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KNOW YOUR

BASE PLATE

OPTIONS

URETHANE

STATORS

INCREASE

PUMP LIFE

PLCS BOOST

UPTIME

MAY 2014PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

PUMPING

GREEN ENERGY

FROM FOODWASTE

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CONTENTS MAY 2014

4 Industry News

10 Trade Show Prof ile

Case Studies 12 Turning a Harbor into a Haven

Water & WastewaterSolutions

18 Uniform Distribution in Headers

and Distribution Systems Part 1 of 2

Maintenance Solutions 22 Know Your Pump Base Plate

Installation Options Part 1 of a 3-Part Series

Pump Solutions

24 A Revolution in Pump Eff icieny All-Flo's A200 pump reduces energy costs, improves performance

Part 2 in a 4-Part Series

Dewatering Solutions 28 A Simple Design for Tough Jobs

Motor Solutions 30 Exceeding Expectations

Moyno's new urethane stators increase pump life for wastewater treatment plant

Power GenerationSolutions

34 ANSI/ASHRAE/IES Challenges Solved

with Software

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Processing Solutions 38 Food Waste to Green Energy Landia's chopper pumps sustain Biogen's renewable energy process

Valves & ControlsSolutions

40 Going for the GoldRuggedized PLCs will boost processing uptime at Lapland gold mine

Sealing Solutions

46 Playing It Cool Mechanical seal primary rings for sealing refrigerants and other low viscosity liquids

Special Feature 48 Hear No Evil, See No Evil,

Speak No Evil How online reviews shape how well your business does both online and off

52 Modern PumpingProducts

Featured Product Release: BADGER METER ModMAG® M1000 Electromagnetic Flow Meter

Pumping Trends 56 Tapping into the Power of e Bell & Gossett's Mark Handzel explains the growing need for energy efficient systems

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No part of this publication may be reproduced or transmitted in any form or by anymeans, electronic or mechanical, including photocopy, recording, or any informationstorage-and-retrieval system without permission in writing from the publisher. Theviews expressed by those not on the staff of Modern Pumping Today , or who arenot specifically employed by Highlands Publications, Inc., are purely their own. AllIndustry News material has either been submitted by the subject company or pulleddirectly from their corporate website, which is assumed to be cleared forrelease. Comments and submissions are welcome, and can be submitted [email protected].

For address changes, please contact Lindey Scott:[email protected]

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[email protected] GARMON General Manager

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LINDEY SCOTT Circulation [email protected]

JAMIE WILLETT Circulation [email protected]

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

TONYA BROWNING Account Executive

RANDY MOON Account Executive

KRISTI NEIL Account Executive

Terry BellDrives and Motion Solution EngineerBaldor Electric Company

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

Process Machinery Consulting

Robert G. HavrinDirector of Technology,Centrisys Corporation

Michael ManciniConsultant and Trainer,Mancini Consulting Services

John M. RoachEngineering Manager

for New Product Development,Trebor International, Inc.:

A Uni t of IDEX

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

Greg TowsleyDirector of Regulatory andTechnical Affairs, Grundfos

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

EDITORIAL ADVISORY BOARD

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INDUSTRY news

TEKNOR APEX WINS SPI’S

2014 INNOVATION IN BIOPLASTICS AWARD

SPI: The Plastics Industry Trade Association will present thesecond annual Innovation in Bioplastics Award to Teknor Apexfor the development of Terraloy® PLA compounds which exhibitboth high impact and heat resistant properties. SPI’s BioplasticsCouncil noted that Teknor Apex’s free-flowing resins, used in

both injection molding and extrusion/thermoforming processes,streamlines the PLA crystallization process, eliminating thepost-annealing or post-crystallization process.

"Teknor Apex is honored to receive the Innovation Awardfrom the SPI Bioplastics Council," says Edwin Tam, manager ofnew strategic initiatives. "The work of our Terraloy technicalteam, headed by technical manager Greg Anderson, along withour research partner Cerestech Inc., has enabled us to enhancepolylactic acid in areas such as heat resistance, impactresistance and processability while retaining key bioplasticvalues such as FDA compliance, high bio-based content, andcompostability."

Tam cited a life cycle analysis showing that TeknorApex's Terraloy PLA compounds with high heat distortion

temperatures produced 125 percent less greenhouse gas thanhigh-impact polystyrene and 40 percent less than low-densitypolyethylene.

“It is so exciting that the SPI announces this prestigiousaward at the Biopolymers Symposium,” says Barbara Fowler,conference director for Smithers Rapra. “Teknor Apex has along history of innovations in bioplastics and truly deservesthis recognition.”

“Innovations such as this are what keeps the plastics industryon the cutting edge of technology,” adds SPI President and CEOWilliam R. Carteaux.

ASHRAE 2014 ANNUAL CONFERENCE

ANNOUNCED FOR SEATTLE

While abundant rain and thriving evergreens keep the city

of Seattle green and lush, the city has taken the concept of“green” to a whole different level. Sustainability is promoted inall aspects of life, which makes Seattle the perfect location forASHRAE’s 2014 Annual Conference, which takes place June 28through July 2.

The Technical Program kicks off June 29, with interactiveprograms and a networking coffee break, and concludes July2. The program addresses broad topics in the applicationof technology to practice, specific applications in groundsource heat pumps, operations and maintenance and indoorenvironmental quality, as well as new reports on research takingplace worldwide.

Featured is a track on Ground Source Heat Pumps State ofthe Art: Design, Performance and Research, which addresses

all aspects of design that lead to optimally performing systemsin addition to avoiding common pitfalls that lead to poorlyperforming systems.

The Conference also features the second annual ASHRAEResearch Summit, which presents innovations in HVAC&Rresearch with particular emphasis on high performance buildingdesign and its role in a clean energy economy, and bringstogether researchers to present and discuss the latest research.

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INDUSTRY news

Researchers present papers, seminars and forums or participatein panel discussions. Also, highlights on ongoing ASHRAEfunded research are presented.

Attendees also can take part in courses offered by theASHRAE Learning Institute, including two full-day professionaldevelopment seminars and seven half-day short courses. Newis a course on building demand response and the coming

smart grid.ASHRAE also offers its Building Energy AssessmentProfessional (BEAP) and Building Energy Modeling Professional(BEMP) exams on July 1.

The Conference takes place at the Sheraton Seattle and theWashington State Convention Center. To register orfor more information, visit www.ashrae.org/seattle.

2014 AHR EXPO ATTENDEES: INTEREST INRENEWABLE ENERGY RESOURCES GROWSAccording to a post-Show survey of visitors thatattended the 2014 AHR Expo, 41 percent of themore than 2,000 respondents said they cameto the world’s largest HVACR event seeking

products related to “Renewable Energy Resources”(Geothermal, Solar, etc.). When these sample resultsare projected across the 42,000 plus visitors, morethan 17,000 HVACR professionals came to New Yorkto find products and solutions that could replaceconventional energy with more sustainable options.

“We’re not surprised,” says Clay Stevens,president of International Exposition Company,

which produces and manages the AHR Expo. “We know theinterest in renewable energy resources is growing rapidly, soit is especially encouraging to see such a wide-spread interestacross all segments of HVACR professionals at the Show.”

Stevens adds that there has also been a steady growth in thenumber of exhibitors showcasing renewable energy products intheir booths. “This is an area where we’ve seen many long-time

exhibiting companies expand their lines, as well as many newerexhibitors with more dedicated product offerings. For example,since we were last in New York in 2008, the number ofexhibitors showcasing solar-related products more than doubledto 66 from 29.”

What Products 2014 AHR Expo Attendees Came To See

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INDUSTRY news

The 2015 AHR Expo will be held at Chicago’s McCormickPlace, January 26 through 28. For more information visitwww.ahrexpo.com .

BLACOH FLUID CONTROL LAUNCHESBLACOH UNIVERSITY ELEARNING WEBSITEBlacoh Fluid Control, a leading manufacturer of pulsation

dampeners and fluid control products designed to improvepump system performance and reliability, recently launchedBlacoh University (www.blacohu.com), an online e-learningapplication for industry professionals. According to Blacoh’spresident Andrew Yeghnazar, Blacoh University is alearning tool dedicated to the discovery, development andcommunication of knowledge relating to fluid dynamics andcontrol across a variety of industries.

With the launch of Blacoh University, Blacoh introduceda companion website to the company’s existing site withfunctionality similar to other learning management system(LMS) applications. LMS refers to various software applicationsranging from systems for managing training and educationalrecords to the distribution of online educational courses with

features focused on interactive learning.As a manufacturer headquartered in the US, Blacoh delivers

products to the marketplace through a global distributionnetwork supported by sales offices around the world. “Weare formalizing the way in which we train and coach ourdistributors, and expanding our horizons by providing learningtools for plant maintenance personnel and the engineeringcommunity,” says Mr. Yeghnazar. “This is not just about

providing information. There is an enormous amount of data outthere. We’re taking that information and presenting it in a waythat makes it relevant and useful.”

Blacoh sees this new endeavor in e-learning as a naturalexpansion of its core business. In the complex world of fluidprocessing and liquid handling systems, Blacoh manufactureshighly engineered products to solve problems commonly

associated with industrial and municipal pumping systems.Blacoh University course curriculum for distributors covers thebasics of pulsation dampening in applications using varioustypes of positive displacement pumps. Courses designed for theengineering community provide more in-depth analysis of fluidprocessing systems in general and design related issues such asacceleration head, water hammer and hydraulic surge.

James Burke, director of engineer ing at Blacoh, wasinstrumental in developing Blacoh University’s EngineeringSeries. “For engineers in our industry, much of what we knowcomes from experience and tribal knowledge. It’s not taughtin school or included in company training programs. Wefocused on what was lacking, gathered detailed and reliablecontent from trusted experts, and developed e-learning courses

specifically for engineers.”Each Blacoh University instructional video is followed with

an online interactive exam and participants are able to tracktheir progress as they go along. Blacoh University certificationsare awarded for completing courses in the Distributor Series.For the Engineer Series, certificates with course informationand credits for professional development hours (PDH) areprovided. ■

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10 | MAY 201410 | MAY 2014 www.modernpumpingtoday.com

TRADE SHOW prof ile

The American Water Works Association’s AnnualConference and Exposition (ACE14) at the BostonConvention and Exhibition Center, Boston, will bring an

estimated 11,000 water experts to Boston June 8 through 12, isthe longest running water conference in the world, having firstconvened in 1881. The event features several hundred expertpresentations and an exposition of more than 500 companiesshowcasing the latest innovations in water technology. TheACE14 agenda features speakers on hundreds of critical water

issues, including conservation and drought management,infrastructure and affordability, desalination and water reuse,emerging contaminants and new treatment solutions, andmore.

THE SHOW BEFORE THE SHOW

Don’t miss the opportunity to get an early look at themany new water industry products and services available.All attendees are welcome as AWWA kicks off the ACE14Exposition with a “Sneak Peek Reception.” Spend timenetworking with colleagues while visiting the exhibitors.Complimentary drink tickets and hors d’oeuvres will beavailable, all made possible by the generous support of theexhibitors. Admission is by conference badge only; registeredspouses and guests are welcome.

INNOVATION AND CONNECTION

The AWWA Pavilion (booth 1128) offers attendees lookingfor the perfect location to find solutions, connect with thewater community, and relax a place to do all three. Stop bythe AWWA Pavilion to network with fellow attendees, relaxon comfortable seating or treat yourself to a complimentarymassage. This fun and interactive area is just the place to learnhow to get involved and take advantage of the many resourcesprovided by the Association.

ACE14Uniting the world of water

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MAY 2014 | 11www.modernpumpingtoday.com

Motivated attendees can also join in the InnovationPavilion presented by Imagine H2O (booth 1834),to visit with the developers of award-winning watertechnology solutions. A key innovation partner withAWWA, Imagine H2O is a nonprofit that inspirespeople to solve water challenges; and their BusinessInnovations Program empowers entrepreneurs and

innovators to develop market-based solutions to waterchallenges.

Featured Innovation Pavilion exhibitors include

• Imagine H2O

• NBD Nanotechnologies, Inc.

• ReFresh

• WatrHub

• WaterSmart Software

• Wellintel

PROFESSIONAL SESSIONS

Organized by technical topic, this year’s programpresents solutions to water sector challenges in definedtracks of professional sessions that span the entirefour-day ACE14 program. You will find sessions on keytopics that address the full spectrum of the issue—fromresearch to planning to treatment to management. It 'sthe one-stop conference for the topics of your choice.A sample of volunteer committee meetings and affiliateevents at ACE14 includes the following:

• Strategic Leadership for Utility Management

• Regulatory Compliance: Tomorrow's Solutions Today

• Potable Reuse: Trends and Opportunities

• Pathogens and Emerging Contaminants: Identificationand Monitoring

• Water Treatment: Enhanced Design Principles

• Optimizing Distribution System Operations

A GUEST OF HONOR

Former mayor of New York City Rudolph Giulianiwill address more than 2000 water professionals fromthroughout North America during the opening generalsession. Sponsored by HomeServe, a leading provider ofhome emergency repair service plans, Mayor Giuliani’saddress will cover his experience as a two-term mayor

of America’s largest city and wi ll include his insights onthe myriad of challenges facing municipal leaders today.His remarks will also delve into security concerns facingcommunities and address the risk facing America’s waterand wastewater infrastructure, while inspiring the watercommunity to take on the challenge of leading U.S.utilities down the road to infrastructure renewal.

“Mayor Giuliani understands from his uniqueexperience the critical role that our water systems—and those who build and care for them—play in thehealth and safety of our communities,” says AWWAchief executive officer David LaFrance. “His presenceat the ACE14 opening general session underscores theimportance of the work water professionals accomplish24/7, every day of the year.” ■

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CASE Studies

One of the great thingsabout language is that twowords can have essentially

the same meaning, but when youread or hear them they create verydifferent images in the mind. Forinstance, two nautical terms have acommon definition: “a place (or inlet)providing shelter for ships, boats or

other vessels.” But when you say theword “harbor,” the image that comesto mind is an area near the coastteeming with all type of watercraft activity, from sailboats andyachts to barges and oceangoing oil tankers. Say the word“haven,” on the other hand, and a completely different image

is created, one that is more idyllic ortranquil, a place of refuge.

The Boston Yacht Haven mayactually be located in Boston Harborin Massachusetts, but its name hasbeen chosen well and is an indicatorof the facility ’s true intentions, whichare spelled out on its website: “This isa place where luxury floats in the air.

Where mega-yachts sit majestically inan exclusive 100-slip marina. Wherenewly renovated deluxe guest suites

indulge in every way. And where the surroundings are aunique blend of beauty and history and a shimmering urbanlandscape. This is Boston Yacht Haven.”

Kent Crawford is the regional manager, USA and Canada, for Blackmer ® and Pump Solutions Group (PSG®). He can bereached at [email protected]. For more information on Blackmer and the company’s full line of pumps andcompressors, visit www.blackmer.com or call 616.241.1611. Blackmer is a member of Dover Corporation’s Pump SolutionsGroup (PSG®), which is comprised of several leading pump brands—Abaque®, Almatec®, Blackmer®, Ebsray, Griswold™,

Maag, Neptune™, Mouvex®

, Quattroflow™ and Wilden®

. More information is available at www.psgdover.com.

About The Author

By Kent Crawford, Blackmer®

and Pump Solutions Group (PSG®)

Turning a Harbor into a HavenTurning a Harbor into a Haven

Boston Yacht Haven meets

the vessel-fueling needs of

its high-end client base with

the reliable assistance of

Blackmer ® GX and X Series

sliding vane transfer pumps

Harbor Fuel 1 is outfitted with Blackmer® GX & X Series pumps, a 2-½-inch (63.5 millime ter) model for high-

capacity fuel transfer, and a 2-inch (50.8 millimeter)version for operations that require lower flow rates.

Harbor Fuel 1 is outfitted with Blackmer® GX & X Series pumps, a 2-½-inch (63.5 millime ter) model for high-

capacity fuel transfer, and a 2-inch (50.8 millimeter)version for operations that require lower flow rates.

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The facility’sreputation is such thatin May 2013 YankeeMagazine gave it its2013 Editors’ ChoiceAward for “Best Lodgingin Greater Boston”(and when was the lasttime something named“Yankee” had somethingnice to say aboutBoston?), saying, “thisluxury lodging offersharbor views, spacioussuites decorated in

nautical style and a hostof shared amenities.”

“This is a first-classfacility with first-classamenities that caters toa first-class clientele,”says Kevin Lussier,general manager of the Boston Yacht Haven. “As such, weknow we have to provide first-class service in every instance.”

ALWAYS ON CALL

One of the most important services that Boston Yacht Havenprovides to its clients is at-the-dock fueling. To do this, BostonYacht Haven contracts with Harbor Fuels, a company thatspecializes in delivering marine diesel for high-speed, in-slip

fueling for a wide arrayof vessel types andgallonage requirements.The fueling services areperformed by a fleetof barges that carrythe fuel to where it isneeded then transloadit into the vessel’s fueltanks.

“A typical day withHarbor Fuels startsat about 5:30 in themorning,” explains

Jackie Gilman, captain

of the Harbor Fuel 1fueling barge, whichwas put into servicein June 2012. “We’rea mobile unit so wecan go in and out ofany destination we

need. We fuel all ferries, commercial boats, private yachts,anywhere from 100 gallons (378.54 liters) a day to 100,000gallons (378,541.18 liters) a week. A typical fueling processdepends on the gallon amount, anywhere from 100 to 500gallons (378.54 to 1892.71 liters) we can do in five to tenminutes tops. A maximum amount off the barge would be10,000 gallons (37,854.12 liters) and it would take an hour-and-a-half at the agreed-upon gallon-per-minute rate.”

Harbor Fuels has built its reputation on providing safe, reliable fuel-t ransfer operations for vesselsthat traverse Boston Harbor. The use of Blackmer® pumps has only helped to enhance that reputation.

Harbor Fuel 1 Captain Jackie Gilman—fondly knownas the “fuel-barge lady”—pulls hose in preparation fora fueling operation. Blackmer® GX & X Series pumps(foreground) help optimize the fuel transfer.

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CASE Studies

As with any fueling operation, strictregulations and safety measures mustbe followed in order to ensure thatall barge personnel, clients and theenvironment are protected from harmduring the fueling process.

“When we’re fueling a yacht we can

come right alongside, make sure weare 100 percent secure and prepare

for the fueling operation, whatever thegallon amount is,” continues Gilman,who calls herself the ‘fuel-barge lady.’“We do the paperwork, make sure wehave good communication and activatethe pump with an electronic key card.Our computer is very smart in that it

remembers every customer, the name,size of the boat, the gallons, everything.”

FINDING THE PERFECT PUMP

While the goal of Harbor Fuels is safe,efficient, reliable delivery of fuel whereand when it is needed, that wouldnot be possible if the delivery bargesdid not incorporate the best pumpingequipment. In the search for the ideal

pumps for its fueling applications,Harbor Fuels turned to Hall TraskEquipment Company, Braintree,Massachusetts, a longtime supplier ofpumping technology from Blackmer®,Grand Rapids, Michigan, which isa founding member of the DoverCorporation’s Pump Solutions Group(PSG®), Oakbrook Terrace, Ill inois. HallTrask Equipment is a third-generationsupplier of pumps, valves, meters andtank equipment for use in industrialfluid transfer and transport applicationsin New England.

“We’ve been a supplier of Blackmerpumps for more than forty years, andwe’ve sold a number of thousandsof Blackmer pumps and been veryhappy with the applications theyfill for us,” says Mike Trask of HallTrask Equipment, who, along with hisbrothers, Paul and Billy, are followingin the footsteps of their grandfather andfather in the family business. “We’vesupplied Blackmer sliding vane pumpsfor this Harbor Fuels barge that wascommissioned last year for high-flow-rate filling of vessels throughout theharbor. This application needed to havevery low maintenance and high outputand we chose the Blackmer pump tomeet the needs of the barge.”

Specifically, Harbor Fuel 1 isoutfitted with a 2-1/2-inch (63.5millimeter) GX Series pump that candeliver high-capacity flow rates upto 121 gallons (461 liters) per minuteand a 2-inch (50.8 millimeter) X Seriesmodel that delivers 70 gallons (264liters) per minute at lower speeds.

Each pump also features a variable-

speed control so that the speeds can beclosely monitored, which increases thesafety of the fuel-transfer process nomatter the flow rate.

“The high-speed pump we generallyhook up to a larger vessel when we’refueling a larger volume, so anythingover 500 to 1000 gallons (1892.71to 3785.41 liters) and up we’re goingto use the high-capacity versus low-capacity pump, which is best fordeliveries of around 400 gallons(1514.16 liters) at a rate of about 60gallons (227.13 liters) per minute,” saysGilman.

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The Blackmer GX and XSeries pumps are able toreliably meet the fuelingdemands of Harbor Fuelsbecause they featureBlackmer’s unique slidingvane method of operation

that enables the vanes toself-adjust for wear whilemaintaining desired flowrates and also providingexcellent self-primingand dry-run capabilities.The mechanical sealand ball-bearingconstruction providemaximum reliabilitywhile the symmetricalbearing support assureseven loading and wear.Maintenance is also quick

and easy as any wornvanes can be replacedwithout needing to removethe pump from the vessel.

“When we’re outfueling, No. 1 is safety andNo. 2 is performance,”says Gilman. “I feel safewhen I’m out there,

Harbor Fuel 1 Captain Jackie Gilman, center, and Boston Yacht Haven General Manager Kevin Lussier, right, have seen their fuelingoperations optimized with the use of Blackmer® Sliding Vane Pumps, which were recommended by Mike Trask, left, Officer, Hall TraskEquipment Co., a longtime Blackmer distributor.

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CASE Studies

the Blackmer pumps are trustworthy,and the performance has been 100percent. Every single delivery has beenoutstanding, the numbers are r ight on,the pressure is right on, the gauges areright on. The quietness it delivers—it is anice, soothing, perfect delivery process.

Usually the higher flow rate, like125 to 130 gallons (473.18 to 492.1liters) per minute, the pump’s going tobe louder, but the faster the volumecoming through the Blackmer pump,down the pipe, through the hose into theboat, it really quiets down.”

After a year of operation on Harbor Fuel 1, Captain Jackie Gilman was completely sold on the safety and performance

of Blackmer® pumps: “They’re wicked awesome,” she exclaims.

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“In the end, we recommendedBlackmer pumps for this applicationbecause of their high efficiencies andperformance throughout the lifetime ofthe pump,” adds Trask. “In fuel-transferapplications, whether on a barge or atruck, Blackmer pumps always stand

out due to their high efficiencies andlongevity.”

CONCLUSION

In order for the Boston Yacht Havento deliver the ultimate serviceexperience for its clients, a lot of

disparate parts need to work in perfectharmony.

“Our clients rightfully expect a best-in-class experience every time and that’swhat we strive to provide them everyday,” says Lussier. “That means thatwe can’t compromise on the quality,

performance and reliability of anyaspect of our operation. That’s where theBlackmer pumps really shine. We placea lot of strict performance demandson them and they have respondedbeautifully every time we have askedthem to.”

That level of reliable performancealso means that after more than a year ofcaptaining Harbor Fuel 1 and workingwith the Blackmer pumps, Gilman“harbors” no fears that the Boston YachtHaven fueling process will continue to benothing other than an idyllic operation.

“When we’re out there on the waterdoing our job we have the Blackmerpumps on board and they help usdeliver the fuel safely and efficiently,”she says. “These Blackmer pumps havebeen wicked reliable and have proventhemselves time and again to be efficient.They deliver 100 percent every time. Itrust them—they’re wicked awesome.” ■

Blackmer® GX Series Sliding Vane Pump

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WATER & WASTEWATER solutions

Cooling applicationsand many sprayapplications

require uniformdistribution of the coolingfluid over the affectedarea. Examples include,

spray lines, spray towers,certain types of airpollution control spraysystems, filter backwashsystems, fire sprinklersystems, and other typesof cooling lines wherethe cooling fluid is a gasrather than a liquid (seefigures 1, 2, and 3).

In all theseapplications, the conventional analysis can be time consumingand involve many repetitive steps. In the environmental field,there is also the challenge of making sure that a collection ordistribution trench has uniform flow over the entire length ofthe trench. Again, the analysis can be difficult, repetitive, andtime consuming. However, some help is at hand.

TWO SYSTEMS: COMPRESSIBLE GASSES ANDNON-COMPRESSIBLE LIQUIDSThere are two types of systems, one using compressiblegasses, and the other using non-compressible liquids. Theanalytical approach to both is similar, but the gas systemrequires additional analysis for compressibility of the gas.Far too often we have seen systems where the pressure closeto the distribution header is quite adequate, but as the flowapproaches the end o f the lateral line from the header, the

pressure is low, and as a result, the flow is low, sometimesmuch less than the design figure. It is this unequal distributionwhich can cause unequal cooling or cleaning in a productionline or spray system.

Here are some simple design tips that will allowdevelopment of effective collection and distribution systemswells for both liquids and gasses. One note of warning though,

if you are designinga sprinkler system forfire protection be sureto have your designreviewed and designedby the sprinkler companyand the fire marshal.

Defer to their wishesbecause it is their system.

WATER AND NON-COMPRESSIBLEFLUIDSThe same techniquecan be used for theheaders and the lateralscoming off of them.The application is

straightforward: How does one get uniform distribution alongthe length of the pipe even if there is liquids being pumpedfrom the pipe or drawn into the pipe? The distribution systemneeds to be tailored to the piping system. The key is the headloss through the pipe.

ORIFICES AND PIPE LOSSESThe formula for energy losses through a nozzle or orifice plateis the same, just the coefficient of discharge is different. Thatformula is shown in Equation 1:

David L. Russell, P.E., is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., aspecialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projectsranging from environmental process designs and hazardous wastes to water systems and wastewater treatment. He can be

reached at 770.923.4408 or by visiting www.globalenvironmental.biz.

About The Author

By David L. Russell, Global Environmental Operations, Inc.

EQUATION 1

Q = Cd*Ao*(2gh)0.5

Where:Cd is the discharge coefficient.

Ao is the area of the orifice, and

2gh is the acceleration of gravity times thehydraulic head.

Liquid Sprays

Liquid Recycle Pumps

BladeEntrainmentSeparator

A liqu id spray section for a scrubbe r (sou rce: U.S Environmental Protect ion Agency incollaboration with North Carolina State University).

Figure 1

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All of it has to be in the sameappropriate units. The coefficient ofdischarge is between 0.59 and 0.61 formost orifice plates, depending uponReynolds Number for the fluid system.Others have reported slightly higher losscoefficients, between 0.60 and 0.66.The higher coefficients were determinedexperimentally on piping systems whichhad four openings around the pipe (seeM. Duchene and E. McBean’s write-up in the American Water Resources

Association’s Water Resources Bulletin,Vol 28, No 3, June 1992).

The challenge in the design is to getthe losses and the flow through theorifice holes equal to the flow in thepipe. This can require a bit of ingenuityin the design process. The ideal situationis to design the distribution system sothat the flow and the losses at the end ofthe pipe are zero.

Without going into a lot of discretemath, one way of designing the system

would be to analyze the pipe at eachperforation. The flow at one location isQ, just before some nozzle or junctionthat takes away a finite amount of flow(q) for a new value of for the flow (Q-q)after the junction. From hydraulics, thatmeans that if the pipe size is the same,

there is a new velocity [V-vq= (Q-q)/ Ap], where Ap is the inside area of thepipe, and the new velocity is (V-vq). Thismeans that the next set of friction lossesin the pipe must be evaluated for a veryshort distance until the next opening orperforation.

If there are n perforations, thecomputation would require n+1 differentfrictional calculations for head loss andfriction in the length of the perforatepipe, and might require a number ofdifferent piping sizes, decreasing to theend of the pipe. That’s just unrealistic

and extremely cumbersome.

A LOOK AHEAD

Next month, in part 2 of this analysis,we’ll continue to examine thesecalculations and their benefits, pluslook closer at formulas for compressibleflow as well as for the calculation ofexpansion factor as it relates to thechange in the density of an ideal gas. ■

SprinklerHead Sprinkler

Pipe

Supply Main

22.4 m

15 m

Filter TankWash Troughs

Filter Sand

Graded Gravel

Perforated Laterals

Filter Floor

Cast-Iron Manifold

Figure 2

Figure 3

A cut away of a s and filter which shows the manifold and the perforated headers.

Layout of a fire sprinkler system.

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MAINTENANCE solutions

Pumps can be found mounted inmany different ways; there aretimes and places to do things at

least cost, and times and places to doit with uncompromisingly h igh quality.Over the course of the next threeinstallments, this article will familiarize

the pump users with the importantaspects of base plate installation andsome of the preferred options availabale.

Before considering the most prevalentpump base plate installation options, weneed to know more about how pump setsare typically shipped to the purchaseror installation site. In general, processpump manufacturers are asked to providepumps as a “set” or assembled packagecomprising pump, driver and base p late(see figure 1).

After ascertaining correct shaftseparation to accommodate the selectedcoupling, and pre-aligning the two shaftcenterlines within perhaps 0.020 inches(0. 5 millimeters), pump manufacturers(whom we assume to be our base plateproviders) spot-transfer mounting holesfrom pump and driver to the base platemounting pads. The pump and base plateprovider then proceeds to drill and tapbolt holes that have a diameter of about0.060 inches (1.5 millimeters) less thanthe mounting holes (“through-holes”)in pump and driver. Mounting boltsare inserted at this stage of the pump

assembly and the complete pump set isnow considered ready for shipment as apre-aligned “mounted” package to thedesignated recipient.

Receiving the conveniently mounted-for-shipping package has, over thepast few decades, led to the erroneous

assumption that the entire package cansimply be hoisted up and placed on afoundation. However, doing so is notbest practice; in fact, how pumps areshipped has relatively little to do withhow they should best be installed in thefield (see reference 1). The old OEM fieldservice person knew about this issue,but wise old field service folks are nolonger employed at the OEM and theones in charge today just want thingsdone fast. Users are not blameless in thematter. They often allow work to proceedwithout either specification or procedure.Some users award contracts to the lowestbidder and then “hope for the best.”

ENSURING LEVEL MOUNTINGWe need to observe that best practicescompanies (BPCs) will not install theequipment as a mounted “set.” Toensure level mounting throughout, pumpand driver are removed from the baseplate. The base plate is now placed on

Heinz P. Bloch, P.E., is one of the world’s most recognized experts in machine reliability and has served as a foundingmember of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME,in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight

decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at [email protected].

About The Author

By Heinz P. Bloch,

Process Machinery Consulting

Know Your Pump Base PlateInstallation Options

Part 1 of a 3-Part Series

A base plate-mounted API610-style mul ti-stage pumpat a Rebuild-Upgrader's Shop (source: HydroAire, Inc.,Chicago, Illinois)

Figure 1 Figure 2a

FoundationBolts Sleeve

Steel base plate with sleeved anchor bolt (left) andleveling screw (on right). A thick steel washer (chock)is shown between leveling screw and foundation (seereference 1).

Figure 2b

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a foundation into which hold-downbolts or anchor bolts (see figure 2) wereencased when the re-enforced concretefoundation was being poured (seereference 2). Leveling screws are thenused in conjunction with laser-opticaltools or a machinist’s precision level to

bring the base plate mounting pads toflat and parallel condition. Flatness andparallelism are measured side-to-side,end-to-end and diagonally. BPCs requirea readily achievable accuracy of 0.001inches per feet (~0.08 millimeters permeter). The nuts engaging the anchorbolts are secured next and the hollowspaces within the base plate as wellas the space between base plate andfoundation filled with epoxy grout.

For proper stretch and long life, theseanchor bolts (see figure 2) must havea diameter-to-length ratio somewhere

between 1:10 and 1:12. The anchorbolts are provided with sleeves or otherflexible fill. The sleeves prevent entryof grout and accommodate the differingamounts of thermal growth of a concretefoundation relative to that of a steel baseplate.

After the epoxy grout has cured, pumpand driver are placed on the base plateand aligned to criteria that conformwith best practices—essentially theworkmanship guidelines and reliability-focused practices of modern plants(see references 1 and 2). The driver isbeing aligned to the pump by adding orremoving shims from under the driver;dial indicators monitor an occasionalsoft-foot condition at the driver’s feet.When the pump is bolted down, softfoot and pipe stress are observed ondial indicators. As the pipe flangesare bolted up to the pump nozzles,sensitivity to piping being flanged up isclosely monitored. Any dial indicatormovement in excess of 0.002 inches(0.05 millimeters) will require makingcorrections to the piping and using force

to pull piping into place is never allowedif the resulting dial indicator movementexceeds 0.002 inches (0.05 millimeters).In essence, process pumps should neverbe allowed to become pipe supports.

STILT MOUNTING

Plants which use stilt mounting (figure 3)often fall short of achieving best-possibleequipment reliability. Best p racticesplants secure their pumps more solidlyon more traditional foundations. Stilt-mounted pump sets lack overall stiffnessbut have been used for small ANSI pumpswhere the sideways-move capability of

the entire installation was thought toequalize piping-induced forces. Amongthe few advantages of stilt-mounting arelow initial cost and ease of floor cleaningin food processing facilities wherehygiene is very important.

However, there are seriousshortcomings since stilt-mounting will notallow pump vibration to be transmittedthrough the base plate to the foundationand into the subsoil. Proper foundationmounting permits transmission ofvibration which can result in a significantincrease in mean time between failu res(MTBF), longer life of mechanical seals

and bearings, and favorably low total lifecycle cost (see reference 3). ■

REFERENCES

1. Bloch, H.P., and A. R Budris. Pump User ’sHandbook: Life Extension, 4th Edition

(2013). Fairmont Press (ISBN 0-88173-720-8).

2. Bloch, H. P., and F. K. Geitner. Major ProcessEquipment Maintenance and Repair , 2ndEdition. Gulf Publishing Company (ISBN0-88415-663-X).

3. Bloch, H. P. Pump Wisdom: Problem Solvingfor Operators and Specialists (2011). JohnWiley & Sons (ISBN 978-1-118-04123-9).

Mounting Bar

Figure 3

ANSI pump set on a stil t-mounted base plate (source: ITT/Goulds, Seneca Falls, NY)

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PUMP solutions

Traditional air operated double diaphragm pumps(AODDP) operate in a very specific way. Compressedair enters the pump through the main air valve and

the main air valve spool, in an alternating fashion, directs

compressed air behind the left and right diaphragm,exhausting the air appropriately.

The left and right diaphragms are connected via a rodthat runs through the center of the pump and thereforetheir movements are interconnected. As the air pressurizesbehind the right diaphragm, the right diaphragm inflates

outward to the right pulling the rod, causing the leftdiaphragm to move inward and to the right.

Paul McGarry is the All-Flo sales and marketing manager for North America. To learn more, visit www.all-flo.com, and

www.aoddpumpefficiency.com .

About The Author

By Paul McGarry, All-Flo Pump Co.

All-Flo’s A200 pump reduces energy costs, improves performance

A Revolution in Pumping Efficiency

PART 2 IN A 4-PART SERIES

Figure 3: Cutaway of All-Flo’s A200 Figure 4: Liquid suction

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Illustrated in figure 3, as theleft diaphragm moves inward, themovement creates suction and fluidis drawn into the pump chamber fromthe bottom suction port. Alternatively,as the diaphragm moves outward,fluid is discharged out of the top

discharge side of the pump.In figure 4, you can see that ballswithin the AODDP act as checkvalves, ensuring proper suction anddischarge of the process fluid.

During this process of alternatingsuction and discharge, air isconsumed and transformed into themechanical energy of the diaphragmmovement and exhausted from theair discharge port of the AODDP. Asshown in the earlier example, thiscan sometimes be costly in terms ofair consumption and the resulting

operating cost of a traditional AODDP.

AN ENERGY EFFICIENT

SOLUTION

The rising cost of energy and itsimpact on standard AODDP operationcosts were the driving factorsbehind the development of All-Flo’snew line of pumps, designed to

reduce operation costs for its users.After three years of research anddevelopment, All-Flo has released theA200 pump, using less than half ofthe compressed air of previous modelsand increasing overall performance inboth suction lift and flow-rate.

To reduce the air consumption andincrease performance, All-Flo made

several modifications to its originalAODDP design:

• Significant reduction andoptimization of “dead space” onboth the liquid and air side of thediaphragm

•

Adjusting the timing of the shiftpoint of the main air valve,

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PUMP solutions

Figure 6: A200 improved efficiency curve

Discharge Flow - Liters/Min.

P r e s s u r e I n l e t / O u t l e t P S I G (

B a r s )

T o t a l H

e a d i n F e e t ( M e t e r s )

Discharge Flow - U.S. Gals./Min.

allowing for a longer operating period in a moreefficient point of the air-valve’s cycle

OPTIMIZING DEAD SPACE

In Figure 5, the diaphragm on the left is shownfully extended. Optimizing the dead space resultsin higher liquid displacement per stroke and a

higher suction lift, that translates into higher self-priming ability. As a result, the dry lift of this designimprovement resulted in an increase from 13 feet(3.96 meters) H20 to 24.4 feet (7.44 meters) H20. Thehigher displacement per stroke led to a maximumflow-rate of 190 gallons (719.23 liters) per minute, alarge improvement compared to the previous limit of165 gallons (624.59 liters) per minute. By optimizingthe dead space on the airside of the pump, the newdesign boasted higher air efficiencies, allowing thediaphragm to be displaced earlier in the air-valvecycle.

IMPROVED AIR-VALVE TIMING

The timing of the shift point of the air-valve alsoplays a key role in the overall efficiency of the pump.All-Flo’s earlier design was substantially less e fficientnear the end of the diaphragm stroke than it was atthe beginning, as it continued to consume air whiledisplacing very little liquid.

By changing the pump’s timing so that the valvewould shift earlier in the cycle, the pump hada negligible loss in liquid displacement and asubstantial decrease in air consumption, resulting ina dramatic increase in the pump’s overall efficiency.

During the design process, the pump’s timingwas optimized, resulting in a final productiondesign which consumed 45 percent less air than itspredecessor. Figure 5 : Dead space of a diaphragm

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THE A200 PERFORMANCE CURVE

Using the same approach to reading a pump curve as inpart 1 of this series, figure 6 shows how the All-Flo A200pump compares to the average AODDP used in the earlierexample.

Reading the chart from the same point, 80PSI inlet and20PSI discharge, you can see that the pump yields 125gallons (473.18 liters) per minute at a cost of 65 SCFM.

With this information, we can calculate the operatingcost for the A200 pump, as we did in the earlier example,for an eight-hour day.

Based on these calculations and the assumed operatingconditions, we can see that the All-Flo A200 pump costs$0.85 to operate for one hour. If the A200 pump was tooperate for eight hours per day, 5 days a week, it wouldcost $1,768 per year to operate.

On an annual basis the results are dramatic—the newdesign consumes 45 percent less air than the previousmodel, resulting in a savings of approximately $1400 peryear for each pump. With the A200 pumps, if a factory ran

100 AODDPs foreight hours eachday, the user wouldsave more than$140,000 annually.

THE A200

DIFFERENCE

Energy is theengine behind allof our economicactivity, but whenconfronted withrising energy costs,customers are leftwith few choices—raise prices oraccept a lowerprofit in order toremain competitive.However, with

AODDPs, usershave a third option,

improving manufacturing techniques and equipment with anew All-Flo A200.

In subsequent articles we will evaluate air consumptionof the new A200 model compared to typical otherAODDPs as well as highlight some real world applicationswhere improvements in overall air-efficiency yield betterbottom lines for those involved. ■

A200 OPERATING COSTS

65SCFM X 1 HP /SCFM = 16.25HP

16.25HP X 0.746KW/1 HP = 12.12KW

12.12KW X $0.07/1 KWHR = 0.85$/ HR

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DEWATERING solutions

The Dragflow dredging and slurry pump has a verysimple design making it easy to use and service. Theagitator picks up materials which are too coarse for

pumping and puts solids in suspension; the pump which ispositioned above then sucks them in easily. All wear partsare made of long life high chromium content. The action ofagitator rejects material that is too large,thus preventing it from blocking the filter.The maximum solid handling capacity ofDragflow Dredging and slurry pumps is4.72 inches (120 millimeters) and largestdischarge in the range goes up to 13.78inches (350 millimeters).

VARIETY AND DURABILITY

Euroflo supply these pumps to awide variety of applications. In deepfoundation works Dragflow hard Ironsubmersible slurry pumps are used forpumping a CM10 bentonite mix as partof the construction process. These pumps

are very tough and abrasion resistant,traditionally standard pumps have beenused for these slurry pump applications,but with foundation depths that exceed 98.43 feet (30meters), the standard slurry pumps are put under extremepressure that can cause premature failures.

Dragflow hard iron submersible slurry pumps offer avariety of HD (high depth) versions of these pumps for hire

or sale to work in deep foundation works that exceed 98.43feet (30 meters), more typically the working parameters ofthese pumps is between 131.23 to 213.26 feet (40 to 65meters) deep, but in more extreme application these slurrypumps can be put to work in applications that exceed328.08 feet (100 meters).

POWER WHERE YOU NEED IT

Dragflow dredging and slurry pumpscan be supplied in both electrical andhydraulic powered formats . They areused for the dredging of canals andharbours, clean- up of locks, extraction ofgravel or sand, emptying of caissons andbulkheads. In mining Dragflow feature inthe clean-up of settling tanks, extractionof coal, minerals and foundry sand. Forindustrial applications Dragflow slurrypumps are used for the extraction of slag,forge scale, calcines, sludge’s, settlingsludges, petroleum, and tar residues.

Dragflow hard iron submersible slurrypumps have been selected on a varietyof projects because of their ability to

pump very abrasive bentonite slurries charged with sandand gravel with a density of 1.3 kg/dm3 at these operatingdepths. Euroflo have supplied pumps to carry out a varietyof trials for the recovery of submerged aggregate, as well asmany other applications throughout the quarrying process

Daniel Langrish is the digital marketing executive for Euroflo Fluid Handling Ltd., who has been providing expert industrialand submersible pump services for more than fifteen years, and specialize in the electrical submersible pump industry.

Euroflo exclusively represents Dragflow submersible slurry pumps. For more information, visit www.euoflo.com.

About The Author

By Daniel Langrish, Eurof lo Fluid Handling Ltd.

A Simple Design for

Tough Jobs

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for mixing and pumping abrasivematerials.

PROGRESS REPORT

For one of our customers in therepublic of Ireland, Euroflo supplied6-inch (152.4 millimeter), 50

horsepower, 37.5 kilowatt hardIron dredging pump, that was usedto recover submerged aggregate.This aggregate which is made upof 60 percent sand, 30 percentgravel, and 10 percent stone with amaximum diameter of 2.36 inches (60millimeters). The pump extracted 100tons (90.72 tonnes) of solids per hourat a depth of 49.21 feet (15 meters).

TAKING ON CORROSIVE FLUIDS

Using a Dragflow hard ironsubmersible dredging pump gives

you an advantage, as they can handleslurries including stones at higherdepths than horizontal surface pumps.It is also very important to verify thepercentage of stone and their diameterwhen selecting the pump to ensure acorrect selection is made.

Pumping abrasive slurries with lowpH is very challenging as conventionalpumps fail in highly corrosiveenvironments. Euroflo are able to offereffective solutions in a large numberof these applications using specialistpumps. Euroflo supplied an Africancopper mine with 6-inch (152.4millimeter) Dragflow submersiblehard Iron slurry pumps which wereconstructed from cast 316 stainlesssteel, which made them a uniquespecial build. These pumps wereproduced to work in these extremeenvironments, typically working inliquids with a pH value of between 2and 3 which is highly acidic.

SAND RECOVERY

Sand recovery / winning are

applications Euroflo have been verysuccessful in providing a suitable longterm solutions, using Dragflow hardiron submersible dredging pumpswith agitators. Euroflo conductedtrials initially to prove the abilityof the pump to recover a highconcentration of sand in suspension.Euroflo for this project used an 8-inch(203.2 millimeter), 50 horsepower,37.5 kilowatt submersible hard irondredging pump with agitator whichafter successful trials was subsequentlypurchased. This submersible dredgingpumps was then attached to its

permanent position on a ladder atthe front of a self-propelled vesselfor dredging with 656.17 feet (200meters) of floating discharge pipe.This submersible pump was poweredinitially by one of Euroflo’s 80KVAportable rental generating sets, before

a unit was eventually purchased andmounted on the vessel. After eighteen

months it had produced in excess of200,000 tons (181,436.95 tonnes)of high quality silica sand, which isequates to approximately 500 tons(453.59 tonnes) per day. Pumpinghigh concentrations of sand takes itstoll on the pump over time, so every

six months the pump is returned toEuroflo’s service center. ■

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MOTOR solutions

T

he City of Hamilton, Ontario’sWastewater Treatment Plantscollect both sanitary and

combined sewage (wastewater).The collection system services notonly the City of Hamilton, but alsothe surrounding areas including thetowns of Dundas, Ancaster, WaterDown, Glanbrook Township, andthe former city of Stoney Creek. TheCity of Hamilton’s Woodward AvenueWastewater Treatment Plant beganoperations in 1964 and today averages108 million gallons (409 million liters)per day with a peak capacity of over158 million gallons (600 million liters)per day.

The City of Hamilton WastewaterTreatment Plants have continuouslybattled with the abrasive quality of theprocessed water. The abrasive sludgehas caused shortened life for theirnitrile stators and became an issue dueto the cost of continuous maintenanceand replacement stators.

ENHANCEMENT OF THEWINDERMERE BASINMoyno partnered with the City ofHamilton to test the new Urethane

stators in their abrasive municipalsludge application. The successfuloperation of the City of Hamil ton’swastewater treatment is vital to thesurrounding environment, especiallythe Hamilton Harbor and itsecosystem. The Windermere Basin is

located in the east end of HamiltonHarbour, at the mouth of Red HillCreek. Over the years, its ecosystemhad been significantly altered andimpacted by human activities.

This project transformed thedegraded body of water, with limiteddiversity, into a healthy, diverseGreat Lakes coastal wetland. Theimprovement plan involved creatinga wetland and constructing hydrauliccontrols, a fi sh way, a power building,

islands, containment dikes, and locallandscaping.

Overall, this project helped createa new aquatic habitat not commonlyseen on this scale. The environmental

benefits will also support increasedpopulations of healthier aquatic andbird species that live in the cleaned upWindermere basin.

The basin also enhances thelandscape in an industrialized zonelocated in Hamilton's east end and

Adam Downey is the new product development manager at NOV Mono and can be reached at [email protected]. NOVMono comprises a group of specialist companies offering progressing cavity pumps, artificial lift systems, industrial mixers,heat exchangers, grinders, screens and aftermarket replacement parts and services, across a broad spectrum of industrialsectors including water and wastewater, oil and gas, chemical, pulp and paper, food and beverage and agriculture. For more

information about Moyno, Inc., call 877.486.6966 or visit www.moyno.com.

About the Author

By Adam Downey, NOV Mono Group

Exceeding

Expectations

Moyno pump™ installed in Hamilton, Ontario WWTP.

Moyno’s new urethane stators increase pump life for wastewater treatment plant

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will provide social benefits to cityresidents.

"This program of work represents alarge-scale project that we could nothave completed without the generoussupport from our federal and provincialpartners," says Hamilton Mayor Bob

Bratina. The mayor went on to notehow the Windermere Basin projectcreated a unique wetland area, vastlyimproving the habitat for local fish andwildlife. “All of these efforts contributeto our local goals for the remediation ofHamilton Harbour," Mayor Bratina adds.

PLAYING A VITAL ROLE

Representatives from the governmentsof Canada and Ontario, and theCity of Hamilton have affirmed theircommitment to improving the publichealth and quality of life.

"Investing in local infrastructurerenewal will build strongercommunities and improve Hamiltonresidents' daily lives," says theHonorable Jeff Leal, Minister of RuralAffairs for Ontario. "The WastewaterTreatment and Windermere Basinprojects demonstrate the Ontariogovernment's ongoing commitment towork with our federal and municipalpartners to address the province'sinfrastructure priorities."

The project will enhance the qualityof life for visitors and residents in theCity of Hamilton and contribute topublic health improvements and theprotection of the environment. Thepositive results of this work will alsohelp remove Hamilton Harbor from theArea of Concern list under the Canada– U.S. Great Lakes Water QualityAgreement.

PREPARING FOR THE FUTURE

The success of the Moyno urethanestator far exceeded their expectations.The City of Hamilton has ordered five

additional new urethane replacementstators for their pumps after the firsturethane stator outlasted the nitrilestator by more than ten times andcontinued to run without failure. Asthe City of Hamilton continues toexpand, the Moyno urethane statorwill lower maintenance costs andsignificantly reduce down time for thecity of Hamilton’s wastewater treatmentoperation.

"The improved wastewater treatmentsystem and Windermere basin are majorachievements," says the HonorablePeter Kent, Minister of Environment.

"Our government is proud to haveinvested in cleaning efforts that willhelp the environment, improve qualityof life for Hamilton residents and thathas created jobs."

Improvements and innovations likethese are key to “Building Together,”

the province of Ontario's long-termplan to repair, rebuild, and renew the

province's infrastructure. Since 2003,Ontario has invested approximately$85 billion in infrastructure. Buildingmodern, efficient infrastructure hascreated or preserved close to 100,000jobs each year, on average, makingOntario's economy more productive

and improving quality of life, now andin the future. ■

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ANSI/ASHRAE/IES

Challenges Solvedwith Software


POWER GENERATION solutions

A

NSI/ASHRAE/IES, Standard 90.1 – 2010; also referredto as the “Energy Standard for Buildings,” has createdthe need for innovation in many industries. In the

world of pressure boos ter control, it can be argued that inrecent history there hasnot been a more seminalevent than the impactof this new standard.Standard 90.1 rewritesthe laws governing waterpressure control anddelivery. This designchange affects the controlstructure and, in somecases, the location ofpressure control devices.As a result, QuantumFloneeded to develop asolution that did notmove these controls, butinstead utilized advancedsystem technologyto simulate the sameeffect. QuantumFlo’sGreenFlo™ logic is anew and innovativealgorithm that beganshipping in January2014 on all QuantumFlopackaged systems in

order to fully complywith the newly adoptedstandard.

OVERVIEW

Variable speed pressureboosting has clearly

become the de-facto pumping control standard. Manufacturersare required to establish a well-planned direction onhow these controls are used to optimally reduce energy

consumption within a project site. ANSI/ASHRAE/IES 90.1(Standard 90.1) took thisenergy efficiency evenfurther by consideringall infrastructure,machinery, lighting,etc. within the buildingin order to facilitate asustainable design thatconsiders all disciplinesof construction. It is adirective to architectsand mechanical andelectrical engineersto produce moreLEED compliant andsustainable structuresthat optimize the energyusage for lower carbonfootprints.

CHALLENGE

The most significantchallenge forQuantumFlo regardingStandard 90.1 is underSection 10, “Other

Equipment,” specifically10.4.2, “Service WaterPressure BoosterSystems.” GreenFlo™directly addresses thechallenge outlined inpoint a.

David Carrier is chief executive officer of QuantumFlo, Inc., a leader in the manufacturing and distribution of advanced,variable speed controlled, packaged pump systems for commercial plumbing, HVAC, municipal, irrigation and industrialmarket applications. He can be reached at 386.753.9702 or via [email protected]. For more information, visit

www.quantumflo.com.

About The Author

By David Carrier, QuantumFlo, Inc.

10.4.2 Service Water Pressure Booster Systems.

Service water pressure booster systems shall

be designed such that:

a. One or more pressure sensors shall be used

to vary pump speed and/or start and stop

pumps. The sensor(s) shall either be located

near the critical xture(s) that determine

the pressure required, or logic shall be

employed that adjusts the set point to

simulate operation of remote sensor(s).

b. No device(s) shall be installed for the

purpose of reducing the pressure of all of

the water supplied by any booster system

pump or booster system, except for safety

devices.c. No booster system pumps shall operate

when there is no service water ow.

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The inclusion of 10.4.2a ismonumental for constant pressurebooster design, which has alwaysmaintained that the discharge pressureof the system must never change.Now Standard 90.1 states that thecontrol point (pressure sensor) shouldbe moved to the top of the building.

This entails that the booster pressurewill adjust in consonance with systemdemand minus the friction loss inthe piping run. The booster systemset point will now change when itshould have never changed in thepast according to the flow rate of thesystem. This means that as the systembegins to reduce in gallons per minute,the set point will now change due todecreased friction-loss in the piping atthe reduced flow.

In the past, the designer would addup the following conditions to arrive ata booster set point:

1. Static height of the plumbingsystem in feet, converted to PSI

2. Residual pressure in PSI requiredat the remote fixture (top ofsystem)

3. Friction losses at 100% designflow, to deliver that water to theremote fixture

Since the friction loss (Item 3)changes as the flow rate changes,a rise in residual pressure wouldoccur at lower flows causing thepressure at the top of the systemto change according to the pipingfriction at the actual flow rate. Thiscauses a slight rise in pressure at theroof when the pump is at or near itsno-flow condition. This is why somemanufacturers would suggest thathydro-pneumatic tanks mounted at theroof could be employed to store this“extra” pressure.

Standard 90.1 has determined thatthe level of inefficiency caused bythis recovered friction is sufficientenough to require the pump to befurther reduced in speed. Therefore, aremote-mounted sensor would providefor a pressure which never changesat the roof of the building due to the

sensor being located there. It has beenreferred to as the “80/20 Rule” forboosters. Eighty percent of the timea typical water pressure booster is attwenty percent capacity or less. If thesensor is now moved to the roof thereis no longer a pressure change as it willtrack only the target pressure requiredthere. Without this pressure change(recovered by the variable frequencydrives, VFDs) these tanks now becomeuseless in remote mount applications asthey rely on the former pressure changethat no longer exists. Without pressurechange, there is no water storage.

Genius E end suction low pressure/high flow VFD booster Genius V - vertical multi-stage high pressure/low flow VFD booster

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POWER GENERATION solutions

Many manufacturers have to comply with this newstandard by advising the plumbing contractor that the sensorprovided (loose) by them must be mounted and wired by athird-party trade (electrical or controls contractor). This addedstep creates a substantial additional cost to the plumbingcontractor as he will need to hire an electrician to completethis work. This is not a good solution to the problem as most

packaged boosters are built and pre-engineered as completeplug and play systems. Field installed components reducethe reliability.

SOLUTION

The best way to address the control challenge of Standard90.1 is through the application of simulation logic.QuantumFlo’s GreenFlo™ is pre-engineered algorithm intheir pump systems. There is no advantage to shipping amachine that relies on the additional labor and expense ofother trades to wire a remote sensor back to the controller,usually at the bottom of the building. This complicates thejob and injects an additional contracting discipline into aplumbing system that should work correctly out of the box.

GreenFlo™ is the solution to the problem of pretestingequipment as if it were already installed on the site beforeit is shipped. This algorithm is built into the current iQFlo™software package and is completely automatic in operation.The “GreenFlo™ Mode Indicator” appears on the mainscreen to inform the user when the mode is active. This is anicon that shows to the immediate left of the QuantumFlo logoon the main system screen.

When the system is in a low flow condition, rather thanmonitoring the remote sensor at the roof, GreenFlo™ is

reading energy consumption through a variety of valuesstreaming from the variable frequency drive in real time. Thecircuit activates at low flow conditions and changes the setpoint according to the pressure entered in the GreenFlo™mode activation screen. The system resets to this new setpoint and when the demand rises above these conditions,it reverts back to the design set point. By using a software-

based solution, the system can continue as a true pre-engineered product that has been factory tested at simulatedjobsite conditions.

When the GreenFlo™ icon is visible, this verifies to theuser that the system is operating in full compliance with

WhisperFlo high flow/high pressure/low noise VFD booster

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Standard 90.1 through GreenFlo™ inlieu of the remote mounted transducer,and it still complies with the codewhich reads:

GreenFlo™ is completely fieldadjustable by the commissioningagent using the “virtual toggle” and setvalue. Since no plumbing system is the

same, this allows the user to adjust theamount of friction to suit any projectneed in the field.

SUMMARY

Pump system manufacturers have twochoices to modify their systems to bein compliance with Standard 90.1.They can provide a transducer, shipped

loose, to be mounted at the remotepoint in the field by a contractor,or they can provide an algorithmwithin the system that simulates thesame effect. Since QuantumFlo isstreaming data at 115,000 bits persecond, GreenFlo™ takes advantage

of this superior logic strategy andmakes compliance with Standard 90.1invisible to the plumbing contractor.GreenFlo™ requires no additionalequipment, is available at no cos tincrease to the plumbing contractoras logic is standard in all QuantumFlosystems, and is fully automatic inoperation.

The goal of QuantumFlo as amanufacturer is to provide thecontractor with a product that wouldnot add any additional cost in theeffort of meeting the requirements of

Standard 90.1 by creating a built-inalgorithm like GreenFlo™ instead ofrequiring other external components tobe installed.

As the leader in pressure boostingand controls technologies, QuantumFlois committed to providing innovativeleadership as the demands of theindustry dictate. GreenFlo™ is

another way they provide contractorsand consultants with products thatcreate opportunity through energyefficiency and sustainable design,superior quality of workmanship and acommitment to industry leadership. ■

Prodigy economy series duplex VFD booster

…or logic shall be

employed that adjusts

the set point to simulate

operation of remote

sensor(s).

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PROCESSING solutions

A piped digester mixing system that utilizes pumpsmade by Landia is helping Biogen with its successfulnew $8.5 million (£5 million) food waste to green

energy operation near Caernarfon in North Wales. TheGwyriAD anaerobic digestion plant first includes a LandiaMPTK chopper pump that mixes 12 percent dry solids in abuffer tank.

A further two MPTKs resuspend grit (when existingdiffusers are not running) by the use of a pressurised ringmain with four jetting nozzles, equally spaced around thebase of a tank containing 9 percent dry solid digestate.

At a maximum particle size of 0.47 inches (12millimeters) and temperature of 140 degrees Fahrenheit(60 degrees Celsius), digestate at dry solids 8 percent isalso pumped by two more Landia MPTK chopper pumpsat a flow rate of 9510 to 19,020 gallons (36 to 72 cubicmeters) per hour at a maximum total head of 49.21 feet (15meters).

The system at Biogen, the UK’s leading food wasteanaerobic digestion specialist, further includes a 4.0

kilowatt 1500 revolutions per minute DG Landia pump totransfer digestate at dry solids 15 percent (but still liquid)maximum particle size 0.79 inches (20 millimeters), at aflow rate of over 5200 gallons (20 cubic meters) per hour.

“Landia’s chopper pumps play an important part in theprocess,” says Biogen’s Julian Stelmasiak, “proving verycapable of handling the different cycles of food waste.”

In addition to renewable electricity (for 700 homes),Biogen’s GwyriAD AD plant also creates high qualitybiofertilizer for farms in the Gwynedd region, as well ashelping the local council make a major reduction in the

amount of waste sent to landfill.Landia UK, which is celebrating its twentieth anniversary

in 2014, also has its pumps and mixers in operationat Biogen’s Milton Ernest plant in Bedfordshire, whererenewable energy is generated from nearly 52,000 tons(47,000 tonnes) of pig slurry and food waste per yeargenerating 1.8 megawatts of green electricity and producesover 36,000 tons (33,000 tonnes) of a nutrient richbiofertilizer.

Soren Rasmussen is the director of Landia, Inc. For more information Landia’s range of applications, call 919.466.0603, email

[email protected], or visit www.landia.com.

About The Author

By Soren Rasmussen, Landia, Inc.

Landia’s chopper pumps sustain Biogen’s renewable energy process

Biogen’s GwyriAD AD plant, a key component of the Gwynedd region’s commitment to renewable energy (©Biogen 2014).

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The plant will process over12,000 tons (11,000 tonnes) offood waste per year by meansof anaerobic digestion and willgenerate 3500 megawatt hoursper year of renewable electricityfor the nationwide grid. Thelocation of the plant also allowsthe biofertilizer produced as part

of the process to be used on localfarmland.

The food waste will be collectedfrom local households and willhelp Gwynedd Council meet itslandfill diversion and recyclingtargets and avoid substantial finesfor failing to meet those targets.The plant also provides a localfacility to recycle food waste fromcommercial customers in the area.All the material being delivered tothe plant will be carried in coveredvehicles by licensed carriers.

The facility is designed to ensurethat, when operational, controlsare incorporated to limit noise andodour at source. All tipping andhandling operations will take placein a fully sealed and insulatedbuilding. Bespoke, high quality airfiltration systems are incorporatedwithin the building to ensure thatodours are controlled at sourceand do not leave the confines ofthe site ensuring that there is nonegative impact on air qualityfor local residents and passing

vehicles.The plant is fully licensed and

regulated by Natural ResourcesWales under The EnvironmentalPermitting (England and Wales)Regulations 2010, and AnimalHealth under Animal By-productRegulations (2005).

Gwynedd Council hasintroduced a weekly service tocollect food waste, in order tomaximise the collection of foodwaste, and increase its recyclingperformance. ■

Landia’s MPTKchopper pump

plays a vitalrole in Biogen’ssuccess.

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VALVES & CONTROLS solutions

Risto Haavisto is the sales manager for ABB Finland. ABB Inc. is a leader in power and automation technologies that enableutility and industry customers to improve their performance while lowering environmental impact. For more information

about ABB’s PLC offerings, visit www.abb.com/plc.

About The Author

By Risto Haavisto, ABB Finland

Going for the

GOLDRuggedized PLCs will boostprocessing uptime at Lapland gold mine

ABB is upgrading the automationsystem at Agnico Eagle's

gold mine in Lapland, witheight of its latest ruggedized PLCsfor controlling equipment in harshconditions and extreme climates. ThePLCs will control the sedimentationprocess of the concentrating mill atEurope's largest gold mine: AgnicoEagle's mine in northern Finland,

which is 93.21 miles (150 kilometers)inside the Arctic Circle near the town

of Kittila.

FACING DOWN A BIG FREEZEABB won the original contract for themain automation system at the goldmine, and configured and installedelectrical automation based on its800xA Extended Automation system

and industrial IT architecture. Theproject involved a large amount of

ABB automation components includingABB's 800 series operator interfacepanels and AC500 PLCs for theunderground control of pumps, airconditioning, the motors used in orecrushing and processing, and so on.

However, a number of items of plantequipment came with automation from

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other vendors, including PLCs thatwere supplied with the sedimentationfacility that forms part of the mine'sconcentrating mill. The PLCs werenormal industrial grade types, buthoused in freeze-protected cabinetslocated outdoors. Since installation,however, this facility has suffered anumber of process stoppages becauseof the environment at the mine -which includes very wet and humidconditions and winter temperaturesas low as -40 Fahrenheit (-40 degreesCelsius). If a process stoppage happensin winter the impact can be severe,as the weather can quickly add to theproblem by freezing and blockingpipelines.

There have been some four or fivestoppages a year, stemming from poweroutages, extreme cold temperatures,or water droplets that form on the PLCmodules when the cabinet doors wereopened. In wintertime, condensationcan happens in seconds—almost theinstant the cabinet doors are opened

and the benefits of the cabinet'singress protection are lost—becauseof the very low temperatures andthe moisture-laden air around theconcentrating mill. The same problemcan also happen in springtime, astemperatures can swing between -13and 59 degrees Fahrenheit (-25 and 15degrees Celsius) from night to day—leading to heavy condensation.

TIME TO UPGRADE

The mine operators decided toupgrade this part of the control systemto improve reliability and uptime.

They were very happy with the PLCsthat provided control in the hot andhumid underground environmentand turned to the supplier of these—main automation vendor ABB—whoproposed a solution based on the XCPLC. XC is an 'extreme conditions'

variant of the well -known AC500 PLCfamily that is installed underground.

It has built-in protection against avery wide variety of threats posed byharsh environmental and operatingconditions including high and lowtemperatures, high humidity, low airpressure, salt mist and hazardousgases, and vibration and shock. In

this case, the new ABB XC PLCs willbe installed at the mine's above-

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VALVES & CONTROLS solutions

ground processingcenter—with someI/O modules locatedat a remote waterpumping locationand connected usingProfiNET.

Mining is oneof the key targetapplications forthis PLC. The harshenvironment atKittila poses noproblem for theXC PLC whichcan operate intemperaturesfrom -22 degreesFahrenheit (-30degrees Celsius), with reliable systemstart-ups in temperatures as low as

-40 degrees Fahrenheit (-40 degreesCelsius), more than meeting theproblems that might arise. Its circuitboards are conformably coated toprotect against moisture ingress.And the PLC is protected againstvibration and shock and will toleratea lot of mechanical stress—such asaccelerations up to 4 g from random

vibrations up to 500 Hz, or 2 g fromsinusoidal vibration. This built-in

protection means that the ABB PLCsare being installed in standard un-insulated stainless steel cabinets—without any need for freeze-protectionheaters.

NEW DESIGN POSSIBILITIES

Ruggedized PLC technology opensup new design possibilities, allowing

automation to besited right where thecontrol I/O is needed,in many cases withouthigh-specificationenvironmentalprotection—as at this

mine is deep insidethe Arctic Circle.Agnico Eagle's gold

mine in Finland islocated in Kittila, inthe northern Laplandregion. With anestimated lifetimeto 2037, Kittila'sreserves are estimatedat almost 33 milliontons (29.94 million

tonnes). The mine employs over 600 staffand contractors, most of whom are local

residents, making a big contributionto the regional economy. Ore wasoriginally mined from two open pits,starting in 2008. Since 2010, the mininghas moved underground. Some 3000tons of ore is currently transported dailyto the surface crusher using undergroundhaul trucks via a 1.86 mile (3 kilometer)long ramp access system. ■

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SEALING solutions

Designing mechanical seals for sea ling refrigerantsand other low viscosity liquids has been a difficultproblem for seal manufactures for many years. It has

now been established that mechanical seals with antimonyimpregnated, carbon-graphite

primary rings and solid siliconcarbide counter face rings cansolve this problem. MetallizedCarbon Corporation, a globalleader in the manufacture ofoil-free, self-lubricating, carbon-graphite materials for severeservice lubrication applications,announces the availability ofmechanical seal primary ringsfor sealing refrigerants and otherlow viscosity liquids.

M-444: MORE THAN

ORDINARY

Low viscosity liquids aredifficult for mechanical sealsbecause the hydrodynamicfilm that they create betweenthe two rubbing seal faces isextremely thin. In order for thisextremely thin hydrodynamicfilm to lubricate the two sealingfaces, the seal faces must stayhighly polished and they mustrun in very close proximityto each other. It is the self-

polishing characteristic of the M-444, antimony impregnated,carbon-graphite material and the high dimensional stabilityof both solid silicon carbide and antimony impregnatedcarbon-graphite that enables these two materials to run in therequired close proximity. Ordinary mechanical seals with resinimpregnated, carbon-graphite primary rings do not have theself-polishing characteristic or the dimensional stability that isrequired for sealing these low viscosity liquids.

PASSING THE TEST

The table presents a list of typical physical characteristics ofthe M-444 mechanical seals. The following are definitions ofterms and descriptions of methods used to obtain the physical

characteristics. Physical

characteristics of carbon/graphitematerials are sensitive to partsize, shape and grain direction.To obtain the data presentedhere, specimens were tested withthe length dimension orientedparallel to the grain direction.

• Apparent Density (ANSI/ASTMC 559) is the mass per unitvolume including permeableand impermeable voids andpores.

• Hardness (ANSI/NEMA CB1)is a material’s resistanceto permanent deformation,particularly indentation orscratching. Shore Scleroscopehardness is determined bydropping a diamond pointedweight on a specimen from astandard height. The reboundup a graduated scale indicateshardness. Six readings takenon opposite sides of thespecimen are averaged toobtain an accurate value.

• Compressive Strength (ANSI/ASTM C 695) is a material’sability to withstand a uniaxial crushing load. Values areobtained from the ultimate crushing force per unit of crosssection. Ultimate strength and yield strength are identical.

• Transverse Strength (ANSI/NEMA CB1) is a material’sability to withstand a transverse or flexural load. Valuesare obtained by loading to failure a rectangular beamsuspended on two knife edges.

Matthew Brennan is the president and CEO of Metallized Carbon, an ISO certified and producer of the Metcar brand of solid,oil-free, self-lubricating materials. For additional information about the company and its services, visit www.metcar.com or

call 914.941.3738.

About The Author

By Matthew Brennan,

modern pumping - 052014

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