, and even with the
flow control valve at 100 percent open, the maximum flow rate
was just over 1,000 gpm. Compare the system in Image 3 with
the system in Image 1, and see if you can determine the root
cause of this system’s problem.
Look again at how these devices compare to normal.
• supply tank level: OK
• pump suction pressure: OK
• pump discharge pressure: lower than normal
• pump dP: lower than normal
• HX inlet pressure: lower than normal
• HX outlet pressure: lower than normal
• HX dP: OK
• FCV: open farther than normal
• system flow rate: normal
• product tank level and pressure: OK

Were you able to determine the abnormality and the cause?

The flow control valve is open farther to maintain the same
flow rate, and this could be due to the lower inlet pressure.
The system pressures downstream of the pump are lower than
normal, and so is the differential pressure across the pump.
This indicates it is producing less head for the same flow rate of
1,000 gpm, so that it is operating below its pump curve. This
shows that there is a pump problem, which could be caused by a
damaged impeller, worn wear rings or a clearance issue.
In any system, there are as many potential problems as there
are components, and as you increase the number of branches,
loops and/or multiple malfunctions, it can become more
challenging to discover the root cause of your problem.
Having a good model or digital twin of your system can let
you make changes and see how the system interacts with itself,
regardless of complexity. I hope these examples have given you
insight into the troubleshooting process and given you new
tools for your troubleshooting toolbox.
Circle 123 on card.

Dominik Fry, P.E., is Engineered Software, Inc.’s business

development engineer and has nearly a decade of experience
in the energy industry while working on some of the nation’s
largest energy projects. Fry earned a Bachelor of Science at
Montana State University. For more information, visit
eng-software.com.

pumpsandsystems.com | May 2019

20 COMMON PUMPING MISTAKES

By Jim Elsey
Summit Pump Inc.

Why Cavitation Occurs & Ways to Treat it

T
he old joke about falling from a
tall building is that “it isn’t the
fall that kills you, it is the sudden
stop at the bottom.” When it comes to
cavitation, it is not the formation of the
vapor bubbles that kills the pump, it is
the subsequent collapse.
There are plenty of articles on net
positive suction head (NPSH) and
cavitation that talk about the bubble
formation and the consequential pump
damage in a broad sense, but the details
of the damage mechanism are rarely
discussed. The focus of this article is
looking into why are we so worried about
a few bubbles.
Cavitation causes an increase in
pump noise and vibration, but more
importantly, a drop in performance,
efficiency and impeller erosion. Not all of
the damage from cavitation is metal loss
or metal damage. Sometimes the issue is
shortened bearing and mechanical seal
life due to the unsteady flows (surging).
Simply defined, “classic cavitation”
from the perspective of centrifugal
pumps is the formation of bubbles in the
pump inlet near the eye of the impeller.
The bubbles form because local pressure
has dropped below the vapor pressure
of the fluid (another way to view this is
that the NPSH margin is not sufficient).
Less than a fractional second later as the
bubbles transit along the low pressure
side of the impeller vanes, they enter a
region of higher pressure and collapse.
I refer to this as classic cavitation
to differentiate it from other causes of
cavitation, such as suction or discharge
recirculation that manifests on the other
side of the impeller vane. Recirculation
cavitation is typically due to operating
the pump to the left side of the pump
operating curve (reduced flows) and away
from the best efficiency point (BEP). The
approach angle of the incoming flow does
not match that of the rotating impeller
inlet vane geometry. Consequently, eddy
currents and turbulence are generated in
between the vanes.
Inside the general area of the eddy
current, the velocity increases and
the pressure decreases as a result.
This action occurs due to the laws of
conservation of energy as explained by
Bernoulli’s equation and the pressure-
velocity relationship. When the local
pressure drops below the vapor pressure,
the cavitation bubbles are formed.
Recirculation cavitation is typically
not caused by insufficient NPSH in
the classic sense. You could have more
than adequate NPSH margin and still
experience recirculation cavitation
because the pump is being operated away
from its BEP.
When this situation occurs, there is a
mismatch in the flow angle as compared
to the impeller inlet incidence angle. The
higher the suction specific speed (NSS)
of the pump impeller, the more likely
recirculation cavitation is an issue.
For more information on the subject of
NSS, see my Pumps & Systems February
2019 article.

High Pressure Side

of impeller vane Cavitation Damage
Suction Recirculation

Cavitation Damage
Discharge Recirculation

“Classic Cavitation” Damage

due to NPSH Issue on low
pressure side of the vane

Low Pressure side

of Impeller vane

Image 1 (top). An outline of where classic cavitation occurs (Images courtesy of

the author)

May 2019 | Pumps & Systems


Cavitation bubbles that break down in
the middle of the impeller passageway
collapse symmetrically (equally from
all directions), so there is less cause
for concern other than potential noise
and perhaps some vibration. Similar
(but different) to boiling water in an
open pan on a stove, the bubble forms
at the bottom of the pan, rises to the
surface and collapses without issue or
harmful effects (technically this is a
burst and not a collapse so almost no
energy is released).
However, when the vapor bubbles in a
pump impeller collapse adjacent to the
metal surface of the vane, there is a much
higher potential for damage and concern
due to metal loss from the substrate.
When the bubble collapses near the vane
surface, it will collapse asymmetrically.
Because of its proximity to the vane
surface, the bubble geometry changes
and makes the action more lethal. When
the bubble collapses, it is not just the
surrounding fluid that rushes in to fi ll
that void, it is more importantly that
the vapor is changing state from a vapor
(back) to a liquid.
I repeat for emphasis that the amount
of energy transferred for a change of
state is very high. You can calculate
the energy using enthalpy equations.
Additionally, the collapse of a vapor
bubble is exponentially more impactful
than if it was an air bubble. With vapor
bubbles there is a change of state from
liquid to vapor and back, while an air
bubble creation or dissipation does
not involve a change of state. Further,
when the vapor bubble collapses
asymmetrically, there is a resulting
reentrant microjet burst that on a local,
nanoscale level is powerful (the local
scale is 1 x 10 -9, that is 10 to the negative
nine exponent or a billionth).
Local pressure forces involved in
the microjet burst can have resultant
shockwaves higher than 10,000 pounds
per square inch gauge (psig). The bubble
collapse phenomena can occur with a
high periodicity of 300 times per second
and all of this action happens at the
speed of sound. The resultant microburst
jet almost always directs at the adjacent
surface in lieu of the fluid stream. The
vane material substrate is subjected
to a localized surface fatigue failure.
The average lifespan of a vapor bubble
from creation to collapse is about 2 to 3
milliseconds. Not everyone agrees if it is
the shockwave or the reentrant micro jet
burst that creates the damage. Likely, it is
the combination.
Hopefully, with this perspective, you
begin to understand how cavitation can
damage an impeller in short order.
On a scientific level, besides the
enthalpy equation mentioned earlier, the
energy of the bubble collapse is simply
a kinetic energy calculation and is a
function of the mass and velocity.
kinetic energy = 0.5 x mv2
Where: m is the mass and v is the velocity
Equation 1
Note that vapor bubbles formed in
water at ambient temperature are of
a much larger size (mass) than if the
water temperature was close to and
approaching 200 F. The larger the bubble,
the more energy and damage. Therefore,
cold water cavitation is much more
dangerous than hot water cavitation.
The root cause for vapor bubble
evolution is often overlooked. Pumps
do not so much generate heat to make
the water flash to vapor, but instead it
is a result of the drop in pressure near
the impeller eye. Remember you can boil
water at 33 F if you reduce the pressure
low enough.
There is some correlation of cavitation
noise (intensity) to impeller damage. I
am not presently aware of a conclusive
formula or method for accurate
determination. I am aware that several
people are conducting studies in this
subject area. Noise level for cavitation
falls in the general range of 10 kilohertz
(kHz) to 120 kHz. The general accepted
21
range of hearing for humans is only 20
Hz to 20 kHz. Perhaps I will devote a
future article to acoustic detection of
cavitation. If you hear cavitation noise,
the pump is likely cavitating, but just
because you do not hear cavitation noise
does not mean it is not cavitating. Some
of the most damaging cavitation occurs
at noise levels outside the audible range.
I also witness many people confusing
cavitation noise with turbulent or high
velocity flow noises.
Sometimes you just cannot have a
cavitation-free system, and you may
wish to treat the symptom in lieu of
the problem. With all of this energy
being dissipated near the surface of the
impeller vane, it is important to note that
all impeller materials react differently to
the exerted force.
For impellers, 300 series stainless is
better than cast iron. Higher chrome
content steels are better yet, while
CD4MCu (duplex alloy) is better than
high chrome stainless. There is good
information and engineering studies
completed in this area. Your empirical
results may differ.
Finally, note that even with high
NPSH margins, where the NPSH available
far exceeds the NPSH required, the pump
may still experience some cavitation. It
is nearly an impossible task to reduce it
to zero.
Jim Elsey is a mechanical engineer
who has focused on rotating
equipment design and applications for
the military and several large original
equipment manufacturers for 48 years
in most industrial markets around the
world. Elsey is an active member of
the American Society of Mechanical
Engineers, the National Association of
Corrosion Engineers and the American
Society for Metals. He is the general
manager for Summit Pump Inc.
and the principal of MaDDog Pump
Consultants LLC. Elsey may be reached
at jim@summitpump.com.
pumpsandsystems.com | May 2019
22 BUILDING SERVICES EQUIPMENT
Variable Speed Pumps 
Provide Long‑Term HVAC Plan  
Solution allows property managers 
to monitor data continuously.
BY STEVEN LANE 
ARMSTRONG FLUID TECHNOLOGY
W
hen the seals fail on 5-year-old pumps, the
conventional approach is to arrange for repair.
But one property management group decided to
replace the pumps completely.
Following a recent scheduled shutdown of the air-condition
system in a west Toronto condominium building (13 floors,
housing 303 owners), the system would not restart. An
investigation revealed that both pumps were leaking badly,
and it was not the first time there had been issues.
Dan Barnabic, author of “The Condo Bible,” provided his
assessment of the expected useful life of building systems
in an article from Huff Post in 2015. After analyzing a
chunk of data, he estimated that cooling systems should
function trouble-free for at least 12 years, heating for
more than 20 years, and plumbing for close to 50 years.
An instance of equipment failing and rusting out after just
five years should be considered an anomaly. There are a few
possible explanations, but in this case, the team suspected
overzealous cost-cutting.
“We guessed they were cheap pumps that the builder had
put in to cut costs,” said Erika Elbert, property manager for
Dell Properties in North York, Ontario. “It was frustrating
that both pumps were leaking and one was shaking so badly
I had to shut it down. If they both failed, our residents would
be without heating and cooling.”
Replacement Solves Operation Issues
The situation seemed urgent. Whether it was the product or
the installation, the two pumps were clearly corroded and
deteriorating in several ways. This suggested unpredictable
maintenance had followed initial warning signs.
Given the possibility of a dual failure and a disruption in
hundreds of dwellings, the condominium board wanted a
more permanent solution.
May 2019 | Pumps & Systems
Image 1. Pump control capabilities include advanced algorithms for
sensorless technology. (Image courtesy of Armstrong Fluid Technology)
The business case for a total replacement was convincing.
“Variable speed technology looked promising,” Elbert
said. “It saves energy and money. When we looked into it, we
realized there would be big savings.”
Pump Technology Is Advancing Quickly
In addition to significant efficiencies from the variable speed
upgrade, new sensorless, Wi-Fi-equipped controls would
provide other advantages. Pump technology has evolved
a great deal in the past five years. Offerings reflect better
engineering along with advanced electronics, mechanics,
artificial intelligence and enhanced communications.
For this condominium, upgrading to new pumps meant
that operating data would now be accessible online and could
be monitored continuously by both the property manager
and by fluid management technicians. The control software
would make it easy to continue to commission the equipment,
optimize performance and diagnose problems. It would also
make it faster to implement efficiency tweaks and service.
The chosen pump replacements were variable speed pumps
with a power range of 1 horsepower (hp) to 1,250 hp, and
a performance range of 25 gallons per minute (gpm) to
25,000 gpm. With integrated intelligent controls, the new
pumps have potential energy savings up to 75 percent over
comparable constant speed or variable frequency choices.
The new pumps also included a software and service
bundle with monitoring and diagnostics capabilities.
 23

Analysts supporting this bundle examine pump conditions,
including vibrations and energy efficiency trajectories. They
also look for any symptoms or trend lines that might lead to
catastrophic failure.
Algorithms Eliminate Sensors
Future software advances can be added to existing
installations, enhancing the capability and longevity of
the technology. Corrections that go beyond efficiency
optimization may also be possible. On-site service is
sometimes easier with connectivity, occasionally eliminating
the need for a specialist in a suit to clamber over pipes in
mechanical rooms to observe equipment status.
Service manuals and demonstration videos can be loaded
into on-board memory, permitting service personnel to access
relevant support years after the original installation of the
equipment. Design engineers have developed pump control
capabilities including advanced algorithms for sensorless
technology, which eliminates the need for sensors. Other
capabilities include soft-starting for lower electrical demand
and reduced risks related to harmonics.
The best pumping solutions also offer intelligent
sequencing, part-load efficiency and demand-based control.
With all of these features, energy savings with today’s
technology can exceed 70 percent, compared to equipment
that was considered modern just a few years ago.
Once the condominium board received the savings model
for new pumps, the discussion was mostly limited to, “How
fast can we move into the 21st century?” Technicians replaced
the them in a few days, with intelligent fluid management
systems that have a flow capacity up to 550 gpm, maximum
pressure of 175 pounds per square inch (psi) and a maximum
temperature of 200 F.
The energy savings should quickly cover the replacement
costs, especially considering the unknown maintenance
issues that might have followed a lesser solution.
Condo owners may be preoccupied with immediate
comfort issues, but they are also benefitting from advancing
technology that created savings to offset the costs of an
unfortunate situation. “The pumps were failing and leaking.
We needed to choose a new route,” Elbert said. “We now have
that in place, and the residents are happy.”
Steven Lane is communications manager for Armstrong
Fluid Technology. He may be reached at slane@
armstrongfluidtechnology.com. For more information, visit
armstrongfluidtechnology.com.

SIMPLE, INTELLIGENT, EFFICIENT!

ADXL... SERIES
• two phase control
• UL rated current 30A...320A
• UL rated motor power
20HP...250HP (480VAC)
• rated operational voltage
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• conformal coating on the boards
• backlit LCD display
• reduced voltage starter with
torque control and built-in
bypass relay
• maximum starting current
• optical port for programming,
data downloads and diagnostics
• NFC technology for
parameter programming
• remote control via
supervision software
• Modbus-ASCII and
SOFT STARTERS
Modbus-RTU communication
protocols
• RS485 communication
with optional card
• quick installation with
AUTO SETUP

LOVATO ELECTRIC INC. - 2017 Georgetown Blvd.

CHESAPEAKE, VA 23325 UNITED STATES
Tel. +1 757 545-4700 - Fax +1 757 545-2900
info@LovatoUsa.com

Circle 124 on card.

pumpsandsystems.com | May 2019

24 BUILDING SERVICES EQUIPMENT
Smart Pumps for  
Commercial Buildings  
ECM technology curbs excessive and under pumping. 
BY BOB “HOT ROD” ROHR  
CALEFFI
T
he evolution of electronically commutated motor
(ECM) technology into the fractional horsepower
market has opened possibilities for building service
end users. The world of building systems depends
upon circulators for hydronics, including heating and chilled
water applications.
Solar thermal has lost some market share in the past few
years but is still a viable market for ECM, hereon referred to
as smart pumps.
How did pumps get so smart? Once a microprocessor is
attached to an efficient motor design, many doors open.
Prior to the release and acceptance of smart pumps,
mainly multispeed technology was available for use. While
that was a step up from single-speed motors, the market
demanded more.
By adding a brain to the package, building circulator
pumps can now be further manipulated to almost the exact
requirements of the end user.
Performance output, record and display data can be
modulated and connected remotely to monitor or adjust.
This is in addition to a more efficient motor design. It is not
uncommon to experience 50 to 80 percent electrical energy
savings from the improved motor design.
There can be a win on the fluid side, also. Current and
widely available circulators have the ability to adapt to ever-
changing requirements found in zoned systems. Smart pumps
The European standard changes occasionally and the bar is set higher.
Pump manufacturers seek out engineered equipment that will meet the
evolving energy standard requirements.
May 2019 | Pumps & Systems
have the ability to sense changing flow requirements and
reduce or increase flow rates to match and maximize the
flow performance.
In building systems zoned with on/off or modulating
valves, the smart pumps shine. Simply put, it is like a cruise
control on the circulator. Excessive over or under pumping
should be a thing of the past.
Much of the high-tech circulator pump technology evolves
from ever-increasing energy standards in Europe, home to
some of the largest hydronic markets and pump engineering.
The color bar graph seen on some pump boxes indicates the
standard and how the product performs to it.
The European standard changes occasionally and
the bar is set higher. Pump manufacturers seek out
engineered equipment that will meet the evolving energy
standard requirements.
Regardless of how the system is zoned, whether it is
motorized on/off valves, proportional thermostatic valves
or zone pumps, there is technology available to fit a
user’s application.
The acceptance of this technology has made it more
affordable. The early entry versions were nearly four times the
price of standard permanent split capacitor (PSC) wet rotor-
style circulators.
Smart pumps, in addition to their electrical savings, can
solve other long-standing problems in buildings.
 25

Excessive velocity and banging or noisy control valves exist

TIPS FOR SMART PUMP TECHNOLOGY
• Always practice safe pumping.
• Run the appropriate calculations to size
the pump.
• Consult with representatives or the
manufacturer for sizing help on these new
“funny curve” smart pumps.
• Include strainers or separators to keep
everything clean and healthy.
• Install isolation valves and gauge ports for
testing, servicing and confirming performance.
• Ensure good fluid quality. Systems may have
plain tap water, a blend of glycols for freeze
protection or conditioners to protect multimetal
systems. The fluid is the lifeblood of all
hydronic systems and circulator pumps know
and appreciate attention to that detail.
in some systems.
With features like auto adapt, the circulator will learn the
fingerprint of the system and make flow adjustments to help
keep pumps from running off their curve.
Until recently, the common circulator included three pieces:
• motor
• bearing
• pump volute
Selection for small applications was limited. These early
workhorse circulator pumps required maintenance and
manual lubrication.
When properly sized and cared for, they lasted for years,
sometimes decades.
So, as the pump spins, a user can keep their hydronic
system’s drama to a minimum.
Bob “Hot Rod” Rohr is currently the training
and education manager, North America
for Caleffi Hydronic Solutions. For more
information, visit caleffi.com.

E ! 0
G ED s 12
N D do
RA EN es Q
T ud
EX incl
Accurate, versatile
Now
chemical pumps
• Cut chemical costs through
higher accuracy metering
• Simple drop-in installation
eliminates ancillary equipment
• Range expanded to include the
Qdos 120: flow rates from 0.001
to 31.7 USGPH and up to 100 Psi

Fully sealed for

life, one minute
tool-free maintenance
R E V O L U T I O N A R Y P E R I S T A LT I C P U M P H E A D

Booth 3231

qdospumps.com
info@wmftg.com

Circle 128 on card.

pumpsandsystems.com | May 2019

 CLEAN
26 WATER
around the world

CLEAN P
umps are essential to the treatment and
delivery of clean water. Leaky pipes and
failing equipment around the world are

WATER
putting water accessibility at risk. In
this section, we examine the state of clean water
around the world and provide some insight into what
companies and municipalities are doing to make the
most of assets.
around the world There are reasons for optimism. The United States
infrastructure bill passed in 2018 is expected to spur
investment. In the European Union, the result of a
Brexit decision will complicate water production
and delivery across the continent. As of press time,
governments were devising plans to accommodate
any outcome so citizens will experience limited
water stress.
Meanwhile, global water providers must shore
up cloud and computing operations. The threat
from cyberattacks grows daily, according to
Netscout’s Worldwide Infrastructure Security Report
for 2018. Research shows that data targeted in
attacks in 2018 was 45 percent larger than in 2017.
Problems are growing globally, but the Middle East
and Asia-Pacific regions are the most vunerable,
Netscout says.

May 2019 | Pumps & Systems

 27

DID YOU KNOW...

55 percent
Sources of drinking
more
than 2 billion
people
of the world’s population
lives in urban areas, and
water in the EU
19,744
it could increase to 68%
by 2050, adding another
2.5 billion people to
Number of desalination urban areas with
50 %
live in countries plants worldwide close to 90% groundwater
experiencing Number of of the increase 36 %
high water stress
150 countries where
desal is practiced
taking place in
Asia and Africa
surface
water 14 %
other

120
The average water
consumption
per person per

!
liters day in the EU
28 billion in
Uganda and
163 million
80 %
countries
worldwide
report insufficient financing
to meet national water
lack access to clean water
in India
Kenya lack
access to
clean water
infrastructure financing targets

An estimated 240,000
water main breaks
occur each
year in the U.S.
11 %
The need for
wastewater
instrastructure in
the U.S. exceeds

6 billion of treated water in

percent of population
that is experiencing
$271
the U.S. is lost every scarcity of drinking

gallons day to leaky pipes water in the EU billion

Sources: European Parliament, U.N. Water, U.S. EPA, American Society of Civil Engineers, water.org, OSIsoft and the International Desalination Association

pumpsandsystems.com | May 2019

 CLEAN
28 WATER
around the world

The State of European 
Drinking Water   
European Union member states attempt to address standardization 
diff erences for ensuring safety and access for its citizens.

BY THOMAS ANGLE, SWISS FLOW SOLUTIONS &
JULIEN CHALET, PROFLUID

M
ost people in the European Union (EU)
have access to high-quality drinking water.
According to a report by the European
Environment Agency in 2016, more than
98.5 percent of tests carried out on drinking water samples
between 2011 and 2013 met EU standards. The EU Drinking
Water Directive (DWD) sets minimum quality standards for
water intended for human consumption (drinking, cooking
and other domestic purposes) in order to protect consumers
from contamination.
Today, the water sector in Europe consumes the equivalent
of about 3.5 percent of the electricity consumption. At the
local level, power charges account for 30 to 50 percent of
municipalities’ bills. The commission study revealed that
Europe has a massive issue regarding water leakage in the
infrastructure. According to the analysis, the average leakage
rate in Europe stands at 23 percent of treated water.
The commission’s solution to address this issue has been
to include transparency requirements for the biggest water
suppliers to publish information on their water leakage and
energy consumption.
Encouraging Drinking of Tap Water
On Oct. 23, 2018, the European Parliament officially
commented on the European Commission proposal to
further improve the quality of, and access to, drinking water
for all people and reduce plastic waste from water bottles.
This update of the rules is intended to increase consumer
confidence and encourage the drinking of tap water.
EU countries are requested to “promote universal access” to
clean water for everyone, especially vulnerable groups with
no or limited access.
This legislation aims to further increase tap water quality
by tightening the maximum limits for certain pollutants

HISTORY OF REGULATIONS IN THE EUROPEAN UNION

B efore 1980, each EU member state adopted their own national regulations
for drinking water. This included certification programs for products that
come in contact with drinking water during the supply process. In general,
these regulations have been implemented in the various member states with
success. The downside is that differing standards within each country have
made it difficult for suppliers to sell products freely across the EU.
Several member states have developed rules on materials and products
in contact with drinking water, resulting in potentially different levels of
human health protection and market fragmentation. It is also common to face
difficulty in finding a unique material that can be approved in all European
markets. Not only does this situation make it more difficult for companies—
especially small and medium enterprises (SMEs)—to export products to other
EU countries, it also hampers innovation.
1980
The first Drinking Water Directive (DWD) was put into place
in an attempt to harmonize the national requirements of the
individual EU member states. This was implemented by the
council of the EU as regulation 80/778/EEC.
Article 8 of this directive stipulated that each member of the
EEC must take measures to ensure no substances used in the
drinking water treatment process remain in a concentration that
would constitute a hazard to public health. About 60 substances
were listed, but no requirements were given for materials and
substances used in the distribution of drinking water.

May 2019 | Pumps & Systems


such as lead (to be reduced by half) or harmful bacteria and
introduces new caps for certain endocrine disruptors. Levels
of microplastics will also be monitored. The new rules would
also increase transparency and provide consumers better
access to information.
Drinking tap water is inexpensive and environmentally
friendly. Members want measures such as installing free
fountains in public places—including shopping centers
and airports—and encouraging restaurants to provide
tap water.
According to the European Commission, access to better
quality water could reduce bottled water consumption by 17
percent. Less bottled water would help people save money and
have a positive impact on the environment, by reducing CO2
emissions and plastic waste.
The European Parliament website shows the
following regarding the use of bottled water:
• Consumption of bottled water per person per
year is 106 liters.
• Amount that could be saved yearly by
households if tap water is substituted for
bottled water is €600 million (approximately
$686 million).
Materials in Contact with Drinking Water
This is a subject of interest to not only pump manufacturers,
but also everyone who provides equipment used in the
production and transportation of drinking water. The history
of the regulations in this area is long and convoluted with
difficulties and frustrations for all producers.
In the EU, general materials requirements are regulated
in Article 10 of the EU DWD (Directive 98/83/EC), and
the enforcement and monitoring process is transferred to
individual member states. National lawmakers are obliged
to implement all measures required to ensure materials
2018
On Feb. 1, 2018, the European Commission
adopted a proposal for a revised DWD to update
the 1998 regulations (98/83/EC1998), improve
the quality of drinking water and provide
greater access and information to citizens.
1998
The DWD was updated as regulation 98/83/EC. Article
10 of this directive specified material requirements by
stating: “Member states shall ensure that substances
and materials in contact with drinking water shall not
endanger human health.“ From this point forward, EU
legislation has covered substances and materials used
for the distribution of drinking water.
29
and products used in drinking water treatment and
distribution do not have a direct or indirect adverse effect on
human health.
This is good in theory, but the majority of the EU member
states currently do not coordinate their implementation
efforts. The result is different national requirements for the
marketing of materials and articles that make contact with
drinking water.
As of today, there are more than 15 certification and
test organizations within the EU that regulate licensing of
products and materials suitable for use with drinking water.
This has resulted in the lack of a common EU standard for
human health protection.
Compliance with all test criteria in the respective
member states is complex and time-consuming for product
manufacturers and often results in a significant financial
burden. In addition, member states often deny market access
to products that are lawfully marketed in other member
states, in contradiction with the mutual recognition principle
as established by EU treaties.
All of these aspects ultimately result in significant barriers
to the free circulation within the EU of products in contact
with drinking water.
History of Material Regulations
In 1998, the European Commission promoted the
development of a European Acceptance Scheme (EAS),
and a standardized European approval system for products
in contact with drinking water began. The intention of
this scheme was to replace individual national approval
systems with one EU approval scheme and to remove trade
barriers within the region.
Due to technical and political obstacles, the EAS project
was abandoned in 2006 without achieving substantial results.
To a limited extent, the project was continued as part of
The commission proposes to update existing safety standards in line with
the latest recommendations of the World Health Organization (WHO), but
also sets an obligation for EU countries to improve access to safe drinking
water for all, and more specifically, to vulnerable and marginalized groups.
The revision of this directive is also an opportunity to integrate the new
priorities of the EU including environment protection, the development of a
circular economy and adaptation to climate change.
pumpsandsystems.com | May 2019
 CLEAN
30 WATER
around the world

the work on standardization under the Construction Products

Directive (CPD). In 2001, the European Commission requested
standardization bodies in the EU to support the EAS in
providing European standards for construction of products
in contact with water intended for human consumption. This
resulted in the production of a few test standards, but never
achieved the expected result.

Fragmentation of Regulations
In order to implement the original intentions of the EAS,
France, Netherlands, the United Kingdom and Germany agreed
in 2007 to pursue a common approach for testing and assessing
products in contact with drinking water on a voluntary basis.
This program is generally known as the Four Member States
(4MS) Initiative. Other countries have also become involved to
one degree or another.
In 2011, the 4MS signed a formal declaration of intent. Up to
now, several harmonized (among the 4MS) approval systems
for materials and products in contact with drinking water have
been developed, although these have not been systematically
implemented at the national level.
Furthermore, in 2014, Denmark, Finland, Norway and
Sweden began the MAID project—an initiative focused
on material and product innovation through knowledge-
based standardization in the drinking water sector. The first
report, Nordic Drinking Water Quality, and the second report,
Regulations and Approval Systems in the Nordic Countries, were
published in November 2017.
During the past few years, there have been reports of other
member states interacting with the above groups, plus some
evaluating their own standards. The result has been a chaotic
situation with little or no progress toward the standardization
of materials throughout Europe.

Current Progress Toward Standardization

In 2015, the European industry decided to join forces for
harmonization of quality standards for products in contact
with drinking water.
This initiative, known as European Drinking Water (EDW),
is an alliance of European associations representing the
industries that manufacture and supply products used in
drinking water applications.
The group established an initiative to support EU
harmonized provisions for products and substances used
Circle 121 on card.

in drinking water, as well as materials in contact with

drinking water.
EDW membership included representatives from the
pump, pipe, valve, tap, fitting, seal, meter, water heater,
water treatment and catering equipment industries, along
with material suppliers. In other words, the entire industry
supply chain.

May 2019 | Pumps & Systems

 31

umps
Europump, representing the European pump industry,
has been active in EDW from the beginning. The first task Seal-less P
of EDW is to be the place where members can discuss the
standardization issue, establish a common view and prepare
proposals for the legislators.
EDW has engaged and cooperated with the EU, national
regulatory authorities and the 4MS group to establish a
sustainable regulatory basis for harmonized procedures for
NO Seals
NO Packing
assessment and certification of materials in contact with
drinking water.
EDW also collaborates with other sectors, such as
water distributors, and explains its view to all interested

NO Problems
stakeholders by organizing conferences or through its website.
The most promising opportunity is the ongoing revision
of the DWD. A major revision of the current provision on
material in contact with the water is seen by the industry as
a possible approach to achieve this harmonization. It is not
foreseen that the DWD would contain the detailed rules, but
rather a framework where the commission could progressively
adopt European lists of allowable substances and materials,
test methods, verification procedures and all necessary
legislative tools.
To this end, EDW approached the three European
institutions: the commission, the Parliament and the council
(i.e., the member states) for support. Each institution has
already expressed its opinion on the DWD revision and
especially on the issue of materials and products in contact
with the water.
Trialogue negotiation is now beginning and could last until Introducing the Hydra-Cell®
the end of 2019.
If the new DWD is adopted and published in 2020, it will
only be the starting point for the harmonization of hygienic
requirements on materials in contact with drinking water.
T200 Pump
Featuring a seal-less design
A few more years will be necessary before a comprehensive
and robust construction,
system is in place.
the new Hydra-Cell T200
provides reliable, low-
Thomas Angle is the Geschäftsleiter (CEO)
maintenance performance
of Swiss Flow Solutions. He is a member of
because it has no packing or
the Pumps & Systems Editorial Advisory
Board. He may be reached at tom.angle@
mechanical seals that leak or wear.
swissflowsolutions.ch. With flow rates up to 95 gpm and a maximum
pressure rating of 3500 psi, the T200 is ideal for
Julien Chalet is a mechanical engineer with a degree from high-capacity delivery in oil and gas fields, mining
Ecole Nationale d’Ingénieurs de Tarbes. A technical manager
operations, for boiler feed, and other applications.
Circle 125 on card.

at PROFLUID, the French association of pumps,

mixers, valves and compressors, he is secretary Request More Info or a Quick Quote
of technical commissions of EUROPUMP,
the European pumps association, and CEIR,
the European valves association. For more
information, visit profluid.org or europump.org.
www.Hydra-Cell.com • sales@wannereng.com

pumpsandsystems.com | May 2019

 CLEAN
32 WATER
around the world

Taking on the Installation of 
5 Raw Water Pumps  
Keeping up with the demand for clean water from this rapidly growing 
population proved a complex challenge.

BY CHUCK SMITH
SULZER

W
ater resources are placed
under increasing strain
as populations expand
and industry grows
within an area. Municipalities and local
government are tasked with planning
for the future and making sure that the
local population has a safe and reliable
source of water.
For one city in Texas, the planning for
a new water treatment plant had been
ongoing for years, to the point that the
population had increased by 20 percent
while plans were made and the finances
secured. After deciding to use a new
source of water, the question was raised
about the best way to move the water
over 390 feet vertically from the lake to
the new treatment plant.

Laying the Ground Work

This project presented a challenge in
terms of design and installation. The
pumping station was located 320 feet
above the 9-foot tunnel that carries
the water from the intake system in
the lake. The position of the pumping
station is enclosed, complicating the
project by making access difficult for the
contractors and the lifting equipment.
After the water was raised to the
surface, it then had to travel almost
a mile uphill to the water treatment
Image 1. Engineers commissioned the pumps before handing them over to the customer.
(Image courtesy of Sulzer)
plant. So, a considerable amount of civil also take ownership of the installation
engineering would also be required to and commissioning. The plant and the
complete this project. manufacturer agreed on an enclosed line
The municipality said that the shaft design. This involves the addition
organization responsible for the design of an enclosing tube that surrounds the
and manufacture of the pumps would full length of the line shaft, allowing

May 2019 | Pumps & Systems


clean water or an oil-based (NSF International approved)
lubricant, to be supplied from the top of the pump before
startup. This is important in deeper settings to ensure
continued reliability of the line shaft bearings.
Once the design requirements for the installation had
been established, the manufacturer identified a large vertical
turbine pump as the most suitable solution. The pumps were
designed as three-stage units equipped with 320 feet of steel
column with a 1,500 horsepower electric motor located on top
of the above-ground discharge head.
Installation Challenges
Five new pumps were built, but the design and manufacture
of the pumps was the easiest part of the project. The challenge
came when the pumps needed to be installed. They were
designed to be assembled in sections to ensure that the whole
process could be completed safely.
Field service engineers planned and completed all of
the pump installation work on-site. Due to the confined
workspace, the delivery of the pump sections had to be
planned logistically so they could be organized in the correct
sequence for assembly.
Circle 127 on card.
33
Each 10-foot pump column section contained the pump line
shaft, its support bearings and the enclosing tube, which was
gradually lowered into the ground.
As the top flange reached ground level, it was held in
place while the next section was connected. This process
was repeated until all 32 sections had been assembled,
and the drive motor and discharge head were in place at
ground level.
The final step was to apply tension to the enclosing
tube, bringing it into alignment using the tension tube
nut assembly, which was located in the packing box.
This straightened the enclosing tube and brought it into
alignment, which should minimize shaft oscillation
during operation.
The pumps have now been running for a considerable
amount of time, and the treatment plant is happy with
their performance.
Chuck Smith is the regional sales manager for Sulzer. He may
be reached at charles.smith@sulzer.com. For more information,
visit sulzer.com.
pumpsandsystems.com | May 2019
 CLEAN
34 WATER
around the world

How to Protect Water 
in Commercial Building 
Infrastructure 
Legionella is a risk when designing water systems.

BY JAMES PETERSON
CRYSTAL IS

O
ver the last few years,
there has been a steady
increase in drinking-
water associated disease
and outbreaks, particularly those
caused by bacterial microorganisms.
According to the Centers for Disease
Control (CDC), a total of 42 outbreaks
were reported across 19 states
between 2013 and 2014.
More than half of those (57
percent) were due to Legionella, a
bacteria that has been determined
by the World Health Organization
(WHO) to be the most detrimental
waterborne pathogen to human
health in the developed world.
While aging infrastructure and
poor maintenance practices play Image 1. Example of a water system design (Image courtesy of Crystal IS)
a role in these statistics, pipes are
not the only reason waterborne
pathogens are on the rise.
A new report in Opflow by the American Water Works the initial design of building water systems.
Association (AWWA) found that approximately 50 percent This new challenge makes disinfection a critical part
of all building water systems can harbor Legionella. These of water systems design. Both the pathogenic nature of
systems could include equipment such as water heaters Legionella as well as new guidelines from the CDC and
and coolers, hot water tanks, booster pumps, beverage the American Society of Heating, Refrigeration, and Air
equipment, washing machines and even central heating and Conditioning Engineers (ASHRAE) for specific applications
air conditioning systems. Therefore, the question around of water use in buildings open up new methods of controlling
controlling for Legionella is no longer a hypothetical “if,” risk at the point-of-use (POU), instead of using more costly
but rather a known risk that needs to be addressed within point-of-entry (POE) systems.

May 2019 | Pumps & Systems

 35

How Legionella Grows & Spreads
Any vessel or appliance that can store or transfer water can
be a potential breeding ground for bacteria. Most water
utilities add chlorine to water to control and mitigate bacteria
growth as water passes through the pipes and underlying
infrastructure.
While this method controls significant growth,
opportunistic bacterial growth begins to be supported by
dead ends, leaks and aging infrastructure as water moves
from the treatment plant to the building.
Without a POE disinfection method, these microorganisms
move freely into the premise plumbing. However, once water
reaches an appliance, it typically passes through a carbon
fi ltration device, which removes the chlorine, again creating
a potentially unsafe environment susceptible to more rapid
bacterial growth.
In appliances or taps, where water sits static when not
running and warms to the ambient temperature, biofi lm
can continue to form and harbor the growth of Legionella.
Biofi lm sticks to and grows on any surface that remains
continually damp or wet, providing an ideal environment for
a range of bacteria, algae and other microorganisms to grow
and spread. The water that subsequently passes through is at
risk for contamination. As equipment is turned on and the
water begins flowing again, pathogens are released into the
water stream. However, flowing water itself is not the only
path for Legionella to spread. It can also become airborne
through steam, mist or splashing, spreading rapidly to the air
throughout the entire building.
Identifying Key Areas at Risk for Legionella Growth
To understand the best solutions to fit specific building needs,
identify the areas most at risk. In alignment with CDC and
the ASHRAE 188 guidelines, building owners must determine
which appliances and pieces of equipment within the building
pose potential for harboring bacteria.
Depending on the building, there are different areas to
consider. Across most buildings, areas to flag include water
storage tanks, water heaters, water fi lters, faucets, pipes,
valves and external hoses and decorative fountains. Hospitals
and health care facilities should be conscious of medical
devices that rely on water, such as continuous positive
airway pressure (CPAP) machines, hydrotherapy equipment,
bronchoscopes and even eye-washing stations in medical labs.

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• Convenient alerts
• Defense-in-depth security
policies
• Multiple security measures
layered to protect your system
• Securely access your data in the
office or field
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(877) 993-1911 | 123mc.com | sales@123mc.com

Circle 118 on card.

pumpsandsystems.com | May 2019

 CLEAN
36 WATER
around the world
In residential buildings, consider showerheads, water
fi lters, humidifiers and air washers, ice machines and hot
tubs. Then, there are use-cases such as cooling towers for a
data center or centrally installed misters at a theme park.
Once these areas are identified, the next step is to prioritize
them based on certain risk factors and criteria.
For instance, health care equipment used in sensitive
occupant situations such as elderly or immunocompromised
patients should be a high priority due to the increased
likelihood of patient infection.
Appliances where stagnation occurs are critical to
address, as they can lead to significant concentrations of
microorganisms due to uninterrupted growth time.
Locations such as pipes or storage containers where water
temperature may approach ambient temperatures create
a more supportive environment for bacterial growth and
therefore need to be protected.
Apart from the equipment, there are external factors that
can lead to bacteria growth. Consider a construction site or,
in the instance of a water main break, vibrations and changes
in water pressure that can break down biofi lm and release
Legionella into the water.
call for
NOMINATIONS!
10
PUMP
PROFESSIONALS
TO WATCH
To nominate someone
VISIT
pumpsandsystems.com/10towatch
May 2019 | Pumps & Systems
Designing Water Systems with Disinfection in Mind
Once present in the water system, containing and eliminating
bacteria is time consuming and expensive. It is critical to
have the right tools and technology in place to mitigate the
risk of growth in the first place. There are few regulations
that address the threat of Legionella since it has only recently
become a growing problem. However, both the CDC and
ASHRAE 188 are beginning to define risk management
strategies that help water system designers identify and
prioritize high-risk areas and situations.
As a result, designers can now use this approach as a
quantitative method to decide what scale of solution is most
appropriate for a specific system.
A localized disinfection facility for the entire building is
certainly an option. One approach is to use chemical dosing
that increases the concentration of disinfectants in the water.
This can be an effective choice for facilities like hospitals that
need to assure safe water at a majority of locations, but the
costs and operating requirements can be a burden beyond
what many building managers can justify. System designs
that find a more limited number of high-risk locations can
quickly compare the costs and maintenance of a full building
Help us honor the most promising
up-and-comers under 40 years
old in the pumps industry.
Visit the site below for more
information and to fill out the
nomination form for the best and
brightest in your company!
Nominations will be closed by 11:59 p.m. ET, June 28.
Winners will be announced in the December 2019
issue of Pumps & Systems magazine.

solution to the costs and maintenance of POU systems
deployed at each high-risk location.
There are several key technologies available for POU
disinfection. UltraViolet (UV) mercury lamp systems are
highly effective at reducing microorganisms; however,
they require at least annual replacements of lamps at each
location and can be prone to scaling, which necessitates
additional maintenance and potentially reduces disinfection
performance. UV light-emitting diode (LED) systems use
similar UV disinfection technology as mercury lamps but
with smaller LED chips. This newer technology offers benefits
comparable to the LED lightbulbs in houses: less frequent
maintenance, consistent performance from on/off cycling and
a smaller footprint for installation. Most of these systems are
only available for POU flow rates—0.5 to 2 gallons per minute
(gpm)—and from a limited number of suppliers.
Finally, high-performance microbial fi ltration cartridges
are made for bacterial reduction, using fine membranes to
fi lter single organisms. These advanced membranes and
their small pore sizes generally require expensive annual
replacements and have the potential to clog if particulate
levels in the water exceed fi lter ratings.
Circle 126 on card.
37
Taking Ownership of Water Quality in Buildings
Bacteria growth is inevitable in many water appliances,
equipment and infrastructure, and water safety in buildings
is critical to ensure what ultimately reaches the end-user
is safe. Working with building operators to understand
these detailed needs and risk potential allows both system
designers and equipment providers to better tailor solutions
to the needs of water safety and occupant health, while
potentially expanding the scope of their contract. Water
system designers and suppliers now have a responsibility to
collaborate with building owners and operators to ensure
protection across the facility.
James Peterson is product manager at Crystal IS. He holds
several patents for light for disinfection and was
named to the 2016 Forbes 30 under 30 list. He has
a Bachelor of Science in mechanical engineering
from Rensselaer Polytechnic Institute. He may
be reached at peterson@cisuvc.com. For more
information, visit klaran.com.
pumpsandsystems.com | May 2019
 CLEAN
38 WATER
around the world

Producing Clean Water for 
Isolated Steel Mill Cooling 
Towers  
Technology purifi es the only 
feasible water source for mill.

BY BRYAN BRISTER
VOLTEA

H
igh-quality water is vital for many industry
applications, from cooling towers at a
manufacturing plant to irrigation systems
at a large agricultural operation.
Most commercial businesses and industrial plants
pull water from the local municipality to power
appliances and equipment, feed lawns and provide drinking
water on-site. However, the municipal water source is not
always the most feasible or easily accessible option, forcing
business owners and consultants to look for other ways to get
the water required.
Steel Mill Challenge
A steel mill in Lorain, Ohio, had recently installed a new
gasification system on-site at the 600-acre facility along the
Black River. The gasification system required the use of a
cooling tower for operation. This cooling tower, however, was
far away from the main water line, and the cost to connect the
two was quoted at $1.2 million. Due to this high cost, the mill
needed to consider other options.
Given the location of the steel mill, the nearby Black River
became the only feasible water source for the cooling needs
of this new gasification system. However, the Black River
presented new problems. Raw river water would require
significant treatment before it could be suitable as a feedwater
source for the cooling tower.
Controlling Scaling & Corrosion
Most cooling towers are designed to remove heat from the
manufacturing process through evaporation and will provide
Image 1. Membrane capacitive deionization experts evaluating cooling
towers at the steel mill (Images courtesy of Voltea)
cooled water across a broad range of applications. Due to
evaporative losses, the water remaining in the cooling tower
becomes concentrated with dissolved solids like calcium,
bicarbonate, chloride and sulfate that will lead to scaling and
corrosion. This buildup can affect overall performance and
even shorten the equipment life span.
The traditional methods of scale and corrosion control
are through dosing chemicals and blowdown—the act of
discharging water at a high total dissolved solids (TDS) level.
This operation results in high volumes of water and
chemicals being discharged to the environment. The quality
of the water introduced to the cooling tower system is
key to process efficiency and the frequency of preventive
maintenance intervals.
Treating River Water
Seasonal weather fluctuations, the presence of silica,
suspended solids and high levels of hardness are a few
challenges faced when attempting to treat raw river water.
The Black River, which runs through parts of northern
Ohio, is one of many Lake Erie tributaries. This area is known
for heavy snowfall, icy conditions and substantial winds in
the winter and early spring, with summer bringing warmer
weather and some rain.

May 2019 | Pumps & Systems

 39

Image 2. Water quality of the feedwater to the cooling tower

Parameter Avg. Black Requirements Product
River Water
These conditions tend to cause higher turbidity in local
Chloride (ppm) 98.5 <50 22.5
rivers due to deicing processes and surface runoff. This can
be a major challenge for treating river water due to the high Sulfate (ppm) 97.5 <50 32.5
fluctuations in TDS and other hardness minerals in the water. Phosphate (ppm) 0.3 <0.2 0.1
For this steel mill, the spring runoff of road salts from the Conductivity
winter season in the local area resulted in the Black River 800.0 N/A 305.0
(µS/cm)
conductivity varying between 400 and 1,400 micro-Siemens Hardness
per centimeter (µS/cm), corresponding to 23 to 180 parts 132.5 N/A 29.2
(ppm as CaCO3)
per million (ppm) chlorides with turbidity spiking up to 800
nephelometric turbidity units (NTU). Consequently, finding a treatment needed. The chemicals also needed to keep this
water treatment system that can self-adjust to these naturally equipment operational required special permitting from the
occurring fluctuations can be a challenge. Ohio Department of Environmental Quality.
A newer, disruptive water treatment technology known as
Delivering High-Quality Water membrane capacitive deionization was also examined as a
with Electro-Deionization possible treatment option for the river water. This technology
There are few options available to treat river water, such was an attractive solution for two reasons:
as from the Black River, and to purify it to the required • It had relatively simple pretreatment requirements.
standards of the steel mill and its cooling tower needs. • No special permitting was necessary because the
Traditional treatment methods such as reverse osmosis technology does not use chemicals.
(RO) were investigated as options for the treatment of the
river water, but they required expensive pretreatment and Membrane capacitive deionization technology removes TDS
ongoing high operating expenses due to the heavy level of from water sources with minimal pretreatment requirements.

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pumpsandsystems.com | May 2019

 CLEAN
40 WATER
around the world

It eliminates dissolved salts and other minerals via direct
current (DC), or electro-deionization, where oppositely
charged salt ions are attracted to electrodes, leaving pure
water flowing out of the cells in a two-step process of
purification and regeneration.
A major difference between this technology and other
systems is its “tunability” feature. This means customers
can choose the specific level of dissolved salts that are
removed—salt removal is thus “tunable.” Not all applications
require the same removal rate, which eliminates any
remineralization needed from using traditional desalination
and softening technologies.
The steel mill selected this electro-deionization technology
because it can require minimal pretreatment, lower expected
energy consumption, minimal intervention and may not
require any special permitting. In addition, the forecasted
operational costs included with the assessment were
acceptable to the steel mill.
The need for high-quality water (lowest controlled
TDS level) prompted the selection and use of the electro-
deionization technology as a solution to treat the Black River
water as the feed source at this location.
Installed at the beginning of the spring season, the electro-
deionization system experienced extreme fluctuations in
feedwater quality. Despite seasonal fluctuations, the system
operated with a simple conventional multimedia fi ltration.
Once the system was installed, the salinity level of the
feedwater to the cooling tower met the requirements of the
manufacturer, as shown in Image 2.
The Black River, previously deemed unfit for cooling tower
applications using traditional desalination technologies, was
now a reliable feedwater source thanks to the implementation
of the electro-deionization technology.
The chemical-free process also enabled the site to
discharge the concentrated effluent of the system directly
back into the river without having to secure an additional site
permit for disposal.
Bryan Brister joined Voltea in January 2014 as COO before
transitioning to CEO in October 2014. Brister has a bachelor’s
degree in biochemistry and a doctorate degree in polymer
science and engineering. He may be reached at bryan.
brister@voltea.com. For more information, visit voltea.com.

PERSPECTIVES
A Source for
WATER/WASTEWATER
Pump Systems Training &
Technical Solutions
The Hydraulic Institute and Pumps & Systems have partnered to
bring you the most comprehensive and easy-to-use pump learning
site on the web. You’ll find...
• Training collections of our best resources
• HI’s entire library of resources sortable by type,
technology, industry, job function, and more
• Articles, blogs and events from HI’s Persepective

NOW LIVE pumpsandsystems.com/HIPerspectives

in partnership with

Circle 116 on card.

May 2019 | Pumps & Systems

 CLEAN
WATER
around the world
41

Pump Effi  ciency, DOE 
Requirements for 2020  
Make sure your pumps are 
compliant with this new energy 
conservation standard.

BY REECE ROBINSON
GRUNDFOS 

A
gradual evolution of U.S. efficiency standards for
equipment over the last four decades has led to the
pump rule going into effect next January.
In 2011, the Department of Energy (DOE)
initiated efforts to develop energy conservation standards
for pumps.
These efforts have resulted in an amendment to The Energy
Policy and Conservation Act (EPCA) of 1975. Part C of Title
III establishes the “Energy Conservation Program for Certain
Industrial Equipment,” which now includes pumps. The
effective date of this rule was March 28, 2016. Compliance
Image 1. Pump equipment category summary
with the new standards established for pumps in this final (Images courtesy of Grundfos)
rule is required on and after Jan. 27, 2020.
Subsequently, in June 2014 the Hydraulic Institute
(HI) published HI 40.6—Methods for Rotodynamic Pump The performance range and capacities for these pumps are:
Efficiency Testing to align with these new requirements. In • 1 to 200 horsepower (hp), shaft power at the best
2015, HI launched the Pump Test Lab Approval Program efficiency point (BEP), at full impeller diameter for the
(PTLAP) to position pump manufacturers to participate number of stages required for testing to the standard
in the HI Energy Rating Program and provide support in • 25 gallons per minute (gpm) and greater (at BEP at full
complying with the testing requirements of the Energy impeller diameter)
Conservation Standard. In December 2016, HI published HI • 459 feet of head maximum (at BEP at full impeller
40.5, a program guideline for the HI Energy Rating Program. diameter and the number of stages specified for testing)
The HI Energy Rating Program was launched to the public in • design temperature range from 14 to 248 F
March 2017. • design for either: a 2- or 4-pole induction motor, or a
The scope of the standards is specified at 10 CFR 431.464 noninduction motor with a speed of rotation operating
and 10 CFR 431.465, respectively, and concerns what is range that includes speeds of rotation between 2,880 and
referred to as “clean water pumps.” 4,320 revolutions per minute (rpm) and/or 1,440 and
This new energy conservation standard includes the 2,160 rpm, and in either case, the driver and impeller
following pump types (also shown in Image 1): end suction, must rotate at the same speed
frame mount (ESFM); end suction, close coupled (ESCC); • for ST pumps, 6-inch or smaller bowl diameter
in-line (IL); radially split, multistage, vertical, in-line diff user • for ESCC and ESFM pumps, specific speed less than or
casing (RSV); and submersible turbine (ST). equal to 5,000 when calculated using U.S. customary units

pumpsandsystems.com | May 2019

 CLEAN
42 WATER
around the world

Image 2. Efficiency levels analyzed with corresponding C-values

Equipment EL 0 EL 1 EL 2 EL 3 EL 4 EL 5
class Baseline 10th eff. 25th eff. 40th eff. 55th eff. 70th eff.
percentile percentile percentile percentile percentile specific load points, normalized
ESCC.1800 134.43 131.63 128.47 126.67 125.07 123.71 with respect to the performance of a
minimally compliant pump without
ESCC.3600 135.94 134.60 130.42 128.92 127.35 125.29
controls. The performance of a
ESFM.1800 134.99 132.95 128.85 127.04 125.12 123.71 minimally compliant pump without
ESFM.3600 136.59 134.98 130.99 129.26 127.77 126.07 controls establishes the standard
IL.1800 135.92 133.95 129.30 127.30 126.00 124.45 pump energy rating, PER or PERSTD.
The PEI is simply a particular pumps
IL.3600 141.01 138.86 133.84 131.04 129.38 127.35 energy rating divided by the baseline
RSV.1800* 129.63 N/A N/A N/A N/A 124.73 energy rating. The data gathered from
RSV.3600* 133.20 N/A N/A N/A N/A 129.10 the 3,000 pump samples resulted in
what is called C-values (Image 2).
VTS.1800* 138.78 N/A N/A N/A N/A 127.15
The baseline levels were taken at
VTS.3600 138.78 136.92 134.85 131.92 129.25 127.15 the 25th percentile (column EL 2).
* For RSV and VTS.1800 equipment, DOE established only baseline and max-tech efficiency levels due to limited data All pumps below the 25th percentile
availability. will not be in compliance with the
standard. When calculating both
PEICL and PEIVL, those values
shown in column EL 2 are to be used
for PERSTD. The PEI is the ratio of
a pump’s energy rating divided by
the energy rating of a minimally
compliant pump (Equation 1).
A PEI greater than 1.00 indicates
that the pump consumes more energy
than allowed by the DOE’s energy
conservation standard and does
Image 3. Weighted average for constant load Image 4. Weighted average for variable load not comply. A value less than 1.00
is taken at 75 percent, 100 percent and 110 is taken at 25 percent, 50 percent, 75 percent
percent of BEP flow rate and 100 percent of BEP flow rate indicates that the pump consumes
less energy than the level required by
the standard and is in compliance.
Excluded from the scope of the DOE requirements are fire
pumps, self-priming pumps, prime-assist pumps, magnet Load Profile for PEI
driven pumps, nuclear controlled pumps and submersible To establish energy ratings for each of the pump classes,
turbine pumps above a 6-inch discharge. There will be a a load profi le was established for both the constant load
separate rulemaking for circulators and pool pumps. and variable load energy indexes. Instead of just rating
constant load pumps at their nominal or BEP, it was agreed
Pump Energy Index (PEI) that evaluating performance at flows slightly less than and
To establish baseline pump efficiency requirements, over slightly greater than BEP flow was more practical as constant
more than 20 manufacturers submitted data on the five pump speed pumps rarely operate at a fi xed flow. Therefore, PERCL
types, which resulted in more than 3,000 unique pumps. The (pump energy rated constant load) is based on the pump’s
pump data submitted was flow, head, power and efficiency. performance at 75 percent, 100 percent and 110 percent of
The DOE used this information to determine the baseline BEP flow. The PERVL (pump energy rated variable load) is
standards and life cycle cost (LCC) analysis. based on pump performance at 25 percent, 50 percent, 75
A new metric has been established with this DOE percent and 100 percent of BEP flow.
rulemaking: the pump energy index (PEI). There are two
PERCL
types: PEICL (constant load) and PEIVL (variable load). PEICL PEICL= (constant load)
applies to pumps sold without continuous or noncontinuous PER STD
controls. PEIVL applies to pumps sold with either continuous
PERVL
or noncontinuous controls. Both PEICL and PEIVL describe PEI VL= (variable load)
the weighted average performance of the rated pump at PER STD Equation 1

May 2019 | Pumps & Systems


Additionally, since the variable flow ratings are based on
variable speed pumps, a reduction in pump head was agreed
on to establish a control curve. The pump head at zero flow
is set to 20 percent of the pump head at BEP flow. Both
indexes, PEICL and PEIVL, use the constant load PERSTD
as the baseline. Therefore, when variable speed pumps are
considered, the PEI will be significantly lower for variable load
pumps compared for the constant load pumps.
HI Energy Rating Program
Under the HI Energy Rating Program, the use of the ER label
will provide owners and end users a tool to predict power
savings obtained from pump system upgrades. Savings are
calculated over the baseline established by the DOE.
Public utilities and power companies can use the ER label
for incentive programs and rebates. Manufacturers can use
the ER label to differentiate products by power consumption
as the ER represents the percent power savings over the
base case. Proper sizing and selection of pumps is vital to
achieving the most efficient pumping system, but is outside
the scope of the ER program.
The energy rating as outlined in the ER program should
PRECISION PUMPS
FOR PROCESS CONTROL
Experience the precision of SEEPEX’s BENEFITS
progressive cavity metering pumps. • Minimal pulsation with no dampeners
These pumps require no valves and
have steady unvarying flow. They can
• Reduced chemical consumption
handle harsh/abrasive chemicals or
• Will not vapor lock
viscous materials which need low shear • Reduced energy consumption
gentle handling. • Lower NPSHA
Low internal velocities and continuous
cavity means low pulsation and greater
material flow accuracy.
Circle 120 on card.
43
only be used when comparing pumps of the same class that
have been properly sized for the application. The energy
rating shown on the label can be used to estimate the power
savings over a minimally compliant pump.
For information on using energy labels to estimate power
savings, as well as all other ER program details, refer to the
following document from HI: HI 40.5-2016—Hydraulic
Institute Program Guideline for HI Energy Rating Program.
HI created a website to support the Energy Rating Program;
for more information, visit er.pumps.org/ratings home.
The site has portals for manufacturers to create ER labels
and certificates as well as a database to search pumps by ER
requirements or by model number and/or manufacturer.
Reece Robinson is Grundfos’ building services technical
content manager. He has been with Grundfos since 1997 and
has held positions in product engineering, product
management and technical training. Robinson
received a bachelor’s in mechanical engineering
from California State University, Fresno. For more
information, visit grundfos.com.
CONVEYING CAPACITY
PRESSURE
UP TO 360 PSI
Visit Us at
AWWA ACE 19
Booth# 4223
SEEPEX Inc.
sales.us@seepex.com
T +1 937 864-7150
www.seepex.com
pumpsandsystems.com | May 2019
 CLEAN
44 WATER
around the world
Instrumentation 
in Clean Water  Leak Detection
Treatment & 
Distribution  
How ultrasonic level controllers can result in  additional leaks or breaks that may
cost and energy savings.
BY JACK ROUSHEY
SIEMENS PROCESS INSTRUMENTATION
W
ater is the most widely
used natural resource
in the U.S., with
approximately 42 billion
gallons consumed daily to support
activities ranging from bathing to
industrial manufacturing, according
to the U.S. Environmental Protection
Agency’s (EPA) “Water Audits and Water
Loss Control for Public Water Systems.”
Yet, in municipalities, approximately 6
billion gallons of water are lost to leaks
every day, and inefficient practices result
in excess energy costs up to 30 percent.
The nation’s aging infrastructure
includes more than 2 million miles of
water distribution pipes, most past
their life expectancy. This means leaks
can go unnoticed until a significant
break occurs. Along with the estimated
240,000 water main breaks that occur
each year, leaks and smaller breaks add
up to a water loss of between 14 and
18 percent of total distribution.
In addition to the energy used to
treat and distribute the water that is
May 2019 | Pumps & Systems
lost, inefficient practices have an impact
on the bottom line. Utilities can be
subject to peak pricing schedules of
electricity suppliers. Unfortunately for
municipalities, peak water demands
coincide with peak electricity demands
of consumers. This increased demand
means higher energy costs for pumps
and, therefore, higher overall costs to
plants. It is estimated by the EPA’s Office
of Water that electricity accounts for
80 percent of municipal water processing
and distribution costs—and utilities can
reduce costs between 15 to 30 percent by
incorporating efficiency practices.
The Solution
There are major areas where efficiencies
can be maximized to impact costs,
efficiencies and reduce environmental
impact. Leak detection technology
allows municipalities to promptly and
accurately locate leaks or breaks in their
distribution systems.
Efficient pumping algorithms
built into pump controllers allow
implementation of economy pumping
routines. This two-pronged approach
results in more cost-efficient operation.
Leaking pipes often go years without
being detected. By reducing lost water
through leak detection technology,
utilities can realize substantial savings.
There are many methods to identify
leaks in water systems. Detection
is often accomplished with manual
equipment or a water auditing service.
These methods limit leak detection to
the duration of the survey, missing
occur between inspections.
Other options include installation
of permanent equipment spanning
the entire length of the distribution
network, such as a separate network of
acoustic leak sensors, to supplement
existing flow meters.
There is a solution that incorporates
leak detection into the flow meters
located in pipelines. This eliminates the
need to install additional leak detection
equipment or perform manual analysis.
Leaks can be monitored on a daily basis,
allowing prompt detection.
Flow meters, such as battery powered
mag meters, include integrated software
optimized for leak detection applications
in the water industry. Leak detection
alarms are set by the user to warn of
any significant deviation from normal
flow. The user specifies the minimum
and maximum flow rates expected under
normal conditions. If flow rates are
detected outside of the set parameters,
the alarm is sounded and the operator is
promptly notified.
Rapid leak detection is central to
minimizing water loss due to breaks
or leaks in a system, and this
automated approach to leak detection
allows for rapid and cost-efficient
operation in a single instrument.
Incorporating leak detection into
a system can help regain the 14 to
18 percent of potential revenue.
 45

Reliable Chemical-
Feed Accessories

Image 1. Incorporating leak detection into a system can help regain

potential revenue lost due to leaks. (Image courtesy of Siemens)
• Improve the performance and reliability of your chem-
feed system with pressure valves, dampeners, calibration
Ultrasonic Level Controllers columns, corporation stops, injection quills, and more.
Water treatment plants are often the largest energy consumer • Robust, quality construction at a competitive price.
for municipal governments. In these energy intense processes, • 3D CAD drawings available on our website.
pumping systems account for the majority of electricity used.
Ask about our Quick Turnaround Advantage
According to a U.S. Department of Energy study, optimizing
pumping systems can reduce energy costs by 20 percent or Griffco Valve, Inc.
more. The first step to implementing energy efficient practices 1-800-GRIFFCO
in water or wastewater systems begins with the “energy sales@griffcovalve.com
hogs”—motors and pumps. www.GriffcoValve.com
Treated water and sewage processing demands surge during
times of peak electricity use, which leads to peak pricing for ISO CERTIFIED • MADE IN USA
the energy consumed by pumping systems. Some rates can Circle 141 on card.
even be 80 percent more expensive per kilowatt hour (kWh)
than off-peak pricing. In order to realize significant savings in
pumping systems, it is imperative to minimize pump operation
during these times. But how can pump routines be scheduled
for off-peak times?
Using a full-featured ultrasonic level controller (ULC)
with integrated pump control algorithms, the pump control
parameters can be set to minimize pumping activity during
on-peak pricing. This is accomplished by setting the schedule
for peak pricing, low-level set point and high-level set point of
the well in the controller.
The ULC will then pump the well down to the low set point
during off-peak pricing, allowing for the well to completely
fi ll when energy is at a premium. During the peak pricing
periods, the controller will maintain a high level in the well
to be pumped out again once the off-peak period returns.
This pumping strategy reduces the energy demand during the
elevated rates and improves the bottom line.
This smart approach to pumping only requires the
investment in a ULC, which can control up to two motors.

Jack Roushey is a product marketing manager for Siemens

Process Instrumentation. He has spent the last
40 years supporting the process instrumentation
markets in various sales and marketing
management roles. For more information, search
“cost of water” at siemens.com.

Circle 142 on card.

pumpsandsystems.com | May 2019

46 INSTRUMENTATION

How a Municipality Saved 
$1.7 M in Wasted Water   
Case studies show how detecting leaks saves resources from going 
down the drain.

BY MICHAEL KANELLOS  
OSISOFT

F
lat Rock Springs was a peaceful, pleasant part of
the landscape.
Unfortunately, it was not a natural spring.
In reality, Flat Rock Springs is a relatively low-flow
leak that had spilled 250 million to 500 million gallons since
the late 1980s, according to Tennessee’s White House Utility
District (WHUD), a municipal agency north of Nashville.
Leakage, or nonwater revenue loss, is a chronic and growing Image 1. A customer of the WHUD thought this pipe break was a
stream. Another WHUD customer named the “stream” Flat Rock
problem for water utilities. On average, a utility should expect Springs. Flat Rock spilled an estimated 250 million to 500 million
to lose around 10 percent to 15 percent of its water on the gallons of water for over three decades before WHUD determined it
voyage from the treatment plant to the faucet. Unfortunately, was a leaky pipe. (Images courtesy of OSIsoft)
the total is often much higher.
Globally, the World Bank estimates that the world
collectively loses 32.6 trillion liters of water a year, or nearly
enough to fi ll China’s Three Gorges Dam to the brim every
year with clean, treated water.

The Source of the Problem

Why is so much water being wasted? There are several
reasons. Water networks are often old (20 percent of San
Francisco’s water lines are over 100 years old), spread out
across thousands of square kilometers and underground.
Additionally, budgets are tight and customers are exceedingly
demanding. Water has to be there. No one wants their shower
to be only “17 percent loaded” like on Netfl ix.
The problem gets even worse in emerging nations.
Approximately 45 percent of the people in the world live in
drylands, defined as regions that get 600 millimeters (mm) or
less of rain a year, according to Alon Tal, a professor at Ben-
Gurion University.
Saving Wasted Water
Here is the good news: leakage can be fi xed. In fact, water
recovery has become one of the cheapest forms of sourcing
Image 2. Evides in the Netherlands has developed a series of apps
that quickly analyze operations data and serve up alarms. The
pictured application shows the location of a recent pipe burst and
how it is spreading.
water. Bluefield Research estimates water from leaks costs on
average $1.21 per 1,000 gallons in the United States, less than
half of the cost of traditional water.
The techniques for reducing leakage vary. WHUD, for,
instance, previously used acoustic sensors to try to locate
drips. As you can imagine, it was often time-consuming
and inefficient. They could hear leaks, but they were not
easy to pinpoint.

May 2019 | Pumps & Systems

 47

In 2015, the utility district took a Use Data to Tap into Savings underground leak. Unusual declines
new tack. It planted flow meters across Maynilad in Manila did something of pressure or flow were taken as
its service to get visibility into water similar, but on a much larger scale. symptoms of a leak. Over the next few
consumption on a roughly block- It used flow, pressure and other years, leakage was cut in half and the
by-block basis. WHUD invested in data from meters and sensors to number of people living in Manila who
meters; data capture and synthesis precisely triangulate the location of an were getting adequate service over the
software that captures and organizes
data so employees understand water
consumption and where it is taking
place; mapping; and installation. This
software captured and organized data
so employees could easily understand
what was going on.
In a clever twist, WHUD did not
track daytime use. Instead, it compared
inflow and outflow between 1 a.m.
and 4 a.m. Daytime use varies; some
people use far more water than others.
But nighttime use, WHUD reasoned,
should be consistently low. Any street
or address where consumption was
more than 26 gallons per minute (gpm)
was a strong indication that the people
living there were either insomniacs who
bathed quite a bit in the middle of the
night or, more likely, living next to an
underground, undetected leak.
Within three days, the utility found a
leak that was losing 280 gpm, or enough
for 2,239 homes for the region. People
thought it was a stream.
In 2015, WHUD found and fi xed leaks
that were costing $400,000 of water
per year. The next year, it recovered
$900,000 with more leaks, bringing the
two-year total to $1.3 million. In 2017,
close to $400,000 more worth of water
was found. These efforts have allowed
WHUD to postpone a $15 million to
$20 million upgrade, which would have
cost the utility $600,000 in interest
payments alone per year. WHUD now
believes it will not need substantial
capital upgrades until 2028.
“Our water treatment plant was Proud Member of the
having to run one hour a day just to American Petroleum Institute NATIONAL PUMP COMPANY
feed that leak,” WHUD geographic 7706 N. 71st Avenue | Glendale, AZ 85303
information systems (GIS) director Carl 800-966-5240 | 623-979-3560
Alexander said. “Without us knowing
there was a problem in that area, we
would have never been able to stumble www.nationalpumpcompany.com
upon it.”
Circle 119 on card.

pumpsandsystems.com | May 2019

48 INSTRUMENTATION

Image 3. United Utilities in the U.K. has developed algorithms that

predict water consumption 24 hours in advance with 98 percent Image 4. A WHUD control console display of consumption, leakage
accuracy and drain overflows by six hours. UU plans to use the losses and maintenance priorities (red, green and yellow). Typically,
information to reduce pumping activity and save energy. The technicians will start their day by checking a screen like this.
applications were developed in-house in conjunction with a university. Previously, it could take hours to merge the data sources.

full day rose from around 50 percent to
more than 90 percent. Pinpointing the
source of leaks also reduced the cost of
repairs by reducing the amount of leaks.
Fixing some leaks has dropped from
$1.7 million to $1,250 per leak.
Other Applications
Once utilities begin using data, their
consumption grows. Evides in the
Netherlands has an in-house technology
initiative called GAMEs in which
engineers are building applications for
detecting sudden breaks or providing
notices to residents about outages. In
the first year, it created 50 experimental
applications and is moving toward
commercializing the most vital ones
into its operations.
In the United Kingdom, United
CENTRIFUGAL
Utilities in Manchester developed
applications for predicting water
consumption 24 hours in advance or
predicting which drains will most
likely clog.
Again, the formula is similar. Real-
time data from machinery is captured,
cleaned and turned into a trend line
by a software application. Sudden
changes mean trouble. The data can
also be plotted on a map or compared to
locations, the historical norm or other
metrics to fuel predictions.
Stopping leaks, of course, will not

PUMPS
solve all of the world’s water problems.
Water utilities, and consumers, are
going to have to adjust their attitudes
Your
You
ur Best
Be
B es
s Value
st Va
alue
e in Self
S Priming & toward water. That means conservation
as a lifestyle, markets for water rights,
ANSI Cen
Centrifugal Pumps and new pricing mechanisms that
put the real cost of consumption
on consumers. The technologies for
increasing supply like desalination and
water recycling will also need to be
lowered in price.
Software also cannot be viewed as a
magic bullet on its own. Data generated
by pumps and other pieces of equipment
Model SN
piles up quickly, so to take advantage
of it requires training and buy-in from
Model 2196 ANSI
Located in Green Bay, WI the organization. Taking on leakage,
however, is an effective way to start to
Providing a Quality rethink the approach to water.
Product at a Fair Market
Price since 1982 TM
Michael Kanellos is the industry
Call: 920-869-4800 PUMP, Inc
champion for water at OSIsoft. For more
Email: sales@summitpump.com www.SUMMITPUMP.com information, visit osisoft.com.
Circle 131 on card.

May 2019 | Pumps & Systems

 PIPING SYSTEM DESIGN 49

Design for Thermoplastic 
Double‑Containment 
Piping Systems   
Consider chemicals, temperature, pressure, expansion and more.

BY RODNEY VAN 
ASAHI/AMERICA INC.

I
n 1988, the Environmental Protection
Agency (EPA) issued regulations for
underground storage tanks (USTs)
and piping systems that handle
petroleum products and hazardous
chemicals. In 2015, regulations that
affected owners and operators installing
secondarily contained tanks and piping
were revised. Owners and operators must
use interstitial monitoring as release
detection for these new or replaced tanks
and piping. EPA regulation 40 Code of
Federal Regulations (CFR) 280 lists more
than 800 chemicals that are considered
hazardous and have to be double-
contained. The Resource Conservation
and Recovery Act 40 CFR 280 defines
USTs as any tank system, including any
piping connected to it, with at least 10
percent of its volume underground.
State environmental guidelines and
enforcement may exceed those of the
EPA. States with an approved UST
Image 1. Large diameter double-containment polypropylene system
program have the lead in UST/piping enforcement where (Images courtesy of Asahi/America Inc.)
states without an approved program work with the EPA to
coordinate enforcement actions. and enforcing 40 CFR for below-ground installations, many
EPA regulation 40 CFR 280 requires that secondary corporations have internal safety and environmental policies
containment must be able to hold leaking media for a stipulating double-containment systems for underground and
minimum of 30 days. overhead piping systems. The Occupational Safety and Health
Drainage or suction systems can be monitored manually Administration (OSHA) does not have a specific double-
while pressurized systems require automated monitoring containment regulation for above-ground piping systems.
so the flow of the media can be restricted to avoid potential The OSHA occupational chemical database lists hazardous
groundwater contamination. Aside from the EPA regulating chemicals and their permissible exposure limits (PELs).

pumpsandsystems.com | May 2019

50 PIPING SYSTEM DESIGN

OSHA recommends 400 F. Chemical resistance and temperature tolerances

Butt Fusion Weld Beads
isolating or enclosing vary from one plastic to another. Many thermoplastic
the process as a way manufacturers provide chemical resistance guides. Consult
to control exposure the manufacturer for applications where there may be many
of personnel to toxic chemicals or ones that are aggressive.
substances.
Pressure
Design Criteria/ Thermoplastics have varying pressure ratings at different
Operating temperatures. Pressure ratings for thermoplastics are reduced
Image 2. Example of a Parameters at elevated temperatures. Knowing the system’s standard
simultaneous butt weld
Materials operating pressure, temperature and heat gain from sun
Thermoplastics should exposure is the starting point. Spikes in temperature may
be considered for a piping system because they have good flow reduce the pressure rating.
characteristics, are corrosion or chemical resistant, are energy It is necessary to examine other conditions that may
efficient and lightweight, install quickly and have a long life affect the operations of the piping. If pressure spikes occur,
expectancy. An assortment of materials exist that offer long- determine for how long and how high.
term performance with little or no degradation after 25 years.
Little maintenance is required because there should be no Temperature
pitting, scaling or corrosion. The design for a double-containment piping system is
similar to single-wall piping design. Chemical, temperature
Chemicals and pressure data are important for the carrier line and
All thermoplastic materials are resistant to a variety of the containment secondary line. Temperature plays a key
organic and inorganic chemicals up to high concentrations role, affecting the pressure rating of the pipe system and
with temperature capabilities ranging from cryogenic to expansion rate. With regards to expansion, it is the rule,

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Circle 129 on card.

May 2019 | Pumps & Systems

 51

Pipe
Depth
Backfill
85% Proctor 9"

Sand
95% Proctor 9"

Deflection of
Leak Containment Pipe Pea Gravel 6"
Solid Vent Hole and Annular Cut Out Detection Restricts Annular
Cable Space 6"
6"

Image 3. Restraint fitting options for a Image 4 (left). Deflection of containment pipe Image 5 (right). Example of an
buried system underground installation

not the exception when engineering a piping system using
thermoplastic materials. As temperatures rise and fall,
thermoplastic materials expand and contract to relieve stress.
Stress analysis can be calculated to determine the amount of
flexibility the system will require.
Expansion
If the chemical or chemicals entering the pipe system are hot,
thermal expansion of the carrier pipe will occur. It can also
occur when a mixture of chemicals creates an exothermic
reaction. The methods used to handle expansion in
double-containment piping systems are similar to those used
in single-wall piping systems. A flexible design system uses
a fitting that anchors both the carrier and containment pipe
and allows the carrier pipe to move inside the containment
line. Containment areas generally may need to be expanded
in order to address the thermal expansion and contraction of
the carrier pipe.
For restraint design, proper use of restraint fittings (what
some call a dogbone) and guides throughout the system will
isolate the fittings from thermal stress and end loads when
temperatures fluctuate.

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Circle 117 on card.

pumpsandsystems.com | May 2019

52 PIPING SYSTEM DESIGN
Burial
When burying thermoplastic pipe, both static loads (weight of
the column of soil on top of the piping) and live loads (traffic)
need to be taken into account.
With static loads, the deeper the burial, the higher the load on
the pipe. Live loads, on the other hand, have a greater effect
on pipe at shallower depths. Other factors to consider when
burying thermoplastic pipe are the type of soil, compaction of
the soil and the design of the trench.
The material PE 100-RC has mechanical properties that
do not require special soil backfi ll or compaction methods.
Double-containment burial calculations are always based on
the outer wall of thermoplastic pipe.
If leak detection cable is to be installed in the interstitial
space, deflection of the material must be calculated.
Installation
Installation costs can be cut considerably by using fusion
welding. Fusion-welded systems can reduce labor by
more than 50 percent. The butt fusion welding method
for thermoplastic pipe fuses the inner and outer pipe
simultaneously (if both are the same material), essentially
creating one weld. Most double-containment systems—
whether metal, thermoset or thermoplastic—are stepped
up a minimum of two sizes from the inner pipe to create an
interstitial space between the two pipes.
Some double-containment systems are coextruded,
meaning the carrier and containment pipe are extruded at
the same time. This saves material and labor costs, since
centralizers do not have to be inserted and welded to center
the carrier pipe in the containment pipe when cut. The
containment pipe steps up one size, versus two sizes, for
fabricated systems. For example, a 1-inch by 3-inch fabricated
double-containment pipe system versus a coextruded 1-inch
by 1 1/2-inch system. Less space is required for the piping.
Common underground process waste systems are drain,
waste and vent. One way to reduce costs is to use a thinner
wall pipe for the containment. Heavier wall materials are
used for the carrier line since the process chemical or process
waste is flowing daily. For example, most manufacturers with
standard dimension ratio (SDR) ratings produce polyolefin
and fluoropolymer piping. For chemical systems, an SDR11
by SDR32.5 polypropylene pipe would have a pressure rating
Image 6 (left). Double-containment pipe and fittings
Image 7 (right). Coextruded PP pipe
May 2019 | Pumps & Systems
of 150 pounds per square inch (psi) for the carrier pipe and
45 psi for the containment pipe. PE 100-RC SDR11 by SDR17
would be 150 psi carrier and 90 psi containment, which
maintains chemical compatibility and reduces cost compared
to an SDR11 by SDR11 containment system.
When using the same material for the containment pipe
is too expensive, using dissimilar materials is another
option that can lower costs. This can be justified because the
containment pipe does not handle the media on a continuous
basis, and the EPA requires that the containment pipe be
able to hold for a minimum of 30 days. Labor goes up when
dissimilar materials are used because the number of joint
connections is double and joining techniques vary. Typical
examples of this are a stainless carrier inside glued
fiberglass reinforced plastic (FRP) containment or fusion-
welded PVDF inside a polyolefin like polypropylene (PP)
or polyethylene (PE).
During material selection, consider the time the liquid
must be retained in the containment pipe. In the event of a
leak, how long will it be before a repair can be made? Is it a
process line that cannot be shut down for a long period of
time? The containment pipe should be capable of holding the
media until the repair can be made.
Probe Option
Grade
Image 8. Leak detection low-point station and sensor buried
Leak Detection
Automated leak detection options such as cable or low-point
sensors set off an alarm to alert plant personnel. Cable
leak detection systems must have minimum clearance
of 3/4 inch in the annular space between the carrier and
containment pipes.
This means a fabricated double-containment system must
be used because coextruded pipe has annular space less than
3/4 inch and continuous ribs the length of the pipe. Pulsed
cable-radar technology has the capability of locating a leak
with ± 0.3 percent of the sensor string or ± 6 feet. Consult the
double-containment supplier for recommendations specific to
the project.

Dogbone Seal
Optional (2 sides)
Image 9. Double-containment ball valve with stem extension
Low-point sensors are another automated option for
drainage or pressure systems. They pinpoint an area or zone
that has developed a leak. Zones are compartmentalized in
order to keep liquid trapped to avoid affecting another zone
and tripping another sensor.
Low-point stations containing leak detection probes can
also be used manually for drainage systems. Other manual
options are manways or sumps or sight glasses with valves for
above-ground installations for visual inspection.
Circle 139 on card.
53
Additional Components
End terminations are needed where the double-containment
is closed off to transition to single-wall pipe. Additional
centralizers or (support discs) are required when pipe is
cut in the field. Floor drains and cleanouts are available for
drainage systems. Many systems use double-containment
valves to isolate the process or shut down in an emergency.
Ensure there is sufficient access to the valves to enable the
replacement of seats and seals. Some double-containment
valve components may require the whole unit to be cut out of
line in the event of valve failure.
Training
It is strongly recommended that the manufacturer trains the
installer on any required equipment and proper installation.
Proper training reduces the potential for pipe failure and its
environmental impact.
Rodney Van is business development manager, Industrial
& Environmental Products, Asahi/America, Inc. He may be
reached at rvan@asahi-america.com. For more information,
visit asahi-america.com.
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Circle 140 on card.
pumpsandsystems.com | May 2019
54 PIPING SYSTEM DESIGN

Designing Piping Systems & 
Pumps Concurrently   
Maintain a high system effi
  ciency with varying demand.

BY STEPHANIE VILLARS 
APPLIED FLOW TECHNOLOGY

D
esign for a pipe network is traditionally a linear
process. A piping system design is chosen, and then
a pump is selected based off the system head. This
process ignores the efficiency of the piping system,
but quickly determines a pump required based on the design.
Using modeling software gives the engineer the power to
analyze multiple scenarios and address the efficiency of the
process. As the engineer must iterate on the system design
and pump choice sequentially, it is easy to miss intermediate
solutions that could potentially achieve greater savings and
efficiency. Designing with the pump and piping system in mind
can lead to significant savings, especially when flow analysis
software with automated sizing capabilities is used.
Why System Efficiency Is Important
The demand for a stronger and smarter water system has
been a priority for several years as systems continue to age
and breakdown. With finite resources available to handle
increasing loads, it becomes clear how important efficiency is
to account for the impact of aging components and changes
to the system. It is not enough to design for the immediate
system, as a rapidly changing market leads to rapidly changing
design requirements. The question becomes how can a high
system efficiency be maintained with varying demand?
There are limits to how much efficiency an engineer can
achieve with hand calculations to determine the ideal sizing
for a pipe system.

Image 1. Cooling system (Image courtesy of Applied Flow Technology)

May 2019 | Pumps & Systems

 55

While the head required for a single analyze an existing petrochemical

pipeline may be simple to calculate,
it becomes more complex for pipe
networks. With a hydraulic solver
to accurately model the system, this
process becomes simpler. Various
system configurations can be calculated
quickly, particularly with software
capable of containing multiple
operating cases within one model.
For simple cases, such as sizing a
control valve for the system, hydraulic
software can be used to set the flow or
pressure demand, then the software
can report the necessary pressure drop
needed from the component.
However, this process becomes more
difficult as the sensitivity of the system
to each component must be determined.
The engineer must select different
combinations to compare as design
cases. With this iterative approach, the
engineer is limited in the number of
cases they can compare.
Consider the cooling system in Image
1. It includes four pumps, four heat
exchangers and 34 pipes, which could
be sized separately. If the pipes are
the same size, the calculation can be
simplified, but the system will require
a larger pump and lose efficiency.
Splitting the pipes into multiple groups
and varying the size for each requires
more time dedicated to modeling and
comparative scenarios for the system.
Savings may increase, but it becomes
more difficult to determine which is the
most efficient design. Since the system
must be sized sequentially, rather than
being sized in tandem, it is possible
to miss intermediate combinations of
system and pump configurations that
are likely more efficient.
This process can be simplified by
using automated sizing software to run
potential cases and iterations. This is
production facility with a hot oil
network. The company created multiple
scenarios to analyze sensitivity to
various elements in the model. After
several oversized elements were
identified, the components were resized
using the software. This allowed for
nearly 1 megawatt (MW) reduction
in power consumption by replacing
eight components.
It is possible that additional savings
over the life of the system could be
found by resizing the pipes. However,
the replacement costs might not
justify the action. This highlights
the importance of performing a
comprehensive system design at the
beginning, in order to minimize large
Complete
costs down the road.
One concern with this sizing process
flow-based
may be that it is sizing for a specific valve control.
case and will not take into account the
possibility of system expansion. The Singer Model
However, a sophisticated sizing 106-SPI-MV is a Single Point
software will also have the ability to Insertion Electromagnetic Flow
optimize for multiple conditions at Meter, installed and calibrated
once to consider the effects of operating in the control valve, to provide
at different points during seasons or accurate flow measurement from
with sections of the model temporarily any Singer Control Valve. It provides
isolated. It is also possible to account water distribution managers with
the ability to monitor tank turn-
for a safety factor directly in the
over and pump flow rates, control
optimization process. This means the
DMAs with flow-based pressure
system can be designed for uncertainty
management, reduce water loss,
in the current demand, as well as
maintain water quality and reduce
consider the difference in operation as labor costs from current system
demand is expanded. flushing programs.
As rising demands introduce new
challenges, choosing the right tools will
To learn more about
help account for variable demand to
Singer valve solutions,
choose not only the best pump, but also
visit singervalve.com
to effectively size the piping system to or call 604-594-5404.
further optimize the system.
Stephanie Villars is an applications
Circle 134 on card.

engineer with Applied Flow Technology

accomplished by entering necessary
design requirements as inputs with the
system sizing as outputs, rather than
guessing the system design and then
verifying the design requirements.
In a recent case, a consulting
company used modeling software to
(AFT). Villars is a graduate of
the Colorado School of Mines
with a Bachelor of Science
in chemical engineering.
For more information,
visit aft.com.
Copyright © 2019 Mueller Water Products, Inc.
All Rights Reserved. The trademarks, logos and
service marks displayed in this document herein
are the property of Mueller Water Products, Inc.,
its affiliates or other third parties.

pumpsandsystems.com | May 2019

56 FIRE PUMPS

Choose the Right Fire Pump  
Learn about the advantages and disadvantages of diff erent pumps used 
for stationary fi re protection.

BY STEVEN BROWN 
STEVEN BROWN & ASSOCIATES, INC.

T
ypical buyers of fire pumps are interested
primarily in the hydraulic performance
of the pump in question—specifically the
gallons per minute (gpm) and the pressure
boost (pounds per square inch [psi]) of the pump.
If a pump can be found to deliver a specific gpm
and psi, and it is listed by a trusted third-party
agency, then the evaluation often ends there.
Rarely is the type of fire pump considered. This
article focuses on centrifugal fire pumps that carry
either an Underwriters Laboratories (UL) or FM Global
label, and are used specifically for stationary fire protection.

Horizontal Split Case
Horizontal split case (HSC) pumps receive their name from
the split design of the casing, where the cover can be lifted
off the pump to expose the internal components. HSC pumps
include two bearings, located on either side of the impeller,
which are useful to withstand the vibration and thrust forces
caused by water turbulence in the suction piping. The casings
can be designed to handle higher working pressures and are
often heavier. The durability of the HSC design allows the
pump to be used for water flows in excess of 5,000 gpm.
An HSC pump is not always mounted horizontally. It is
possible to have the same durability features with a vertical
mount. The HSC pump is often connected to an appropriate
driver by a coupling or drive shaft. When mounted
horizontally, this can create a larger footprint. Because of a
concern for floor space, HSC pumps are not typically chosen
for flows below 1,000 gpm.
The efficiency of an HSC pump’s impeller is dependent on
even water flow entering the eye (or inlet). There are two
entry points of water into an HSC pump’s impeller, which is
where the term “double suction” is used. If water enters the
impeller unevenly, hydraulic imbalance can occur and cause
stress to the pump shaft or bearings. The need for smooth,
laminar flow in the suction piping of an HSC pump is why
the National Fire Protection Association (NFPA) 20 has
Image 1. Horizontal split case fire pump (Image courtesy of Steven
Brown & Associates)
established strict rules regarding the length of straight piping
required on the suction side of an HSC pump (see NFPA 20
2013 4.14.6.3.1, and 4.14.3.1). As a general rule, the larger
the volume of water to be pumped, the more important it is to
produce smooth laminar water flow into the pump casing.
The orientation of an HSC fire pump must be
predetermined when the is manufactured and installed. The
pump must be built for either right-hand (clockwise) or left-
hand (counter-clockwise) operation from the vantage point of
the driver. For diesel-driven fire pumps, the pumps can only
be operated at a clockwise rotation. Failure to install properly
can lead to a pump disassembly and reassembly to the
correct rotation in the field (if driven by an electric motor) or
rearranging piping (if diesel-engine driven).
The extra bearings, larger impellers and overall larger
size of the horizontal split-case fire pump raise the cost. The
initial investment can provide end users with a pump that
will last longer and is easier to service.
End Suction Horizontal
End suction centrifugal pumps get their name from the
pathway the water takes to enter the pump. Typically, the

May 2019 | Pumps & Systems

 57

NEWEST ADDITION TO THE FEDCO PUMP LINEUP

water enters one side of the impeller.
On horizontal end suction pumps, this
appears to enter “the end” of the pump.
Unlike the HSC, the suction pipe and
motor or engine are parallel to each other,
eliminating the concern about pump
The FEDCO SLP Series Pump
for general water process
applications at low pressures.

n Desalination
SLP
SERIES PUMP
rotation or orientation.
Since water enters one side of the n Irrigation
impeller, the ability to have bearings on
both sides of the impeller is lost. Bearing
n Marine
support is from the motor or the pump n Mining
power frame, so they do not operate well
on large water flow applications.
n Power Plants
One benefit of an end suction pump can n Water Treatment
be a lower initial cost. If the pump can
perform at a given rating and pressure,
then the pump will work. If driven by a Contact us
diesel engine, another advantage is the +734.241.3935 • sales@fedco-usa.com
ability to situate the engine in parallel
Fluid Equipment Development Company, LLC
and near a wall (assuming proper air
800 Ternes Drive, Monroe, MI 48162 USA
ventilation is considered).
The removal of the impeller requires Singapore Office Dubai Office
removal of the motor to provide space.
+65.9784.3813 +971.04.242.3856
Often this is a complex procedure for Circle 133 on card.
those maintaining the pump.

End Suction Vertical Inline

Space savings and lower initial cost are
two advantages of these designs. The
process of water entering the impeller
is identical to a horizontal end suction
pump. However, the casing is designed so
that the motor is mounted on top, and the
pump flanges are made to coincide with
the same elevation centerline. As far as
centrifugal pumps go, this requires the
smallest space in a pump room.
These pumps are also available to take
advantage of smaller fire pump ratings: 50
gpm, 100 gpm, 150 gpm, etc., often with
single-phase electric motors. Historically,
HSC pumps have been manufactured at
only 250 gpm and 500 gpm ratings. The
vertical inline pump helps fi ll in the gaps
of pump gpm ratings.
The mechanical design of a vertical
inline pump (VIP) is often the least
expensive. The pump impeller is attached
to the motor shaft and is cantilevered in
the pump casing. There is no hydraulic
balance needed for the water entering
the pump volute, but there is minimum
Circle 137 on card.

pumpsandsystems.com | May 2019

58 FIRE PUMPS
bearing support for vibration. This
results in a limited use in fire pumps
Your
Y ourr B
Be
Best
es
st Va
Value
alue
e above 750 gpm.
If debris clogs the pump impeller, the
in Progressive motor and impeller rotating assembly
must be lifted up and out of the pump
Cavity Pumps casing together, while still assembled.
For large motors this can be difficult.
If the motor size exceeds 50 hp, special
equipment may be needed. Since these
pumps are typically chosen for their
small size, the pump room itself may
be small as well. An allowance for space
to accomplish future repairs should be
made (see NFPA 20 2013 4.12.1.1.6,
which cautions installers to allow for
proper clearances).
Vertical Shaft Turbine
Vertical shaft turbine (commonly
referred to as “vertical turbine”) pumps
have impellers that are submerged in
the water source. These pumps include
a bowl assembly, which contains several
impellers on a vertical shaft (where
the discharge of one impeller directly
feeds the suction of the next impeller,
and so on), a column assembly built to
a specified length, and a discharge head
assembly, which holds the motor or
right-angle gear drive. In a mechanical
room, the discharge head assembly of
a typical vertical turbine pump is the
only visible part of the pump.
These pumps are helpful in areas
where water is scarce, but also when
Providing a Quality installing an above-ground water
storage tank is not desirable. An added
Product at a Fair Market advantage to a vertical turbine pump is
Price since 1982 that almost any length and discharge
Call or Email: pressure can be ordered. Several
920-869-4800 impellers can be added for additional
sales@summitpump.com pressure. When properly installed,
there is no longer a concern about air in
the suction pipe or priming concerns.
With each additional impeller, you are
Circle 132 on card.
adding to the pump “churn” or shut-
off point on its curve. So, additional
unwanted pressure is often seen at
TM lower operational flows.
PUMP, Inc These pumps can be challenging to
service. The pump must be removed or
www.SUMMITPUMP.com
May 2019 | Pumps & Systems
disassembled, which often requires use
of a roof hatch in a room so that a crane
can lift it out for examination. Since
these pumps are custom-built, the lead
times can be long—from eight to 20
weeks depending on the manufacturer
and models.
Special care must be made before
operating a vertical turbine pump for
the first time. The shaft and impellers
must be properly adjusted to lift them
off the bowl casings prior to operation.
Rotary Gear Pump
Rotary gear pumps are used for a wide
variety of pump applications, from high
viscosity or low NPSH requirements.
Unlike the other pump types discussed,
a rotary gear pump can be built to
self-prime. Due to its small size,
portable rotary gear pumps are often
used in rural areas to pump water from
ponds or streams.
The rotary gear pump operates
through positive or fi xed displacement
of the liquid being pumped. This is
accomplished through pump gears,
which move a specific amount of
liquid per gear revolution. There is no
throttling this type of pump, so a relief
valve is required.
In the fire protection field, rotary
gear pumps are especially useful
for high-pressure and high-hazard
applications—specifically to handle
foam concentrate. Some brands can
operate dry since the rotating elements
never touch due to timing gears. This is
extremely important when operating
with foam and petrochemical products.
While these pumps are smaller than
centrifugal pumps, they can have
more operating noise. Their hydraulic
efficiencies are slightly less than other
types of pumps, which is why they are
often used with high-viscosity liquids.
Steven Brown is president at
Steven Brown & Associates. He may
be reached at 302-652-4722, ext.
100. For more information, visit
stevenbrownassociates.com.

Fluid Handling in Commercial Building Pumps &
Uniform Flow Requirements
By Hydraulic Institute
Our commercial building has
many pumps, but I am not
clear on what fluids are being
handled. What types of fluids
are being pumped/handled?
Fluid streams within a commercial with solids and minimize clogging are
building are generally water based
but sometimes include chemicals for
disinfecting. The water-based fluids may
be characterized as follows:
• potable (domestic) water
• nonpotable, clean water
• wastewater
• greywater
• glycol and water mixtures
Potable (domestic) water is city or well that the water mixed with the glycol be
water that has been treated and is safe
for human consumption.
Nonpotable clean water contains
minimal or small solids; however, it is not
suitable for human consumption.
Wastewater may include household
and commercial solids, large solids,
stringy material, sanitary waste, plastic
scraps, food waste, sticks, leaves,
abrasive materials and other inorganic
and organic solids. What becomes more
prevalent in wastewater flows, though,
are personal wipes, towels, cleaning
cloths and household cleaning materials
that are marketed to be discarded
through the sewer system.
HI PUMP FAQS 59
These materials, in addition to the pumping considerations, refer to HI’s
stringy materials and rags, can bind new guidebook Pump Application
to create a large mass that can lead to Guidelines for Commercial Building
clogging issues in the wastewater Services at pumps.org.
pump and associated piping.
Rotodynamic pumps designed to deal What are the requirements
for uniform flow into a
referred to as solids-handling pumps. pump suction?
Greywater can be water from a sink
or bath that is kept separate from In general, the flow of liquid into
wastewater from toilets and sewer any pump should be uniform, steady
systems. It may also be harvested and free from swirl and entrained air.
rainwater that is collected in a cistern. Lack of uniformity can cause the
Glycol and water mixtures have pump to operate away from the optimum
properties that diff er from water. The design condition/curve and at a lower
viscosity is increased, the boiling point hydraulic efficiency.
is increased and the freezing point is Unsteady flow causes the load on the
lowered. Glycol is typically added to impeller to fluctuate, which can lead to
hydronic systems to prevent the liquid noise, vibration, bearing problems and
from freezing at temperatures below the fatigue failures of pump shafts.
freezing point for plain water. The negative impact of these
Propylene and ethylene glycols are phenomena on pump performance
typically used in commercial buildings. depends on pump specific speed and
Most glycol manufactures recommend size, as well as other design features of
the pump that are specific to the given
treated to prevent minerals commonly pump. A comprehensive assessment
found in city water supplies from reacting of which pump types may be expected
with the glycol. to withstand a given level of adverse
The fluid streams within buildings phenomena with no ill effects has not
may contain one or more of these been performed. However, in general,
characteristics. The properties of larger pumps and axial flow pumps
these fluid streams create different (high specific speed) are more sensitive
considerations that need to be addressed to adverse flow phenomena than
when selecting a pump for the intended smaller pumps or radial flow pumps
service. Th e pump user should identify (low specific speed).
and communicate to the pump American National Standards Institute
manufacturer the nature of the (ANSI) standards for the design of pump
fluid for each application to ensure free surface intakes and suction cans
reliable operation. (ANSI/HI 9.8 Rotodynamic Pumps for
For more information on fluids Pump Intake Design), and for pump
pumped in commercial buildings and piping (ANSI/HI 9.6.6 Rotodynamic
pumpsandsystems.com | May 2018
60 HI PUMP FAQS

50 YEARS AND RUNNING STRONG

Cat Pumps produces the longest-lasting, most durable high-pressure
triplex pumps on the market. With over half a century of field-proven Pumps for Pump Piping), provide
reliability, the surest way to maintain production is to specify Cat Pumps. standard practices for the design of
A Wide Range of Pressure and Flow: pump intakes and piping that provide
100 to10,000 psi (6.9 to 689 bar) | 0.13 to 240 gpm (0.49 to 908 lpm) flow profi les into the pump that will not
adversely affect the pump.
Whatever your specs and application, Cat Pumps has the right pump.
Take the next step to more dependable pumps today. However, it is not always possible
to design intakes or piping per the
(763)780-5440 ¥ info@catpumps.com standard designs, and there are instances
where pumping equipment is large and
additional consideration is required.
In these cases, the standards mentioned
allow for physical model studies to be
conducted with stated acceptance
criteria to qualify the design per
the standards.
A physical hydraulic model is a
reduced-scale replicate of the geometry
that controls approach flow patterns,
operated according to certain similitude
laws for flow, velocity and time. The
© 2019 Cat Pumps 19037 1/19
physical model testing qualifies the
intake and pump piping design to the
Circle 135 on card. standard by ensuring that:
• the surface vortices and subsurface
vortices are below a certain
classification and frequency
NSF/ANSI 61 • the swirl angles are consistent and
below a certain degree

CERTIFIED • the time-averaged velocities at a

point in the throat of the inlet bell
or at the pump suction are within
a certain percentage of the cross-
Proco Products, Inc. continues to bring you the best section velocity
in rubber expansion joints for potable water systems. • the flow for double suction pumps are
equal (within a specified percentage)
Find our complete range of NSF/ANSI 61 on each side of the pump
Certified Joints at procoproducts.com
For more information on designing for
uniform flow entering the pump, refer
to ANSI/HI 9.6.6 and ANSI/HI 9.8 at
pumps.org.

HI Pump FAQs® is produced by the Hydraulic

Institute as a service to pump users,
contractors, distributors, reps and OEMs. For
more information, visit pumps.org.

THE EXPANSION JOINT AND CHECK VALVE PEOPLE

209-943-6088 | procoproducts.com

Circle 136 on card.

May 2018 | Pumps & Systems

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62 SEALING SENSE

API 622: Valve Packing for Fugitive Emissions

Most emissions escape through the valve stem.

By Mark Freeman
FSA Member, EGC Enterprises, Inc.

T
he American Petroleum Institute
(API) has developed two commonly
used standards designed
specifically for the petroleum industry.
They include API 622 “Type Testing
of Process Valve Packing for Fugitive
Emissions,” and API 624 “Type Testing
of Rising Stem Valves Equipped with
Graphite Packing for Fugitive Emissions.”
API 622 and API 624 may be specified
by an end-user. Valve OEMs must use
API 622-approved packing for any valve
on test for API 624.
Fugitive Emissions Test Standards
Since the introduction of the U.S. Clean
Air Act in 1963, the U.S. Environmental
Protection Agency (EPA), as well as
individual states, have set increasingly
stringent restrictions regulating fugitive
emissions from industrial facilities.
Fugitive emissions are any chemical
in a physical form that can unknowingly
leak from an installation. Valves account
for more than 51 percent of all fugitive
emissions, including greenhouse gas.
Eighty percent of these emissions come
from the valve stem—representing
more than 300,000 tons annually.
It is generally estimated that a high
proportion of emissions come from
hydrocarbon gasses such as methane.
The consequences of these losses are
far-reaching. They include the loss
of product in terms of the cost of
fugitive emissions, cleanup costs, loss
of production time and labor costs to
repair leaks.
Plants handling fugitive emissions are
expected to implement leak detection
Image 1 (left). Testing fi xture
Image 2 (right). Thermo toxic vapor analyzer (Image courtesy of Yarmouth Research)
and repair (LDAR) protocols monthly.
The EPA monitors leak detection using
“sniffing” technology. Although alternate
test methods are being used, fines
for falling out of compliance can cost
some companies millions. So, reducing
fugitive emissions not only protects the
environment but also saves money for
industrial facilities.
Recently, there has been a focus on
replacing the “repair” in LDAR with a
more proactive, preventative approach
that focuses on valve design and low
emissions (low E) performance at the
manufacturing level.
API 622
The first in a series of embedded low E
valve and packing standards is API 622,
which was revised for the third time. This
is a test standard for the packing itself.
It uses a standardized test fi xture and
eliminates all the variable conditions
inherent in each valve. By using a test
fi xture and a specified set of conditions,
a variety of packing sets from multiple
manufacturers can be evaluated under
the same conditions.
The third edition of API 622 restricts
leakage of the packing set to a maximum
of 100 parts per million volumetric
(ppmv), while eliminating the single
previously allowed gland bolt adjustment.
This edition also adds the requirement
of an 1/8-inch packing sample test,
which has been problematic in valve type
testing, alongside the 1/4-inch packing,
which has been used exclusively in all
earlier revisions.
Currently, API 622 is a performance
test. It runs a span of 1,510 mechanical
cycles (from open to close) at 600
pounds per square inch gauge (psig)
operating pressure over five thermal
cycles. Measurements of test gas leakage
(methane) are taken periodically
throughout the test.
During the thermal cycling test,
the fi xture operates at ambient
temperature for 150 cycles. At that

May 2019 | Pumps & Systems

 63

Table 1. stuffing box dimensions and tolerances (Image courtesy of EGC Enterprises)
Item 1/8-inch Packing Fixture 1/4-inch Packing Fixture
Stem diameter 11.05 mm to 11.1 mm (0.4355 in. to 0.4375 in.) 25.2 to 25.4 mm (0.992 in. to1.0 in.)
Stem straightness Max. 0.04 mm per 305 mm (0.0016 in. per 12 in.) Max. 0.04 mm per 305 mm (0.0016 in. per 12 in.)
Stem cylindricity 0.04 mm max. (0.0016 in. max.) 0.04 mm max. (0.0016 in. max.)
Stem surface finish 0.40 µm Ra to 0.80 µm Ra (16 µ-in. Ra to 32 µ-in. Ra) 0.40 µm Ra to 0.80 µm Ra (16 µ-in. Ra to 32 µ-in. Ra)
Stuffing box diameter 17.46 mm + 0.06 mm or – 0.0 mm 38.1 mm + 0.25 mm or – 0.0 mm
(0.6875 in. to 0.6900 in.) (1.5 in. to 1.510 in.)
Stuffing box depth 19.05 mm ± 1.5748 mm (0.75 in. ± 0.062 in.) 44.5 mm ± 1.5748 mm (1.75 in. ± 0.062 in.)
Stuffing box surface 3.20 µm Ra + 1.25 µm Ra or – 0.625 µm 3.20 µm Ra + 1.25 µm Ra or – 0.625 µm
finish (125 µ-in. Ra + 50 µ-in. Ra or –25 µ- in.) (125 µ-in. Ra + 50 µ-in. Ra or –25 µ- in.)
Gland bottom machined
0.15 mm (0.006 in.) max. 0.15 mm (0.006 in.) max.
flat
Gland to stuffing box
0. 63 mm to 0.190 mm (0.0025 in. to 0.0075 in.) 0.13 mm to 0.38 mm (0.005 in. to 0.015 in.)
diametrical clearance
Stem to gland (flange)
0.254 mm to 0.381 mm (0.010 in. to 0.015 in.) 0.5 mm to 0.8 mm (0.020 in. to 0.030 in.)
diametrical clearance
Gland stud diameter 3/8 in. - 16 UNC (2 pieces) 5/8 in. - 11 UNC (2 pieces)

point, the temperature is increased to
500 F, running another 150 cycles. This
sequence repeats four additional times,
and the final stage of the test runs for
10 cycles at ambient temperature.
The test fi xture is designed to resemble
a 4-inch, 300-pound gate valve, using a
1/4-inch cross-section packing sample
and a 4-inch stem stroke (or the distance
traveled from fully open to fully closed,
see Image 1). Stem diameter is 1 inch and
box diameter is 1.5 inches for a 1/4-inch
packing cross-section size.
This test fi xture is detailed within
the test standard so that every test,
independent of location, can be
compared and evaluated. Leakage of
up to 100 ppmv is permitted. Leakage
measurements are taken using an organic
vapor analyzer (Image 2) to measure
hydrocarbons and volatile organic
compounds (VOCs). The test no longer
allows one adjustment of the gland bolts
if the packing set began to leak.
API 624
This is a test for the valve itself, including
the stem packing. The intention of this
test is to measure the low E capability of
a valve over an accelerated lifecycle. API
624 is a valve-type test meant to evaluate
the total performance of the valve itself
and not the packing alone.
The packing used in an API 624 tested
valve should be previously tested to
measure up to API 622 requirements.
All the variables within a given valve
design are being tested in API 624, while
the packing has been proven to be, at
least theoretically, suitable for use in a
low E valve.
The test runs a span of 310 mechanical
cycles at 600 psig operating pressure
over three thermal cycles. All the while,
periodic leakage measurements are
taken of the test gas, which is specified
as methane.
During the thermal cycles, the valve
will run at ambient temperature for 50
cycles. The temperature is increased to
500 F, and the valve is cycled another
50 times.
Finally, the valve is returned to
ambient temperature for a run of 10
cycles. Allowable leakage during this test
is 100 ppmv at the stem and bonnet seal.
No stem seal adjustments are allowed.
If at any point the leakage exceeds 100
ppmv, the test is considered a failure.
The API taskforce is working on a new
revision of API 624 and has expanded its
line of valve standards by adding API
641 for emission-type testing of quarter-
turn valves.
Next Month: Sealing High-Speed
Shafts in Turbo-Machines
We invite your
suggestions for article
topics as well as questions
on sealing issues so we
can better respond to the
needs of the industry. Please direct your suggestions and
questions to sealingsensequestions@fluidsealing.com.
Mark Freeman is the
marketing director for
EGC Enterprises, Inc.
For more than 25 years,
he was CEO of Mark
Freeman Advertising.

pumpsandsystems.com | May 2019

64 FLOW METERS

Accurate Flow Measurement: Understanding pump performance

involves a basic knowledge of related

Critical for Water System Pumps specifications and performance curves.

Choosing a Metering Technology

By Chris Sizemore Industrial, commercial and municipal
Badger Meter organizations have a choice of flow
measurement technologies for achieving

T
accuracy and safe water contact in
he need for safe, healthy and protection for products in contact with pump control applications. A variety of
clean water is of fundamental potable water. The standards require that mechanical and electronic meters are
importance in industrial, prefabricated domestic pump systems available for liquid flow measurement.
commercial and municipal environments. have certification as an entire system. The most commonly used options range
There are standards governing the use from turbine meters with stainless steel
of certain equipment in these settings, Understanding Pump Performance wetted components, to electromagnetic
which provide guidance and can have the Manufacturers involved with food meters and both inline and clamp-on
effect of law in some jurisdictions. and beverage production and other ultrasonic meters—all of which can be
Accurate control of pumps is critical in sanitary processes, as well as operators safe for use in potable water.
potable water applications. The goal is to of municipal water systems, use pumps Turbine meters are a proven
improve efficiency with precise tracking compliant with the SDWA. These pumps technology and low-cost solution for
of water volume through distribution are made of stainless steel or other smaller line sizes. They are known for
systems, while identifying potential nonhazardous materials and must be accuracy, wide turndown and repeatable
performance problems. This requires easy to disassemble and clean. measurements. Turbine meters produce a
effective flow measurement. Accurate control of pump systems is high-resolution pulse rate output signal
a critical concern in such applications, proportional to fluid velocity and, hence,
Background which are often characterized by to volumetric flow rate. These devices
Regulatory and legislative efforts intermittent low flows and reduced water are limited to clean fluids and require
to reduce the lead contained in all consumption. Today, water delivery periodic recalibration and service.
plumbing-related products that come systems feature large pipes with low-flow Some turbine-based flow meter designs
in contact with potable water has velocities and low overall volume capture. are available in a lead-free bronze alloy.
increased. United States federal and The flow generated by a pump is They comply with lead-free drinking
state agencies stipulate that components volumetric in nature. The precision of water provisions and can be certified to
of potable water systems comply with any measurement is heavily dependent the NSF/ANSI standards. All components
the U.S. Environmental Protection on the fluid properties. Inaccuracies in of these lead-free alloy meters comprise
Agency’s Safe Drinking Water Act flow metering can be caused by process the certified system.
(SDWA) through standards established conditions including temperature Nutating disc flow meters are also
by NSF International, a not-for- changes, pressure variations, air commonly used in water metering—
profit, nongovernmental organization entrapment and wear of components. particularly with smaller lines. They
recognized for its expertise in health and Data indicates that pump flow output have a reputation for high accuracy and
environmental sciences. can vary significantly due to component repeatability, but viscosities below the
Standards addressing potable degradation, environmental or system threshold adversely affect performance.
water applications include NSF/ANSI changes, or a combination of these. Since most potable water processes
Standard 61: Drinking Water System Flow rates through pumps are metered involve liquids that are conductive,
Components—Health Effects and NSF/ for a number of reasons: to calculate electromagnetic flow meters are
ANSI Standard 372: Drinking Water distribution system losses by subtracting suitable for many associated flow
System Components—Lead Content. the total of readings from total supply; to measurement tasks. These meters help
NSF Standard 61 is a drinking water optimize disinfection; to treat corrosion; meet measurement accuracy objectives,
approval, whereas Standard 372 is a to monitor overall pump performance; enabling more efficient pump operation
method of measurement for determining and to determine gross billings in at a lower cost. They provide diagnostics
“lead free” (weighted average of 0.25 custody transfer. to deliver enhanced reliability, process
percent or less) characteristics. Standards Most aspects of a pump’s performance insight and reduced costs.
61 and 372 are intended to ensure health can be associated with the flow of fluid. Electromagnetic flow meters have

May 2019 | Pumps & Systems

 65

become an affordable long-term solution
for a wide range of applications. They are
designed to achieve up to ± 0.2 percent
accuracy and the nonintrusive, open-flow
tube design virtually eliminates pressure
loss. The meters have no moving parts
or flow obstructions and are relatively
unaffected by viscosity, temperature and
pressure when correctly specified.
Electromagnetic meters have signals
that are linear with flow. Turndown can
approach 20-to-1 or better without losing
accuracy. They offer encoded outputs.
Many are choosing noncontact
ultrasonic flow meters, which are
inherently compliant with NSF
regulations and installation without
disturbing or cutting the pipe. Providing
a turndown ratio that is comparable to
electromagnetic flow meters, modern
ultrasonic meters have been enhanced
with increased power and sampling rates.
Transit-time ultrasonic meters are
designed to determine bidirectional
flow rates. Ultrasonic waves transmit
upstream and downstream through the
pipe wall and liquid flowing in the pipe.
By measuring the difference in the travel
time and knowing the pipe size, the
meter determines the velocity and flow.
Clamp-on transit-time ultrasonic
meters have no moving or wetted parts,
can suffer no pressure loss and can
provide maintenance-free operation.
By measuring the speed of sound of the
fluid, they can report changes in fluid
temperature and/or other properties.
Clamp-on ultrasonic flow meters can
troubleshoot a wide range of flow issues,
particularly in pumps. These ultrasonic
meters reside outside the pipe and enable
installation flexibility across a wide range
of pipe sizes, no contact with internal
liquid and no moving parts.
A clamp-on ultrasonic flow meter
can be a valuable tool to manage pump
and system performance. The meter can
provide the baseline and load profi le
information needed to optimize system
efficiency and reduce energy consumption
and costs.
Using cloud-based data analytics,
the latest flow meters enable greater
visibility and control. The interval meter
data provides actionable intelligence to
optimize water management. Cellular
endpoints broadcast meter reading and
event data to system software. This helps
identify leaks and other anomalies in
performance.
Chris Sizemore is a technical sales
manager for Badger Meter Flow
Instrumentation. He joined
the company in 2013 and
also has held roles on the
technical support team.
For more information, visit
badgermeter.com.

SMART
WATER IS:
AMI WITHOUT THE INFRASTRUCTURE
CELLULAR KEEPS IT EASY.
In the past, AMI was only available to those with the resources to operate a traditional
fixed network. Today, utilities are leveraging highly reliable and secure cellular networks
to make their meter reading more efficient, scalable and interoperable for the long term.
BEACON® Advanced Metering Analytics is smart water. Smart water is Badger Meter. SMART WATER IS BADGER ME TER
Visit us at booth #2608 during ACE19 to discover more. (800) 616-3837 | badgermeter.com/ACE2019

Circle 122 on card.

pumpsandsystems.com | May 2019

66 PRODUCTS
New & Notable Technology
Products selected by the Pumps & Systems editors
1 BEARINGS
GRAPHALLOY Grade GM 690 bearings have been
granted water regulations advisory scheme (WRAS)
approval as GRAPHITE METALLIZING continues
to expand the GRAPHALLOY product line to meet
drinking water regulations worldwide. WRAS
approval specifies that GRAPHALLOY GM 690
bearings are “suitable for contact with wholesome
water for domestic purposes” because the material
has met the requirements of BS 6920-1. Previously,
NSF International certified two other grades of
GRAPHALLOY for use in municipal well pumps
and water treatment plant applications. These
GRAPHALLOY bushings provide solutions that can
eliminate requirements for lubrication systems,
including prelubrication. graphalloy.com
Circle 201 on card.
2 SEALS
The ISOMAG Magnum series of seals provide
bearing protection with magnetically energized
lapped flat faces that create a positive liquid tight
seal preventing lubricant leakage and the ingress
of contaminants in both static and dynamic
conditions. Isomag provides bearing protection
on a variety of centrifugal equipment (e.g. pumps,
motors, gearboxes, steam turbines, etc.).
isomag.com
Circle 202 on card.
To have a product considered for this section, please send the information to Drew Champlin, dchamplin@cahabamedia.com.
May 2019 | Pumps & Systems
3 METERING PUMP
MILTON ROY’s PRIMEROYAL series pumps have
robust mechanisms and a modular design.
PRIMEROYAL pumps have multiple liquid end
and capacity-control options for the specific
requirements of various applications. The
PRIMEROYAL range provides accurate dosing of
a broad spectrum of fluids at flow rates that can
reach maximum 13,068 gallons per hour (49,470
liters/hour) in the triplex configuration. With its
modular design and range of options, PRIMEROYAL
pumps can be configured for different needs.
miltonroy.com
Circle 203 on card.
4 PERISTALTIC PUMP
SmartFlex LRP Series peristaltic pumps,
which are pressing shoe-type pumps from
HAYWARD GORDON, do not require lubricant
and use 3 to 50 percent less power. The chemical
resistant Halar coated units provide corrosion
protection. The roller pumps transfer and meter
corrosive or abrasive fluids safely. The pump can
be shut down immediately upon hose failure. This
can prevent pump casings full of contaminated
lubricant that need to be handled, disposed of and
replaced. Trial pumps are available.
haywardgordon.com
Circle 204 on card.
6
5 COVER KITS
ALLIED MOULDED’s HMI cover kits feature a rigid
design for mounting securely to the outside of
enclosures and provide protection/access to critical
components. They are UL recognized and maintain
a NEMA 4X seal, making them well-suited for
applications in harsh environments. HMI cover kits
are available in six sizes, with solid opaque or clear
covers, along with multiple cover latching options
and a prop arm. alliedmoulded.com
Circle 205 on card.
6 SUBMERSIBLE PUMP & DRIVE UNIT
Versatile and stackable, with fast install times and
easy setup, the 42-inch MWI Hydraflo mixed-flow
submersible pump and drive unit helps get the job
done effectively and can save up to 75 percent on
civil works costs. This submersible pump and drive
unit has up to 600 horsepower, 55 feet of head and
flow rates as high as 60,000 gallons per minute.
mwipumps.com
Circle 206 on card.
 67

7 8 PUMP ALARM
7 BEARINGS
The PackRyt ORM bearing from SEALRYT
works in concert with mechanical seals and can
eliminate shaft movement. ORMs can allow the
seal faces to stay together, track true and live in
a protected environment. This can be especially
necessary when using split mechanical seals.
This product may multiply expected seal life.
sealryt.com
Circle 207 on card.
NAVI SOLUTIONS’ Notify wireless pumping
system alarm provides immediate notification of
pumping system failures directly to maintenance
personnel by email and text, independent of other
building systems and networks. Notify is built
on an ISO 9001 compliant alarm processor and
cloud service that monitors 25,000 sites within
the wireless industry. Notify operates over a
preactivated, secure 4G LTE cell data VPN. Notify
delivers relevant user defined notifications of
previously undetected, unreported or unpredicted
pumping system failures. navi-llc.com/notify
Circle 208 on card.
9 FLOW GRINDER
The Channel Monster FLEX is the newest
addition to JWC ENVIRONMENTAL’s wastewater
sewage grinder family of products. The Channel
Monster FLEX is a high flow grinder constructed
of a separate FLEX grinder and solids diverter
screening drum brought together with a FLEX
Frame. This modular design allows for the
flexibility of servicing the cutting element and
screening drum element separately. It achieves
high flows while using a perforated screen instead
of horizontal screening bars. jwce.com
Circle 209 on card.

ISO 9001:2015

CLEARLY
SUPERIOR
FILTRATION
UNMATCHABLE EXPERIENCE IN
FLOW CONTROL TRANSACTIONS

Jordan Knauff & Company is a knowledgeable and

Prepare To Be
experienced provider of a comprehensive line of
investment banking services to the pump, valve and
(Melt) Blown Away!
filtration industries (“Flow Control”). Now offering NSF Certified
Nominal Rated Melt-Blown
Our lines of business include: selling companies, Cartridges.
raising debt and equity capital, and assistance
on acquisitions. Proudly Made in the USA

To learn more about Jordan Knauff & Com-

pany, contact any member of our Flow
Control team. Access our Flow Control research
at www.jordanknauff.com/research-library.

G. Cook Jordan, Jr. David A. Kakareka

Managing Principal Vice President Contact us at 1.800.543.5843 or info@shelco.com to learn
cj@jordanknauff.com
312.254.5901
dkakareka@jordanknauff.com
312.254.5907
why Shelco is the only place for all your filtration needs!
100 BRADLEY STREET • MIDDLETOWN, CT 06457 • WWW.SHELCO.COM
MEMBER FINRA, SIPC INFO@SHELCO.COM • 1-800-543-5843
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pumpsandsystems.com | May 2019

68 PUMP USERS MARKETPLACE

Advertisers
Advertiser Name RS# Page Advertiser Name RS# Page Advertiser Name RS# Page

AdEdge Water Technologies Inc. . . . . .102 17 Inline Industries . . . . . . . . . . . . . . . . . . 123 19
AE Pumps . . . . . . . . . . . . . . . . . . . . . . . . 158 71 Integrity Pump & Motor . . . . . . . . . . . 129 50
Argal Pumps . . . . . . . . . . . . . . . . . . . . . . .148 69 Jordan, Knauff & Company . . . . . . . . 138 67
Ashcroft . . . . . . . . . . . . . . . . . . . . . . . . . . .103 15 Load Controls, Inc . . . . . . . . . . . . . . . . . 126 37
Automationdirect.com. . . . . . . . . . . . . .107 IFC Load Controls, Inc . . . . . . . . . . . . . . . . . .160 70
Badger Meter Inc . . . . . . . . . . . . . . . . . . 122 65 LobePro Rotary Pumps.. . . . . . . . . . . . .152 71
Blacoh Fluid Control . . . . . . . . . . . . . . . 108 BC Lovato USA . . . . . . . . . . . . . . . . . . . . . . . .124 23
Blue-White Industries Ltd. . . . . . . . . . .109 7 Magnatex Pumps. . . . . . . . . . . . . . . . . . .149 69
Carver Pump Company . . . . . . . . . . . . 139 53 MasterBond Inc. . . . . . . . . . . . . . . . . . . .144 69
CAT Pumps . . . . . . . . . . . . . . . . . . . . . . . 135 60 Milton Roy. . . . . . . . . . . . . . . . . . . . . . . . .117 51
Dan Bolen & Associates . . . . . . . . . . . . 155 70 Mission Communications . . . . . . . . . . .118 35
Drive Source International, Inc. . . . . 127 33 Moving Water Industries
EASA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC Corporation (MWI). . . . . . . . . . . . . . . . 156 71
Equipump, Inc.. . . . . . . . . . . . . . . . . . . . 154 70 Mueller Company . . . . . . . . . . . . . . . . . 134 55
FEDCO . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 57 National Pump Company . . . . . . . . . . .119 47
Flomatic Corp. . . . . . . . . . . . . . . . . . . . . 115 18 Navi Solutions . . . . . . . . . . . . . . . . . . . . 150 69
Flowrox . . . . . . . . . . . . . . . . . . . . . . . . . . .111 13 Pinnacle-Flo . . . . . . . . . . . . . . . . . . . . . . .166 68
Franklin Electric . . . . . . . . . . . . . . . . . . 112 9 Proco Products, Inc. . . . . . . . . . . . . . . . 136 60
Griffco Valve, Inc. . . . . . . . . . . . . . . . . . .141 45 Rocky Mountain Valves . . . . . . . . . . . . .165 68
Harmsco . . . . . . . . . . . . . . . . . . . . . . . . . .142 45 Rotech Pumps & Systems, Inc.. . . . . . .157 71
HCP Pumps America, Inc. . . . . . . . . . . 104 3 Scalewatcher Inc . . . . . . . . . . . . . . . . . . .145 68
Hydraulic Institute . . . . . . . . . . . . . . . . .116 40 Seepex . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 43
Shelco Filters . . . . . . . . . . . . . . . . . . . . . .143 67
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . .161 70
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . .162 71
Sims Pump Co. . . . . . . . . . . . . . . . . . . . . 130 39
St. Marys Foundry. . . . . . . . . . . . . . . . . .146 69
Summit Pump Inc . . . . . . . . . . . . . . . . . 131 48
Summit Pump Inc . . . . . . . . . . . . . . . . . 132 58
Thordon Bearings, Inc. . . . . . . . . . . . . . 121 30
Titan Flow Control, Inc. . . . . . . . . . . . . 137 57
Titan Manufacturing, Inc.. . . . . . . . . . .147 70
Tuf-Lok International. . . . . . . . . . . . . . 159 71
Val-matic Valve & Mfg. Corp. . . . . . . . .140 53
Vanton Pump & Equipment Corp . . . .110 11
Vaughan Company . . . . . . . . . . . . . . . . .105 5
Vega Americas . . . . . . . . . . . . . . . . . . . . 106 1
Vertiflo . . . . . . . . . . . . . . . . . . . . . . . . . . . .151 69
Vesco Plastics Sales . . . . . . . . . . . . . . . . 153 70
Wanner Engineering. . . . . . . . . . . . . . . 125 31
Watson-Marlow Pumps . . . . . . . . . . . . 128 25
The Index of Advertisers is furnished as a courtesy, and
no responsibility is assumed for incorrect information.

Eco-Friendly PINNACLE-FLO, Inc.

Hard Water Conditioning PUMPS & PARTS
INDUSTRIES: Chemical Process
Refinery • Oil & Gas Municipal
Food Process Markets

PRODUCTS: ANSI Process

API 610 • Centrifugal Solids-
handling Self-prime • Centrifugal
MUD • Air Operated Double
Diaphragm Pumps

Eliminates Corrosion AND Bacteria

• Removes scale from pipe work
• Removes scale from heat exchangers
and steam boilers
• Increases life of capital equipment
• Saves 50% on cooling tower make up
water

SCALEWATCHER North America PINNACLE-FLO.COM

Call 800-504-8577 | www.scalewatcher.com Houston, Texas • 832-303-1245 • sales@Pinnacle-Flo.com
Circle 145 on card. Circle 166 on card. Circle 165 on card.

May 2019 | Pumps & Systems

 69

ABRASION RESISTANT
Silicon Carbide Filled Epoxy
Adhesive Supreme 45HTQ-4
■■Robust chemical resistance
■■Serviceable from -100°F to +450°F
■■Very high compressive strength
■■Exceptionally long pot life
SATURNevo pump installed at El Paso Zoo, TX

SATURNevo
FRP centrifugal aquarium
MPLE

pumps made
for seawater &
zoos
SA

corrosive fish farms

CU RED
liquids
electrochlorination

RO process

theme parks

resorts

malls
+1.201.343.8983 • main@masterbond.com
STMFOUNDRY.COM 419-394-3346 a.malik@argal.it | www.argalpumps.com

Circle 144 on card. Circle 146 on card. Circle 148 on card.

Sub ANSI magnetic drive pumps

IN STOCK, READY TO QUICK SHIP.

Phone: 713.972.8666 | Toll Free: 866.624.7867

FAX: 713.972.8665
3575 West 12th Street, Houston, TX 77008

www.magnatexpumps.com
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pumpsandsystems.com | May 2019

70 PUMP USERS MARKETPLACE

EXECUTIVE SEARCH/RECRUITING

“Serving the Pump &

Rotating Equipment, Valve,
and Industrial Equipment
Industry since 1969”
Circle 147 on card.
Domestic & International
Specializing in placing: MONITOR PUMP PERFORMANCE
• General Management • Engineering
• Sales & Marketing • Manufacturing • Flow Rate univeRsal PoweR Cell
• One Size Adjusts for
JASON SWANSON • JULIAN MUELLER • PumP Condition All Motors, From Small
up to 150HP
DAN BOLEN • dRy Running • Works on Variable Frequency
Drives, 3 Phase, DC and
120 N. 44th Street, Suite 325 • Cavitation Single Phase
Phoenix, Arizona 85034 • 10 times more sensitive than
(480) 767-9000 • BeaRing FailuRe just sensing amps
• 4-20 Milliamp, 0-10 Volt
Email: jason@danbolenassoc.com
www.danbolenassoc.com Call now FoR youR FRee 30-day tRail
Circle 155 on card. 888-600-3247
Circle 160 on card.

Solve
dry start
Circle 161 on card. problems with
Vesconite Hilube
REPLACEMENT • REPAIR • RECOVERING bushings
• Aftermarket pump parts for most models of ● Increase MTBR
Lobeflo®, Muniflo®, Lobeline®, Vogelsang®, ● No swell
:

and Borger® Pumps

● Low friction = reduced
• Repair of Rotary Lobe Pumps
electricity costs
• Manufacturer of the Muniflo Rotary Lobe Pump
(originally manufactured by Wemco since 1985) ● Quick supply.
No quantity too small
Are you looking for obsolete LobeFlo® (SSP/MGI) Pump Parts?
We are the answer! Tollfree 1-866-635-7596
www.equipump.com | www.muniflopump.com vesconite@vesconite.com
800-783-5623 | fax 800-693-5623 | info@equipump.com www.vesconite.com
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May 2019 | Pumps & Systems

 71

• Self-aligning & self

grounding
• High pressure
rated
• Stainless or
mild steel
• Low cost
• High end pull
Tuf-Lok International
Phone: 608.270.9478 • www.tuflok.com
Circle 159 on card.

OUR EXPERTS CAN HELP

Circle 158 on card. Every job is different. Our experienced,
licensed engineers will work with you
to design a cost-effective solution that
is the right fit for your application -
To subscribe to our print or digital
potentially saving millions of dollars.
editions and to sign up for our
newsletters, visit our website and When you need to move large volumes
click on SUBSCRIBE of water quickly and efficiently - call MWI.
Circle 162 on card. PUMPSANDSYSTEMS.COM Offering a wide range of axial and mixed
flow pumps with flows from 10K-1M gpm.

Call for a free

project review:
954-426-1500

mwipumps.com
Why LobePro Rotary Lobe Pumps?
• Low maintenance - • Excellent for abrasives, Circle 156 on card.
“in place” wear part solids & viscous fluids
replacement • Forward and reverse
• Run dry ability pumping operation
To learn more or get a custom quote,
email PumpSales@lobepro.com

912-466-0304 • www.LOBEPRO.com • Made in USA

Circle 152 on card.

MOBILE
CONNECTIONS
facebook.com/pumpsandsystemsmag

twitter.com/PumpsSystemsMag
ON THE GO linkedin.com/groups/1592537

Circle 157 on card.

pumpsandsystems.com | May 2019

72 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T
he Jordan, Knauff &
Company (JKC) Valve Stock
Index was down 2.9 percent
over the last 12 months, while
the broader S&P 500 Index was
up 9 percent. The JKC Pump Stock
Index fell 9.9 percent for the same
time period.1
The Institute for Supply
Management’s Purchasing
Managers’ Index (PMI) increased
1.1 percentage points to 55.3
percent in March. Comments
from the survey panel reflected
expanding business strength
supported by gains in new orders
and employment. The New Orders
Index gained 1.9 percentage points
rising to 57.4 percent, while the
Employment Index gained 5.2
percentage points reaching 57.5
percent. The Export Orders Index
fell to 51.7 percent, its lowest level
in two and a half years.
Growth of global manufacturing
production remained weak in
March according to the latest J.P.
Morgan Global Manufacturing PMI.
With a reading of 50.6 percent,
the index was unchanged from
February and is slightly above
the neutral 50 percent mark.
Overall, new orders stagnated and
international trade flows declined.
On a regional basis, PMI readings
Image 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
May 2019 | Pumps & Systems
were above 50 percent in
China, the United States,
Brazil and the United
Kingdom. Below 50
percent readings were seen
in the Eurozone, Japan
and South Korea. March
saw a modest increase
in global manufacturing Image 1. Stock indices from April 1, 2018, to March 31, 2019
employment, with staffing
Local currency converted to USD using historical spot rates. The JKC Pump and Valve
levels rising in China, the Stock Indices include a select list of publicly traded companies involved in the pump and
U.S., the Eurozone, Japan, valve industries, weighted by market capitalization. Source: Capital IQ and JKC research.
Brazil and the U.K.
U.S. natural gas consumption Instead of running at higher Reference
increased by 10 percent in 2018. usage rates, refineries have 1. The S&P Return
The electric power sector accounted increased capacity by 783,000 figures are provided
by Capital IQ.
for 35 percent of total domestic barrels per calendar day between
use, with industrial accounting for December 2013 and 2018.
28 percent, residential 17 percent, On Wall Street, the Dow Jones Jordan, Knauff
commercial 12 percent and other Industrial Average, the S&P 500 & Company is an
investment bank
uses at 9 percent. Index and the NASDAQ Composite based in Chicago that
U.S. refinery runs (gross inputs to gained 0.1 percent, 1.8 percent provides merger and
petroleum refineries) averaged 17.3 and 2.6 percent, respectively, in acquisition advisory
services to the
million barrels per day in 2018, the March. Positive developments on pump, valve and
highest annual average on record the trade war with China and the filtration industries.
and the fifth consecutive year of Federal Reserve Bank’s decision Please visit
jordanknauff.com for
record-high levels. to keep interest rates unchanged further information.
U.S. refinery runs are expected to were major issues for the markets. Jordan, Knauff &
be relatively flat in 2019 and then For the quarter, the Dow Jones Company is a member
of FINRA.
reach a new record of 17.8 million Industrial Average, the S&P 500
barrels per day in 2020. Refinery Index and the NASDAQ Composite
usage as a percentage of operable rallied 11.2 percent, 13.1 percent
capacity averaged 93.2 percent in and 16.5 percent, marking the S&P These materials were
prepared for informational
2018, an increase of 2.1 percent 500 Index’s best quarterly rise since purposes from sources that
are believed to be reliable
from 2017. the third quarter of 2009. but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
Image 3. U.S. PMI and manufacturing shipments any investment offering or
deployment of capital.
Source: Institute for Supply Management Manufacturing
Report on Business and U.S. Census Bureau
 JUNE 30 - JULY 2
Mandalay Bay Resort & Convention Center i Pre-Convention Education June 29

Attend the Premier Event

for Rotating Equipment
Connect with leading manufacturers and suppliers of pumps
and pump supplies, electric motors, predictive and preventative
maintenance equipment, bearings and more.
Participate in expert-led training on topics like:
- Emerging & disruptive technologies.
- Simplified sales development.
- Motor-driven systems marketplace trends.
Enjoy entertainment and networking events for an
unforgettable Las Vegas experience.

Register today at www.easa.com/convention

Have you joined yet?

More than 90% of EASA members repair pumps in addition to
other electromechanical equipment.
Join the association of pump repairers and receive a discount on your
convention registration, access to EASA’s technical support service
and more.

Visit www.easa.com/join
to get started!

EASA • 1331 Baur Blvd. • St. Louis, MO 63132 • +1 314 993 2220 • www.easa.com
 PROTECT
YOUR SYSTEM
FROM DAMAGE
Detect and Record Transient Pressure

PLANT OPERATORS OFTEN DON’T SEE DANGEROUS

ABNORMALITIES UNTIL IT’S TOO LATE.
SurgeWave™ Transient Monitoring Systems solve the need for
pipeline operators to detect and record transient pressure events
occurring in water, wastewater and petroleum pipelines. With
SurgeWave™ installed, notifications are immediately sent to
designers, engineers, manufacturers and operators alike. They
can then assess pipeline performance issues such as pressure,
flow and pump speed in order to perform the necessary
corrections and maintenance.

Visit BlacohSurge.com to learn more.

Circle 108 on card. 800.603.7867 | 951.342.3100 | Sales@Blacoh.com