ModERn

TodAy
PRoviding SoluTionS foR ThE WoRldWidE PuMP induSTRy

SEPTEMBER 2014

THe FuTure oF

WATER REUSE

Improved
CoolIng Tower
FIlTraTIon
STormwaTer
SoluTIonS
aT work
key FaCTorS For
proTeCTor SealS

CONTENTS
4
10

SEPTEMBER 2014

Industry news
trade show ProfIle
Case studIes

12 Inventive Results Under Pressure

Ultra-high pressure waterjet technology provides powerful and safe downhole casing and pipe cutting solutions

16 Thinking Globally and Acting Locally to Preserve a Natural Wonder

Septic tank replacement using a low pressure sewer system (LPS)
Part 1 in a 3-Part Series

water & wastewater solutIons

12

20 A Material of the Future

New innovations in FRP lightweight composit access covers

24 Recycling Earth's Rapidly Shrinking Resource

A basic primer on how food and beverage plants can reuse water effectively and efficiently
Part 2 in a 3-Part Series

28 A Holistic Approach to Process Control

Providing process improvement and energy savings
Part 2 in a 2-Part Series

MaIntenanCe solutIons

32 Improving Cooling Tower Filtration

The Southern Hemisphere's largest entertainment complex reduces maintenance and treatment costs
Part 1 in a 2-Part Series

38

PuMP solutIons

34 How to Select Diaphragms for AODD Pumps

Asking the right questions and utilizing the best available tools will help AODD pump operators maximize diaphragm life
Part 2 in a 2-Part Series

dewaterIng solutIons

38 California Logistics Center Finds Stormwater Solution

Motor solutIons

40 The New Frontier of Self-Lubricating Solutions

A closer look at the benefits of carbon-graphite solutions across a range of applications

40

www.modernpumpingtoday.com

P.O. Box 660197 | Birmingham, Alabama 35266

Power generatIon
solutIons

@modpumpmag

42 Polish Utilities Adopt Advanced Actuation Solutions

SIPOS projects illustrate the capabilities of actuators

ProCessIng solutIons

46 Fouling and Cleaning Profiles of Filter Membranes

A comparative analysis of four membrane cleaning profiles using Micro-90 Alkaline Cleaning Solution
and Micro A07 Citric Acid Cleaner

ValVes & Controls

solutIons

ruSSell HaddoCk COO/Publisher

[email protected]
JeFF FleTCHer Associate Publisher
[email protected]
randy armISTead Associate Publisher
[email protected]
J. Campbell Editor
[email protected]
donna Campbell Editorial Director
[email protected]
SCoTT gordon Art Director
[email protected]

50 Precise Gas Measurement for Mud Logging Operations

ST100 thermal mass flow meter provides solution for oil and gas upstream production operations

52 Gas and Flame Detectors Protect Portable LNG Vaporizers

Remote drilling sites have a new option to monitor mobile equipment

CHrIS garmon General Manager

[email protected]
lIndey SCoTT Circulation Manager
[email protected]
JamIe wIlleTT Circulation Consultant
IngrId berky Administrative Assistant
nanCy malone National Sales Manager
Tonya brownIng Account Executive

sealIng solutIons

54 How to Cost-justify Bearing Housing Protector Seals

randy moon Account Executive

Key factors for reliability-focused process pump users

Part 1 in a 4-Part Series

58

Modern PuMPIng ProduCts

Featured Product Release: FLUID METERING INC. CeramPump QDX Hazardous Duty Metering Pump

www.highlandspublications.com

312 Lorna Square | Birmingham, Alabama 35216

T: 866.251.1777 | F: 205.824.9796

PuMPIng trends

60 Flexible Manufacturing Means Sustainable Manufacturing

The importance of Industrial and Systems Engineering for manufacturers

TIm garmon
President
larry daugHeTy
Vice President

dennIS daugHeTy
Vice President

EDITORIAL ADVISORY BOARD

Terry Bell

Drives and Motion Solution Engineer

Baldor Electric Company

Heinz P. Bloch, P.E.

Consulting Engineer,
Process Machinery Consulting

Robert G. Havrin
Director of Technology,
Centrisys Corporation

Michael Mancini

Consultant and Trainer,

Mancini Consulting Services

John M. Roach

Engineering Manager
for New Product Development,
Trebor International, Inc.:
A Unit of IDEX

Lisa Riles

Business Development Manager,

Wastewater Pumps
Xylem Inc.: Flygt

Greg Towsley

Director of Regulatory and

Technical Affairs, Grundfos

Trey Walters, P.E.

President, Applied Flow Technology

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

means, electronic or mechanical, including photocopy, recording, or any information
storage-and-retrieval system without permission in writing from the publisher. The
views expressed by those not on the staff of Modern Pumping Today, or who are
not specifically employed by Highlands Publications, Inc., are purely their own. All
Industry News material has either been submitted by the subject company or pulled
directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
[email protected].
For address changes, please contact Lindey Scott:
[email protected]

INDUSTRy news
ROTORK
RECEIVES
LETTER OF
APPRECIATION
FOR ANGOLAS
LATEST FPSO
START-UP

The recent startup of the CLOV

FPSO (Floating
Production,
Storage and
Offloading)
vessel in Angolas
Block 17 offshore
oilfield has
been marked
with a letter of
appreciation to
Rotork from the
leading Korean
engineering
company DSME (Daewoo Shipping and Marine Engineering).
DSME performed the design and construction of the CLOV
FPSO on behalf of Total E and P Angola, with much of the work
carried out in Angola as a part of Totals commitment to increase
local content in its projects. Since 2011, Rotork Fluid Systems
has supplied more than 400 heavy duty CP and GP Range
pneumatic valve actuators on the project. Rotorks professional
performance throughout the duration of the contract and

4 | SEPTEMBER 2014

contribution to the timely start-up has been recognised with the

letter of appreciation.
A total of 34 subsea wells will be tied back to the CLOV
FPSO, which has a processing capacity of 160,000 barrels of
oil a day and a storage capacity of nearly two million barrels.
The Rotork actuators are installed in many areas of the vessels
processing plant, including those parts designed to limit
environmental impact by eliminating flaring under normal
operating conditions, recovering heat from turbine exhaust and
recovering vent gases.
The CLOV FPSO is one of a number of Rotork Fluid Systems
contract successes in Angolas offshore oil industry. These
include over 500 pneumatic actuators which were supplied
for the Pazflor FPSO in Block 17, following similar orders for
the Kizomba A and B FPSOs in Block 15. Rotork pneumatic
and electro-hydraulic valve actuators are also used on Angolas
onshore LNG pipeline network, delivering gas from offshore to
the processing plant at Soyo.

ABB DELIVERS STRONG ORDER GROWTH

AND CASH IN Q2

ABB today reported strong order growth, stable revenues and

a significant increase in cash from operations for the second
quarter of 2014. The lower operational EBITDA margin mainly
reflects ongoing project-related challenges in the Power Systems
(PS) division. Orders of $10.6 billion were 14 percent higher (13
percent on a like-for-like basis) compared with the same quarter
in 2013. Base orders accelerated and large orders grew more
than 70 percent. The positive growth momentum was supported
across all regions.

www.modernpumpingtoday.com

INDUSTRy news
Last October we said that we will drive organic growth
through penetration, innovation and expansion and now we
are delivering results, says ABB chief executive officer Ulrich
Spiesshofer. Our focused actions are paying off and support
overall increased order momentum. In the second quarter we
saw encouraging growth in our two largest markets, the US and
China.
The strong order intake resulted in a positive book-to-bill ratio
of 1.04x. ABB delivered steady revenues of $10.2 billion despite
the lower opening order backlog. Group operational EBITDA was
impacted by a loss in the PS division related to ongoing project
charges in large engineering, procurement and construction
(EPC) projects for offshore wind and solar power generation. New
management has taken strict actions to de-risk the PS portfolio
and adjust capacity. In addition to the exit from the solar EPC
business, ABB is implementing a new business model for offshore
wind EPC. As said previously, PS is likely to weigh on earnings
in the coming quarters," Spiesshofer says. We are driving the PS
turnaround as a top priority and made good progress in lowering
the exposure.
Operational EBITDA margin was stable to higher for the
remaining divisions, excluding the expected dilutive impact of
the Power-One acquisition in Discrete Automation and Motion.
Cash from operations improved by more than 60 percent to $888
million in the quarter.
ABB successfully executed on its announced strategic portfolio
pruning of businesses that have limited synergies with the rest of
the portfolio. Since October last year, we have moved quickly
on our commitment to optimize the portfolio in a value-creating
way and to strengthen the focus on the core, Spiesshofer says.

6 | SEPTEMBER 2014

For the second half of the year we will continue to push

hard on our organic growth initiatives in a mixed market
environment, he says. We will drive our relentless execution
on cash and further step up the momentum on cost savings. We
are confident that our balanced growth and execution initiatives
will yield positive results for our shareholders.

THE BILCO COMPANY

RELEASES NEW
COLT NATURAL
VENTILATION
PRODUCTS CATALOG

The Bilco Company, a

manufacturer of specialty
access products, has
released its new 2014
Colt Natural Ventilation
Products Catalog,
detailing Colts line of
natural ventilation and smoke and fire control products for the
commercial markets. The catalog is available free of charge
by calling 800.366.6530, emailing [email protected] or
downloading it at www.bilco-colt.com.
Bilco partnered with Colt, a United Kingdom-based
manufacturer of smoke and natural ventilation products, earlier
this year and now serves as the companys distributor of natural
ventilation and smoke control products in North America. The
Natural Ventilation Products Catalog features a user-friendly
layout, complete with information on the benefits of and the
products and options available.

www.modernpumpingtoday.com

INDUSTRy news
Natural ventilation is becoming an increasingly important
design strategy for commercial buildings, particularly in GREEN
building design. With careful design, buildings can be cheaper
to maintain and operate and the addition of fresh air and
natural daylight creates a more pleasant and productive working
environment for building occupants. Colts products provide an
innovative and attractive solution for design professionals and
building owners.

PROCO CELEBRATES THIRTY YEARS

Proco Products, Inc. is proudly celebrating

our thirtieth anniversary this year. Since
1984, Proco Products has been dedicated
to providing quality products coupled
with superior customer service. Proco is a
manufacturer of rubber, metal and PTFE expansion joints as well
as the ProFlex Series rubber duckbill check valves. To learn more
about Proco Products, Inc., visit www.procoproducts.com.

PCM GRAPHIC GUIDELINES EVOLVE

TO ACCOMPANY GROWTH

For fifteen years, PCM has evolved in many different areas:

technically, with a lot of innovations proposed to the customers
(the new HyCare and EcoMoineau C pumps are available
in the market since 2012); humanely, PCM has known a large
increase of staff the past few years; and geographically due to
the international expansion. Indeed, PCM is now divided into
four clusters and has more than twenty branches and subsidiaries
worldwide, gathering about 600 employees from 35 different
nationalities (more than 50 employees have been recruited in

8 | SEPTEMBER 2014

2013). PCM continues to evolve to be closer to its customers:

PCM Group Australia Pty Ltd. has opened in April 2013, LLP
PCM Kazahkstan in July 2013 and recently PCM Chile Spa in
April 2014. Also, PCM has decided to change the logo and the
graphic guidelines of the company to accompany the growth of
the Group, continuing to express its dynamism and its innovation
mind.

NEW HARTZELL AIR MOVEMENT SALES

REPRESENTATIVE OFFICE IN ARIZONA
AND NEW MEXICO

Hartzell Air Movement announces that Climatec Engineered

HVAC Solutions is now their new manufacturers sales rep office
in Arizona, New Mexico, and El Paso, Texas. Climatec Engineered
HVAC Solutions has been in business since 1975. Selling Hartzell
industrial fans will be a smooth transition for the rep firm, who
already sells other complementary products such as dampers,
louvers, and air handling equipment.
Senior airside application engineer at Climatec Engineered
HVAC Solutions, Mark Addler states, We are thrilled to join
forces with Hartzell, an established industry leader with a wellengineered, heavy duty group of products. The main markets
in the rep firms territory consists of semiconductor production,
mining, agriculture, and wastewater treatment.
Chuck Abramson, director of sales at Hartzell Air Movement
explains, Climatec is a perfect fit for Arizona and New Mexico.
They already have great relationships with several key customers
through their other product lines, and now with the addition
of Hartzell industrial fans, they will be able to provide their
customers with a complete solution.

www.modernpumpingtoday.com

TRADE SHOW profile

WEFTEC 2014
The worlds largest annual water quality exhibition continues to grow

EFTEC, the Water Environment Federations Annual Technical

Exhibition and Conference, is the largest conference of its
kind in North America and offers water quality professionals
from around the world with the best water quality education and training
available today.
Also recognized as the largest annual water quality exhibition in the
world, the expansive show floor provides unparalleled access to the most
cutting-edge technologies in the field; serves as a forum for domestic and
international business opportunities; and promotes invaluable peer-to-peer
networking between its more than 22,000 attendees.
WEFTEC has shown continual growth for both the technical program and
exhibition. WEFTEC 2013, which was held in Chicago, set new registration
and exhibit floor space records. WEFTEC 2014 is expected to be an equally
successful event.

EXPANDED EXHIBIT FLOOR

WEFTEC 2014 features an improved and expanded exhibitor floor that is

responsive to the requests of WEF members and past attendees. This years
exhibition will be the first to feature a wide range of dynamic learning and
networking opportunities as well as a reimagining of past event favorites.
Stormwater Pavilion: Specially dedicated area on the exhibit floor to
showcase stormwater treatment products and services including a theater
for programming.
Innovation Pavilion: Specially dedicated area on the exhibit floor to
showcase innovative water treatment technologies and programming.
Technical Sessions on the Floor: Access up to 20 technical sessions
on the exhibit floor to stay informed on the latest practices from industry
leading speakers.
Public Official Tours on the Floor: Selected groups of public officials
tour the exhibit floor to learn more about the water and wastewater
industry and how to best represent their constituencies.
Mobile Sessions on the Exhibit Floor: Technical presentations will take
place in several different booths containing related equipment to allow you
to hear details from the experts. Move from booth to booth as a group and
get your questions answered in an educational format. For example, mobile
sessions this year will include topics such as UV disinfection, phosphorus
removal, and decentralized treatment.

WORKSHOPS AND FACILITY TOURS

WEFTEC workshops and facility tours enhance the attendees educational

experience. With more than twenty workshops over two days, attendees
are offered hands-on, interactive courses with subjects covering topics
from wastewater microbiology to management development. Facility tours
offer attendees a technology in practice experience, with the opportunity
to visit active projects, construction, and/or operations at sites within the
local host community.

OPERATIONS CHALLENGE

Operations Challenge is the water quality industrys premier professional

skills competition. Recognizing excellence in wastewater operations, the
five events demonstrate the range of talents possessed by contemporary
water quality practitioners. Operations Challenge exposes participants
to emerging practices and products in a competitive, educational, and
social atmosphere. Participating teams must be endorsed by their Member
Association.
10 | SEPTEMBER 2014

TECHNICAL CONFERENCE
The technical conference,
workshops, and facility tours
aremust-attend educational
opportunities. The technical
conference includes the
following tracks:
Industrial Issues and
Treatment Technology
Municipal Wastewater
Treatment Process and
Design
Residuals and Biosolids
Management
Collection Systems
Stormwater Management
Watershed Resources
Management and
Sustainability
Water Reclamation and
Reuse
And many more.

www.modernpumpingtoday.com

Dont Miss The Top Exhibitors This Year!

Make Your Plans Now and Schedule
an Appointment TODAY!
87th Annual Water Environment Technical Exhibition and Conference
September 29October 1, 2014 New Orleans Morial Convention Center

ADEDGE TECHNOLOGIES
678.835.0052
www.adedgetechnologies.com
Booth # 2058

A.W. CHESTERTON CO.

978.469.6945
www.chesterton.com
Booth # 4363

CORNELL PUMP COMPANY

503.653.0330
www.cornellpump.com
Booth # 5737

ENVIRONMENT ONE CORPORATION

518.346.6161
www.eone.com
Booth # 5117

FLOWWORKS, INC.
888.400.3288
www.flowworks.com
Booth # 2252

FRANKLIN ELECTRIC
717.504.2625
www.franklinwater.com
Booth # 7945

www.modernpumpingtoday.com

GORMAN-RUPP CO.
419.755.1011
www.grpumps.com
Booth # 2528

GRUNDFOS
513.405.4866
www.grundfos.us
Booth # 3429

THE HILLIARD CORPORATION

607.733.7121
www.hilliardcorp.com
Booth # 5159

KSB
804.222.1818
www.ksbusa.com
Booth # 4761

LAKESIDE EQUIPMENT CORPORATION

630.837.5640
www.lakeside-equipment.com
Booth # 4228

PIONEER PUMP
503.266.4115
www.pioneerpump.com
Booth # 2801

PULSAFEEDER, INC.
585.292.8000
www.pulsa.com
Booth # 6329

QUARTZ LAMPS, INC.

484.301.9233
www.qlistore.com
Booth # 7247

SEE WATER, INC.

888.733.9283
www.seewaterinc.com
Booth # 2641

SINGER VALVE
604.594.5404
www.singervalve.com
Booth # 7313

TECHTOP INDUSTRIES
678.436.5540
www.techtopind.com
Booth # 7347

VAF FILTRATION SYSTEMS

303.425.4242
www.vafusa.com
Booth # 2557

SEPTEMBER 2014 | 11

CASE Studies

terjet technology
Ultra-high pressure wa
provides powerful and safe downhole casing
and pipe cutting solutions
By nancy lauseng, Jet Edge

entura Oil Inc., a Minnesota-based waterjet service

contractor to the oil, gas, and mining industries,
has developed a unique downhole casing and pipe
cutting system that can fit inside pipes as small as 2 inch
(51 millimeter) diameter and cut multiple layers of grouted
casing in a single pass with a 55,000 PSI (3800 bar) abrasive
waterjet.

A DISTINCTIVE CHALLENGE

Operable in hazardous environments, Centura Oils CenJet

90 casing and pipe cutting system is designed especially

Four layers of casing were jet cut six inches below the
surface casing at 30.5 feet (9.3 meters). After removing
this section the overcoring bit can be reduced, resulting
in a successful retrieval of the entire string.

for oil, gas and mining applications, including plug and

abandon operations. Its cutting process does not exceed
140 degrees Fahrenheit (60 degrees Celsius), minimizing the
chance of ignition.

A POWERFUL PAIRING

The CenJet 90 is powered by a 55,000 PSI, 200 horsepower

Jet Edge waterjet intensifier pump and features a modified
Jet Edge Permalign abrasivejet cutting head that is coupled
to coiled steel tubing or conventional threaded rods. The
system, which is capable of cutting 16 inch (406 millimeter)

Very small casing sever and slot cut, 300 feet (91 meters)
deep.

The hydraulic cylinders on the drill supporting the cutting

head bled down while cutting causing this spiral effect.

All photos courtesy Centura Oil Inc.

About The Author

Nancy Lauseng is the marketing manager for Jet Edge. For more information about Jet Edge, visit www.jetedge.com or call
800.JET.EDGE (538.3343) or 763.497.8700. For more information about Centura Oil, visit www.centuraoil.com or call
952.545.6431.

12 | SEPTEMBER 2014

www.modernpumpingtoday.com

Left: Various used cutting heads, 4 inch (102 millimeter) OD to less

than 2 inch (51 millimeter) OD.
Above: Jet Edge pump 2000 feet (609.6 meters) below surface in
a mine.

thick steel, is deployed into the pipe

or casing and cuts from the inside. It
can perform cuts up to 300 feet (91
meters) from the surface and can cut at
any angle, horizontal, vertical and even
overhead.
The CenJet 90 uses only 4 gallons
(15 liters) of water and 1 pound (0.45

www.modernpumpingtoday.com

kilograms) of garnet abrasive per minute.

Garnet is a natural stone that can
normally be disposed of in a landfill. The
effluent created by the waterjet cutting
process is circulated to the surface using
formation water, treated water in strata
prone to swelling, or nitrogen for an
explosion-proof environment. The returns

We knew
immediately that
we had a new
product and service
to take back to the
oilfields. We can
now cut at any
angle and fit inside
extremely narrow
pipes. And its
waterjet, so we can
work in hazardous
environments.
Michael Uthe,
Centura Oil
president

SEPTEMBER 2014 | 13

CASE Studies
CenJet 90 system
fits inside 2-inch (51
millimeter) diameter
pipe and cuts multiple
layers of grouted casing
in single pass

and cuttings are handled in accordance

with industry standards.

A FLEXIBLE SOLUTION

Centura Oil originally developed

the CenJet 90 as an environmentally
friendly downhole waterjet cutting
system for stimulating oil and gas well
Jet cutting using polymer enhanced circulation aids in
Three layers of casing cut at 300 feet (91 meters) deep
production at depths of over 4000
carrying returns to the surface.
recovered after overcoring.
feet (1219 meters). It modified the
system for casing and pipe cutting
for a recently completed project at
a uranium mine. During this 2.5 year project, Centura
Centura Oils worldwide services include waterjet
Oil staff worked 2100 feet (640 meters) underground and
well recompletion and production enhancement, well
successfully cut hundreds of pipes and grouted casings at
plug and abandonment, and mobile waterjet cutting. The
distances up to 300 feet (91 meters), many at a 70-degree
company also sells its CenJet 90 systems under a licensing
angle.
agreement.

14 | SEPTEMBER 2014

www.modernpumpingtoday.com

CASE Studies

Thinking Globally and Acting Locally

to Preserve a Natural Wonder
Septic tank replacement using a low pressure sewer system (LPS)
Part 1 of 3
By Wayne Ackart, Town of Jerusalem (new york),
and Clark A. henry and Michael Crowley, Environment one

he Town of Jerusalem, New

York, is a picturesque settlement
blessed with year-round
recreational activities, award-winning
wineries, a portfolio of properties listed
on the National Register of Historic
Places and desirable real estate on the
shores of the glacier-formed Keuka
Lake.
Beneath the surface, however, the
turn of the millennia found failing
septic systems were threatening the
region's scenic landscape. The Keuka
Watershed Improvement Cooperative
(KWIC) verified that deteriorating
septic systems mixed randomly with
a few primitive holding tanks were
compromising the lake's water quality.
The town had required homes to
be scrutinized every five years. If
an existing septic system flunked
inspection, corrections were required
which often included the installation
of a new tank and drain field at a cost
of $20,000 to $30,000 per residence.
In many instances there was not
enough room to put in an up-to-date
replacement.

A PRIME LOCATION

One of the primary reasons why

lakefront homes are sought after in
Jerusalem is the pristine shoreline held
dear by 4500 residents and thousands
of visitors. However, eutrophication
generated by septic seepage and other
sources of nutrient loading frequently

lead to poor water quality resulting in

blooms of aquatic vegetation, algae and
a potential change in the ecological
balance of aquatic habitat.
The town recognized a solution
was needed but its particular situation
presented some challenging site
conditions.
The Y-shaped Keuka Lake is one
of the eleven Finger Lakes, so called
because of their north-south axis in
the west-central region of upstate New
York. Its 11,730-acre surface area
stretches about 20 miles (32 kilometers)
long but from east to west it spans a
narrow half-mile to two miles wide.
Most of Jerusalem's waterways flow
into the lake where Keuka College and
Keuka Lake State Park also reside.
Hundreds of vacation homes
(seasonal occupancy is only
approximately 20-percent full-time
residents) are located very close to the
lake, often on small building lots with
very little room for septic leach fields.
A high water table and ineffective
subsurface drainage means the drain
fields have poor percolation to begin
with, so decline is rapid and inevitable.
The region's geography is gashed by
several gullies and deep ravines that
run down to Keuka Lake; valleys and
rolling hills used primarily as farm land;
and, steep slopes on the waterfront.
It was precisely the natural beauty
and rocky terrain the region prizes
that would make it laborious,

environmentally disruptive and almost

certainly cost-prohibitive to excavate
for conventional gravity sewering.

BUILDING A PLAN

Gravity sewer systems are the original

central sewers with origins in the
Roman aqueducts and are almost as old
as the biblical city of Jerusalem itself.
The bulky systems might require rock
blasting and digging trenches 20 to 30
feet (6.1 to 9.1 meters) deep to install
large mains and lift stations.
When planning began in late 1999,
the town calculated the probable
construction cost for a conventionaltype system was six million dollars,
almost 50-percent more than a $3.2
million low-pressure sewer system (LPS)
also being considered. A decade later,
a top-level summary of project costs
calculated a final tab of $4,080,000
including administrative ($190,000),
technical services ($600,000),
construction ($2,920,000) and
contingency ($370,000).
Community leaders in Jerusalem were
aware of several successful regional
and local LPS installations. The project
team, consisting of representatives from
the Town of Jerusalem; Clough, Harbour
& Associates LLP (CHA); Siewert
Equipment Company; and Environment
One Corporation, investigated these
projects and learned from them.
Over a period of several years the
project team researched the type of

About The Authors

Wayne Ackart, P.E. is town engineer for the Town of Jerusalem. Clark A. Henry is director of engineering at Environment One.
He can be reached at [email protected]. Michael Crowley is LPS system designer at Environment One. For more information
on Environment One Corporations full line of grinder pumps and LPS solutions, visit www.eone.com or call 518.346.6161.

16 | SEPTEMBER 2014

www.modernpumpingtoday.com

sewer system that would best serve

residents. Because of topographical
constraints, the Town determined
that the most economically and
environmentally favorable solution
was to construct a low-pressure sewer
system.

LOW-PRESSURE SEWER SYSTEMS

The town chose E/One because

it has a proven record of successful
installations around lakes with
conditions similar to the Town of
Jerusalem's proposed project. Other
E/One waterfront LPS jobs include
Martha's Vineyard, Baja California
(Mexico), Hawaii, and many lakefront
communities around the United States.

A CLOSER LOOK AT BLUFF POINT

In order for the town's LPS to maximize

its impact, planners chose to site the
project at Bluff Point, which gives
Keuka its distinct Y shape and is one of
the more dramatic lakeside hills in the
Finger Lakes. It provides scenic vistas
from many of its roadways and cottages
along the shore.

LPS technology is a simple, effective

and inexpensive solution which has
been effectively used for more than
forty-five years to collect and convey
wastewater. The technology was
initially adopted in the United States
and Scandinavia and is increasingly
utilized throughout the developed
world. Published case studies of well
implemented and smoothly operating
systems are widely available.
Low-pressure sewer systems begin at
a grinder pump station installed at each
residence, which accepts wastewater,
grinds its contents into fine slurry and
transports it through small-diameter, 2to 4-inch (51 to 102 millimeters) PVC
pipes buried just beneath the frost line
to roadside force mains or treatment
facility.
The proposed LPS for the Town of
Jerusalem eliminated the need for 12
lift stations with a total cost savings
of $900,000. Nor did it require a rock
excavation outlay pegged at $775,000.
Unlike conventional gravity central
sewers, which use up to 24-inch (610
millimeter) pipe and require deep
excavation, an LPS system is not
destructive to the landscape's natural
or built features and requires less
maintenance.

THE ROLE OF GRINDER PUMPS

The grinder pump manufactured by

E/One is a self-contained unit barely
bigger than a washing machine with
a one horsepower motor, controls
and level-sensing built into a single
unit. It is activated automatically and
runs for very short periods. Electrical
consumption of the grinder pump is
lowa household that uses 250 gallons
(946 liters) of water per day should
consume less than 10 kilowatt-hours
per month to run the pump.
E/One has assembled more
than 500,000 grinder pumps at its
Niskayuna, New York, headquarters. Its
pumps comprise the largest installed
base of pressure sewers in the world
and E/One alone provides LPS service
to more than one million people
worldwide.
www.modernpumpingtoday.com

SEPTEMBER 2014 | 17

CASE Studies
Most of the residences are located
lakeside on East Bluff Drive and are
below the road elevation. The lakeshore
elevation of 715 feet (218 meters) is
on average 25 feet (7.6 meters) below
the centerline of the road. Toward the
north end of the district, the road is 50
feet (15.2 meters) or more above the
lakeshore elevation. Most residents
would be required to have a sewage
pump to pump up to a gravity sewer
located under the road.
A gravity system to service these farflung residences distributed on roller
coaster elevations was not feasible. With
LPS, the wastewater discharged from the
grinder pumps can be propelled uphill
from the homes, through diverse ground
challenges and even around contours.
It is effective for distances at more
than a mile from force mains or water
treatment facility.
E/One, the town determined, was the
only manufacturer offering a proven
semi-positive displacement type grinder
pump able to perform under higher
head conditions present in this project.
Unlike centrifugal pumps, the E/One
grinder pump produces a nearly
constant discharge rate over a wide
range of head conditions, including
negative head.
The project plan plotted a 5.5mile (8.9 kilometers) long LPS that
discharged into a manhole and flowed
to an existing treatment facility in the
neighboring Village of Penn Yan. An
agreement was reached between the
two municipalities that the Town of
Jerusalem would pay Penn Yan based
on the anticipated flows the new LPS
system would be discharging into the
treatment plant.
The town decided it would own
and operate the new system. The
homeowners only responsibility
would be to provide electrical
power (estimated at $24 annually) to
operate the grinder pumps. The Town
utilized blanket property easements
so it possessed the flexibility to locate
the grinder pump stations wherever
necessary on the small rocky building
plots.

ENVIRONMENTALLY-FRIENDLY
INSTALLATION

As with thousands of other installations,

E/One's grinder pumps were set in
the footprint of the propertys septic
tank or just adjacent to it making the
installations far less environmentally
disruptive to private landscapes.
18 | SEPTEMBER 2014

www.modernpumpingtoday.com

The equipment included the

following:
29,000 LF of force main pipe
30,000 LF of pressurized lateral
pipe
265 E/One Series 2000 grinder
pump stations and alarm panels
265 check valves and curb (shut
off) valves
25 concrete vaults for flushing
connections and air relief valves
25 flushing connections
5 air release valve stations
1 bioxide feed odor control
system
Because of the seasonal occupancy
of most town residents, three
informational community meetings
were held on Memorial Day, the
Fourth of July and Labor Day of 2000.
A referendum regarding the project
was voted on during a meeting
held on Memorial Day of 2001. The
referendum passed by a three-to-one
margin.

A LOOK AHEAD

A decade after the installation was

complete, the Town of Jerusalem
and E/One decided to revisit the
project. Parts Two and Three of this
article provide a ten-year (20032013) review of Operation and
Maintenance (O&M) data and a
hydraulic performance analysis
comparing expected design flows
to quantitatively measured flows for
the 265-unit septic tank replacement
project.

Follow us on

Twitter

REFERENCES
1. Goncz, Daniel J., Pressure Sewer System
Design, Construction and Operation
History at Lake Latonka, Mercer County,
Pennsylvania, June 2010.

@ModPumpMag

2. Albro, Henry S., Ownership of Pressure

Sewer Systems, with key contributions
from the towns of Chelmsford and Marion,
Massachusetts.
3. EPA R2-72-091 November 1972, A
Pressure Sewer System Demonstration.
4. Wastewater Collection System Modeling
& Design, First Edition, Haestad, Walski,
Barnard, Harold, Merritt, Walker &
Whitman, 2004.
5. Water Environment Federation (WEF)
Alternative Sewer Systems, Second
Edition, Manual of Practice FD-12, 2008.
6. Submersible Sewage Pumping Systems
(SWPA) Handbook, Fourth Edition, SWPA
2012.

www.modernpumpingtoday.com

SEPTEMBER 2014 | 19

WATER & WASTEWATER solutions

A Material of the

Future

New innovations
in FRP
lightweight
composite
access covers

By Jo Stott, fibrelite

oday
composite
materials
are used in wind
energy, marine,
construction,
aerospace,
military and
defense,
automotive, pipes,
access covers,
tanks and many
more applications.
Composites offer
several advantages
over traditional
materials: higher
tensile strength,
lighter weight,
greater corrosion
resistance, no
re-sale value (so
wont be stolen),
better surface
finish and easier
processing.
US-based
manufacturer
Fibrelite has seen
a tremendous
increase in
inquiries for
their lightweight
composite access covers from industries keen to move away
from the traditionally used metal and concrete and change
specifications to composites (a future material).

CORROSION RESISTANCE

According to a study by the National Association of

Corrosion Engineers (NACE), the direct cost of infrastructure
corrosion was over $22 billion in 2002 in the United States
alone. Adjusted for inflation, the direct cost of corrosion

in 2013 was
estimated to be
over $42 billion
on an annual
basis. It has been
estimated that
at least 25 to 30
percent of annual
corrosion costs
could be saved if
optimal corrosion
management
practices were
employed.
Fiber reinforced
plastic (FRP)
products are now
being widely used
for applications
where corrosion
can destroy
underground
infrastructure.
Perhaps the prime
reason for using
FRP products
is because of
their inherent
corrosion
resistance.
The corrosion
resistance of FRP
is a function of
both the molding technology and the specific resin used
in the laminate. Today, various resin systems are available
which can provide long-term resistance to almost every
chemical and temperature environment.
One application in which FRP is being widely adopted
worldwide and changing specifications away from metal
is with manhole access and service trench covers. By
helping to reduce the costs of corrosion, composite covers
can allow utilities and other operators of underground

About The Author

Jo Stott is the marketing director for Fibrelite. Technical experts from Fibrelite will be on hand at this years WEFTEC to
demonstrate new product innovations at Stand 7913, Hall 11. For more information, visit www.fibrelite.com.

20 | SEPTEMBER 2014

www.modernpumpingtoday.com

infrastructure to improve the financial

strength of their enterprises.

TRIED AND TRUSTED

Founded on a tradition of quality and

innovation, Fibrelite has been at the
forefront of composite technology
since 1980. The first ever composite
manhole cover was designed by
Fibrelite for gas stations, to eliminate
health and safety issues associated
with traditional metal covers. Today,
Fibrelite is established as a leading
world player in its specialist field,
with a global reputation for high
quality products.

ERGONOMIC DESIGN:
HEALTH AND SAFETY FRIENDLY

With recent statistics attributing over

half of injuries (resulting in absence
from work) to manual handling its
already known that reducing hazards
in this area is a priority on a global
scale. Because of legislation restricting
acceptable manual handling weights,
we are seeing a global trend towards
lighter weight FRP composite manhole
and access covers, which also have
the benefits of ease of handling.
Lightweight composite covers
that provide safe and easy access
eliminating unsafe manual handling
issues are replacing aging concrete
and heavy cast iron access covers
all over the world. By using lighter
materials, operational injuries are
prevented, work sites are made
safer and ease of installation and
maintenance is made available to
utility workers and contractors.
The design of these lightweight
covers incorporates up to two lifting
points for specially designed lifting
handles. These allow the operator to
remove the cover without trapping
fingers or bending over thus
maximizing the safety of the lifting
technique. The weight is kept close to
the body preventing back injury; one
of the main causes of absence from
work and personal injury claims.
www.modernpumpingtoday.com

SEPTEMBER 2014 | 21

WATER & WASTEWATER solutions

CUSTOMIZED,
COLORED COVERS FOR
IDENTIFICATION

In response to customer
demand, Fibrelite now
offers company logos and
other brand markings on
its covers. Any style logo
or other marking can be
permanently molded into
the upper surface of the
cover in single or multiple
colors. For additional brand
or product identification,
or to blend in with the
color or layout of a facility,
Fibrelite can mold its
composite covers in nearly
any color or combination of
colors.

22 | SEPTEMBER 2014

By introducing the
pigment directly into the
resin system during the
molding process, Fibrelite
ensures that the color is
not merely applied on
the surface of the cover.
Instead, the coloring is
evenly and completely
infused throughout the
composite cover and will
not fade or wear over time.
Customers have utilized
Fibrelites molded marking
and coloring process to
identify underground
systems in a unique and
highly visible way. Color
can also be used as a quick
and reliable method of

identifying underground
systems, thereby
providing maintenance
or emergency personnel
with more accurate
information about any
hazards or special
conditions related
to the underground
infrastructure.

NO METAL, NO THEFT
The metal theft epidemic
is not going away. There
are few industries that
can hide from the thieves
and the water industry
is still being severely
affected. Cast iron and
steel manhole covers and

www.modernpumpingtoday.com

drainage grates are routinely

stolen for the scrap value of
the metal cover or grate.
And while the financial
cost of replacement is quite
high, the thefts also lead
to open manholes which
create significant hazards.
Composite covers can solve
this problem as the fiberglass
material used has no
inherent scrap value. With
the inability to melt down
composite covers into quick
cash at the junk yard; there
is no incentive for thieves to
steal the covers in the first
place.

NO MORE WET, WORN

AND SLIPPERY METAL COVERS

FRP composite manhole covers are ideal for problem areas,

particularly those prone to skid related accidents. Traditional
cast iron covers quickly become polished and therefore
provide a poor level of grip which can lead to serious
accidents through increased risk of skidding and slipping,
even more so when wet.
Fibrelites covers incorporate a molded anti-slip tread
pattern equivalent to a modern high grade road surface. In
fact, Fibrelites anti-slip/skid surface is guaranteed for the

www.modernpumpingtoday.com

life of the cover providing

a Polished Skid Resistance
Value PSRV60> when
wet which exceeds the
requirements of HA 104/09,
part 5, for potentially high
risk sites, says David
Holmes, technical director
and head of product
innovation.

HIGHLY ENGINEERED

Fibrelite's access covers

are lightweight, durable
and very strong. They are
manufactured using hightechnology Resin Transfer
Molding (RTM) production
methods to create a highly
engineered, monolithic
composite product. This offers the best strength to weight
ratio in the industry, allowing for maximum load bearing
strength and durability while remaining lightweight and
easy to handle. Fibrelites standard manhole covers also
offer watertight solutions in a wide range of sizes and
shapes.
Fibrelites comprehensive range of FRP composite trench
covers are perfect for covering large areas, gullies, trenches
and ducts where occasional or frequent access may be
required. In fact, custom sizes are also available.

SEPTEMBER 2014 | 23

WATER & WASTEWATER solutions

Recycling Earths
Rapidly Shrinking
Resource
A basic primer on how food and beverage plants
can reuse water effectively and efficiently
Part 2 in a 3-Part series
By nate Maguire, greg Claffey, and Keel Robinson, Xylem

n the first part of this series,

we examined some of the
benefits of reusing wastewater,
especially as it relates to food and
beverage processing, as well as
guidelines for identifying the right
treatment options for a specific
need. Well continue that focus in
this installment. When a facility
is looking to apply an advanced

treatment process, they can be

broken down into two categories:
biological and disinfection.

BIOLOGICAL TREATMENT

Under biological treatment there

are two subcategories: Sequencing
Batch Reactor (SBR) and Membrane
Bio Reactor (MBR). Generally, SBR
will have lower capital requirements

than MBR, but MBR systems will

cost less to operate. They combine
biological treatment with membrane
filtration to provide a high quality
effluent, meet stringent nutrient limits
for phosphorus and nitrogen, and
have a smaller footprint compared to
SBR technology. For a more detailed
comparison of SBR to MBR, refer to
Table 2.

SBR Versus MBR Cost-Benefit Analysis

Category

Sequencing Batch Reactor (SBR)

Membrane Bio Reactor (MBR)

Footprint

Large

Medium to small

Installation Costs

Higher

Lower

Operating Costs

Lower operation and maintenance costs

Higher operation and maintenance cost

Other

Requires pre-treatment for

reuse applications

Can be customized depending on

wastewater composition

Table 2: SBR versus MBR cost-benefit analysis

About The Authors

Nate Maguire is the Americas business unit director, industry, and agriculture for Xylem's applied water systems business
unit; Greg Claffey is Xylems director of treatment sales, North America; and Keel Robinson is Xylems North America
reuse marketing and business development manager. Xylems well-known global brands provide world-class products,
comprehensive solutions, and unmatched applications expertise in more than 150 countries. To implement a water reuse
system in your facility, visit www.xyleminc.com/food.

24 | SEPTEMBER 2014

www.modernpumpingtoday.com

Disinfection Technologies Cost-Benefit Analysis

Category

Chlorine

UV

Ozone

Footprint

Large

Small

Medium

Installation Costs

Low

Medium

High

Operating Costs

Low to medium

Average to high

Average to high

Other

Requires the intensive use of

chemicals

Energy intensive but no

chemical

Requires additional mixing

processes

Table 3: Disinfection technologies cost-benefit analysis

DISINFECTION

Under disinfection treatment there are

three categories: chlorine, ultraviolet
(UV), and ozone. The most basic
form is chlorine disinfection. In this
treatment type, water is filtered with
hypochlorite to generate chlorine
residual that inactivates pathogens
such as bacteria.
UV technologies are chemicalfree and require less contact time
than chlorine disinfection. In these
systems, water is channeled through
a reactor that emits UV light at
low wavelengths to destroy the
DNA structures of microorganisms,

www.modernpumpingtoday.com

including bacteria, viruses, yeasts

and molds. Virtually any liquid can
be used with this technology, so it is
often found in beverage-processing
plants; however, UV is sensitive
to the clarity of the water. Higher
clarity water requires less energy to
treat, and, as a result, pretreatment
of wastewater is common in systems
where UV disinfection is used.
Ozone and Advanced Oxidation
Processes (AOP) are powerful
oxidation treatment technologies
that generate hydroxyl radicals,
the strongest oxidant used in
water treatment. AOP is an ideal

disinfection approach to treat

recalcitrant contaminants that are
otherwise not removed by other
technologies. AOP and ozone
technologies are commonly coupled
with other filtration technologies.
Table 3 outlines a cost-benefit
analysis of common disinfection
technologies.
In addition to the biological and
disinfection techniques presented
above, there are other advanced
treatment technologies that can
be used either separately or in
conjunction to fulfill wastewater
discharge requirements.

SEPTEMBER 2014 | 25

WATER & WASTEWATER solutions

Types of Filtration
lgG
Na

Insulin

Ions

NSA

Proteins

Smallest
visible
particle

HIV
Hepatitis C

B. dininuta

Viruses

Bacteria

Pollens
Fibrous Media

Membranes
RO/NF

0.0001

UF

0.001

MF

0.01

0.1

P/F

10

100

h
Particle Size ( m)

RO/NF = Reverse Osmosis

UF

= Ultrafiltration

MF

P/F

= Microfiltration

= Particle Filtration

Table 4: Types of filtration

MEMBRANES

Membrane filtration, using technologies such as

microfiltration and ultrafiltration, provides suspended solids
removal found in the processing of foods and beverages.
These technologies can remove some pathogens, viruses
and bacteria. See Table 4 for a breakdown of filtration
types.

REVERSE OSMOSIS (RO)

In reverse osmosis, salts and many dissolved organics

are removed through a semi-permeable membrane.
RO is used when the highest quality reuse water
is needed, such as high-pressure boiler feedwater
or any use where low salt and contaminant levels
are required. RO can be expensive and generate
a concentrated brine waste stream that must be
managed via proper disposal.

A LOOK AHEAD: PUMPING SYSTEMS

Treating water is only the first step to ensuring

wastewater is recycled and reused efficiently
and effectively within a plant. It is important for
organizations to also consider the transportation and
storage of water reuse. Pumps serve two purposes in
a reuse system: transporting and pressure boosting. In
the conclusion to this series, well address the keys
for selecting the right pump, implementing a water
reuse system, and ensuring standards for sustainability
and safety.

REFERENCES
1. Shiklomanov, Igor. World Fresh Water Resources. Water in
Crisis: A Guide to the Worlds Fresh Water Resources.Ed. Peter
H. Gleick. 1993. Print.
2. The Water Resources Group. Background, Impact and the Way
Forward. Rep. 26 Jan. 2012. 16. Web.
3. EMD Millipore. Filtration Basics. Millipore Membranes and
Filtration. Web.
4. United States. Environmental Protection Agency. 2012
Guidelines for Water Reuse. Sept. 2012. Web.
5. The Coca-Cola Company. 2012/2013 GRI Report Water
Stewardship. Rep. Web.

26 | SEPTEMBER 2014

www.modernpumpingtoday.com

WATER & WASTEWATER solutions

A Holistic Approach
to Process Control
Providing Process Improvement
and Energy Savings

Part 2 of 2
By Tilo Stahl, BioChem Technology, inc., and frank diScuillo Jr.,
City of lebanon Authority Wastewater Treatment Plant

n part one of this two part series, we introduced the

City of Lebanon (PA) Authority Wastewater Treatment
Plant (WWTP) and described the objectives and the
challenges associated with integrating the controls of
a complex biological nutrient removal system. We also
described the core elements of the control system that was
installed: the BACS aeration control system and the BIOS
nitrogen controller. In part two we will describe the start-up
and operation of the holistic controls and show how they
contribute to the overall success of the plant.

EXAMINING THE RESULTS

In the first phase of the system start-up the BACS aeration

control portion of the control system was tuned while the
BIOS process control remained switched off.
Good control of the blowers is critical to controlling
aeration, and this was achieved in close cooperation with
the blower manufacturer. Blowers are typically controlled
to maintain a constant pressure rather than a specified flow
rate, so the master controls of the single-stage centrifugal
blowers used at the Lebanon plant had to be reprogrammed
for this application. In the end, the blowers could reliably
and repeatably achieve flow rates within 1 percent or 25
scfm of the set point. The transition phase when blowers are
switched on or off to meet changing demands was also well
managed by the blower master controls.
The aeration control was tuned to limit set point changes
to a pace that the blowers can match, to ensure fastest
possible system response to loading changes without
instability.
The aeration control logic also opens and closes air flow
valves (in this case butterfly valves with modulating duty
actuators, as is common in WWTPs) to distribute the air

to the control zones according to the calculated needs of

the respective zones. It uses a dynamic most-open-valve
(MOV) logic so that the blowers always operate at the lowest
possible system pressure, which minimizes aeration energy.
In the case of Lebanon, this means whenever the swing
zones are aerated, the MOV is on one of the swing zones,
because these zones, with fine bubble diffusion, will have
a higher restriction than the IFAS zones with their coarse
bubble diffusers. When the swing zones are not aerated,
their valves will close and the MOV will move to one of
the IFAS zones. At the same time, the system pressure will
drop from about 7.55 psi with aerated swing zones to about
6.75 psi when only the IFAS zones are aerated. This requires
that the transition conditions be well managed to prevent
pressure oscillations and resulting instability. The interaction
between the blower master control and the aeration control
was tuned to achieve this without disturbances.

DISSOLVED OXYGEN COMPARISONS

Figure 6 shows the dissolved oxygen (DO) set points and

actual DO in the swing zones and IFAS zones through a
complete on-off-on cycle of aerating the swing zones, with
a corresponding reduction and increase in the DO set points
of the IFS zones. You can see that the DO set points slowly
ramp down to ensure stable operation, and the actual DO
tracks well with only minimal lag. The header pressure also
stabilizes quickly at the respective system pressure.
Using the fan law for constant diameter impeller fans:
Q1/Q2 = (RPM1/RPM2);
P1/P2 = (RPM1/RPM2)2;
PWR1/PWR2 = (RPM1/RPM2)3

About The Authors

Tilo Stahl, PhD is a systems engineer at BioChem Technology, Inc., and Frank DiScuillo Jr. is the superintendent of the Lebanon
(Pennsylvania) Authority Wastewater Treatment Facility. BioChem Technology specializes in the monitoring, optimization, and
control of wastewater treatment processes. For more information, visit www.biochemtech.com. The consulting engineer and
process designer on the project was K. Friedrich Updegraff, vice president at Gannett Fleming, Camp Hill, Pennsylvania.

28 | SEPTEMBER 2014

www.modernpumpingtoday.com

at equal flow Q1 = Q2, you

find that at P1 = 7.55 psi and P2
= 6.75 psi
3

PWR2/PWR1 = (6.75/7.55) /2=

0.845
Therefore, at the lower pressure
the blowers are drawing 15.5
percent less power. This adds up
to a significant cost and energy
savings over the life of the plant.

THE FUNCTION OF THE BIOS

The BIOS process control part of
the integrated controls concept
was started up after the aeration
controls were tuned and proved to
be stable.
The function of the BIOS is to:

1. determine the precise amount

of aeration required to
achieve the process goals,
which includes calculating
the optimal DO set points
in all aeration zones and
aerating the swing zones
Figure 6: Dissolved oxygen (DO) set points and actual DO in swing zones and IFAS zones
whenever the aerobic
capacity is needed
2. control the internal recycle
rate to maximize denitrification in the first anoxic zone
without overloading the system
3. control the trickling filter bypass to add carbon to the
first anoxic zone whenever it is carbon deficient.
Figure 7 shows the performance of the integrated BIOS
and BACS over a 36 hour period. It shows how the BIOS
reacts to the changing load, as represented by the influent
ammonium concentration, by adjusting the DO set points of
the IFAS zones and switching the swing zones between a DO
of 0.0 (off) under low loading conditions and 3.0 (on) when
the ammonia levels are higher. Since the BIOS calculates
the reaction rates (ammonia removal rates) as a function of
temperature, biomass, hydraulic retention time, residual DO
levels and other factors, the switch point for the swing zones
is variable. It is not sufficient to simply select an ammonium
level at which to switch the swing zones between aerated
and anoxic.
Over the described period the swing zones are aerated for
75 percent of the time, so the aeration savings based on the
most-open-valve logic alone add up to about 4 percent. The
DO set point control adds about another 15 percent savings,
for a total of 19 percent aeration energy savings. Since the
aeration blowers are by far the largest energy consumers in
any wastewater treatment plant, typically making up 50 to 70
percent of total energy usage, this is a significant contribution
to both the sustainability and the cost structure of the plant.
The BIOS also controls the mixed liquor recycle flow
(IMLR) and the trickling filter bypass flow to improve
denitrification performance and total nitrogen removal.
Figure 8 shows the response of the BIOS to changing nitrate
levels in the effluent flow.
www.modernpumpingtoday.com

SEPTEMBER 2014 | 29

WATER & WASTEWATER solutions

The goal is to load the anoxic zone
with the highest possible level of
nitrates that can be processed under
the given conditions, and introduce
the precise amount of carbon via the
trickling filter bypass that is needed
to process the nitrates. It can be seen
in the graph that as the nitrates drop
below a set point of 2.5 mg/l the
IMLR increases to increase the nitrate
loading, and the bypass increases to
add additional carbon. As soon as the
effluent nitrate exceeds the target the
IMLR decreases. At the same time the
bypass flow drops when the nitrate
readings drop below the set point and
increase when the nitrates start to
climb, but the bypass flow continues
to add carbon to treat the increased
nitrate levels even after the IMLR
drops. The bypass flow decreases
whenever the nitrate levels drop
below the set point.
With these control systems, the
plant is consistently meeting its
process goals.

Figure 7: Performance of the integrated BIOS and BACS

SUMMARY

The City of Lebanon Authority

Wastewater Treatment Plant was
tasked with achieving stricter
nutrient removal limits without
physically expanding the plant. An
additional objective was to improve
the sustainability of the plant by
minimizing energy consumption.
To support this goal it introduced
a holistic process control system
to optimize the operation of the
secondary treatment, which consists
of an IFAS system with anoxic swing
zones.
The control system integrates the
control of the blowers, the airflow
valves, the mixed liquor recycle
rate and a trickling filter bypass. The
controller demonstrated that it can
consistently and reliably meet the
process goals and provides aeration
energy savings of about 19 percent
over static control systems.

30 | SEPTEMBER 2014

Figure 8

www.modernpumpingtoday.com

MAINTENANCE solutions

Improving Cooling Tower Filtration

The Southern Hemispheres largest entertainment complex reduces maintenance and treatment costs

Part 1 of 2

By glenn dobbs, vAf filtration Systems, and Roy Mcdougall,

hydrochem Water Treatment Systems

eeping an open recirculation

cooling water system clean
accomplished three crucial
operational goals and a fourth
overriding goal for sustainability:
1. Assists in maintaining heat transfer
efficiency0.025 millimeters
of fouling equates to 10 percent
reduction in cooling efficiencies
(see reference 1),
2. Reduces maintenance costs, and
3. Enhances the effectiveness of the
water treatment program, which
4. All contribute to reduced costs
and increased cooling tower
system life.
Open systems are prone to fouling
from airborne contaminants, water
borne contaminants and contaminants
associated with a process. Air contains
dust, dirt, organic matter, insects,
microbiological organisms and gasses.
Make-up water can contain a variety
of dissolved salts, suspended solids
and microbiological organisms.
Systems can also produce suspended
solids from within due to corrosion,
scale and microbiological growth.
Filtration is commonly employed
to remove these contaminants from
the water and improve the circulating
water quality. Centrifugal sand
separators (which are not considered
filters), deep bed media filters, and
automatic screen filters all offer
varying effectiveness in the way each
technology actually removes material
from the circulating water. Each of
these technologies also differs in their
respective benefits and associated
costs. Filtration, separation and

Figure 1: The deep bed sand media installation

other water cleaning systems can

be either in-line or side stream, and
basin cleaning systems can enhance
contaminant removal. Understanding
these technologies and their
differences are necessary for proper
technology selection.

CASE STUDY

The following case study describes one

end-users experience with multiple
filtration technologies and their
inherent advantages and disadvantages
in their cooling tower systems. In
part 1, well examine deep bed and
sand media systems. In next months

conclusion, well take a closer look

at centrifugal sand separators, piston
operated self-cleaning screen filters,
and finallywhat is becoming the
technology of choice for cooling tower
filtration applicationsautomatic selfcleaning screen filters.
A patented self-cleaning screen
filtration technology was supplied by
VAF Filtration Systems from the USA
and was installed and commissioned
by Hydrochem of Australia in 2013
at a major entertainment complex in
Australia. VAF's V-Series filters were
supplied to replace three other types
of filtration technologies serving ten

About The Authors

Glenn Dobbs is president of VAF Filtration Systems, Arvada, Colorado, and has developed the company into providing stateof-the-art self-cleaning screen filtration products worldwide removing suspended solids down to 10 micron. Roy McDougall
is senior projects manager for Hydrochem of Australia and has provided cooling tower treatment services including filtration
for more than thirty years. For more information, visit www.vafusa.com.

32 | SEPTEMBER 2014

www.modernpumpingtoday.com

Opened

Closed

Closed

Opened

Filtering Mode

Closed

Opened

Opened

Closed

Flushing Mode
Figure 2: Typical sand media configuration

individual cooling tower systems.

The older filtration technologies were
not meeting the end-users strict Key
Performance Indicators for cleanliness,
and subsequently the cooling systems
required an unacceptably high
frequency of manual cleaning. So the
end-user chose to install a newer filter
technology to minimize problems
associated with the older technologies.
The replaced technologies included
deep bed media, centrifugal separators
and piston operated self-cleaning
screen filters. The following describes
each installation, the technologies
installed and the end-user's
experiences with each.

DEEP BED MEDIA FILTRATION

One hotel building in the complex

has a cooling plant consisting of four
common cooling towers with 7925
gallons (30,000 liters) total system
volume. These were originally fitted
with six deep bed media filter units
that operated for approximately two
years. In that time the deep bed media
systems maintained the cooling towers
in a clean state; however, they were
found to require very large amounts of
water for backflushing which caused
the cooling tower system to lose the
majority of chemical treatment every
time the filters were backflushed. The
www.modernpumpingtoday.com

media filters were then reconfigured

to utilize two filters per week on a
rotating basis to minimize the water
losses.
However excessive water loss
through backflushing was still found to
be a problem. In addition to the water
loss, a number of the media vessels
control valves failed and allowed large
volumes of media into the cooling
system damaging the chiller system's
VSD's (variable speed drives) and
fouling the condensers. Also, the
required periodic replacement of
media was very expensive.
The media filters were replaced
with two VAF V-250 filters which are
operating well maintaining the cooling
tower basins in a clean state while
removing the residual media from the
system.
Deep bed or sand media filters
typically require a relatively large
volume of water to backflush the
media of contaminant trapped
within. With a sand media system
that requires 1,200 liters of waste to
backflush, the equivalent size of VAF's
self-cleaning screen filter uses only 30
liters to backflush. Backflushing sand
media takes full flow for at least three
to five minutes, and the tank being
flushed must be completely off line
during the backflush process.

SAND MEDIA

Sand media can remove most

particulate that are 10 micron and
larger; however, it is difficult to
backflush heavy particles (such as
dirt, sand or calcium carbonate)
collected from the tower without
losing some of the media during each
flush. Therefore, expensive periodic
replacement of the media is required.
Sand media is excellent for removing
organic particulate including algae
and sediment from the water and
retaining those particles in the media.
It has been shown by the EPA that sand
media filtration on cooling towers
and hot tubs provides an excellent
habitat for bacteria such as Legionella
since the organics combined with the
sedimentation held within the media
are the major source of nutrients for
Legionella (see reference 2).

REFERENCES
1. Systems and Equipment Handbook (2000),
ASHRAE.
2. Legionella: Human Health Criteria
Document (1999), Office of Science and
Technology / Office of Water, United States
Environmental Protection Agency.

SEPTEMBER 2014 | 33

PUMP solutions

How to Select DiapHragmS

for aoDD pumpS
Asking the right questions and utilizing the best available tools from Wilden will help AODD pump operators maximize diaphragm life

PART 2 OF 2
By Rob Jack, Wilden and Pump Solutions group (PSg)

n the first part of this article, we

discussed some of the materials that
have been tested extensively for use
in diaphragms in AODD pumpsrubber,
TPE (thermoplastic elastomer) and PTFE
(Polytetrafluoroethylene or Teflon)
with special attention given to rubber
diaphragms. In this months installment,
we will examine TPE and PTFE
diaphragms and conclude by rating and
comparing all three diaphragm materials
for the properties and attributes that
make them suitable for different
applications.

THERMOPLASTIC ELASTOMER
(TPE) DIAPHRAGMS

TPE diaphragms are manufactured

by injection molding. As a result of
their dimensional stability and tensile
strength, TPE diaphragms do not need
fabric reinforcement. Following are the
available types of TPE diaphragms:

Polyurethane is an outstanding
general-purpose diaphragm
for nonaggressive chemical
applications such as water,
wastewater and seawater. It
provides excellent flex life, abrasion
resistance and durability at an
economical price.
Wil-Flex provides a low-cost
alternative to PTFE with a cost
comparable to neoprene. Made
of Santoprene, Wil-Flex is ideal
for use with acidic and caustic
fluids such as sodium hydroxide,
sulfuric acid or hydrochloric acid.
Exhibiting excellent flex life,
abrasion resistance, temperature
range and durability, it is widely
used in the chemical process, food,
pharmaceutical and wastewater
industries. Versions of Wil-Flex are
available that comply with FDA 21
CFR 177 standards for food and
beverage applications.
Saniflex is an excellent material
for food processing applications.
Made of Hytrel, it exhibits good
flex life and excellent abrasion
resistance. Hytrel also offers
superior sealing or seal energizing
due to its low compression set
characteristics. Saniflex versions are
available that comply with FDA 21
CFR 177 standards.

Geolast exhibits enhanced

oil-resistance and low oil swell
making it ideal for petroleum
industry applications. Equivalent to
nitrile (Buna-N), Geolast provides
moderate flex life and good
abrasion resistance over a wide
temperature range at a lower cost
than fabric-reinforced Buna-N.

POLYTETRAFLUOROETHYLENE
(PTFE) DIAPHRAGMS

Because it is one of the most chemically

inert compounds available, PTFE can be
used with an extremely wide range of
fluids. Also known as Teflon, PTFE is
excellent for highly aggressive fluids such
as aromatic or chlorinated hydrocarbons,
acids, caustics, ketones and acetates.
Its properties provide excellent flex
life and moderate abrasion resistance.
In addition, PTFE complies with FDA

About The Author

Rob Jack is a development engineer IV for Wilden and Pump Solutions Group (PSG ). Wilden is a leading manufacturer of
air-operated double-diaphragm (AODD) pumps. He can be reached at 909.422.1784 or [email protected]. For more
information, visit www.wildenpump.com. Wilden is an operating company within Dover Corporations Pump Solutions Group
(PSG), which is comprised of several leading pump companies, including Abaque, Almatec, Blackmer , Ebsray, Finder,
Griswold, Maag, Mouvex , Neptune, Quattroflow, and Wilden. Find more information at www.psgdover.com.

34 | SEPTEMBER 2014

www.modernpumpingtoday.com

21 CFR 177 and USP Class VI

standards for food, beverage and
pharmaceutical applications.
Because PTFE is non-elastic, a
backup diaphragm of a different
material must be used to provide
flexibility and memory. Material
options for backup diaphragms
are Neoprene, Saniflex and high
temperature Buna-N.

RATING AND COMPARING

DIAPHRAGM MATERIALS

frequency of cleaning fluids,

pump operation (intermittent
or continuous), and how often
diaphragms are being replaced.
On average, diaphragms that
need to be replaced more often
than every three months warrant
further evaluation as to the right
fit for the application.

CONCLUSION

Whether pumping water,

aggressive acids, food products
Using extensive material testing
or solid-laden slurries, there is
and field data, Wilden compiled
a Wilden diaphragm for every
Correct diaphragm material selection for each application is critical to assure
a Diaphragm Selection Guide
application. The challenge
safe and efficient AODD pump operations.
that compares and rates the flex
can often be selection of the
life, abrasion resistance, chemical
optimum diaphragm that will
resistance, temperature limits
assure safe, efficient, cost
and relative cost of each material
effective and trouble-free
type. It is important to note that
operations. Determining the
this chart should be used only as
correct diaphragm requires
a guideline and in conjunction
carefully identifying and
with thorough additional research
factoring all process and
and expert advice to determine
application parameters into the
the suitability of diaphragm
analysis. A valuable resource to
materials for individual
assist with diaphragm selection
applications because one factor
is the network of Wilden
Wilden offers the widest selection of diaphragms for nearly every
can affect another.
distributors, who have extensive
application. From aggressive chemicals to highly abrasive materials to
When using the chart, always
training in AODD pump
extreme operating temperatures, Wilden has the right diaphragm for superior
strive for an A or B rating and
technology and applications.
durability, higher performance and significant labor savings.
keep the applications maximum
Because one selection factor
fluid temperature as close to the
can offset another, expert advice
center of the Operating Temperature Limits as possible. The
should be obtained in determining compatibility based on all
selection of C -rated materials is generally not recommended
factors.
but may be necessary in rare exceptions where fluids are highly
NOTES
specialized or processed under extreme conditions. For some
Hytrel, Viton and Teflon are registered trademarks of DuPont
applications, two different materials may be suitable with cost
Company.
being the final deciding factor.
Geolast and Santoprene are registered trademarks of ExxonMobil.
Other factors to consider in selecting the right diaphragm
Saniflex and Wil-Flex are registered trademarks of Wilden.
include the hardware configuration of the pump, type and
www.modernpumpingtoday.com

SEPTEMBER 2014 | 35

DEWATERING solutions

California Logistics Center

Finds Stormwater Solution
By CulTEC technical staff

he Rialto, Calififornia-based
I-210 Logistics Center is part
of a proposed master-planned
project located on and around the Rialto
Municipal Airport. The 1445 acre site is a
premier West Rialto location, with highprofile corporate neighbors including
Target, Under Armour, Black & Decker,
Solo Cup and Kuehne + Nagel. The
718,000 square-foot (66,704.4 square
meter) industrial distribution warehouse
will house products until they are ready
to be shipped to their final destinations
across the country.
Upon completion,
the Logistics Center will
feature a cross-dock
facility with 32 feet
(9.75 meters) minimum
warehouse clearance,
185 to 344 feet (56.39 to
104.85 meters) concrete
truck courts, 112 dock
loading doors, each 9
by 10 feet (2.74 by 3.05
meters) high, and 249
trailer parking spaces
each measuring 10 by
53 feet (3.05 by 16.15
meters). Approximately 3380 square-feet
(314.01 square meters) of the building
will be dedicated to the office space.

THE CHALLENGE OF A DUALSYSTEM DESIGN

In addition to designing the facility,

engineers from SB&O Inc. collaborated
with EW Harmon Contracting, Inc. to
design and install a stormwater detention
and retention system to comply with
water quality requirements as well as
provide stormwater pre-treatment to the
site.
Engineers determined that the most
economically effective method of

Engineers determined that a combination of underground

chambers and above-ground retention/detention basins
would be the most economically effective method.

stormwater management would be to

combine an underground network of
chambers with a separate above-ground
system consisting of retention/detention
basinsa relatively new practice. A
challenging aspect of the dual-system
design was determining how the two
systems would interact with each other,
and how to keep siltation out of the
underground system, into which water
from the above-ground system migrates.
To mitigate water quality concerns,
engineers chose to raise the inlets in
the above-ground detention basins so
that the silts had a chance to settle
prior to flowing into the underground

chamber system consisting of 726 units.

Two CULTEC StormFilter 330 units
filter runoff before it enters a CULTEC
Separator Row. The StormFilter 330 is
a chamber-shaped secondary filter which
contains two removable pass-thru filters.
Water passes thru the filter baffles and is
captured or settles to the bottom of the
unit. For maintenance, the StormFilter
housing can be vacuumed out and the
filter bags may be replaced or cleaned
and reused.

THE SEPARATOR ROW:

A CLOSER LOOK

The Separator Row, comprised of a

select row of underground chambers, is
enveloped with No. 410 filter fabric
and sits on top of two layers of woven
geotextile fabric. The Separator Row
pre-treats runoff by capturing silts and
fine particles in a row of chambers prior
to runoff overflowing into the rest of the

for More information

CULTECs technical staff offers free design assistance including preliminary calculations and job-specific CAD details.
For more information about CULTEC stormwater management chambers and other products, call 203.775.4416 or visit
www.cultec.com.

38 | SEPTEMBER 2014

www.modernpumpingtoday.com

infiltration basin. To help maintain the

stormwater system, debris can be easily
vacuumed out using a water jet, which
pushes water toward the catch basin
and sump while removing waste.
The Recharger V8HD was selected
for the Logistics Center because it
both maximizes storage in a small
footprint and satisfies the other design
requirements of the site. The internal
manifold feature available on the
stormwater chamber allows for a more
cost-effective and condensed bed size
since a costly and time consuming
custom pipe and fitting external
manifold fabrication is not required.
Smaller chamber-like feed connectors
are inserted into side portals located
on the sidewalls of the stormwater
chambers to create the internal
manifold. Installation is quick and
efficient.

high as possible to direct the flow to the

street.

A WINNING TEAM

This was our first time working with

CULTEC, and we look forward to teaming
up with them again in the future, recalls
Brooks. Their team was very responsive
and helped us get the job done quickly
and efficiently.

CULTEC introduced its Contactor and

Recharger HDPE septic and stormwater
chambers in 1986, which helped begin
a revolution toward the use of plastic
construction products. Since then, several
product developments and strategic
alliances have seen the chambers used as
subsurface retention or detention systems
and as replacements for ponds, concrete
structures or pipe and stone installations.

MEETING REGULATORY
REQUIREMENTS

Regulatory bodies called for a

stormwater solution that would mitigate
the proposed flows to be equal to or
less than the existing flows on site
particularly for higher-flow flood
conditions. Moreover, to meet water
quality regulations, a certain volume
had to be retained onsite and infiltrated
into the ground to accommodate lowerflow water quality requirements.
Water flows into the above-ground
detention/retention basins and fills
about a foot deep before overflowing
into the CULTEC chambers located
underground, says Don Brooks,
engineer with SB&O Inc. The two
systems combined provide the detention
and retention volumes required to
meet the regulatory requirements of the
county.
Each Recharger V8HD chamber
measures 32 inches (812.8 millimeters)
high and 60 inches (1524 millimeters)
wide and has a bare chamber capacity
of 8.68 cubic feet (0.25 cubic meters)
per linear foot. The bed of chambers
provides the site with a total of 72,857
cubic feet (2063.08 cubic meters) of
storage. In addition, the V8HD model
is able to withstand traffic loading
with minimal covera major site
requirement since the chambers will
largely be covered with parking areas.
Further, there is no underground storm
drain system to tie into, so the runoff
outlets are located to the street surface.
For this reason, the engineers were
eager to keep the storage elevation as
www.modernpumpingtoday.com

SEPTEMBER 2014 | 39

MOTOR solutions

The New Frontier

of Self-lubricating SolutionS

A closer look at the benefits of carbon-graphite solutions across a range of applications

By Matthew Brennan, Metallized Carbon Corporation

etallized Carbon Corporation,

a global leader in the
manufacture of oil-free,
self-lubricating, carbon-graphite
materials for severe service lubrication
applications, is committed to expanding
the benefits these products can offer to a
range of applications.
For example, todays rotary vane
pump users can now benefit from
custom vanes, rotors, and end plates
for use in pumping both liquids
and gases. The carbon-graphite
components provide superior
lubrication in most environments,
and are ideal for pumping liquids
with poor lubricating qualities, strong
chemicals that attack metals, and to
pump air, vacuum, combustion products
and gasoline vapors. Also, aviation
engineers are discovering the benefits
of carbon- graphite bushings for use in
aircraft engine gear pumps that pump
fuel.

CUSTOM VANES, ROTORS, AND

END PLATES FOR ROTARY PUMPS

Metallized Carbons carbon-graphite

vanes, rotors, and end plates are
used in such dry running applications
as automotive anti-smog pumps
and gasoline vapor pick up pumps,
breathable air pumps and vacuum
pumps. In-liquid applications include
vending machine beverage pumps,
fuel and liquid chemical pumps, and
medical liquid pumps.
Metallized Carbon supplies the
carbon-graphite vanes, rotor, and end

Pressure tight and

dimensionally stable
carbon graphite end plates
offer the benefit of a close
clearance seal with the
rotor and vanes.

plates to rotary pump

and compressor manufacture and
rebuilders. The materials are chemically
resistant and are compatible with FDA
food and beverage regulations. They
have a low wear rate running in both
gas atmospheres and low viscosity
liquids.

IDEAL FOR BOTH

LIQUIDS AND GASES

Carbon graphite vanes can withstand

the rubbing of the vane tip against the
housing bore and the rubbing of the

side of the vane against the slots in

the rotor. Lightweight carbon graphite
rotors save energy and withstand the
rubbing against the vane and the end
plates. Carbon graphite end plates are
pressure tight and dimensionally stable
so that they can make a close clearance
seal with the rotor and vanes. They also
withstand the rubbing of both the vanes
and rotor.
These materials work best in severe
service applications With dimensionally
stability and high strength-to-weight

About The Author

Matthew Brennan is president and CEO of Metallized Carbon, an ISO certified and producer of the Metcar brand of solid,
oil-free, self-lubricating materials. For additional information about the company and its services, visit www.metcar.com or
call 914.941.3738.

40 | SEPTEMBER 2014

www.modernpumpingtoday.com

ratio, the components are

available in several grades
of Metcars proprietary
carbon/graphite material.
Metcar engineers
assist in selecting the
optimum grade based on
application, environment,
housing materials,
revolutions per minute,
and other parameters.
The components can be
supplied to meet custom
prints and specifications.

UNIQUE MATERIAL WITH

NUMEROUS ADVANTAGES

A second major advantage of

carbon-graphite bushings is that
they are self-lubricatingthey
can run dry for short periods of
time without catastrophic pump
failure or significant wear.
In addition, carbon-graphite
bushings are dimensionally
stable, which permits the
close bushing to shaft running
clearances that are required in
gear pump applications.
Finally, these carbon-graphite
CARBON-GRAPHITE
bushings have a relatively low
BUSHINGS FOR
elastic modulus. While elastic
AIRCRAFT ENGINE
enough that they can be pressFUEL PUMPS
fit into the metallic gear pump
Since carbon-graphite material possesses no atomic attraction to a metallic shaft, even
housing with no difficulty,
A more unique severe
the thin fuel film provided by aviation fuel is sufficient to lubricate metallic shafts running
in the carbon-graphite bushings.
after being properly press-fit,
service lubrication
the carbon-graphite bushings
application for carbonare pre-stressed in compression.
graphite bushings is in use in gear
Aviation fuel is a low viscosity liquid
Therefore, they exhibit nearly the same
pumps that pump aviation fuel for
that produces only an extremely thin
coefficient of thermal expansion as the
aircraft engines. Here, the carbonhydrodynamic film, too thin to provide
metallic gear pump housing material.
adequate lubrication for traditional metallic
graphite bushings are used to support
This assures that the running clearance
bushings. But since carbon-graphite
both the drive gear shaft and the
between the shafts and the bushings will
idler gear shaft. Metcar carbonmaterialin contrasthas no atomic
remain the same throughout the entire
graphite bushings are preferred for
attraction to a metallic shaft, the thin fuel
operating temperature range of the
this application because they can use
film is sufficient to lubricate metallic shafts
aviation fuel as the bushing lubricant.
running in the carbon-graphite bushings.
pump.

www.modernpumpingtoday.com

SEPTEMBER 2014 | 41

POWER GENERATION solutions

Polish Utilities Adopt

Advanced Actuation Solutions
SIPOS projects illustrate the capabilities of actuators
By gerda noelp, SiPoS Aktorik

s part of SIPOS Aktoriks impressive global portfolio of electric

actuator installations, the companys technology plays a
pivotal role in a two million Euro modernisation programme at
Rakowice Water Treatment Plant (WTP) in Poland. As a result of the
upgrade, the station, supported by SIPOS electric actuators, will be
designed to be maintenance free. A complete overhaul of actuation
technology at the plant has resulted in a suite of SIPOS actuators
replacing all existing valve control devices.

In-situ speed adjustment influences selection of SIPOS Aktorik actuators at

Rakowice Water Treatment Plant.

BENEFITS OF INTEGRATED FREQUENCY CONVERSION

Due to the scale of the scheme, with just under 100 drives, SIPOS
PROFIBUS DP enabled actuators were selected to manage the valve
control automation processes. A primary reason for the adoption of
SIPOS actuators was the devices integrated frequency converter,
which enables the actuator speed to be adjusted in-situ to precisely
meet the schemes process requirements.
Rakowice WTP, which has been in operation since 1961, is the
primary plant for the area. Together with the Modlowa station, the
WTP, which comprises 14 filter tanks, provides 90 percent of the
regions water. The WTP features 13 active wells with an average depth
of 98.4 feet (30 meters): four wells have been newly constructed, and
five have been modernised.

MAINTENANCE FREE AND FULLY AUTOMATED

The commissioning of the actuator installation including sales, service

and support was managed by SIPOS local partner, AUMA Poland.
Commenting on the significance of the contract, AUMAs Kamil Gawel
says, This is a prestigious WTP scheme which is a primary plant for
the area. The modernization initiative is a major investment which
has required the most advanced automation solutions and the coordination of a large number of suppliers. The installation is therefore
a flag-ship project which illustrates the capabilities of the actuators,
the skills of the local team and the working synergies between AUMA
and SIPOS.
The station will be maintenance free and fully automated. There
will be a modern automation system control with monitoring: this is
important to ensure water safety.
Extensive consultation was held and, in discussion with the WTP,
an agreement was reached regarding the number of drives and the best
control solution, which was PROFIBUS DP.

ACTUATORS ADOPTED

Rakowice is the latest in a series of water sector contracts secured in

A series of Polish utility projects have adopted SIPOS variable speed actuators.

Sophisticated actuation control from SIPOS includes 7000 revolutions per

stroke at the Pila hydro scheme in Poland.

About The Author

Gerda Noelp is an international sales manager for SIPOS Aktorik, a world leading actuator manufacturer with around one
hundred years experience. For more information, email [email protected] or visit www.sipos.de.

42 | SEPTEMBER 2014

www.modernpumpingtoday.com

THIS SecTIon SponSored by

Poland by SIPOS; other schemes that
have previously adopted the companys
actuators include the Belchatow water
treatment plant and WwTWs at Sieniawa
and Siedlce.
An ability to counter the damaging
impact of water hammer and dedication
to service/support were common
selection themes for SIPOS across all the
Polish applications. Reasons for adoption
of SIPOS actuators at Belchatow
included an ability to support the
schemes large scale emergency valves
and capability to address water hammer.
Modernisation of the Sieniawa
plant has supported the works role as
provider of the largest drinking water
supply to the City of Krosno. Originally
built over twenty years ago, a full scale
automation upgrade is taking place with
SIPOS open-close actuators featuring
PROFIBUS DP playing a key role.
Variable speed functionality was cited
as one of the reasons for selecting SIPOS
for the installation.
A further water industry application
for SIPOS in Poland is the waste
water plant at Siedlce. Soft start/speed
reduction, a Polish menu, fieldbus
capability and high service standards
were listed among the selection criteria
for SIPOS products.
The scope of SIPOS actuators
extends to the automation of water
level management and a Polish casestudy example of a hydra scheme
application is found on the Gwda
River. Requirements to ensure precise
control included an extremely long
actuator run time of over half an hour
at 160 revolutions per minute and 7000
revolutions per stroke. The demands
were met by non-intrusive, encoder
version actuator devices.
With established credentials for
providing high performance solutions,
SIPOS impressed operators with the
capabilities of its valve control devices.
Sophisticated features that set the
companys products apart included
soft-start functionality and an automatic
retry if blocked response. Other options
explored, including alternative actuators
and a potentiometer, could not meet
the exacting demands of the scheme:
the maximum revolutions achieved by
alternative technology equated to just
five thousand turns.

www.phase-a-matic.com

investment in research and development,

training services and high quality
products, SIPOS places key focus on
providing comprehensive, pro-active
service. Technical support goes beyond
planning and reliable delivery, complete
support is provided throughout the
installation phase to ensure rapid
start-up and long term, trouble-free
actuator operation. Regular inspection

and preventive maintenance increases

operational safety, reduces the risk of
failures and enables early detection of
damage or potential system problems.
Spare parts requirements are also
reduced as SIPOS actuators have been
designed to keep these to a minimum.
Design and software adaptability also
reduces spare parts, as most elements
are interchangeable.

GLOBAL EXPANSION

Growth in Poland reflects global

expansion for SIPOS electric actuation
technology. Along with its innovation,
www.modernpumpingtoday.com

SEPTEMBER 2014 | 43

44 | SEPTEMBER 2014

www.modernpumpingtoday.com

PROCESSING solutions

A comparative analysis of four membrane cleaning profiles using Micro-90

Alkaline Cleaning Solution and Micro A07 Alkaline Cleaning Solution
By Jennifer Sun, international Products Corporation

ouling and cleaning profiles of four types of filter

as anticipated in their filtration processes. Laboratory-based
membranes were obtained using Micro-90 and/
performance data, along with technical support and sufficient
or Micro A07. Simulated fouling processes were
samples for on-site cleaning trials, ensure a quick and
successful transition to a more effective cleaning regimen.
performed by using either a synthetic oil emulsion or a
In this project, a GE
combination of the synthetic oil
emulsion and a calcium acetate
Osmonics SEPA CF II filtration
unit was used for the simulated
salt bridge mixture. Excellent
fouling-cleaning experiments on
recovery of permeate flux was
PURPOSE
four types of filter membranes
obtained with the lowest to be
To evaluate the cleaning efficiency of
using Micro-90 and/or Micro
96 percent. The results prove
Micro-90 and Micro A07 on four GE flat
A07 as the cleaners. Because
that Micro-90 and Micro A07
sheet membranes in the GE Osmonics SEPA
of the pH constraints of the
are effective at cleaning these
CF II filtration unit. The four membranes
Cellulosic NF and the Ultrafillic
types of membranes.
include a Cellulosic NF polymer, a
membranes, only Micro A07
In all four trials, some
proprietary thin film, polyethersulfone, and
was evaluated in these trials.
delamination of the membranes
an Ultrafillic UF membrane.
Properties of the four GE
occurred around their
membrane polymers are listed
perimeters, probably due to the
in Table 1.
seeding of the membranes in
the filtration unit.
Some flux variation occurred during the trials because the
EXPERIMENTAL
optimal pressure of each membrane was controlled manually.
1. Materials and reagents
This can be seen in instances where the flux rate exceeds 100
a. GE Osmonics SEPA CF II filtration unit (GE Water &
percent.
Process Technologies);
b. Wanner Engineering Back Pressure Relief Valve (Wanner
INTRODUCTION
Engineering, Inc.; Part No. 111-706);
Simulated cleaning profiles are valued by potential customers
c. Power Team SPX Hydraulic Hand Pump (SPX Corporation,
as providing assurance that candidate cleaners will perform
Model A, 1000 psi);

Table 1: Properties of gE Membranes Evaluated

POLYMER

GE PART #

MWCO (Daltons)

MAX PRESSURE (Bar)

pH RANGE

CLEANER(S)

Cellulosic NF

1156755

2000

15

28

Micro A07

Thin Film

3002314

1000

40

1 11

Micro-90 and
Micro A07

PES / PS

1221929

10,000

10

1 11

Micro-90 and
Micro A07

Ultrafillic

1221962

50,000 proteins

29

Micro A07

About The Author

Jennifer Sun, PhD, is a research scientist for International Products Corporation and can be reached at [email protected]. For
more information or free samples for testing, call 609.386.8770, email [email protected], or visit www.ipcol.com.

46 | SEPTEMBER 2014

www.modernpumpingtoday.com

d. Wanner Engineering Hydra-Cell

P200 Metering Pump (Wanner
Engineering, Inc.);
e. SEPA CF TF (thin film) NF membrane
(GE's Water & Process Technologies,
Part No. 3002314);
f. SEPA PES UF membrane (GE's Water
& Process Technologies, Type: PW,
Part No. 1221929);
g. SEPA CF Ultrafilic UF membrane
(GE's Water & Process Technologies,
Type: MW, Part No. 1221962);
h. SEPA TF (thin film) NF membrane
(GE's Water & Process Technologies,
Type: CK, part No.1156755);
i. Synthetic oil emulsion: P-80 Rubber
Lubricant Emulsion (International
Products Corp., Lot#130808);
j. Micro-90 Concentrated Cleaning
Solution (International Products
Corp., Lot# 140303);
k. Micro A07 Citric Acid Cleaner
(International Products Corp., Lot#
130205);
l. Anhydrous calcium acetate (Lot#
J18Q096, Alfa Aesar - a Johnson
Matthey Company);
m. Graduated cylinders (100 and 10
milliliters);
n. Distilled water (Eagles Peak Spring
Water, Inc.);
2. Set-up
a. Set-up of the GE Osmonics SEPA CF
II filtration unit system is shown in
figure 1.
Within the filter cell is a 75 mil (2
millimeter) cavity. Two stainless steel
shims of 5 mil and 2 mil were placed in
the bottom half of the cell cavity. A 65
mil foulant spacer was placed on top of
the two steel shims. The filter membrane
with its shiny side downwards was
placed over the high foulant spacer by
using the four guide posts protruding
from the bottom half of the cell for
proper positioning. A permeate carrier
was then placed on the top half and then
rinsed with distilled water. The top half
of the cell was mounted to the bottom
half using the guide posts for proper
alignment. The designated pressure for
each respective membrane was obtained
using the hydraulic hand pump. The
pressure seals the filtration cell and holds
it in place.
The hydraulic pressure and concentrate
pressure used for different membranes
are summarized in Table 2 as well as
the foulant type and fouling time. The
recommended pressure ranges of each
membrane were followed. The foulant
www.modernpumpingtoday.com

figure 1

Figure 1: Set-up of the GE Osmonics SEPA CF II filtration unit System (cited from a report done by Al Gabbianelli,
chemist; International Products Corporation).

figure 2
CELLBODY
TOP

PERMEATE
CARRIER
P/N 1142817

PERMEATE
OUTLET

MEMBRANE
ELEMENT

FEED
SPACER
P/N 1232558
CONCENTRATE
PRESSURE
GUAGE

SHIM
P/N 123 104
O-RINGS
GUIDE
POST

CELL BODY
BOTTOM
CONCENTRATE
FLOW CONTROL
VALVE
CONCENTRATE
OUTPUT

CONCENTRATE
FEED INLET

CONCENTRATE
CONTROL
ASSEMBLY
P/N 1149418

Figure 2: Detailed assembly of the filter cell (cited from the instruction manual for Sterlitech SEPA CF Cell
Membrane Element Cell).

SEPTEMBER 2014 | 47

PROCESSING solutions
Table 2: operation Conditions for different Types of Membranes
MEMBRANE

HYDRAULIC
PRESSURE (psi)

CONCENTRATE
PRESSURE (psi)

Thin Film

200

100

4000 ppm P-80+10 mM Calcium acetate

in 1 liter distilled

10

PES

200

40

10 ppm P-80 in 1 liter distilled water

Ultrafillic

200

40

4000 ppm P-80+10 mM Calcium acetate in

1 liter distilled water

15

Cellulosic NF

200

100

750 ppm P-80 in 1 liter distilled water

30

types and the fouling time were selected on the basis of the
needed degree of fouling.
The foulants and fouling time varied according to the
different membranes. The general procedure for all the tests
was:
1. Circulate with 2 liters distilled water for 15 minutes to
remove any preservatives.
2. Record the filling time to a pre-established volume
(used for calculating J0).
3. Foul and record the filling time.
4. Rinse with 12 liters of distilled water and record the
filling time.
5. Clean with 2 percent of Micro-90 and/or Micro A07
(40 grams of a cleaner in 2 liter of distilled water).

FOULANT

FOULING TIME
(min.)

Repeated this whole process if both cleaners were used.

The Cellulosic NF and Ultrafillic membranes were only
cleaned with Micro A07 because of their narrower pH
range (Micro-90 has a maximum pH value of 9.8).
6. Rinse with 16 liters of distilled water and record the
filling time.

RESULTS AND DISCUSSION

The flux of a membrane was calculated using the following

equations:
Flow (milliliters / minute) = Permeate volume in
milliliters / (drain time in seconds / 60 seconds /
minute).
Flux (gallons / square feet / day) = Flow (ml / min) x
1440 (minutes / day) / 0.1514 square feet Filtration Area
/3785 (mil / gallon).
Recovery of flux (J/J0)*100 =the ratio of a flux after a
treatment to the original flux (NOTE: The effective filtration
area of the GE Osmonics SEPA CF II unit is 5.71 by 3.82
inches or 0.1514 square feet).
In figure 3, a profile of the fouling and cleaning process
of the proprietary thin film membrane is displayed. The
synthetic oil emulsion and calcium acetate mixture was
recirculated for ten minutes in order to sufficiently foul
the membrane. Since this membrane tolerates pH values
between 1 to 11, both Micro-90 (pH 9.6) and Micro A07
(pH 3.0) were evaluated. Both cleaners restored the flux rate
to baseline.
The PES membrane was easily fouled after 5 minutes
of recirculating a 10 ppm concentration of the synthetic
oil emulsion in distilled water. This quick fouling is likely
a result of the larger pore size (MWCO dextran: 10 K)
absorbing and subsequently trapping the emulsified oil.
However, both Micro-90 and Micro A07 were effective
at cleaning the emulsified oil from the PES membrane.
Micro-90 and Micro A07 returned 98.9 and 99.6 percent
flux recoveries, respectively.
The large pore size (MWCO: 50 K protein) of the
Ultrafillic membrane required 15 minutes of recirculation
in order for the synthetic oil emulsion and calcium acetate
mixture to foul it. Because this membrane cannot tolerate
pH values above 9.0, MICRO A07 was the only cleaner
used. MICRO A07 achieved a flux recovery of 96.0 percent,
which is significant given the low flux after fouling was 9.3
percent.

48 | SEPTEMBER 2014

www.modernpumpingtoday.com

figure 3

Fouling and cleaning profile of SEPA CF TF (Thin Film) NF membrane

Fouling and cleaning profile of SEPA PES UF membrane
Figure 3: Fouling and cleaning profile of SEPA CF TF (Thin Film) NF membrane and of SEPA PES UF membrane.

figure 4

Fouling and cleaning profile of SEPA CF Ultrafillic membrane

Fouling and cleaning profile of SEPA TF (Cellulosic NF) NF membrane
Figure 4: Fouling and cleaning profile of SEPA CF Ultrafillic UF membrane and SEPA TF (Cellulosic NF) NF membrane.

The Cellulosic NF membrane required 30 minutes of recirculating the

synthetic oil emulsion at 750 parts per million in order to sufficiently foul it.
The difficulty to foul this membrane may be related to its nano-sized pores; the
particle size of the synthetic oil emulsion was too large to be entrapped in the
pores. The subsequent cleaning and rinsing with Micro A07 proved effective to
restore the flux back to 99.2 percent of the original.
www.modernpumpingtoday.com

SEPTEMBER 2014 | 49

VALVES & CONTROLS solutions

Precise Gas
Measurement for
Mud Logging
Operations
By Randy Brown

ST100
thermal mass
flow meter
provides
solution for
oil and gas
upstream
production
operations

il/gas
engineers
looking for a
next-generation air/
gas flow meter to
support mud logging
operations will find
that the futureready ST100 Series
thermal mass air/
gas flow meter from
Fluid Components
International (FCI)
offers the ability to
measure flare gas flows
under variable and low
flow rate conditions.

DOWN IN THE
MUD

Upstream oil/
gas production
companies around
the globe depend on
mud logging service
companies to analyze
mud samples that help
them maintain the correct direction
for their drilling field operations. In
mud logging, samples of rock cuttings
from bore holes are brought to the
surface by recirculating drilling
media (mud) for analysis by a mobile
laboratory to determine the lithology
and fluid content of the sample.

As the mud is returned to the

surface from down the hole, it also
contains natural gas that is vented to
a flare stack and burned off at low
flow rates typically from 15 to 20
fps. U.S. Environmental Protection
Agency (EPA) Directive 40 CFR Part 98
requires measurement and reporting

of these flare gas emissions from mud

logging operations. To provide the
U.S. EPA required flare gas data, mud
logging service companies need an
accurate, reliable gas flow meter able
to measure gas flow at relatively low
flow rates. FCIs ST100 Series Thermal
Mass Gas Flow Meter provides

for More information

Fluid Components International is a global company committed to meeting the needs of its customers through innovative
solutions for the most challenging requirements for sensing, and measuring flow, pressure and temperature of gases. For more
information, visit www.fluidcomponents.com.

50 | SEPTEMBER 2014

www.modernpumpingtoday.com

excellent accuracy at low flow rates

combined with a turndown far in
excess of 100:1, with an insertion
style probe offering low pressure
drop.

PERFORMANCE THAT ACHIEVES

The ST100 Series Flow Meter sets a
new industry benchmark in process
and plant air/gas flow measurement,
offering the most feature-rich and
function-rich electronics available.
The ST100s performance delivers
unsurpassed adaptability and value
to meet plant gas flow measurement
applications for today and tomorrow.
Whether the need is for 4-20
mA analog, frequency/pulse, alarm
relays or digital bus communications
such as HART, Fieldbus, Profibus or
Modbus, the ST100 is the solution.
Should a plants needs change over
time or an upgrade be desirable,
the ST100 Flow Meter adapts as
necessary with a plug-in card
replacement that can be changed out
by plant technicians in the field.
The ST100 Flow Meters unique
graphical, multivariable, backlit LCD
display/readout brings new meaning

www.modernpumpingtoday.com

to the term process information.

It provides the industrys most
comprehensive information with
continuous display of all process
measurements and alarm status, and
the ability to interrogate for service
diagnostics.

DESIGNED FOR EASE OF USE

The user-friendly ST100 stores up

to five unique calibration groups to
accommodate broad flow ranges,
differing mixtures of the same gas
and multiple gases, and obtains up to
1000:1 turndown. Also standard is an
on-board data logger with an easily
accessible, removable 2-GB micro-SD
memory card capable of storing 21
million readings.
The versatile ST100 Series is
comprised of two core model
families: ST and STP. ST meters
measure both mass flow and
temperature, and the exclusive
STP family adds a third parameter,
pressure, making the ST100 the
worlds first triple-variable thermal
flow meter. Both families include
single-point and dual-element models
as configurations outfitted with FCIs

exclusive in-situ calibration option,

VeriCal.

A VERSATILE TOOL

The ST100 can be calibrated to

measure virtually any process gas,
including wet gas, mixed gases and
dirty gases. The basic insertion style
air/gas meter features a thermal flow
sensing element that measures flow
from 0.25 to 1000 SFPS (0.07 NMPS
to 305 NMPS) with accuracy of 0.75
percent of reading, 0.5 percent of
full scale.

TOUGH AND PRECISE

Designed for rugged industrial

processes and plants, ST100 Flow
Meters include service up to 850
degrees Fahrenheit (454 degrees
Celsius) and are available with both
integral and remote (up to 1000 feet
[300 meters]) electronics versions.
The ST100 is agency approved for
hazardous environments, including
the entire instrument, the transmitter
and the rugged, NEMA 4X/IP67 rated
enclosure. Instrument approvals
in addition to SIL-1 include ATEX,
IECEx, FM and FMc.

SEPTEMBER 2014 | 51

VALVES & CONTROLS solutions

Gas and Flame detectors

Protect Portable lnG
VaPorizers
Remote drilling sites have a new option to monitor mobile equipment
By Angela Sauceda, general Monitors

perators at remote liquefied natural gas (LNG)

production sites who rely on portable or skid mount
vaporizer production equipment will find General
Monitors provides comprehensive gas and flame monitoring
to prevent accidental explosions and fires.

A SOLUTION BUILT FOR THE FIELD

Gas wells are typically drilled at remote sites. Often times it

is a result of either the location of the gas, proximity to the
public or a combination of both situations. Regardless, power
is rarely available and prohibitively expensive to obtain.
Drillers have found a way around this obstacle by employing
portable vaporizers and temporary liquefied natural gas
(LNG) sources.
LNG trucks are sent to potential drill sites along with
portable vaporizers. After the connection is made,
Compressed Natural Gas (CNG) is available to run a large
power generator that is capable of providing power to
the entire drill site. Once the site is producing gas and
is self-sustainable, the LNG truck and vaporizer are
moved to the next site.

DETECTORS FOR ANY NEED

General Monitors S4000CH Combustible Gas Detector

provides thorough, continuous monitoring of combustible
gases via its robust catalytic bead technology. The unit
features one person calibration and can virtually selfcalibrate by simply activating a magnetic switch and
applying gas. It is designed to monitor natural gas and vapors
within the lower explosive limit (LEL) and provide status
indication and alarm outputs. It complies with ANSI/ISA
12.13.01-2000 performance requirements for combustible
gas detectors. The S4000CH is an intelligent sensor for the

SAFETY FIRST

Safety monitoring devices are always employed

when liquefied natural gas is being produced,
used or stored due to its inherently explosive
nature. LNG is stored at -260 degrees Fahrenheit
(-126 degrees Celsius) and as it is slowly
warmed and vaporized it rapidly expands to 600
times its liquid volume. These harsh conditions
are stressful on piping and valves which can
result in potential leaks of combustible gas that
endangers people, equipment and facilities.
General Monitors mission is to benefit society by
providing solutions through industry leading safety
products, services, and systems that save lives and
protect capital resources from the dangers of hazardous
flames, gases, and vapors.

About The Author

Angela Sauceda is the marketing communication manager for General Monitors and can be reached at 949.581.4464 or
[email protected]. Founded in 1961, General Monitors is a global leader in process monitoring and safety in
combustible, toxic and flammable environments. For more information, visit www.generalmonitors.com/oilandgas.

52 | SEPTEMBER 2014

www.modernpumpingtoday.com

detection of combustible gases and

vapors. The microprocessor-based
electronics process information at the
sensor site within an explosion-proof
housing. A digital display provides
indications and display codes that
can be viewed through a window in
the cover. A red LED above the digital
display signifies an ALARM condition,
while a red LED below the digital
display signifies a WARN condition.
Analog signal (4-20 mA) and relays
provide remote and/or discrete
indications of the sensors operation.
Optional dual redundant Modbus,
HART or HART and single Modbus
provide digital communication.
The IR400 Point IR Gas Detector
uses infrared technology to sense
for combustible gases and vapors to
quickly and reliably detect liquefied
natural gas leaks. The detector
comes factory pre-calibrated, has a
three-second response time, takes
only minutes to set-up, operates
with less than 4.8 watts of power,
and is inexpensive to operate and
maintain. The IR400 continuously
monitors combustible gases in the
lower explosive limit (LEL) range and
provides a 4 to 20 mA analog signal
proportional to the 0 to 100 percent
LEL concentration. Gas calibration is
available to LEL values defined by ISO
10156/NFPA 325 and IEC 60079-20.
A Modbus communications interface
is also provided for informational /
programming purposes. Sensor data
and status information from the IR400
can be transmitted to a variety of
General Monitors readout units.
Fire is usually manifested in heat
(IR), smoke, light (visible), and flame
(UV). Flame is the gaseous region
of a fire where vigorous combustion
chain reactions take place. These
reactions emit radiation covering the
infrared, ultraviolet and the visible
spectral regions. The FL3100H UV/
IR Flame Detector monitors for both
ultraviolet and infrared (UV and IR)
spectral ranges and is highly immune
to false alarms caused by radiation
sources. Continuous optical path
monitoring (COPM) checks both
optical path integrity and electronic
circuitry once per minute; a wide field
of view enables greater fire detection
coverage. The flame detector's
electronics are integral within its
explosion-proof housing, allowing
detector information to be processed
at the point of detection.
www.modernpumpingtoday.com

TOTAL PROJECT MANAGEMENT

To protect natural gas production
sites, General Monitors offers a
complete line of fixed hydrocarbon
gas and flame detectors. The
companys advanced catalytic bead,
infrared point, and ultraviolet/
infrared (UV/IR) technologies
provide highly reliable hydrocarbon

hazard monitoring in rugged

environments. Whether the
requirement is single-point gas and
flame detection or a large multipoint integrated safety monitoring
system, General Monitors provides
the solution with a single-point
of responsibility for total project
management.

SEPTEMBER 2014 | 53

SEALING solutions

How to Cost-justify
Bearing Housing PART
1 of 4
Protector Seals
Key factors for reliability-focused process pump users
By heinz P. Bloch, Process Machinery Consulting

uch is known about the negative effects of moisture

and particle contamination in process machinery
lubricants. Dirt and water ingress often occur
because the sealing capability of conventional lip seals
and straight cylindrical labyrinth seals is limited, at best.
Reliability-focused user companies therefore insist on
better means of excluding both moisture and dust from
equipment bearing housings. The desired degree of debris
exclusion from pumps and similar fluid machines is more
likely accomplished with bearing housing seals that go
beyond traditional lip seals. These newer components are
collectively and interchangeably called bearing housing
protector seals, bearing protector seals, and/or bearing
isolators.
But bearing housing protector seal designs undergo
continuous improvement and our old notions about
configurations and styles may occasionally have to be
reassessed. Also, we need to first understand the degree to
which bearing housing contamination reduces bearing life.
It helps to consider the ingress protection afforded to pumps,
electric motors, and small steam turbines by modern rotating
labyrinth-type protector seals. Our knowledge base must be
supplemented by understanding industrial standards. Finally,
there are reliability expectations for modern bearing housing
seals.

WHERE CONTAMINANTS COME FROM

Moisture typically enters bearing housings as moist air or a

stream of water from hose-down operations. Unless suitable
bearing housing seals are used, a contamination-inducing
interchange of housing-internal and housing-external
(ambient) air takes place in the form of breathing. Bearing
housings are certain to breathe because we cannot change
the laws of physics: At constant pressure, rising temperatures
cause gas volume expansion and dropping temperatures
cause gas volume contraction. Open or inadequately sealed

bearing housings then allow pressure equalization and

continuous back-and-forth travel of contaminated air.
In contrast, fully sealed bearing housings undergo
changes in the pressure of the sealed-in mass. Sealing
without allowing air interchanges requires bearing protector
designs which resemble face seals. Full sealing also implies
elimination of housing vents. Because temperature changes
cause the pressure of a sealed-in mass of air to deviate from
the pressure of ambient air, a particular lubricant delivery
method may have to be modified or adjusted when using
modern face seals together with plugged vent ports.
Finally, lube oil contamination may have quite unexpected
origins. As will be seen, certain bearing protector seals are
designed with a dynamic O-ring in close proximity to a
sharp-edged O-ring groove in one of the opposing stationary
components. Accidental contact with these sharp edges can
shave off slivers of black O-ring material. These slivers can
find their way into the oil (see reference 1). We should not
overlook this potential contamination source.

CONTAMINATION EFFECTS ON BEARING LIFE

In many industrial and arid environments airborne dust,

sand, or water droplets are being ingested in sufficient
quantities to exceed bearing manufacturers anticipated
values by factors of 100 and more (see reference 2). That
being the case, operation without sealing or with inadequate
sealing of bearing housings will prove very costly and is
virtually never found in reliability-focused user companies.
In figure 1, prominent bearing manufacturer FAG
emphasizes that the seriousness of contamination depends
also on the ratio of a lubricants operating viscosity divided
by its rated viscosity (see reference 3). There obviously
could be an almost infinite number of combinations in the
amount of contamination and in the actual versus rated
ratios of viscosity v/v1. However, v/v1 ratios from 0.5
to perhaps 1.0 and a small amount of oil contamination

About The Author

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

54 | SEPTEMBER 2014

www.modernpumpingtoday.com

are considered typical for most

industrial environments. Using
0.5 for v/v1 and plotting from the
mid-point of the zone labeled
contaminants in lubricant (Zone
III) to the mid-point of the zone
labeled high degree of cleanliness
in the lubricating gap, (Zone ll) we
would find a four-fold increase in
bearing life for the cleaner oil. At a
viscosity ratio of 2:1, the projected
bearing life increase traversing from
contaminated to clean would be
approximately seven-fold. Because
Zone I is labeled ultra- clean it is
not considered here. In other words,
one would not expect to find this
degree of cleanliness in open-air
fluid machinery and associated
driver bearing housings.
Reliability professionals
understand the life-limiting
effects of lube oil contamination.
Therefore, they find it easy to
cost-justify and/or retrofit superior
means of bearing protection (see
reference 4). In lieu of inexpensive
lip seals, more expensive rotating
bearing protector seals are making
significant inroads. Thoughtfully

www.modernpumpingtoday.com

10

I
5

II

23

III

0.5

0.2

0.1
0.05

0.1

0.2

0.5

v
v

10

Figure 1: Contamination adjustment factor a23 (vertical scale) vs. viscosity ratio v/v1 (horizontal scale) in
contaminated (Zone III), clean (Zone II) and ultra-clean (Zone I) lubricants (source: reference 3).

SEPTEMBER 2014 | 55

SEALING solutions
engineered and truly superior rotating
labyrinth seals are increasingly
applied by users concerned with
bottom-line and life-cycle costs. As
of 2014, the most advanced bearing
housing seals are found in well over
100,000 process machines. They
include centrifugal pumps, fans and
gear units.

Authoritative data on the effects

of lubricant contamination can also
be obtained from a second leading
bearing manufacturers General
Catalog. For the example shown in
reference 5, SKF applied its New
Life Theory to an oil-lubricated 45
millimeter radial bearing running
at constant load and speed. Under

ultra-clean conditions (i.e., nc = 1),

this example bearing was calculated
to reach 15,250 operating hours at
90 percent probability of survival.
The SKF catalog text (see reference
5) goes on to explain that, if the
example were to be calculated for
contaminated conditions such that
nc = 0.02, bearing life would be only
287 operating hours. We believe this
is powerful analytical evidence in
support of industry moving towards
better bearing housing protection.

A LOOK AHEAD

As this series continues, we will

examine how rotating labyrinth seals
work and ask several questions of
interest to the reliability-focused
professional. Also, well take a closer
look at both industry standards and
user standards for motors, applications
for steam turbines, and application
criteria for face-type bearing protector
seals. In the end, we hope to show
that by understanding the different
demands of these applications, cost
justification can be quite simple.

REFERENCES
1. Bloch, H. P. and A.R. Budris, Pump Users
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 Users 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.

56 | SEPTEMBER 2014

www.modernpumpingtoday.com

MODERN PUMPING products

fluid METERing, inC.

CeramPump QXd
hazardous duty Metering Pump
The CeramPump
QDX Hazardous
Duty Metering Pump
from Fluid Metering
has proven to be an
Featured Product Release
excellent choice for
methanol metering
for wast water
denitrification due to its unique valveless design. This is
especially true for applications in small to mid-size treatment
facilities where flow rates are extremely low causing valved
pump designs to become air-bound and lose prime.
The CeramPump has only one moving part in contact
with the process fluid, a rotating and reciprocating ceramic
piston. Similar to conventional piston pumps, the pistons
reciprocation performs the pumping function. However, this is
where the similarity to conventional piston pumps ends.
The piston simultaneously rotates during the pumping cycle
and is synchronized to alternately open and close the inlet
and outlet ports of the pump effectively functioning as a
valve. At no point are the inlet and out ports interconnected,
thus eliminating the need for check valves. The pump drive
is FMIs QDX Hazardous Duty Drive, typically required for
pumping methanol.

For more information, visit www.fluidmetering.com.

PulSARluBE

M Automatic Single Point lubricators

In todays economy Pulsarlube understands the pressures industry is under: reducing costs, making
equipment last longer, and maximizing profits. We get it. We have the expertise as well as the experience
to create custom solutions for every lubrication challenge our customers face. The innovative Pulsarlube
M automatic lubricator is designed to ensure reliable lubrication as well as cut lubrication/maintenance
costs by at least 30 percent by precisely lubricating your valuable rotating equipment via an advanced
computerized system. It contains a vertical positive displacement feed pump, motor/gear set and
microprocessor, which when combined, allows an output pressure of more than 30kgf/cm2 (425psi). It is
ideal for lubricating hard to reach/hazardous locations via its remote installation capability of up to eight
lube points. For more information, visit www.pulsarlube.com.

WEg ElECTRiC
CfW100 Mini drive

WEG Electric introduces its new CFW100 Mini Drive with advanced technology features in
a small package. The CFW100 is a single-phase variable speed drive designed with OEMs
and end users in mind. It is the smallest VFD with HMI on the market and has power ranges
of 1/4, 1/3, 3/4, and 1 horsepower at 230 VAC with single-phase in and 1.5A, 2.6A and 4.2A
three-phase output current. Its simplicity and flexibility are unsurpassed with design features
such as built-in HMI, DIN rail mounting, detachable fan for easy maintenance and plug-in
modules for communication and I/O options. All this in a size no larger than a typical panel
contactor. For more information, visit www.weg.net or contact your local distributor.

58 | SEPTEMBER 2014

www.modernpumpingtoday.com

WoRld ChEMiCAl

yd-gWn Submersible Mag-drive Pump

Carbon fiber reinforced polypropylene makes the YD-GWN the worlds only fully corrosion-resistant,
non-metallic mag-drive submersible pump designed for acids and alkaline solutions. Ferrite magnets
and high-tech ceramics isolate the motor from the pump, eliminating the possibility of motor failure
from seal leaks. Also, it is thermally protected to automatically stop the pump for abnormal loads or
high temperatures. The YD-GWN (5002) pumps up to 87 gallons per minute and 37 feet TDH
using 1.5 horsepower 3ph / 460V and compact type YD-GWN (25A6) is up to 31 gallons
per minute and 28 feet TDH using a 1/3 horsepower, 1ph, 115V. For more information, visit
www.worldchemicalusa.com.

SKf

Spherical Washers
SKF Spherical Washers optimize bolt mounting of machinery and bolted equipment
by integrating unique design features promoting ideal performance in industrial,
marine, and all other heavy-duty bolted joint applications. The all-spherical two-piece
washer automatically adjusts under compression to compensate for up to four degrees
of angular deviations. This creates an exact parallel plane between the inner face of
the bolt head and inner face of the nut to distribute the load evenly over the entire
inner contact surface areas. Any need for on-site machining (spot facing) to achieve
parallelism is eliminated.For more information, contact Garry Stewart at 281.925.2847,
[email protected], or visit www.skfusa.com.

vAf filTRATion
SySTEMS

v-200SA
-200SA Self-Cleaning
Automatic Screen filter
ilter
The V-200SA featuring the most
advanced and cost effective
self-cleaning screen filtration
technology available today is ideal
for flow rates from 30 to 220 gallons
per minute (7 to 50 cubic meters per
hour). The patented drive mechanism
used in the V-200SA is the most
efficient and simplistic design
available resulting in fewer moving
parts, simpler controls, lowest
flush rates available, multiple pass
cleaning, and limited maintenance
requirements. Constructed using
316L stainless steel, the inherently
corrosion resistance material
of the V-200SA ensures a long
service life under a wide range of
water quality conditions. Process
water, cooling tower filtration,
pre-filtration of membrane,
irrigation, or wherever suspended
solids are removed down to 10
micron are applications perfectly
suited for the V-200SA. For more
information, call 303.425.4242 or
email [email protected].

www.modernpumpingtoday.com

Standard model
(1-12 channels)

Expandable model
(12-48 channels)

MEggiTT SEnSing SySTEMS

vibralink Switchboxes

The new VibraLink enclosures feature an industry-exclusive LED

that indicates when data can be collected. Enclosures are custom
manufactured to user specifications of size, material and output
to meet every monitoring need. VibraLink switchboxes provide
a convenient termination for up to 48 cables, for safe and fast
data acquisition. All Meggitt enclosures feature radio frequency
interference (RFI) filtering, differential switching and a grounding
lug. MIL-C-5015 and BNC output connectors provide quick
connectivity to portable data collectors. Online connectivity output
is available for route-based or online monitoring. LEDs indicate
when sensor bias output voltage (BOV) levels have stabilized,
and data is ready to be collected. The VibraLink series includes
enclosures compatible with triaxial and dual-output sensors. Other
housings include termination junction boxes, cable reduction
boxes, and transmitter enclosures. For more information, visit
www.wilcoxon.com or e-mail [email protected].

SEPTEMBER 2014 | 59

PUMPING trends

Flexible Manufacturing Means

Sustainable Manufacturing
The importance of Industrial and Systems Engineering for manufacturers

or todays manufacturers, the

shift is on from mass production
to mass customization. Dr. Ola
L. A. Harrysson is co-director of the
Center for Additive Manufacturing
and Logistics at North Carolina State
Universitys Fitts Department of
Industrial and Systems Engineering.
He is also a professor and Fitts
Fellow in Biomedical Manufacturing.
Dr. Harrysson spoke with Modern
Pumping Today to offer his insight on
the growing need for flexible and adaptive approaches in the
domestic manufacturing sector.
MPT: What is Industrial and Systems Engineering (ISE) and how
does it prepare engineers for the future?
Dr. Ola L. A. Harrysson: Industrial and Systems Engineering
is a fairly broad field including manufacturing, but the main
objective is to optimize processes and make them more
efficient and more profitable. ISEs have been helping numerous
industries with scale-up problems and taking technologies from
the laboratories and making them main stream. ISE students
learn how to solve problems and to create systems to handle
anything from ordering raw materials, schedule of production,
and manufacturing, to quality control and logistics. These new
technologies will change the supply chain in many ways and
ISEs will be well familiar with these challenges.
MPT: How does ISE relate to the shift from mass production to
customization?
Dr. Ola L. A. Harrysson: Mass customization requires flexible
manufacturing systems, which is one of the main topics for
ISEs. For a US company to be competitive in the international
market they usually need to be able to offer services that the
competitors dont. In many cases this means that US companies
will need to be more agile and make what each customer wants
instead of mass producing. ISE students are very knowledgeable
in the just-in-time concept and make to order, which are basics
concepts for mass customization. ISE students probably spend
more time learning about mass customization than any other
engineering discipline.
MPT: How do you foresee the role of public and private
partnerships in tomorrows manufacturing field?
Dr. Ola L. A. Harrysson: Public-private relationships seem to
be more common these days and might play an important role
in the future. The ISE AM research group has collaborated with
small companies through SBIR/STTR efforts for many years with
mixed results but our current involvement with America Makes
60 | SEPTEMBER 2014

has pushed these collaborations much further by involving

large companies as well. In the past it was very difficult to get
numerous educational entities as well as private companies to
collaborate on the same project but that is now happening. The
European Union has forced collaborations between the nations,
educational institutions, and private companies for many years
through their funding. The students that are involved in these
research projects will learn to collaborate and to coordinate with
multiple parties within different organizations. These are skills
that will help them in the future since this will most likely be a
model that will stay for a while.
MPT: In fields related to infrastructure development, especially
in industrial pumping, the recent decades have felt a brain
drain, with retiring engineers not being replaced by newer
graduates. How can the industry best attract tomorrows best
minds?
Dr. Ola L. A. Harrysson: Industries need to be active in their
recruitment of tomorrows engineers, and they need participate
at an early stage. Students who are approached early and offered
internship opportunities will often return to the companies upon
graduation given that they are challenged and rewarded for their
work. We have had many students who have completed several
rotations as interns, and they usually end up at the company that
impressed them the most by challenging them and giving them
responsibilities. Further, the industry should be actively involved
in the educational programs by identifying the skills that they
need and providing real-life opportunities for the students in
form of course projects or case studies.
MPT: What are some of the keys to establishing a flexible
and sustainable manufacturing sector domesticallyand a
workforce prepared for it?
Dr. Ola L. A. Harrysson: The US is currently falling behind
the rest of the world when it comes to additive manufacturing
research and development and the government needs to invest
more in this sector. The ISE Department at NCSU has been
working in AM for over twelve years and have been pushing
the manufacturing aspect of it. However, it has been very
difficult until recently to secure funding for the research and
development. We have been teaching courses in these areas
for a long time and more universities need to follow to provide
engineers with sufficient skills. The hands-on aspect of AM is
very important since these technologies are new to most people.
Although the high-end equipment is very expensive and difficult
for universities to afford, AM has the potential to level the
playing field since these technologies tend to be very automated
and the need for manual labor is minimal. The equipment cost
the same in most countries and the materials are provided by
a few vendors so US companies have the chance to again be
competitive in mass customization.
www.modernpumpingtoday.com