modern pumping - 122014

THE AGE OF PUMP

OPTIMIZATION

MEASURING TRUE PUMP

PERFORMANCE

SHREDDING WASTEWATER

DEBRIS

DECEMBER 2014PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

ON TAP: THE WORLD’S BEST

MUNICIPAL DRINKING WATER

CONTENTS DECEMBER 2014

20

32

46

4 Industry news

10 trade show ProfIle

Case studIes 12 Measuring the True Performance of Pumps in Operation 16 Shredder Pumps Installed at Historic Ellis Island

water & wastewater solutIons 20 Channel Monster® Shreds Debris, Ragging Monster grinder cuts $78,000 from energy costs in Santa Margarita Water District

22 The Village of Montpelier Improves Efficiency with New Gas Chlorinator System

MaIntenanCe solutIons 26 Performance Evaluation for Rotary Vacuum Filters EDG-trac Knife Advance System proves efficient and cost-effective

PuMP solutIons 28 The Age of Pump Optimization and the Impact on Sustainable Design

dewaterIng solutIons 32 Solid Foundation for Business District TerraFirma's groundwater system supports 100 Saint Paul development

Motor solutIons 36 Intelligent Pumping Systems Easier diagnostics, monitoring, and troubleshooting of PLCs with web-enabled user interfaces

Power generatIon solutIons 40 Power Where It's Needed Most Franklin's new solar pumping technology proves itself in Africa

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ProCessIng solutIons 42 High-precision Ingredient Metering for Spreadable Butter Dairy giant Arla uses multiplex pumps with a broad adjustment range

ValVes & Controls solutIons 46 Quality Meets Quantity In the field and in the lab, YSI measurement tools offer detailed monitoring and control

sealIng solutIons 48 How to Cost-justify Bearing Housing Protector Seals Key factors for reliability-focused process pump users Part 4 in a 4-Part Series

52 Modern PuMPIng ProduCts Featured Product Release: MEGGIT SENSING SYSTEMS REF2500 Handheld Shaker

PuMPIng trends 56 The Gift of Doing Good Louis Allis president, Bruce Bailey, on corporate responsibility and the rewards of giving back

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J. CAMPBELL Editor [email protected]

DONNA CAMPBELL Editorial Director [email protected]

SCOTT GORDON Art Director [email protected]

LISA AVERY Assistant Art Director [email protected]

JAMIE WILLETT Circulation Consultant

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

TONYA BROWNING Account Executive

JERRY DICHIARA Account Executive

RANDY MOON Account Executive

CINDEE STANDRIDGE Account Executive

Terry BellDrives and Motion Solution Engineer

Baldor Electric Company

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

Process Machinery Consulting

Robert G. Havrin Director of Technology, Centrisys Corporation

Michael ManciniConsultant and Trainer,

Mancini Consulting Services

John M. Roach Engineering Manager

for New Product Development,Trebor International, Inc.:

A Unit of IDEX

Lisa RilesBusiness Development Manager,

Wastewater PumpsXylem Inc.: Flygt

Greg TowsleyDirector of Regulatory and Technical Affairs, Grundfos

Trey Walters, P.E.President, Applied Flow Technology

EDITORIAL ADVISORY BOARD

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INDUSTRY newsARMSTRONG FLUID TECHNOLOGY RECEIVES PRESTIGIOUS CUSTOMER VALUE AWARDArmstrong Fluid Technology has been presented with a prestigious Frost & Sullivan Best Practices Award in recognition of world-class performance in business strategy, operations and customer service. At a gala ceremony in Toronto on December 2, 2014, members of the senior leadership team were presented with the Customer Value Award in recognition of the outstanding return on investment provided by Armstrong solutions.

In particular, Frost & Sullivan highlighted Armstrong’s Design Envelope technology which redefines the traditional economics of energy and sustainability to provide both lowest installed cost and lowest lifetime cost. The Frost & Sullivan Best Practices Awards recognize superior leadership, technological innovation, customer service, and strategic product development. Frost & Sullivan's industry analyst team studies companies internationally, across a wide range of industries. The performance of each company is benchmarked and measured independently through primary interviews, and secondary industry research that identifies best practices and evaluates candidates using a 10-step process. Based on a 360° research methodology, the evaluation considers corporate performance in seven key areas: Competitive Intensity; Customer Dynamics; Industry Convergence; Disruptive Technology; Global Mega Trends; New Business Models; and Emerging Markets.

Earlier this year, Frost & Sullivan examined the business practices of Armstrong Fluid Technology, along with major

competitors in the UK and European markets and selected Armstrong to receive the Customer Value Award.

U.S. WATER RECEIVES THE CALIFORNIA GAME CHANGER COMPANY OF THE YEAR AWARD U.S. Water Services, Inc., the leading national provider of integrated solutions for water treatment, has received the California Game Changer Company of the Year Award.

The honor was presented by the California Governor’s Office of Business and Economic Development, Oliver Rosenbloom, and accepted by U.S. Water’s Alexandra Causey at the 100th Annual Vanguard Awards Dinner on November 20 at Chico State University.

In an effort to conserve freshwater resources, California facilities are actively working to reduce water use 20 percent by the year 2020. U.S. Water has been working with California agriculture, medical centers and businesses throughout the state using integrated solutions that combine chemical, equipment, engineering, automation and service to help facilities achieve this goal. The California Game Changer of the Year Award recognizes individuals and companies who have


INDUSTRY newsmade a significant statewide impact either economically or regarding key issues within the State of California.

On receiving this award, U.S. Water founder and CEO Allan Bly states, “U.S. Water is proud to be recognized for our record of achievement in the State of California. Our people and integrated water solutions approach are working very effectively to reduce water use and improve business and plant efficiency not only in California, but throughout the United States.”

HIDROSTAL LAUNCHES NEW WEBSITE WITH PUMP FINDER FEATUREHidrostal Ltd, the UK’s expert in pumps and pumping systems, is pleased to announce the launch of its brand new website.

The site has been designed to offer an enhanced browsing experience with clear functionality and navigation. Users will find information on Hidrostal’s full range of products and applications and be able to download the technical data and case studies showing the pumps in operation.

In addition the site now includes the Pump Finder, a dedicated pump selection programme which enables the customer to select the right solution for their own application. The client can select the duty from the full range graph and then search by the type of pump required. The selection will grant access to the full range of technical data including CAD drawings, pump curves and installation arrangements. This will enable the customers to make the preliminary selections for their pump station designs instantaneously.

Neil Langdown, managing director of Hidrostal Ltd comments “The website, in particular the Pump Finder, has been developed

in consultation with our customer base i.e. consultants, contractors, end users and distribution partners – we believe that we have delivered on our promise to marry ease of use with the provision of technical information”

To view Hidrostal’s updated website, visit www.hidrostal.co.uk.

NEW WATER STOCK ADDED TO DIRECTORY OF GLOBAL WATER STOCKS Investorideas.com, (www.investorideas.com) global news source covering leading sectors including water, issues the updated water stocks directory for November. The Water Stocks Directory lists publicly traded water companies listed on the TSX, TSX Venture, OTC, NASDAQ, AMEX, NYSE, ASX, AIM and other leading global Stock Exchanges.

Recently added to the directory is Mount Everest Mineral Water Ltd. Mount Everest Mineral Water Ltd (BSE: MOUNTEVE.BO) produces, sells, and distributes natural mineral water under the HIMALAYAN brand name in India. Its customers include hotels, airlines, embassies, etc. The company also sells its products through retail outlets, malls, multiplexes, hypermarts, and fine-dine restaurants. In addition, it exports its products worldwide. The company was incorporated in 1991 and is based in Mumbai, India. Mount Everest Mineral Water Limited is a subsidiary of Tata Global Beverages Limited.

The stock directory features water stocks ranging from desalination companies to bottled water stocks, to infrastructure, water treatment and technology as well as other sub sectors. The directory is in PDF format and features hyperlinks to stocks symbol(s), company URL’s and company's description.


INDUSTRY newsFor investors following water stocks this is one of the most comprehensive directories in the sector available.

PLASTICS MACHINERY SHIPMENTS CONTINUED TO RISE IN Q3Market demand for plastics machinery continued to grow in the third quarter of 2014, according to statistics compiled and reported by SPI: the Plastics Industry Trade Association’s Committee on Equipment Statistics (CES).

“The market conditions that drive investment in new industrial equipment have prevailed throughout all of 2014, and I expect these conditions to persist in 2015. These are: low interest rates, and the need for increased productivity in order to meet rising aggregate demand," according to Bill Wood, the plastics market economist who analyzes and reports on the plastics machinery market sector for the CES.

Shipments of primary plastics equipment (injection molding, extrusion and blow molding equipment) for reporting companies totaled $301.4 million in Q3. This is 6 percent higher than the revised shipments total of $284.3 million in Q2 of this year, and is down only 2 percent compared with the robust total from Q3 of 2013. For the year to date, the total value of primary equipment shipments is up 6 percent compared with last year.

A closer look at the CES data show that the shipments value of injection molding machinery decreased 4 percent in Q3 of 2014 compared with the total from Q3 of 2013. For the year to date, shipments of injection molding machinery are up 4 percent. The shipments value of single-screw extruders dropped

14 percent in Q3 compared with last year. For the year to date, single screw extruder shipments are down 6 percent. The value of shipments of twin-screw extruders (which includes both co-rotating and counter-rotating machines) jumped 33 percent in Q3. For the year to date, shipments of twin screw extruders are up 35 percent. The shipments value of blow molding machines advanced by an estimated 27 percent in Q3. For the year to date, shipments of blow molding machinery are up an estimated 25 percent.

The CES also compiles data on the auxiliary equipment segment (robotics, temperature control, materials handling, etc.) of the plastics machinery industry. New bookings of auxiliary equipment for reporting companies totaled a record-breaking $108.2 million dollars in Q3. This represented a gain of 8 percent compared with the total from Q3 of 2013. For the year to date, bookings of auxiliary equipment are up 12 percent.

The trend upward in the CES data on plastics machinery shipments corresponds with the trends in the two major data series compiled by the U.S. government that measure activity levels in the industrial machinery sector. According to the Bureau of Economic Analysis, business investment in industrial equipment escalated by 16 percent (seasonally-adjusted, annualized rate) in Q3 when compared with Q3 of 2013, and for the year to date investment is up 13 percent. The other important machinery market indicator, compiled by the Census Bureau, showed that the total value of new orders of industrial machinery jumped 47 percent in Q3 when compared with the total from last year, and for the year to date industrial machinery orders are up a stellar 34 percent. ■

As the largest and most comprehensive HVACR event, the AHR Expo attracts tens of thousands of attendees from all facets of the industry,

including contractors, engineers, dealers, distributors, wholesalers, OEMs, architects, builders, industrial plant operators, facility owners and managers, agents and reps.

Since 1930, the AHR Expo has been the HVACR professional’s leading resource for new products, new ideas and new services. It’s a hands-on, interactive event that showcases a wide spectrum of equipment, systems and components. This unique industry forum creates a dynamic learning environment unequaled in size and scope by any other industry event.

LARGEST EDUCATION PROGRAM IN SHOW HISTORYThe 2015 AHR Expo includes its largest number of seminars, workshops, certification reviews/exams and new product presentations in the event’s history. Attendees will have a wealth of educational opportunities to choose from as the leading associations, publications and organizations serving the HVACR marketplace have come together to create the industry’s most comprehensive educational program.

Designed to give HVACR professionals the information tools they need to improve their businesses, perform their jobs more effectively and stay abreast of new technology and trends driving the industry, more than 120 educational sessions covering a variety of topics will be offered during the world’s largest HVACR trade show. These educational offerings range from more than three-dozen free sessions, nearly two-dozen paid courses, and over sixty exhibitor new

2015 AHR EXPOThe World’s Largest HVACR Marketplace

TRADE SHOW prof ile

DECEMBER 2014 | 11 www.modernpumpingtoday.com

product presentations in the New Product and Technology Theaters.

“This show’s line-up is our largest ever and covers many key issues that engineers, contractors, OEMs, facility managers, manufacturers and other HVACR professionals should know about to be successful,” said Clay Stevens, president of International Exposition Company (IEC), which produces and manages AHR Expo. “When you include all the new technologies and solutions being featured by the nearly 2000 exhibiting companies on the Show floor, AHR Expo truly is an unparalleled learning environment.”

AN EXCITING TIME FOR THE INDUSTRYNow is the time to meet face-to-face with the leading figures in this growing industry. According to a recent ASHRAE and AHR Expo survey sent to more than 1000 HVACR manufacturers worldwide, there is growing optimism for improving economic prospects in 2015. Based on survey results, 87 percent of the respondents said their prospects for business were either “excellent” (26 percent) or “good” (61 percent) for the coming year. Thirteen percent of the respondents felt prospects were “fair.”

These results reflect a significant 8 percent jump over last year’s survey that found 79 percent of respondents expected the economy would be better in 2014 than 2013. It also represents a sizable 17 percent increase in optimism over the previous year’s survey when 70 percent of the respondents thought 2013 would be better than 2012.

In keeping with this positive outlook for next year, 96 percent of the HVACR manufacturers believe 2015 sales will continue to increase, with 47 percent expecting sales increases of between 5 percent and 10 percent. Twenty nine percent of respondents forecast sales increases more than 10 percent, and 20 percent expect increases of less than 5 percent. Only 3 percent expected sales to remain the same. This represents a 6 percent jump over last year’s forecast and an impressive 16 percent increase over the 2013 survey. ■


CASE Studies

A recent large-scale testing program was conducted across Ontario in which the actual performance and efficiency of water pumps was assessed and compared

against original manufacturer specifications. The results were interesting and lifted the veil of uncertainty which often surrounds such matters and exposed opportunities where substantial savings in energy efficiency were available.

FIELD TESTING CRITICAL TO UNDERSTANDING PERFORMANCEThe vast majority of tests were conducted using the innovative and highly accurate Thermodynamic Method which measures the thermal energy gain in the pumped water, among other parameters including pressure and power supplied to the pump motor, to compute pump inefficiency directly. This method was found to be highly, although sometimes not universally, applicable relative to its conventional method counterpart which relies heavily on flow measurements which can be difficult to obtain with accuracy in many practical settings.

The results:

• 9.3 percent average reduction between manufacturer’s original peak efficiency and actual peak efficiency; and

• 12.7 percent average reduction between manufacturer’s original peak efficiency and actual efficiency at typical

operating point noting that, in practice, pumps often operate outside of their range of peak efficiency.

• The average wire-to-water efficiency was found to be 69.4 percent, meaning that more than 30 percent of the input

energy is lost due to pump, motor and drive inefficiencies, with the pump inefficiency making up the vast majority of this loss.

SAVING MONEY THROUGH OPERATIONAL CHANGESWith accurate and reliable knowledge of the actual performance of pumps, the information is available to support changes in the way existing pumps are operated, including their scheduling, utilization and combinations. This can be a very cost-effective way of reducing energy costs with minimal investment required and, based on the results of the testing, there is ample room to consider such operational improvements with positive effect.

SAVING MONEY THROUGH REFURBISHMENTTests conducted before and after pump refurbishments show encouraging results, with the recovery of lost efficiency—measured as the difference between peak manufacturer

efficiency and peak field efficiency before refurbishment—commonly in the range of 50 to 70 percent, depending on specific circumstances. Thus, sufficient information is now available to construct credible business cases supporting the refurbishment of pumps.

Fabian Papa and Djordje Radulj are with HydraTek & Associates, a consulting firm specializing in hydraulic and energy investigations of fluid systems. They can be reached at 416.238.7681 or at [email protected] and [email protected]. For more information on HydraTek’s Ontario-wide pump performance and efficiency testing project, or to request a full copy of the final report, visit www.hydratek.com/opa.

About The Authors

By Fabian Papa and Djordje Radulj, HydraTek & Associates

THE TRUE PERFORMANCE OF PUMPS IN OPERATION

Calibration of temperature probes for Thermodynamic Method


Sample pump testing results comparing actual performance to original manufacturer specifications

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CASE Studies

Calibration of temperature probes for Thermodynamic Method

Pump performance and efficiency testing services are readily available and highly informative.

ESTABLISHING TESTING SCHEDULESIt is quite common for managers to establish routine schedules for asset management activities (e.g., lubricant or bearing replacement, component cleaning, etc.) based on a uniform frequency such as every two years, every five years, etc. When it comes to pump testing for purposes of controlling energy usage, it is sometimes more practical to consider pumps on the basis of their energy consumption, noting that the amount of energy consumed by pumps increases with: (1) the size of the pump and its motor; and (2) its utilization rate. That is, a large pump that is rarely used can easily consume less power than a more modestly sized pump that is used regularly. Testing and potentially refurbishing a pump that is not used sufficiently consumes financial resources without producing the benefit sought (or return on investment).

To assist managers with this, a graphical guideline for pump test frequency was developed based on economic principles to ensure a positive return on investment. Of course, this is not meant to be interpreted rigidly, and certainly other important factors may cause some pumps to be tested more frequently than the graphic would suggest, such as the criticality of a pump to a system’s performance. One can easily envision a small system supplied by pumps only (i.e., a closed system) which, upon the failure of a pump, may no longer be able to deliver any service.

Numerous other examples easily come to mind as well. In these cases, more routine testing of critical pumps will help to identify early warning signs to avoid such crisis situations. Amongst other useful times to test pumps include immediately upon installation to both verify initial performance relative to design requirements, as well as to establish an in-situ (rather than factory) baseline from which trends can be drawn with results from future tests. ■Sample efficiency recovery from pump refurbishment

Pump testing frequency guideline

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CASE Studies

Ellis Island, in the shadow of the Statue of Liberty, is

one of America's most popular historic sites. The island is one of a number of small, naturally occurring islands in New York Harbor. Over many years, this island—which for millions of people represented the gateway to the New World—was enlarged from its original 3.3 acres to its current 27.5 acres by adding landfill from ships ballast and possibly excess earth from the construction of the New York City subway system.

The island was not always a point of entry for immigrants or a tourist destination. By the time it was purchased in the 1770s by Samuel Ellis, it had served as a hanging site for pirates, a harbor fort, and an ammunition and ordinance depot. The U.S. Government purchased the island from New York State in 1808. Just before the War of 1812 broke out a series of structures were erected that served as a defense system for New York Harbor. Ellis Island was approved as a site for fortifications and on it was constructed a parapet of three tiers of circular guns.

ELLIS ISLAND ESTABLISHED AS AN IMMIGRATION STATIONIn January 1892 the federal government took over the processing of immigrants from the states and opened a new immigration station on Ellis Island. Over the next sixty-two years more than twelve million immigrants were processed at the site. Approximately 1.25 million of those came in 1907 alone. Consequently, carpenters and masons were constantly working to enlarge and build new hospitals, dormitories and kitchens and the island's facilities were rapidly expanded between 1900 and 1915.

Immigration decreased as the United States entered World War I and during this time the

island was taken over by the U.S. Navy and the Army Medical Department. In 1920 Ellis Island reopened as an immigration receiving station. However, after World War I immigrants applied for visas at American consulates in their country of origin. After 1924 the only immigrants passing through Ellis Island were those who had problems with their paperwork, war refugees

popular historic sites. The island is one of a number

occurring islands in New

years, this island—which

enlarged from its original

landfill from ships ballast and possibly excess earth

the time it was purchased

pirates, a harbor fort, and

ELLIS ISLAND ESTABLISHED AS AN IMMIGRATION STATIONIn January 1892 the federal government took over the processing of immigrants from the states and opened a new immigration station on Ellis Island. Over the next sixty-two years more than twelve million immigrants were processed at the site. Approximately 1.25 million of those came in 1907 alone. Consequently, carpenters and masons were constantly working to enlarge and build new hospitals, dormitories and kitchens and the island's facilities were rapidly expanded between 1900 and 1915.

decreased as the United States entered World War I and during this time the

Mike Bjorkman is vice president of BJM Corp. and has more than thirty years of experience in the pump industry. He serves as director of marketing and IT for BJM Pumps, LLC and All Test Pro, LLC. Both companies are subsidiaries of BJM Corp. BJM Pumps, established in 1983, supplies electrical submersible pumps to industrial and municipal markets throughout the United States, Canada and South America. For more information, visit www.bjmpumps.com.

About The Author

By Mike Bjorkman, BJM Corp.

Shredder Pumps Installed At Historic Ellis Island


and displaced people. In 1954 the last detainee was released and Ellis Island officially closed.

In 1965 President Lyndon Johnson declared Ellis Island part of the Statue of Liberty National Monument. Between 1976 and 1984 Ellis Island was opened to the public on a limited basis. In 1984 Ellis Island underwent a major restoration—the largest historic restoration in U.S. history.

This was the historic foundation upon which the modern infrastructure of Ellis Island was built. In recent years the island has become one of the most popular tourist destinations in the National Park Service. That means a lot of visitors and the need for well working infrastructure.

On October 28, 2012, Hurricane Sandy swept over Ellis Island, Liberty Island, and much of the East Coast. The Ellis Island Immigration Museum reopened on a limited basis one year later, but repairs to the buildings and infrastructure would continue for many months.

Although the damage to Ellis Island was extensive, the island's antiquated sewage system was fraught with problems long before

Hurricane Sandy came ashore. At that time, New Jersey-based Pump Express Services had been providing maintenance to the island's sewage ejector system for a couple of years.

According to Pump Express sales manager Fred Hettinger, in the two years before Sandy they were called to the island numerous times in response to high water alarms, clogging and ultimately a failed pump. "They had a two-pump system and when one pump failed they let the system run on the other," he

says. Then, the second pump failed "and they had nothing."Hettinger explained that a significant problem was that the

old pumps were a simple ejector type and didn't break down solids. Along with the sewage flow on the island there was also a significant amount of debris—with synthetic fibers being particularly problematic—that routinely clogged the system.

In addition to the clogging problem, physically getting to the pumps in order to service them was a lengthy and labor-intensive ordeal. "The old system required four techs and an entire day to service a clog. A man had to physically descend into the 30-foot pit to detach and later reattach the pump," Hettinger says.

ABOUT PUMP EXPRESS SERVICESPump Express Services, in business for more than 35 years, is headquartered in Wallington, N.J., and provides pump and electric motor repair, rebuild, maintenance and installation services to clients in New York, New Jersey, Connecticut and surrounding areas. Visit www.pumpexpressservices.com for more information.

ABOUT PUMP EXPRESS SERVICESPump Express Services, in business for more than 35 years, is headquartered in Wallington, N.J., and provides pump and electric motor repair, rebuild, maintenance and installation services to clients in New York, New Jersey, Connecticut and surrounding areas. Visit www.pumpexpressservices.com for more information.


CASE StudiesLeft with only minimal sewage disposal, and faced with a

grand reopening to the public targeted for July 4th, 2013, the island's maintenance engineers reached out again to Pump Express Services—this time for a more permanent solution.

BJM'S SK SERIES ELECTRIC SUBMERSIBLE SHREDDER PUMPS GET SYSTEM BACK ON LINE"We submitted a proposal to replace the old pump system with a pair of 15 horsepower BJM shredders," Hettinger says. "We've been using BJM shredders for four or five years now and everything we've been able to throw at them they've been able to handle."

In addition, Pump Express proposed replacing two 20-foot (6.1 meter) sections of steel pipe, along with discharge and base elbows, installing a more efficient rail system and resurfacing

the base of the sewage pit. Instead of four techs and an entire day, the new system can be serviced by two techs in four hours. The two new BJM shredders lent themselves well to this new configuration.

If a customer is ordering a new pump it's likely because the one they have has failed or is about to. Hettinger said that an important additional benefit of ordering the BJM Pumps was that the lead time for their delivery was about half of what it would have been for new ejector pumps equivalent to the ones that had failed. He said that was impressive considering "all this stuff has to be built. A lot of times the parts still have to be manufactured." The BJM pumps were delivered in about four weeks. The estimated delivery time for the ejector pumps had been ten weeks.

In April 2013 Pump Express installed a pair of 900-pound (408.2 kilogram) BJM SK Series shredder pumps into the revamped Ellis Island system. The pumps can handle 845 gallons (3198.7 liters) per minute of wastewater at heads of up to 94 feet (28.7 meters).

The SK Series pumps were chosen specifically because they are designed to shred solids before passing the liquid. The shredder pumps leave solids slightly larger than if they were passed through a grinder pump. The shredding action is produced through use of a unique FangTM non-clog cutting impeller with tungsten carbide vane tips against a high-chrome "tooth shaped" diffuser plate. The cutting tips shred solids against the pump suction plate, continuously ripping the solids apart with 360-degree shredding action. The SK Series shredder pump works on many objects that would clog an ordinary pump.

Other quality features built into the SK Series pumps that supported their recommendation for the Ellis Island installation include the following.

• The 304 stainless steel motor housing helps protect the pumps from abrasion and premature wear caused by the harsh saltwater environment.

• The motor is protected by double mechanical seals. The lower seal is made of silicon carbide/silicon carbide and the upper seal is made of carbon/ceramic. In addition, a lip seal has been installed above the impeller that helps prevent abrasives, such as sand, from entering the seal chamber.

• Winding protection and NEMA Class F motor insulation allow the motor temperature to rise to 230 degrees Fahrenheit (110 degrees Celsius). An automatic switch turns the pump motor off if the temperature and/or amp draw gets too high. When the motor cools the switch will automatically reset and the pump will restart.

• A hardened cast iron exterior stands up to rough handling and pumping of sandy water unlike pumps with soft resin impellers or plastic exterior components. (Specifications may differ between models.)

CONCLUSIONAbout six months after installation a team from Pump Express went back to Ellis Island to make sure the new pumps were performing as anticipated. "We're now going on a year and a half and haven't had any issues," Hettinger says. That's a vast improvement over the previous average of a visit every six months. "I bet in the last eighteen months if we had had to go out there three more times it would have cost them half of what the upgrade cost them," he adds. ■

ABOUT PUMP PRODUCTSPumpProducts.com was a result of the expansion of Pump Express Services’ standards: proficiency, reliability and knowledge. PumpProducts.com is an online store that took advantage of contemporary technology to serve, not only the local community, but the entire nation; Amalgamated with expert in-house connoisseur application engineers, Pump Products has become, not only a store, but an environment with Product engineers that have a plethora of knowledge accumulated through both hands-on experience and technical data from industrial leaders and professionals. In addition, a knowledge base of information is included for consumer self education, because we believe a smart consumer is our best consumer. Pump Products is our solution to bring Pump Express Services’ quality to the nation, distanced only by a phone call or e-mail. We are always prepared with expert counseling to provide better solutions for the industry, consumer, and the nation. For more information, visit www.pumpproducts.com.

ABOUT PUMP PRODUCTSABOUT PUMP PRODUCTSPumpProducts.com was a result of the expansion of Pump Express Services’ standards: proficiency, reliability and knowledge. PumpProducts.com is an online store that took advantage of contemporary technology to serve, not only the local community, but the entire nation; Amalgamated with expert in-house connoisseur application engineers, Pump Products has become, not only a store, but an environment with Product engineers that have a plethora of knowledge accumulated through both hands-on experience and technical data from industrial leaders and professionals. In addition, a knowledge base of information is included for consumer self education, because we believe a smart consumer is our best consumer. Pump Products is our solution to bring Pump Express Services’ quality to the nation, distanced only by a phone call or e-mail. We are always prepared with expert counseling to provide better solutions for the industry, consumer, and the nation. For more information, visit www.pumpproducts.com.


WATER & WASTEWATER solutions

When the Santa Margarita Water District (SMWD) was formed in 1964 by a group of ranchers who wanted a reliable water source for their cattle, the

district served more cows than people. Since then, the area has grown to over 150,000 homes and businesses, and the SMWD maintains over 1200 miles (1931 kilometers) of water and sewer lines across a 62,674 acre service area. Keeping up with both the water needs and sewage disposal of the community has come with significant challenges, particularly due to both the increase in influent and change in the makeup and durability of the sewage running through the district’s reclaimed-water facility.

A VALUED WATER SOURCEBuilt in 1977, the reclaimed water facility was initially intended to provide water for landscape irrigation in the district. During a typical twelve-month period today, the facility brings in 680 million gallons (2.57 billion liters) of sewage and sends out 620 million gallons (2.34 billion liters) of reclaimed water. Originally, the facility relied on a mechanically-cleaned bar screen to remove debris from the waste system.

Over time, safer, more reliable solutions came on the market, and the bar screen was replaced by a CMD single-drum Channel Monster® from JWC Environmental® that would shred debris before it reached the pumps, preventing clogs or damage. Ron Johnson, facilities supervisor for the SMWD facility, said pump clogging hadn’t been an issue since the Channel Monster was installed—until two years ago, when the composition of the influent became heavily loaded with disposable wipes.

“We have a bank of four VFD controlled pumps at the facility, and typically we run an alternating cycle with two pumps operating and then switching to ensure equal runtime for all the pumps,” Johnson says. “This operating sequence with

Kevin Bates is the global marketing director for JWC Environmental based in Costa Mesa, Californai. JWC Environmental is a world leader in solids reduction and removal for the wastewater industry with its Muffin Monster grinders and Monster screening, compaction and washing systems. Bates has more than twenty years of experience working with global industrial leaders to solve challenging technical problems spanning a wide range of markets including wastewater, construction and mining.

About The Author

Monster grinder cuts $78,000 from energy costs in Santa Margarita Water District

By Kevin Bates, JWC Environmental

Channel Monster ® Shreds Debris, Ragging


the pumps modulating around 50 Hertz kept up with plant flow requirements. But starting in about 2012, the pumps would begin to lose efficiency as the wipes loading increased and we would have to run all four pumps to maintain plant production. Once they reached 60 Hertz we would need to shut down the plant to derag the pumps.”

SHUTDOWN COSTS ADD UPThe deragging process started to become necessary every two to six weeks, requiring two operators for about two hours each time to complete the task. “And due to some aging isolation valves that leaked, the plant needed to be entirely shut down during deragging,” Johnson says. These unplanned shutdowns were costing the district an acre-foot of reclaimed water production per month, and the labor costs added up to about $15,000 per year.

Beyond the mounting monetary cost, the safety concerns were equally troubling. “The most efficient method of removing rags is to pull them through the inspection port as one large ball,” Johnson says. “But this procedure, besides being unpleasant, exposes a worker to potential sticks from sharps in the rag balls.”

SEARCHING FOR A SOLUTIONJohnson began looking for a long-term solution to the ragging problem, since both the cost and safety concerns were not sustainable for the district. “We considered changing out the current pumps to a new set of chopper pumps, but this option came with a $100,000 price tag and wasn’t really going to solve the problem,” Johnson says. “We still needed to maintain our inlet Channel Monster to take care of the larger debris the pumps couldn’t handle.

Johnson ultimately decided to upgrade the facility’s Channel Monster to a new perforated metal drum configuration. The coil drums of the original Channel Monster were designed to capture large debris and push it into the grinder’s cutter stack for size reduction. As sewage has evolved and non-dispersible wipes have become a major part of the waste stream, the infrastructure to deal with it has needed to change as well. The perforated drum on the newest generation of Channel Monsters was designed to better capture the wipes and rags that flow through traditional coil drums. “This upgrade cost significantly less than purchasing a whole new set

of pumps,” Johnson says. “Plus, this is a solution that will completely eliminate the pump clogging problems we were having for the long term.”

A BRIGHTER FUTURESince the new Channel Monster drums were installed, the district has had zero pump-clogging issues at the facility, and

has returned to using two pumps at a time instead of all four. Energy costs have decreased $78,000 per year and manual pump deragging has been eliminated. “While the cost savings and the eliminated safety risks are quantifiable, our choice to go with a new Channel Monster, to me, is priceless,” Johnson says. ■



When Bill Blakely, the water treatment superintendent of

the Village of Montpelier, Ohio, commented that the village had “pretty good tasting water,” little did he know that his opinion would be a bit of an understatement. 2007 is the third year that the village has won the gold medal for the World’s Best Municipal Drinking Water.

AWARD-WINNING WATERThis award was given by the annual International Water Tasting Event in Berkeley Springs, West Virginia. The Village of Montpelier also won the gold medal in 2003 and 2006.

Founded in 1845 as a railroad town, the Village of Montpelier is located in Williams County in north western Ohio. Although its population is only 4,300 this prestigious award has certainly helped to put Montpelier on the proverbial map.

What inspired the village to enter the contest? “Pretty good tasting water” and a little friendly competition with a

neighboring town. “The city of Kent, Ohio, entered the Berkeley Springs Water Tasting Competition and won fifth place,” states Blakely, “We thought we had some pretty good tasting water, so we entered the contest, and out of the last seven years, we have won the gold medal three times.”

As a novelty, the Village of Montpelier has even had their water bottled and labeled.

FINDING THE RIGHT EQUIPMENTMr. Blakely runs a very smooth operation at the Village of Montpelier’s water treatment plant. But the plant did have challenges to overcome when it

came to water disinfection equipment. “Prior to 1994 we used a gas chlorinator brand that needed

continual work on their heads,” says Blakely, “they would constantly leak or stick and need replacement components.”

“Factory repair was never offered at that company, so we would tear into the unit and order the parts needed. Sometimes the part we needed was backordered,” Blakely says, “then,

Keith Thompson currently serves as president of the Gas Chlorine Education Committee, a non-profit corporation organized on behalf of interested parties in the water treatment industry. He is also general manager of Chlorinators Incorporated, a company in the water treatment industry that designs, manufactures, markets, and sells equipment for water disinfection and purification throughout the world. For more information, call 772.288.4854, email [email protected], or visit www.regalchlorinators.com.

About The Author

By Keith Thompson, Chlorinators Incorporated

The Village of Montpelier Improves Efficiency with New Gas Chlorinator System

Josh Fritsch, Chief Operator (left) and Bill Blakely, Water Treatment Superintendent (right) share a toast with their very own drinking water.


when the parts did come in, we had the extra cost of labor time of having to rebuild it ourselves. So, we always had to have an extra head on the shelf.”

BUILDING THE NEW FACILITY The village’s old water treatment plant was built in 1939—not suited to today’s standards. So, in 2005 the village undertook the project of building a brand new water treatment facility.

“When we were looking to replace the existing gas chlorinator equipment,” Blakely states, “we inquired information from area reps and also talked with them at the state AWWA [American Water Works Association] convention. The Regal Gas Chlorinator with the automatic switchover feature and fewer moving parts really caught our eye. We’ve never regretted the change,” Blakely adds.

Although the plant switched to the Regal Gas Chlorinator in 1994, Blakely states, “When we built our new plant in 2005 we made sure to specify Regal. We didn’t want anyone else’s chlorinator.”

DAWN OF A NEW DAYThe Village of Montpelier, Ohio, has never used anything other than gas chlorine for water treatment.

“I am familiar with sodium and calcium hypochlorite because I operate two other small water treatment plants—one at Lake Seneca and the other, a small housing subdivision just outside of Bryan, Ohio,” says Blakely.

Sodium was not practical for use at the Village of Montpelier due to shorter shelf life and waste of product due to degradation.

“I prefer gas over sodium or calcium hypochlorite,” Blakely states. “With gas there is no degradation. It’s contained and remains at 100 percent available chlorine. Calcium hypochlorite starts at 65 percent, and sodium hypochlorite starts at 12.5 percent, and then diminishes with age.”

“I also have less exposure to chlorine by using gas rather than sodium or calcium hypochlorite. I get exposed to more gas by opening a container of calcium hypochlorite than I do switching chlorine gas tanks, and I don’t ruin clothes like I do when using sodium hypochlorite,” Blakely states.

CALCULATING THE COST PER POUND OF SODIUMThis formula assumes that after degradation occurs, a constant 10 percent solution of sodium hypochlorite remains. (But, keep in mind that sodium never remains constant.)

Price per gallon of sodium X 1.2 (which equals 1 pound of gas) = price per pound.

1.5 lbs of calcium @ 65% = 1 lb. of CL2 gas

IN THIS CUSTOMER’S EXAMPLE:

$2.00 X 1.2 = $2.40 per pound of sodium hypochlorite In the Montpelier, Ohio, area calcium hypochlorite costs around $2.40/lb.

Montpelier pays 46 cents per pound of chlorine gas.



Regal flow pacing valve products have helped the village, which uses ground water, eliminate the trials and errors of the past.

“The SmartValves we installed at the new plant work super. Our system is flow proportional, so if I want to adjust the gallons per minute from 1400 (5300 liters) in the summer to 1000 (3785 liters) in the winter, I just dial back my wells, and the Regal SmartValve will compensate automatically to achieve the same dosage,” states Blakely.

IN SUMMARYThe Regal system has helped the Village of Montpelier eliminate downtime, save money, and lessen labor—all essential elements in running a smooth water treatment operation.

“In the fourteen years that I’ve been with the Village, I’ve sent one chlorinator head to the Regal factory, and I got it back promptly—in seven days,” states Blakely, “but because we were using the switchover units, we had no downtime.”

“Regal is a good fit for us. The less maintenance-intensive, the better,” says Blakely. ■

THE COST OF SODIUMCost concerns were another reason why the village does not use sodium.

“Sodium and calcium hypochlorite are also more expensive than gas. As far as I’m concerned, gas chlorine is the cheapest way to go,” says Blakely, “We pay 46 cents per pound for gas chlorine. Sodium hypochlorite costs around $2 per gallon, and calcium hypochlorite costs around $2.40 per pound. If you look at the cost per pound per the form of chlorine, factor in the degradation, gas is a lot cheaper.”

THE FULL SET-UPIt is evident that gas chlorine is the Village of Montpelier’s choice disinfection product, and they couldn’t be more pleased with the brand that they have chosen for the past fourteen years—Regal.

“With the Regal Switchover unit, when one tank goes empty it automatically switches to the standby tank, and you never have a drop in chlorine. It maintains a constant feed rate,” says Blakely.

“I can be doing other things. We can get to it—change the tank—at our convenience,” according to Blakely, “This is important because we have a small staff, and we don’t have time to baby sit the chlorine tank when it is about to go empty.”

2.5

2

1.5

1

0.5

0

Disinfection Costs

GAS CL2 $0.46/lb.

SODIUM $2.40/lb.

CALCIUM $2.40/lb.

Montpelier’s Regal System set-up includes switchover units, SmartValves™ and vacuum monitors.


MAINTENANCE solutions

Tristar, Ltd. is a manufacturer of fabricated components and equipment, including remanufactured filtration systems. The Encoded Digital Guidance (EDG) system is

designed to improve filtration performance and reduce energy costs. The EDG-trac Knife Advance system is an ancillary system for a rotary vacuum drum filter (RVDF), which consists of an advancing knife, single motor gear drive, and associated controls. In the EDG-trac Knife Advance system, accumulated solids are cut away from the filter drum surface much more efficiently, while maintaining acceptable solids separation and improving liquid throughput.

OPPORTUNITY AREASRemanufacturing is an important means of extending the life of a product and reducing environmental impacts. It was anticipated that, when compared to conventional systems, a remanufactured filter system, which incorporated the newly designed EDG-trac Knife Advance System, would use less energy and water, produce a drier sludge cake, and have a higher filtrate throughput. NYSP2I assisted Tristar with quantifying these improvements.

The goal of this project was to evaluate Tristar’s EDG-trac Knife Advance System at a manufacturing facility and quantify energy reduction, suspended solid removal efficiency, and increased throughput for this system as compared to a traditional RVDF system.

WORK PERFORMEDNYSP2I performed a comparative analysis of the two systems at a chemical manufacturer who was replacing two traditional RVDF systems with two remanufactured systems built by Tristar. The performance of the traditional operating RVDF system and Tristar’s

remanufactured “EDG-trac” system was measured using the following key parameters: energy use, filtration rate, sludge moisture content, and effluent quality (suspended solids).

RESULTS FROM THE FIELDTriStar states that it will rebuild or remanufacture existing RVDF units at its facility or retrofit the EDG-trac system to an RVDF at a customer’s plant. The Tristar Edge-trac Knife Advance System, as installed in a remanufactured rotary vacuum drum filter, exhibited the improved performance results as compared to a traditional RVDF system.

An independent field test at a leading chemical manufacturer in Buffalo, New York, showed that the EDG-

trac system increased filtration throughput by 700 percent

on average and reduced energy consumption

by 87 percent

Charles M. Harrigan III is the sales and marketing director at TriStar Ltd. He can be reached at 716.873.0081 or via email at [email protected]. Established in 1985, TriStar Ltd. is a remanufacturer of filtration equipment including Rotary Vacuum Drum Filters, Belt Filters, Vacuum Belt Filters, and Filter Presses. In addition, TriStar manufactures a proprietary line of Hot Water Sets. For more information, visit www.tristarltd.com.

About The Author

By Charles M. Harrigan III, TriStar Ltd.

EDG-trac Knife Advance System proves efficient and cost-effective

Rebuilt 3x1 rotary vacuum drum filter upgraded with EDG-trac Knife Advance System filtering candle filter backwash.


on a per-gallon filtered basis. The study was recently conducted by the New York State Pollution Prevention Institute (NYSP2I) at the Rochester Institute of Technology (RIT). In the study (consisting of two batch tests) the performance of an existing RVDF was measured. The entire filter was then replaced with a remanufactured RVDF and EDG-trac system from TriStar, and the new filter was evaluated under the same process conditions.

IMPROVED FILTRATION PERFORMANCE, LOWER ENERGY COSTSIdeal solids penetration into a pre-coat filter is 2 to 5 thousandths of an inch. The EDG-trac system removes as little as 1.4 thousandths of an inch per revolution at a drum speed as low as 0.2 RPM. This extends pre-coat life by not cutting away clean pre-coat while maintaining acceptable solids separation and improving liquid throughput, according to TriStar.

EDG-trac also features a highly efficient, single-motor VFD to reduce energy use and cost. A fully automated PLC controls the advance speed, retract speed, and drum speed, allowing precise control and providing valuable information to operators, the company states. An automatic high-speed retract mode reduces time between cycles and allows the filter to be recycled and put back online quickly.

TriStar says that the company can remanufacture an entire RVDF including EDG-trac at 60 to 70 percent the cost of a new filter in eight to ten weeks. It can also retrofit the EDG-trac system to any installed RVDF. TriStar also fabricates a wide range of process equipment including pump skids, heat exchanger skids, pre-coat systems, frames, platforms, piping systems, and other custom projects. The company also provides welding services including piping, valve ends, equipment repair, sanitary piping, and stainless steel tubing. ■

EDG-TRAC AT A GLANCE

• 700 percent increase in water filtration throughput.

• 87.4 percent reduction in energy use, on a per gallon filtered basis.

• Comparable sludge moisture content and suspended solids removal efficiencies.

• Tristar is targeting the creation of five New York state jobs to expand manufacturing of EDG-trac.

For additional information about the New York State Pollution Prevention Institute at the Rochester Institute of Technology, visit www.nysp2i.rit.edu.

To download a PDF file of EDG-trac literature and the independent report, visit www.tristarltd.com/news.html.

Maximum Performance Guaranteed

[email protected]

VERTICAL MACHINING:SAFE AND EFFICIENT

THE NEW EMAG VL-MACHINES

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+ Small footprint = Reduced fl oor space cost

+ Integrated automation = No additional cost

+ Simple workpiece conveyor & interlinking = Flexibility and lower automation costs

+ Short traverse distances = Minimal idle time, high performance

+ Operator friendly = Quick set-up, change-over

+ Standardised parts strategy = Low maintenance costs

+ High energy effi ciency = Reduced energy cost


PUMP solutions

We live in an age of energy optimization. It seems the world has finally rallied

around the idea that addressing wasted energy in pumping applications represents a huge financial gain to owners and a substantial efficiency gain to energy providers.

All you have to do is ask a motor manufacturer and I am sure you will get an impassioned response related to governmental energy standards. In just

the past several years, we have gone from EPACT to EISA Motor Efficiency Standards and it now appears that this is going to be “refined” yet again.

It’s great that these regulations have continued to push the envelope on motor efficiency, but they never seem to consider the application. Motors do the work applied to them, but the intelligence is in the control. It is the sum of the parts acting as a system that contributes to the overall savings

and energy efficiency of a piece of equipment, not just the motors.

THE LAWS THAT DRIVE ENERGY OPTIMIZATIONOur company builds many pressure booster pump stations that regulate constant output pressure control. Output pressure is our process variable (PV), the primary element we use to maintain a constant feedback loop to maintain pressure regardless of the flow

Dave Carrier is president and CEO of QuantumFlo, Inc. With nearly 100 years combined industry experience, QuantumFlo has promoted and expanded the new packaged system technologies to the pump systems market. For more information, visit www.quantumflo.com.

About The Author

By Dave Carrier, QuantumFlo, Inc.

The Age of Pump Optimization andthe Impact on Sustainable Design

Forbes Regional Hospital, Monroeville, Pennsylvania


through the pump. We have chosen to do this using electronic rather than hydraulic control. Incredibly, electronic (variable speed) pressure control has only become the preferred means of control within the past ten to twelve years. Prior to this, hydraulic control (pressure regulating valves) was the chief control standard.

As you look around at the current industry, you will likely notice the proliferation of variable speed motor control from large process applications to small fractional horsepower circulators. It makes sense to vary pump speed when you are trying to control a multitude of potential process variables from flow to temperature, to differential pressure and discharge pressure.

So why has variable speed control become so ubiquitous? The simple answer to this lies in the pump and fan affinity laws. These physical laws state the following:

1. A pump or fan increases or decreases flow in proportion to the speed of the motor.

2. A pump or fan increases or decreases in pressure as the square of the speed change.

3. A pump or fan increases or decreases in energy as the cube of the change in speed.

It is easy to see that, based on these three laws, pumps and fans can have the greatest potential differential of energy based on a change in the motor speed. The best part of this is, only a small change in speed yields a fortune in energy reduction due to the cubic relationship to pump speed. If you perform this basic math, a 20 percent motor speed reduction (.80 x .80 x .80 = .512 or 51.2 percent total energy) nearly cuts your power in half.

Adding the VFD to this application saves far more energy than simply specifying an EISA compliant motor. This requires the engineer to apply the proper components to get to the next level of energy efficiency made possible by the affinity laws.

Under LEED 2009, there are 100 possible base points distributed across six credit categories:

• Sustainable Sites• Water Efficiency• Energy and Atmosphere• Materials and Resources• Indoor Environmental Quality• Innovation in Design

Up to 10 additional points may be earned: four additional points may be received for Regional Priority Credits, and six additional points for Innovation in Design (which includes exemplary performance credits for existing credit categories).

• Buildings can qualify for four levels of LEED certification:

• Certified: 40–49 points• Silver: 50–59 points• Gold: 60–79 points• Platinum: 80 points and above *

* Information in these two areas was pulled from the USGBC and LEEDUser websites. (www.usgbc.org and www.leeduser.com)


PUMP solutionsTHE IMPACT OF LEED CERTIFICATIONWe apply many of our products to the world of commercial building trades. Since the advent of sustainable design, many standards have adopted these green efforts. One effort to improve sustainable design and provide resources to these efforts is the U.S. Green Building Council (USGBC). USGBC has established a roadmap toward sustainable design known as Leadership in Energy and Environmental Design (LEED).

LEED goes beyond the general standards that apply to specific trades within the building such as structural, HVAC, civil, etc. and is an attempt at looking at the total environmental impact of the building. The USGBC committee evaluates the total impact of the structure, including its carbon footprint, or greenhouse gas emissions. When LEED accreditations are followed, existing building emissions can be offset by following the rules of sustainable design such as a “green roof,” which would provide plant life to offset CO2.

The overarching goal of these new efforts is simple: save energy. Since most

energy is saved by speed reduction, as in the affinity laws, the primary purpose of these standards is to search for every opportunity to save energy, and thereby, the environmental impact of that energy consumption.

Consider the case of LEED credit for new Construction and Energy Optimization (NC-2009 EAc1). This LEED credit deals with optimization of energy loads within a building. Since the booster system is one of many VFD pump and fan loads within the structure, you can see how substantial an impact this could represent. In fact, EAc1 is by far, the most important credit within the LEED accreditation system

as it relates to total points available. This area alone represents up to 19 total points, comprising nearly half of your minimum qualification. You cannot shoot for LEED Platinum without considering the requirements of EAc1.

THE ADOPTION OF ANSI/ASHRAE/IES STANDARD 90.1ANSI/ASHRAE/IES Standard 90.1 is the world’s most adopted building energy code, and yet many plumbing consultants do not realize that it affects booster pumps systems in a major way. Constant speed pumps have been some of the greatest energy vampires in the commercial building space, sucking energy from the source to do nothing more than charge a water riser so someone can walk up to a toilet and flush it.

In the past, this flushing sound signified the owners’ cash being sucked from his wallet, as a pump that does not change in speed uses 100 percent of its full power all the time to make certain that water is available at each fixture. From an energy perspective, the booster was the low hanging fruit of the energy optimization movement, but 90.1 did

Bank of America Plaza, Tampa, Florida


not stop at just the standard operational savings. The committee wanted more.

The Standard also requires the consultant to either move the variable speed pressure control sensor to the farthest point in the building, or employ software logic to simulate the operation of this remote control. What this does is dial-out the piping friction between the booster and the farthest point in the system. By eliminating piping friction from the control, the pump is allowed to slow even more when the flow rate doesn’t always require this additional friction loss. This is a concept that comes from the HVAC industry, as most of the pressure required by a closed loop HVAC system is due to piping friction loss. However, the friction contribution of an open-loop plumbing system is not as substantial. Nevertheless, Standard 90.1 wants this energy back.

VIRTUAL SIGNALINGThere is a secondary option in lieu of the remote set point whereby the system could be controlled via virtual signaling—or logic in the programming that simulates the effect of a remote

sensor. This is probably the simpler way to accomplish the reduction in speed without having to involve another contractor besides the plumber; namely an electrician to run the signal wires.

As a result, pump system companies have recommended the use of virtual signaling in lieu of the extra labor and contractor disciplines. (For our company, QuantumFlo, this algorithm is called GreenFlo™). This process measures the flow across the pump and changes the set point when the flow rate is low and the additional pressure is no longer required. The setting then resets when flow is increased back to the range requiring the extra boost. The best part of using logic control versus physically moving the sensor is that the system can maintain its factory-tested and pre-engineered status, which is the primary reason the consultant specified this pre-engineered device in the first place.

INCREASED OPPORTUNITY FOR BOOSTER SYSTEMSStandard 90.1 (as written) was adopted in October of 2011 and provided a two-year window for states to comply,

so most U.S. consultants are already required to design to it. However, many plumbing and mechanical engineers do not even realize that the section regarding the use of VFD-based plumbing pumps even exists. It was then adopted by the International Energy Conservation Code (IECC) in 2012 making it the most prominently implemented.

It does not seem typical to consider that a booster system pressure would actually change according to the flow conditions, but as technology advances, so does the opportunity to use it for the betterment of our world. ANSI/ASHRAE/IES Standard 90.1 is being used in these new designs to assist the engineer in this endeavor and the manufacturer is also there to answer the call to continually innovate and implement these useful energy optimizers.

It is imperative that the engineering community continue to learn and engage with the community of technology and manufacturing in order to find these energy optimizers which, when taken in total, can contribute greatly to the energy consumption footprint of these buildings. ■


DEWATERING solutions

TerraFirma Earth Technologies was selected by general contractor GE Johnson to install a groundwater control system and innovative groundwater collection

and treatment system designed by Terracon in the heavily travelled Cherry Creek business district in Denver, Colorado. TerraFirma, an elite groundwater control contractor, is the newest arrival among top-tier players in Denver’s burgeoning construction sector. The firm has opened a permanent satellite office in the Denver Tech Center.

A SURPRISE ON THE JOBSITEWhen ground was broken in February, 2014, neither GE Johnson, 100 Saint Paul, LLC (owner), nor the geotechnical consultant Terracon, could predict unforeseen conditions that would require on-the-spot installation of additional dewatering features than were originally designed. TerraFirma worked congruently with the owner, general contractor, and design consultants to come up with an innovative, supplemental dewatering system that averted delays and minimized costs.

According to TerraFirma’s David Giles, the original design included widely

spaced deepwell dewatering wells meant to maximize drawdown, while minimizing the rate of groundwater flow, in an effort to prevent migration of potentially contaminated groundwater from adjacent properties. The modified system meant adding mini-vacuum wells directly adjacent to the building’s elevator pits and a permanent dewatering sump pit that TerraFirma was able to custom design on

the job, making for a unique hybrid of dewatering methods to better suit the actual soil and jobsite conditions.

TerraFirma’s president David Giles explains, “Usually when we pump water from the ground, we pipe it directly to a storm sewer drain. However, there was concern that this ground water was contaminated from three sources: chemicals from a dry cleaning business, hydrocarbons from a previously demolished fuel station, and dissolved metals, which occur naturally in the earth.

“By isolating the supplemental dewatering to just those few areas needing it, we saved precious time and reduced costs. Also, by limiting supplemental dewatering efforts to just those few areas, we reduced the required

Josh Peltier and partners David Giles and Mike Giles founded TerraFirma Earth Technologies in 2004 with the mandate of elevating the quality and professionalism of the dewatering industry. Headquartered in Houston, TerraFirma helps owners and contractors throughout the United States maintain acceptable groundwater levels for both temporary projects and permanent installations. Contact TerraFirma’s Houston office at 281.720.1212, or the Denver office at 720.893.0556. For more information, visit www.tfearth.com.

About The Author

By Josh Peltier, TerraFirma Earth Technologies

Solid Foundation for Business DistrictTerraFirma’s groundwater system supports 100 Saint Paul development

TerraFirma Earth Technologies installed an innovative dewatering and ground water treatment system at 100 Saint Paul, a retail and office development in the rapidly expanding Cherry Creek business district. The firm has made Denver a permanent home to a satellite office.

Electrical submersible pumps were placed near the bottom of each dewatering well.


amount of groundwater to be pumped, thereby reducing the risk of pulling in contaminants identified on adjacent properties during the investigative phase of the project.”

Brian Lawrenson, GE Johnson’s superintendent, adds, “The project is situated in the heart of Cherry Creek, with very little or no laydown. TerraFirma worked with us during the logistical challenges we faced daily. Due to the complexity of the site excavation and ever-changing conditions, GE Johnson had TerraFirma install two areas of vacuum-well assemblies to provide additional localized dewatering. TerraFirma reacted quickly to these unforeseen conditions

and was able to minimize the impact to the construction schedule.”

A CLOSER LOOKThe final dewatering system included 11 extraction wells, 1 injection well, 42 mini-vacuum wells, 3 perimeter HDPE groundwater discharge manifold lines, and a groundwater treatment system. “It was first time I have seen such a unique groundwater collection and treatment system design in my 28 years in this business,” says Giles. “It was much easier and less expensive to design and install this at the outset,

Going deeper. TerraFirma’s well modification in progress. Wells must be lowered as excavation advances.

TerraFirma utilizes Holland's Rotary Lobe wellpoint pump for its mini-vacuum well dewatering system. The traditional deepwell dewatering wells can be seen in the background.


DEWATERING solutions

just to cover the possibility that it would be needed. Had we not planned in advance for the three possible discharge routes and needed them, it would have been expensive to do so later. Terracon deserves credit for a really unique design.”

According to Giles, in the end Terracon’s samplings were all within limits, and the water didn’t have to be redirected away from the sewer. The injection wells will remain in place after completion of the construction and incorporated into a separate, permanent dewatering system.

EXPERTISE IN ACTIONDavid Cross of 100 Saint Paul, LLC, was pleased with the result. “TerraFirma brought a high level of expertise and extensive knowledge base to the table when we hit the bottom of the hole. They were instrumental in bringing about a speedy resolution to unforeseen subsurface conditions to the benefit of the general contractor and the project owner.”

100 Saint Paul, a Class A office and retail development, is scheduled for tenant occupancy in the summer of 2015. As of November 18th, the steel

Completed installation of the PVC mini-vacuum well- assembly following drilling of the borehole, utilizing track mounted Geoprobe hollow stem drilling rig.

Placement of the PVC dewatering well assembly following drilling of the bore hole with the track mounted Watson drilling rig.

Completed installation of the PVC mini-vacuum well- assembly following drilling of the Placement of the PVC dewatering well assembly following drilling of the bore hole with


Unique, innovative groundwater collection lines allowed clean groundwater to be directed to the city storm sewer drain, contaminated-treatable ground water to an onsite groundwater treatment system, or contaminated, untreatable groundwater to be re-injected back into the ground, to its original source.

Unique, innovative groundwater collection lines allowed clean groundwater

structure rises to eight levels above grade over three below-grade parking levels. TerraFirma’s past deep excavation projects include athletic stadiums, hospitals, high-rise facilities, transportation facilities, airports, tunnels, power plants, dams, waterways, petro-chemical plants, and municipal infrastructure sites such as pumping stations, treatment plants, as well as sewer and gas pipelines. ■

Safety meeting. TerraFirma provides ongoing training and certification for its crew members. All safety initiatives are continuously reviewed and updated to keep employees proficient in new safety policies and procedural methods. The firm calls this plan “Target Zero”, and its goal is to achieve zero accidents and injuries during every dewatering project.


MOTOR solutions

As pumping systems become increasingly intelligent, smart devices are at the core of most solutions. The “smarts” in the system may reside in many locations,

some examples include—PLCs/PACs, an HMI or a VFD. In the world of pumping, this has resulted in challenges

such as:

• Pumps are frequently located in remote locations—requiring time and expense to address these needs

• Access to proprietary software along with specific knowledge of operating in these software environments.

• Lack of local expertise to diagnose and troubleshoot

MANAGING TIME AND COSTS The results have been added time and costs in terms of operator training and in getting the right personnel with the right software to be present at the controller. The widespread

Siva Kanesvaran is a senior design application engineer for Schneider Electric. As a global specialist in energy management with operations in more than one hundred countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in utilities and infrastructure, industries and machines manufacturers, non-residential buildings, data centers and networks and in residential. For more information, visit www.schneider-electric.com/us.

About The Author

By Siva Kanesvaran, Schneider Electric


adaptation of Ethernet based technologies along with a notable drop in the cost of implementing Ethernet in controllers have enabled for web-based user interfaces to be integrated directly into the PLC’s and PAC’s. The result is a means to connect to a PLC using a web browser and to access customizable screens for configuration, diagnostic and possibly even maintenance purposes.

Configuring a control system during start-up may require observation of the status of communication links and control variables. Some this data may not be published to the HMI as it may not be needed in day to day operations. Including more information on the HMI screen increases clutter and complexity within the interface. The solution is to abstract some of this data from the HMI and utilize some of the in-built Ethernet web server functions.

THE ROLE OF REMOTE MONITORING In addition to configuration and parameterization, remote monitoring possibilities are another a key value enabled by intelligent pumping solutions. Let’s use energy management as a key example. While the first couple of key actions revolve around enhancing the controls relative to energy consumption, monitoring provides closed loop feedback to ensure continuous system performance. Lack of such feedback will likely result in a relapse in energy performance.

The data available via the web server enables an effective first level of support. To illustrate this, imagine a situation where a PLC is not communicating with one of its controlled variable frequency drives. Without any further details besides the lack of communication, the root cause may be a

Active Energy Efficiency

Optimize through automation

& regulation

Monitor, maintain, improve

Energy Audit& Measure

Passive Energy Efficiency

Fix the basics

Low consumption devices,insulation material, power

factor correction

HVAC control, lighting control, variable speed drives...

Meters installation, monitoring services, EE

analysis software

The next generation of MachineStruxure™ from Schneider Electric is an intuitive solution for machine automation.

Energy Management Diagram


MOTOR solutionsphysical connection issue, or an issue at the device level. The monitoring of the Ethernet link status as well as the ability to ping the device via the web server would indicate if a good physical connection is present which allows for troubleshooting to progress by process of elimination. This helps reduce situations where service personnel are dispatched to a site only to find the problem to be caused by something simple such as a disconnected cable.

The web server also includes a scope tool that allows for PLC variables to be compared and monitored over a web browser. This allows for specific parts of control logic or a process to be monitored in real-time without having the same specific parts published in the HMI of the system.

Further to standard web server functionality, pump and pump systems manufacturers may choose to include custom web pages that could contain specific dashboards on the

status of various parts of the system. These may have a variety of uses for maintenance or service personnel and end users.

The added benefit here is that end user or service personnel are now working with a graphical environment on a browser instead of a ladder diagram in the software

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The Magelis line offers user-friendly interfaces for a variety of industrial needs.

environment. Essentially this reduces support costs and will increase customer satisfaction at the end user as they are empowered to perform some of their own troubleshooting.

IMPROVED CUSTOMIZATIONHow easy or hard are these pages to create? Some systems require for the custom pages to be defined from scratch in HTML along with JavaScript for example, while others utilize screen development tools within the PLC programming environments. The screen development tools may include drag and drop objects that can be configured for a variety of functions which reduces development time significantly.

The concept of intelligent pumping is frequently associated with system performance measurements such as energy consumption, and indeed these solutions contribute heavily to these goals. Combined with the added benefits of monitoring, diagnostics and troubleshooting via web enabled user interfaces, intelligent pump control solutions will continue to be a game changer. ■


POWER GENERATION solutions

Though the Kampani School and Clinic in the Zimbabwe’s remote Tsholotsho District aren’t far from the world famous Victoria Falls, it had been twenty

years since either had a reliable source of fresh drinking water. Women and children walked an average of seven miles a day to haul surface water by bucket—and many of the clinic’s patients suffered from water-borne diseases. That all dramatically changed in 2013 when Franklin Electric’s Franklin Wells for the World Foundation (FWWF) installed five wells in the region powered by Franklin’s innovative new SubDrive SolarPAK pumping system. Now more than 12,000 people—many for the first time in their lives—have easy access to clean water.

AN AREA OF NEED, THE POWER TO HELPAccording to Franklin chairman Scott Trumbull, “Five thousand children a day die in Africa of water-borne diseases. But that problem could be solved if they could get to the aquifers 200 feet (60.96 meters) under their feet. We established Franklin Wells for the World Foundation in 2009 to address that problem.”

Since then, FWWF has installed wells in Kenya, Sudan, Botswana, and Zimbabwe using Franklin’s proven submersible pump systems powered by diesel generators. With the introduction of the new SubDrive SolarPAK in 2012, Franklin saw an opportunity to make new FWWF installations even more efficient and reliable.

“With the SubDrive SolarPAK system there are no moving parts other than the highly reliable pump that is 200 feet (60.96 meters) underground,” explains Trumbull, “So it will be a much longer lasting solution for those communities.”

LIFE-SAVING TECHNOLOGYIn fact, SubDrive SolarPAK technology gives water pump installers and users the option to use solar as the power source on virtually any 4-inch (101.6 millimeter) well. The rugged, high-output system is capable of a wide range of applications, including irrigation systems, tank and cistern filling, renewable energy projects and rural water supply for villages, cottages and homesteads. Thanks to the SolarPAK’s variable frequency drive (VFD), the pump produces water even on cloudy days or with minimal sunlight.

For more information on Franklin Wells for the World Foundation, visit www.fwwf.org, or contact Brooke Moore at 260.827.5395 or via email at [email protected]. For more information on Franklin Electric products, visit www.franklinwater.com or www.franklin-electric.com/solar.

For More Information

By Jason Nees, Franklin Electric

Franklin’s new solar pumping technologyproves itself in Africa

POWERWhere It’s Needed Most

Access to clean water is the driving purpose behind Franklin Electric’s Franklin Wells for the World Foundation.

POWER


Besides the Kampani School and clinic, FWWF also installed new wells at the nearby Jabulani, Jakalasi, Mpindo and Zigo schools. Because the SubDrive SolarPAK system is designed to deliver higher flow rates than most existing solar powered products, each one of the new Zimbabwe installations is able to fill large, above-ground water tanks at the rate of 1320 to 2640 gallons (5000 to 10,000 liters) a day.

“Each one of those will provide enough water for drinking, bathing and garden irrigation,” says FWWF director Attie Jonker. “For many of the people in the region—especially the children—that’s literally the difference between life and death.”

FRANKLIN WELLS FOR THE WORLD FOUNDATION In 2014, the Franklin Wells for the World Foundation also completed a project in the Chibombo District of Zambia, South Africa. The project consisted of water well installations at five schools in the community.

Mwanje Primary school was founded in 2000 by the community after seeing an increase in the drop-out rates for children in the community, especially among girls, due to the long distance to the nearest school (Shimukuni Basic school is located approximately 3.7 miles [6 kilometers] from Mwanje). The community mobilized themselves and constructed temporal structures and the school was run by community members as volunteers.

The nearest source of water for the school was a community borehole about 0.9 miles (1.5 kilometers) away, and the entire community of about 4000 people collect their water from the same borehole. The borehole was equipped with a hand pump, which was often broke down.

The Franklin Wells for the World Foundation drilled a well at the school, equipped it with a Franklin Electric Solar Pumping System, and erected two 1320 gallon (5000 liter) overhead tanks, one for the school and one for the community.

A video of the applications by Franklin Wells for the World in Africa narrated by Scott Trumbull, is available at youtube.com/fecorporate. ■

The SubDrive SolarPAK system is designed to deliver higher flow rates than most existing solar powered products.

Installation of Franklin Electric Solar Pumping System.

Solar panels being installed.


PROCESSING solutions

Spreadable butter is one of the primary products of the Danish/Swedish dairy company Arla. At their facility in Götene Arla is producing the brand Bregott for

the domestic market in Sweden. To be able to reproduce the specific characteristics of the different types exactly, ingredients must be precisely metered. For ten years, the production facility in Götene has used pumps from Lewa GmbH for this purpose, which are not only designed for high discharge pressures but also have an accuracy of ± 1 percent, meeting the manufacturer's strict requirements. From the different variants of the Ecoflow pumps, which are also very suitable for the production of food items, Lewa was able to configure a perfect solution for Arla in 2010.

TEAMING WITH ARLAWater, rapeseed oil, and brine—those are the most important, exclusively natural ingredients to give the butter Arla produces in Götene, Sweden its medley salty flavor and its spreadable consistency. The mixing system for the plant must meet the strictest of hygienic requirements and—even more importantly—meter with high precision to ensure consistent product quality. Since the Ecoflow pumps from the

Jörg Sommer is the Ecoflow pumps product manager. Lewa GmbH was founded in 1952 as a family company by Herbert Ott and Rudolf Schestag, and today is the world's leading manufacturer of metering and process diaphragm pumps as well as complete metering systems for process technology. For more information, email [email protected] or visit www.lewa.com.

About The Author

By Jörg Sommer, Lewa

High-precision Ingredient Metering for Spreadable Butter DAIRY GIANT ARLA USES MULTIPLEX PUMPS WITH A BROAD ADJUSTMENT RANGE


Leonberg manufacturer Lewa stand out not only for the fact that they are suitable for high discharge pressures, but also because they ensure good reproducibility, about thirty of them were installed in different plants, including nine diaphragm pumps and one packed plunger pump in the facility in Götene.

ABOUT ARLA FOODSArla Foods is a Swedish/Danish dairy group headquartered in Viby near Aarhus in Denmark. The originally Swedish company was founded over 100 years ago. In spring 2000, the Arla group merged with the Danish company MD Foods. The core markets of the company are Denmark, Sweden, Finland, Great Britain, Germany, and the Netherlands. After the merger with Hansa Milch eG in Mecklenburg-Vorpommern and the takeover of the Allgäuland cheesemakers in Bavaria in 2011 as well as—shortly afterwards—the merger with the Milch-Union Hocheifel eG in Rheinland-Pfalz have put Arla in the top three dairies in Germany.

Arla provides a broad product portfolio of well-known brands, such as Apetina, Buko, Kærgården and Castello as well as numerous trademarks for the partners in the group. Their product line includes, among other things, butter and dairy spreads, cheese, milk, and dairy beverages, as well as lactose-free products. The company is also the world's largest maker of organic dairy products.

Arla has production facilities in thirteen countries and sales subsidiaries in twenty more, employing 18,112 people as of the start of 2013. That makes the company the fourth largest dairy company in the world. Its 2012 sales were about 8.460 billion Euros, with profit of around 254 million Euros.

Among other things, the Ecoflow pumps used at Arla/Götene are outstanding for their low dead space as well as their smooth stainless steel surfaces (1.4571). That makes the entire pump extremely well-suited for the food industry and for CIP cleaning.


PROCESSING solutions

During a visit to the Arla plant in Götene at the start of 2013, the responsible Lewa product manager Jörg Sommer (right), got an idea of how the basic ingredients of water, rapeseed oil, and brine are processed to make spreadable butter. Bertil Holmstedt (left), technician, and Klas Erikson, maintenance team leader at Arla Foods Götene/Sweden, were quite satisfied: "These pumps not only satisfy the strictest of hygienic demands, but also meter very precisely."

In line with the modular principle, different drives were combined, each with two to six pump heads. With the Ecoflow, up to 1320.86 gallons (6 cubic meters) per hour per pump head can be conveyed. The discharge pressure supported can reach up to 500 bar. Depending on the application, for Arla’s pumps the range is up to about 264.17 gallons (1 cubic meter) per hour and 15 bar.

Since the entire production facility runs at a highly automated level for both hygiene and efficiency, the pumps must be able to work nearly maintenance-free, so that the process chain needs to be interrupted as little as possible. "The pumps are in operation about twenty hours a


day, although not all at one time. And they have to work at a reproducible metering accuracy of ±1 percent, says Klas Erikson, maintenance team leader at Arla Foods Götene/Sweden. "The strict requirements for precision and robustness that our application demands have been met by Ecoflow pumps to our complete satisfaction."

DURABLE DIAPHRAGM METERING PUMPS FOR HYGIENIC APPLICATIONS Thanks to the patented DPS Diaphragm Protection System, also used in the Ecoflow series, the diaphragm needs no positioning and the pumps can start reliably from any operating condition. The result is a high level of process reliability and resilience. The special technology permits an absolute suction pressure of up to 0.1 bar. So they keep working reliably even after operating errors or in case of extreme operating conditions, such as high suction pressure or a closed suction line.

Moreover, the pumps also have the advantage that the diaphragm can be changed quickly and easily. Automatic stroke adjustment and additional frequency control of the motor permits the large adjustment range of the pumps be regulated reliably and the entire process can be documented. The concept is extremely well-suited for the traceability of batches and the high quality requirements in today's food industry.

MULTILAYERED DESIGN "Aside from the usual standards for the food industry, we have also made sure that the pumps can easily be cleaned," adds Erikson. Due to its minimal dead space and smooth stainless steel surfaces (1.4571), the entire pump is outstandingly well-suited for the food industry and for CIP cleaning. The hermetically sealed, oscillating diaphragm pumps are used, where high production quality and precise recipe settings must remain consistent over years. Due to their operational reliability and the high metering accuracy, the pump is also used for toxic, environmentally harmful, abrasive, viscous, sensitive, and expensive fluids. The diaphragm monitoring—in combination with the multilayered design of the sandwich diaphragm structure—reliably prevents any contamination of the product.

All components that come into contact with the medium are designed to be suitable for foods. When selecting the materials, Arla paid particular attention to the fact that the seals of the valves must remain elastic even after years of contact with the brine. Since salt has a corrosive effect over time, the

decision was made to use Gylon, a type of Teflon. The diaphragm consists of pure PTFE, which is compatible with biological tissues. Due to the high energy efficiency, low maintenance costs, and long service lifetime of the sandwich diaphragms, the system costs and lifetime costs remain remarkably low. ■


VALVES & CONTROLS solutions

At the most recent WEFTEC trade exposition, YSI, a Xylem brand, showcased their IQ SensorNet continuous monitoring and control system, which

featured in tandem with their Orthophosphate Analyzer as well as a new line of UV-Vis UV Sensors to address water quality in the wastewater market.

The IQ SensorNet is a modular water quality system for a complete sensor network ideal for an assortment of installation needs. The system enables a wastewater treatment plant to monitor every aspect of their process—from pre-sedimentation to the biological tanks to the effluent. A single module can link up to twenty sensors measuring different parameters, from DO and pH to ammonium, turbidity, and temperature.

Also featured at WEFTEC this year was the P 700

Orthophosphate Analyzer, which can be used as a stand-alone analyzer or in conjunction with other sensors in an IQ SensorNet continuous monitoring system. The P 700 measures the amount of orthophosphate (also known as soluble reactive phosphorus and commonly referred to as phosphate) throughout the wastewater treatment process, and the continuous data it provides can help verify

phosphate elimination and improve operational efficiency.

Since phosphorus is the nutrient in short supply in most fresh waters, even a modest increase in phosphorus can, under the right conditions set off a chain of undesirable events in a stream, including accelerated plant growth or algae blooms, and the death of certain fish, invertebrates, and other aquatic animals. The P 700 has proven to be an important tool for

Xylem’s analytics businesses are leading manufacturers of premium field, portable, laboratory and online analytical instruments used in water and wastewater, environmental, food and beverage, pharmaceutical and life science applications. The company’s meters, sensors, analyzers and related consumables are used daily by thousands of end users worldwide. To learn more about YSI visit www.ysi.com. To also learn more about the complete range of analytics products from Xylem, visit www.xylemanalytics.com.

For More Information

By Peter Bornhorst and Patrick Higgins, Xylem Inc.

QUALITYMEETSQUANTITYIn the field and in the lab, YSI measurement tools offer detailed monitoring and control

YSI IQ SensorNet

YSI IQSN Orthophosphate


municipalities aiming to limit the discharge of phosphorus to meet permit requirements and improve operations and costs by cutting treatment chemical volume.

The P 700 can run itself continuously for up to eight months without needing a user calibration or a reagent change. And when networked with other sensors in an IQ SensorNet system, data from the P 700 displays in the network just like any other sensor.

“The IQ SensorNet has been a valuable tool for wastewater facilities across the US,” says Tim Grooms, director of marketing for YSI, “And when you link it up with the Orthophosphate Analyzer, you can really get a complete picture of the water quality process.”

Also, a new line of UV-Vis UV Spectrophotometer Probes from YSI, measuring numerous parameters as part of the IQ SensorNet system, were debuted at WEFTEC. The new sensors are rugged and have built-in ultrasonic cleaning for lower maintenance requirements over the life of the sensor. The new spectral sensors can measure a broad spectrum (256 wavelengths for each measurement) for increased accuracy, and can measure COD, BOD, TOC, Nitrate/Nitrite, and TSS. Single wavelength sensors are also available for UVT-254 and NOx, and there are new variations of FDO and ViSolid sensors for Class 1, Div 2 rated zones (explosion proof).

To address the needs of the wastewater and laboratory markets, YSI also highlighted their TruLab instruments, a complete line of lab instruments ideal for routine and precise measurements of pH, mV, ISE, and temperature for water quality data. Compatible with the TruLab products—or for use with any instrument with a BNC connector—YSI will also launch the TruLine ion-selective electrodes (ISEs), a brand new line of ISE electrodes for the laboratory setting.

According to Grooms, “We think our TruLab line, with its flexibility, stable measurements, and 15 new sensor

options, is going to be another valuable tool for laboratories that need quality measurements of numerous parameter concentrations. And now with the TruLine ISEs, for customers measuring ion concentrations in the wastewater industry, our lab products portfolio is really stronger than ever.”

While the TruLab 1110 is ideal for routine pH/

mV lab measurements where a robust workhorse meter is required, the TruLab 1310 and 1310P (with printer) provides precise lab measurements and automatic Good Laboratory Practice (GLP) documentation, plus a USB interface for data transfer and backup. All TruLab instruments offer auto-buffer recognition plus recalibration prompts. The TruLab 1320 and 1320P (with printer) are two-channel instruments with simultaneous measurement of pH, ISE orORP. The 1320 series logs calibration information for GLP compliance and has a USB interface for data transfer and backup.

In addition, YSI is also introducing the new TruLine ISE electrodes for its TruLab product line.

The wide variety of TruLine sensors—offering fifteen electrodes for sixteen different parameters—are compact in design, available as glass or plastic probe bodies, can be ordered with or without temperature and with a refillable option.

The new TruLine electrodes are proven, highly versatile laboratory electrodes for the most demanding measurements. The glass electrodes include the temperature sensor and can be ordered with a platinum or ground junction. Each pH electrode comes with individual serial number and quality certificate.

Together, the TruLab and the extended line of TruLine ISE electrodes provide laboratories across multiple industries the ability to conduct easy, fast, and highly repeatable measurements. ■

YSI IQSN UV VIS Sensor

YSI ISE Electrodes


SEALING solutions

In this final part of the four-part series, we will examine face-seal options for bearing protection and

provide an example cost justification tabulated for advanced bearing housing protector seals. The reliability advantages and easy cost justification for bearing housing protector seals are widely known, and in the installment, we will provide examples taken from Best-In-Class plants that will benefit process pump users across a range of applications.

FACE-TYPE BEARING PROTECTOR SEALS AND APPLICATION CRITERIA There are a number of face-seal options for bearing protection. Face-type (or face-contacting) seals use springs or, in figure 9, magnets to apply the needed closing force. Although they cost more than rotating labyrinth seals, face-contacting seals are often used in gearbox units. As to their capabilities, a manufacturer of magnetic seals explains aerospace applications and case histories at 300 degrees Fahrenheit (149 degrees Celsius) / 5 psi / 21,000 rpm; 392 degrees Fahrenheit (200 degrees Celsius) / 14.5 psia / 14,407 rpm; at temperatures ranging from 65 to 350 degrees Fahrenheit (18 to 177 degrees Celsius) / 20 psi / 28,018 rpm, and many more. When a hydrodynamic oil film is maintained between the faces, the coefficient of friction can be less than 0.05. The coefficient is normally higher during early periods of

operation when the film and interface are being developed. Once developed, the film helps control wear, reduces frictional heat, and stops bounce, or chatter.

Dual-face magnetic seals (figure 9) were first introduced to process plants in the early 2000s. They have an excellent performance record and hundreds of reliability-focused users have contributed to an impressive reference list. Dual-face

Heinz P. Bloch, P.E., is one of the world’s most recognized experts in machine reliability and has served as a founding member of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME, in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at [email protected].

About The Author

By Heinz P. Bloch, Process Machinery Consulting

How to Cost-justifyBearing HousingProtector Seals Key factors for reliability-focused process pump users

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Figure 9: Dual-face magnetic seal and O-rings (2, 4, 6, 10), snap ring (11), rotating face (1), stationary faces (3), stationary face holder (9), stationary magnets (8), magnet carrier (7), and outer body (5) (source: AESSEAL, Inc., Rotherham, UK, and Rockford, TN).


magnetic seals are typically designed for shaft peripheral velocities approaching 20 m/s, which is within the operating speed of an estimated 99 percent of all centrifugal process pumps. Large gear speed reducers and vertical shaft fan drive shafts often use dual-face magnetic seals.

For maximum life, especially at high speeds, face loads are usually kept low; about 15 psi is typical. Proper cooling and / or lubrication must be provided to remove frictional heat. Lubrication, of course, is present in the overwhelming majority of oil-lubricated bearings in centrifugal pumps, gear speed reducers, and other machines operating in process plants. In the very few instances where bearing lubrication would not reach the adjacent magnetic bearing housing protector seal, it might be wise to question the adequacy of bearing lubrication as well.

DUAL MAGNETIC SEAL EXPERIENCEDual magnetic seal experience is well documented. Serious designers and manufacturers have, since 1971, successfully adapted mechanical seal face technology to bearing protector seals. Manufacturers observing proper face materials and flatness criteria have prospered. Their products have been of service to reliability-focused users. Conversely, manufacturers who years ago tried to cut corners by using lowest cost materials ran into difficulties maintaining seal face flatness. Today, as never before, it is important to seek out and buy products from knowledgeable vendors.

Knowledgeable vendors are found after separating sales talk from facts. We must ask how subassemblies or components really work. We must look at the dimensions and the design criteria. Above all, we should use common sense. The old adage that more parts mean more failures is flatly contradicted by the modern automobile. An engine built in 2014 probably has more parts than an entire automobile built in 1930. Also, a modern aircraft navigational system requires more skill to maintain than many an old compass. Which system would we choose for a modern aircraft? Common sense clearly furnishes the answer: We choose the complex system and employ an experienced maintenance technician.

Modern industry can achieve optimum reliability performance by manufacturing well-designed components for users willing to capitalize on these designs. In reviewing bearing protector seals, potential users must place science-based facts above marketing claims. A business-as-usual approach whereby vendors handing out trinkets are given preference over vendors who dispense technology is at odds with reliability performance and best-practices goals.

Face-type seals can also be used in electric motors as long as they are applied within their respective design envelopes. The dual-face magnetic seal of figure 9 complies with ATEX, the European testing authority for components operating in explosive atmospheres. The European Health & Safety Executive also tested and certified the safe sparking and hazard-related performance of these dual-face magnetic seals.

COST JUSTIFICATION CAN BE QUITE SIMPLESome users are in a position to interrogate their own plant’s failure records to determine lube related failures. While reluctant to publish their experience, consulting engineers often receive informal feedback from such facilities. This

then allowed us to derive a rather direct cost justification sheet for a refinery with 1380 installed process pumps. We start with a logical sequence:

1. Number of pumps installed 1380

2. Number of pumps that had experi-enced repairs in a 12-month period 250

3. Mean-time-between-failure (MTBF) in years (1380 / 250) 5.5

4. Average cost of a pump repair, includ-ing all overhead costs (see reference 1) $12,000

5. Roughly 50 percent of these repair events involved bearing lubrication issues

125

6. Roughly 50 percent of lubrication is-sues are attributed to contamination 62

7. Yearly cost of contamination on this refinery’s pumps (62 * $12,000) $744,000

8. Cost of a superior bearing protector seal $500

9. First year cost of retrofitting bearing protector seals (250 * $500) $125,000


SEALING solutionsBecause Best-In-Class refineries

report an 11-year MTBF, we can assume that in the following year 62 pumps no longer fail every 5.5 years, but fail every 11 years. On each of those 62 pumps, the yearly cost of repairs is no longer $2182 ($12,000/5.5), but $1091 ($12,000/11). The yearly avoided

repair cost per pump is $1091; for 62 pumps we avoid a total of $67,642.

During the next year, the upgraded 250 pumps will have an MTBF of 11 years (achievable per references 1 and 8); the remaining 1130 will have an MTBF of 5.5 years. Therefore, 205 (1130/5.5) of the larger group and 23 (250/11) of the smaller group need

repairs. The total needing repair in year 2 is 228 (205+23). Compared to year 1, there will be 22 (250-228) avoided repairs in year 2. At $12,000 per incident, we will have saved $264,000 (22 * $12,000), but will spend $114,000 ($228 * 500) for retrofitting bearing protector seals to the 228 pumps undergoing repair in year 2.

We would go through identical iterations for the few next years and could readily calculate the value of failure avoidance through such systematic retrofits.

CONSIDER THIS SUMMARYBoth reliability advantages and easy cost justification for bearing housing protector seals are widely known. Numerous articles and at least twelve books deal with the subject. However, marketing-driven and often misleading claims abound in a world where one rarely gets to hear the full story.

Still, reliability-focused best-of-class companies make it their goal to investigate the merits of tradition and the value of advancement. They draw a number of conclusions:

1. Credit belongs to manufacturers for entrepreneurship and for designs that have rightly replaced lip seals in many process plant machinery applications.

2. Many old-style bearing housing seals have serious limitations. These limitations are rooted in the laws of physics and the concepts of lubrication and wear.

3. Reliability-focused users examine both test data and the construction features of cost-competitive products, both old and new. To be relevant, cost must be calculated on the basis of full life cycles. The reliability-focused buyers will then draw their own, fact-based conclusions.

4. Superior designs will (usually) require better installation tools than heavy hammers; also, no process plant tolerating hammer blows on bearings and seals will be profitable in the long run.

5. In the hands of value-conscious engineers and technicians,


advanced rotating labyrinth seals and dual-face magnetic seals have saved process plants hundreds of thousands of dollars.

Observing the work processes and procedures at process plants is as important as examining their stipulated goals and aspirations. We noted a strange paradox: Everyone talks “reliability” but many only pay lip service to the term. To be exact--many managers are driven by short-term goals only. Similarly, some wage personnel have voiced concern that their jobs may be phased out when there are fewer equipment failures, so why cooperate? And while allowing modern components in one’s plant may run counter to some instincts, it doesn’t run counter to logic and experience.

Finally, there is ample evidence that business-as-usual attitudes and procurement decisions based on advertising claims alone will not yield best-in-class performance (see reference 8). True reliability professionals investigate first the facts. They periodically update their knowledge base and when they have the facts, they freely share them with anyone who is teachable. There are even times when engineers and technicians “see the light” before a manager does. When that is the case, consider making your points based on evidence. It is the key to a facility’s long-term productivity and competitiveness. ■

REFERENCES

1. Bloch, H. P. and A.R. Budris, Pump User’s Handbook: Life Extension, 4th Edition, Fairmont Press, Inc.: Lilburn, GA (2013). ISBN 0-88173-720-8.

2. Adams, V., R., Barry Erickson, Bill Needelman, and Michael D. Smith, “Proceedings of the 13th International Pump User’s Symposium,” Texas A&M University, Houston, TX (1996): 71-79.

3. Eschmann,P aul, Ludwig Hasbargen, and Karl Weigand, “Ball and Roller Bearings,” John Wiley & Sons, New York, NY (1985): 183, ISBN 0-471-26283-8.

4. Bloch, H. P.; “Twelve Equipment Reliability Enhancements with 10:1 Payback,” NPRA Paper RMC-05-82, Presented at NPRA Reliability and Maintenance Conference, New Orleans, May 2005.

5. SKF Catalog 140-170, August 1988: 40 (Figure 17).

6. “API-610, Standard for Refinery-Type Centrifugal Pumps,” 8th and later Editions, The American Petroleum Institute, Washington, DC.

7. Derrick, R, W. Martiny, and W. McDonald, “Pulp-Coated Motors: The Effect on Motor Life,”

Engineering Conference Book, TAPPI, Technology Park: Atlanta, GA (1986).

8. Bloch, H. P., Pump Wisdom: Problem Solving for Operators and Specialists, John Wiley & Sons: Hoboken, NJ (2011). ISBN 978-1-118-04123-9.


MODERN PUMPING products

NET IRRIGATEWireRat® 4.0Net Irrigate, a manufacturer of Wireless Agricultural Irrigation Monitoring (WAIM) technology, is excited to announce WireRat® 4.0, an update to its WireRat technology that offers pivot owners new benefits like the ability to self-test the system and increased battery performance. Since its release in 2011, WireRat technology has become the agriculture industry’s best selling alarm solution for copper theft on center pivot irrigation systems and additional agriculture equipment. WireRat technology offers farmers the ability to better protect the valuable copper wire on their pivot irrigation systems and other equipment by immediately sending alerts to your phone when a span cable is cut. The technology works seamlessly with all brands of center pivots and requires no external power. New for the WireRat 4.0 is the ability to self-test by simulating span cable cuts without causing any damage to your equipment. Every month the system will auto-test the copper wire, ensuring the alarm is not compromised during the off season. For more information, visit www.netirrigate.com.

HDI INSTRUMENTSCertif ied HDI 2000P Mud/Standpipe Gauge SystemHDI Instruments LLC, a leading provider of battery-powered, stand-alone gauge systems based in Houston, Texas, today announces the release of the Certified HDI 2000P Mud/Standpipe Gauge System. The electronic platform of the HDI 2000P is the same as the twenty-year, field proven HDI 2000B Panel Gauge, known worldwide for its accuracy, reliability, and safety enhancing properties. In addition to these field proven, stand-alone Gauge Systems, HDI also provides the HDI 9000 Choke Console and the HDI 3200 Mud Gas Separator Monitoring System which incorporate a series of Gauge Systems integrated for the individual rig’s needs. Contact HDI at [email protected] regarding inquiries for the 2000P or other well control products.

MEGGITT SENSING SYSTEMSREF2500 Handheld Shaker

The ReferenceMate portable vibration reference quickly and easily checks operation and set-up of accelerometers and velocity sensors in the field. Ensure confidence in the entire measurement chain before beginning expensive tests and calibration. The highly competitive REF2500 promotes continuous cost savings through affordability and steady equipment performance.

Key features of ReferenceMate:

1. Three user selectable frequencies which work in both peak and RMS mode

2. Easy front panel operation

3. Compatible with sensors weighing up to 250 grams (standard IEPE, triaxial, velocity)

4. Extended battery life

Featured Product Release

For more information, visit the ReferenceMate portable vibration reference source product page at www.wilcoxon.com/referencemate.cfm.

release of the Certified HDI 2000P Mud/Standpipe Gauge System. The electronic platform of the HDI 2000P is the same as the twenty-year, field proven HDI 2000B Panel Gauge, known worldwide for its accuracy, reliability, and safety enhancing properties. In addition to these field proven, stand-alone Gauge Systems, HDI also provides the HDI 9000 Choke Console and the HDI 3200 Mud Gas Separator Monitoring System which incorporate a series of Gauge Systems integrated for the individual rig’s needs. Contact HDI at [email protected] regarding inquiries for the 2000P or other


HAYWARD FLOW CONTROLECP Series Thermoplastic Quarter Turn Electric ActuatorHayward Flow Control announces the addition to our industry leading line of Actuation and Controls of the new ECP Series Thermoplastic Quarter Turn Electric Actuators. The ECP features a GFPP (Glass Filled Polypropylene) housing that provides the actuator superior corrosion resistance and performance in environments and atmospheres where most metal actuators cannot. The ECP Series are available in several sizes for use with Hayward ball- and butterfly valves up through 6”/DN150. Available in torque ranges from 221 in/lbs / 25Nm to 796 in/lbs / 90Nm, all ECP actuators feature a manual override, LED status light and Namur style mounting for solenoids and ISO5211 mounting base. The product line is available in 115/230V and 12/24V voltages, with digital positioner and battery fail safe kits available as options. For more information, call 888.429.4635, email [email protected], or visit www.haywardflowcontrol.com.

BIONOMIC INDUSTRIESSeries 5000 Counter Current Packed Tower ScrubberBionomic Industries, Inc., an industry-leading manufacturer of proven air pollution abatement, product, and heat recovery technologies, has announced availability of their latest concept, the high efficiency Series 5000 Counter Current Packed Tower Scrubber with increased versatility. Series 5000 Packed Towers incorporate Bionomic’s maximum throughput Hi-Flow™ random or structured packing, high efficiency mist eliminator designs, and a variety of clog resistant liquid distribution systems match engineered to more precisely meet specific application requirements. An optional dual packed bed arrangement enables removal of multiple contaminants using different scrubbing reagents within the same unit. For more information, call 201.529.1094, email [email protected], or visit www.bionomicind.com.

GROSCHOPP, INC.Brushlesss DC Gearmotors and ControlsWorking to set the standard for quality in the fractional horsepower motor industry, Groschopp, Inc. introduces a highly reliable, robust, and economical Brushless DC Motor and Control package. Groschopp’s family of brushless DC motors and gearmotors have been tested for pairings with the brushless DC control product line giving engineers a brushless DC motor and control package designed for optimal operation. Groschopp’s brushless DC motors are highly efficient and provide high power density, all in a compact design. The closed loop controls are designed to deliver commutated power and variable speed control, maintaining excellent speed regulation over a wide range of loads. Compact, economical, and efficient, Groschopp’s Brushless DC Motor and Control packages are ideal where high torque, high speed, quiet operation, and low maintenance are needed. For more information, call 800.829.4135 or visit www.groschopp.com.

DEZURIK, INC.APCO ASU Combination Air ValveThe APCO ASU Combination Air Valve is an innovative new concept in air valve technology. This single body combination valve features a patented air release and air/vacuum mechanism that is specifically designed to deal with media containing grit, solids and grease. The unique design provides varied and predictable air flow over a wide range of air release conditions. A large diameter Air/Vacuum Disc provides high volume air flow for rapid venting during pipeline filling and allows high volumes of air to enter the pipeline during draining. During normal pipeline flow conditions, the dual-range air release design prevents air build up and resultant flow restrictions under changing conditions and through the full flow range. For more information, visit www.dezurik.com.


MODERN PUMPING products

SIPOS AKTORIKSIPOS SevenA new electric valve actuator range has been launched by SIPOS Aktorik. The SIPOS Seven series features a number of breakthrough innovations to enhance the flexibility and functionality of actuation technology. Pioneering advancements include large color display, simple ‘joystick’ control and USB interface. SIPOS Seven products include the Ecotron, Profitron and high precision, HiMod. Full Color Display: SIPOS Seven’s large, full color display is a first for an electric actuator. Designed to be easy to read, all essential information is visible and is configurable by the user in a variety of different languages. Simple animations provide step-by-step instructions for actuator set-up and operation, reducing the need for instruction manuals on-site. For more information, visit www.siposseven.com.

AUMAAUMA Support App for AndroidAfter the successful launch of the AUMA Support App for Apple devices earlier this year, the electric actuator manufacturer now announces a new version of the app for Android devices. Designed to make life easier in the field, the app gives engineers on-site rapid access to all device-related documents, including technical data sheets, operation instructions, wiring diagrams and inspection certificates. These documents are made available by simply scanning the name plate of an AUMA actuator using a smartphone or tablet PC connected to the Internet. The actuator is identified by means of a data matrix code on the name plate, and the actuator-specific documents are displayed within a few seconds. Documents can be printed, forwarded via e-mail, or saved on the mobile device. The AUMA Support App for mobile devices using the Android operating system is available free of charge from the Google Play Store. The version for iOS-based devices is available from the Apple Store. For more information, visit www.auma.com.

GTI PREDICTIVE TECHNOLOGY, INC.VibeRMS LTGTI Predictive Technology, Inc., creators of the iPad Vibration Analyzer, unveils VibeRMS LT—the complete, affordable condition documentation solution for iPad. Developed for the iPad, VibeRMS LT is a single channel vibration documentation tool. Users can view live vibration data (velocity, acceleration, displacement) and create reports at the site on the iPad. Reports include machine data, spectrum data, alerts and alarms, user notes and integrated photos from the iPad. The Build Machine function includes templates for common machine types (motors, pumps, fans) and the ability to combine machine types to create machine train templates. Machine templates can also be built on-site using a photograph of the machine. Measurement points are added by the user to complete the template. VibeRMS takes advantage many of the functions included in the iPad like camera functions, touch screen, and instant email of reports. For more information, email [email protected] or call 888.473.9675.

CASHCO, INC.PTR-1 RegulatorThere’s a lot more to the new PTR-1 from Cashco Inc. than an identity based product designation. Formerly known as the T1 valve when the product was acquired with the acquisition of Kaye MacDonald in 1999, the PTR-1, which stands for Pressure Temperature Regulator, now comes with all of the information a customer needs to match the regulator to the application. That includes a technical bulletin, an IOM (installation, operation and maintenance) manual, and assembly drawings for all line sizes and item numbers. The PTR-1 is similar to the recently introduced ULR-1. However, in addition to the CA1 mounted on a DA4 pressure reducing regulator, customers also purchases a Model 135 Low Temperature Probe, which is inserted into the lines they want to control. If the pressure in the line gets too cold, the probe will open and bleed the gas out of the cover dome of the DA4, thus shutting the DA4 off and protecting the downstream apparatus. For more information, call 785.472.4461 or visit www.cashco.com.


YSI, A XYLEM BRAND Pro10 and Pro1020 Handheld MetersExpanding their handheld meter line, Xylem’s YSI brand has introduced the YSI Pro10 and Pro1020 options. Both of these new handhelds are YSI Pro basic meters for the wastewater market, are extremely versatile and rugged—even in the harshest environments—and they will both measure pH and ORP (redox). The Pro1020 will also measure Dissolve Oxygen (DO) to broaden the handheld offering. For more information, visit www.ysi.com/productsdetail.php?Pro1020-103.

METALLIZED CARBON CORPORATION Metcar Bearings for Dry Running at High Temperature Metcar bearings are ideal for use in continuous dryers, high temperature conveyors, kiln cars, and high temperature ventilation dampers. They are also a great choice for other high temperature equipment, including continuous bakery ovens, screw conveyors, valves, and paint dryers. Several Metcar Grades have received FDA approval for use in contact with foods and pharmaceuticals. Metcar bearings for dry running can be provided to customer prints or custom-designed for specific application dimensions and tolerances. Standard pillow blocks and flange blocks with Metcar bearing inserts are available with cast iron, stamped steel, or stamped stainless steel housings. Metcar high temperature bearings are also available shrink-fitted into metal housings or metal retaining rings. For more information, call 914.941.3738 or visit www.metcar.com.

METTLER TOLEDOGPro™ 500 TDL Analyzer Series ExtensionCompact, explosion-proof spectrophotometers with advanced SpectraID™ signal processing are the hallmark of the GPro 500’s design. The analyzer’s ruggedness and small footprint allow installation in the most difficult locations. With the availability of reliable CO TDLs for installation in combustion on fired heaters, package boilers and similar power applications, users can now switch from oxygen-only, fixed-point control to combined oxygen and CO trim control. This can significantly reduce fuel costs and NOx emissions. Building upon the unique probe concept, new process adaptions are available to enable the deployment of Tunable Diode Laser (TDL) technology in measurement locations never previously possible. Further, Mettler Toledo now makes full use of the platform concept of the GPro 500 Series by introducing CO and moisture spectrometers that are freely selectable with any suitable process adaption. For more information on the GPro 500 TDL product line, visit www.mt.com/tdl.

HAMILTON CASTERColossus 200-Ton Toting CasterHamilton Caster is well known for making heavy duty industrial casters—and now, one of the biggest. Hamilton recently designed and built four 100,000-pound capacity casters for a federal contractor. Fully assembled, each caster towers 52 inches above the factory floor and weighs more than 8000 pounds. Together, they represent Hamilton’s highest payload capacity ever: 200 tons. Each Colossus caster was designed with a spring-loaded suspension system to absorb shock. The swivel construction consisted of 32-inch and 18-inch diameter raceways flame hardened to 55-60 HRC with a total of (96) 1-1/2-inch diameter bearing balls. Each caster also featured an eight position swivel lock for directional control, a huge 7-inch diameter oscillating axle to accommodate uneven surfaces, and a foot-operated braking system. For more information, call 800.733.7655 or visit www.hamiltoncaster.com.

with a total of (96) 1-1/2-

position swivel lock for


PUMPING trends

W ith over a century of experience, Louis Allis specializes in

manufacturing industrial electric motors for some of the most demanding applications in the world. Also, under the direction of their president and CEO, Bruce Bailey, Louis Allis employees participate in a variety of philanthropic and charitable causes through a mix of financial donations and service hours every year. As the holiday season approaches, Mr. Bailey took time to share some of his thoughts on giving in general and the specific humanitarian crisis facing refugees in the Syrian conflict. He can be reached at [email protected]. More information about Louis Allis, their products, and their philanthropy can be found at www.louisallis.com.

Modern Pumping Today: For people unfamiliar with the details of the Syrian refugees’ plight, what would you most want them to understand?

Bruce Bailey: It is important to understand the scale of the problem. There are over 1.5 million Syrian refugees in Lebanon alone, and 6.5 million displaced internally. This is a protracted crisis, and refugees have depleted savings and cannot afford rent, food, heating fuel, and have little access to education or health care. The majority live in unfinished buildings and informal tents and huts—many of which are in poor repair and have poor drainage and, thus, are susceptible to flooding and the cold. This is the worst global crisis of our age after the genocide in Rwanda.

MPT: With wide-ranging experience in the water and wastewater fields, how can Louis Allis and similar companies effect the most change where their skills and expertise are needed?

Bruce Bailey: Unless you see the need first hand it’s hard to wrap your mind around just how bad the refugee crisis really is. You cannot imagine living in a tent with three feet of snow on the ground, no running water, no bathrooms, and dirt for floors. Tents are susceptible to flooding and leakage, and settlements have poor drainage and wastewater disposal options.

Also, hundreds of thousands of children were left without education for the last three years, and the ones who still have parents spend their days either begging or hanging around in the camps vulnerable to terrorists’ recruitment. Funding to improve shelters specially now—when winter is approaching—would be most effective. The number one request coming from adult refugees is funding to expand educational efforts. We currently are working toward a school for three hundred children and with plans to expand to two thousand.

MPT: Where do you see the role of “giving back” for people in your industry? What are some ways you integrate this within your corporate culture?

Bruce Bailey: There is no greater joy to be found in this life than helping the orphans, widows, and people living in utter poverty. As the saying goes, it is truly better to give than to receive.

We see giving back as our social responsibility. It’s not really a choice for us it’s who we are. But by the grace of God, any one of us could have easily been born into one of these countries like Syria, Iraq, and Iran where people are in dire need.

We have been blessed with as many resources in this country compared to the rest of the world. There are huge needs in the refugee camps for fresh water and waste disposal. We have the solutions, so all we have to do is deploy assets. ■

The Gift of Doing GoodLouis Allis president, Bruce Bailey, on corporate responsibility

and the rewards of giving back

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PRESSURE & FLOW

The right amount of water pressure and fl ow is critical to protecting pipes, preventing loss of prime and avoiding dead head conditions.

That’s why you need the iQPump®1000 from Yaskawa. The most intelligent pump controller available gives you complete control of your irrigation needs for water land management resulting in lower installation costs, simpler

operations and greater energy savings. The iQPump®1000 can be easily integrated into any pump station, or retrofi tted into an existing system.

When the right amount of pressure and fl ow is critical, call Yaskawa.