Modern Pumping

MODERN TODAY
PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY SEPTEMBER 2013
REBUILDS
MAXIMIZE
PUMP LIFE
DUAL DRIVE PUMPS FOR WATER WORKS PREFABRICATED LIFT STATIONS DELIVER ACCURATE FLOW RATES MADE EASY
CONTENTS
6 12
SEPTEMBER 2013
14 On TOPS of the World 18 Life in the Fast Lane
Industry News Trade Show Profile Case Studies

Prefabricated lift stations deliver faster x for private sewer utility Five-axis water jet cutting system eliminates taper, cuts 3D parts
22 Going Global
Landia pumps and mixers provide long-term solutions from East to West
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26 Tuning the Accuracy of Lift Station Flow Rates: Part 1 of 2 30 Pump Rebuild Protection to Help Maximize Pump Life
Water & Wastewater Solutions Maintenance Solutions Pump Solutions

Part 2 of a 3-part checklist of improvement options and considerations
34 Highest Precision in the Laboratory

Newly developed diaphragm pump delivers micro-ow metering in high-pressure laboratories
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36 Best Practices for Pump Reliability
42 Rapid Results
Dewatering Solutions
Bedford Pumps power slalom for Pinkston
44 Driven Toward Innovation

Dual drive pumps and compressors for the water works industry
Motor Solutions
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www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266

@ModPumpMag
48 High Temperature Bearings for Oil Field Flares 52 Recipe for Success
Power Generation Solutions Processing Solutions

Danfoss VLT Drives are secret ingredient for artisan cheese maker
RUSSELL HADDOCK COO/Publisher russell@modernpumpingtoday.com JEFF FLETCHER Associate Publisher jeff@modernpumpingtoday.com RANDY ARMISTEAD Associate Publisher randy@modernpumpingtoday.com J. CAMPBELL Editor jay@modernpumpingtoday.com DONNA CAMPBELL Editorial Director donna@modernpumpingtoday.com SCOTT GORDON Art Director scott@modernpumpingtoday.com LISA AVERY Assistant Art Director lisa@modernpumpingtoday.com CHRIS GARMON General Manager chris@modernpumpingtoday.com LINDEY SCOTT Circulation Manager lindey@highlandspublications.com JAMIE WILLETT Circulation Consultant jamie@modernpumpingtoday.com INGRID BERKY Administrative Assistant SHANNON COLEE Account Executive NANCY MALONE Account Executive RANDY MOON Account Executive DON MORGAN Account Executive DREW OAKLEY Account Executive
56 Comprehensive Analysis of Measurement Instruments
Valves & Controls Solutions

Side-by-side microphone tests come through loud and clear for PCB Piezotronics
58 Maximize Your Filtration with High-Capacity Pleated Cartridges 62
Sealing Solutions Modern Pumping Products Pumping Trends
64 Of Pandas, Penguins, and Black Hats

Shanley Pump and Equipments Brad Miller previews the new frontier of search engine optimization
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TIM GARMON President LARRY DAUGHETY Vice President DENNIS DAUGHETY Vice President
EDITORIAL ADVISORY BOARD

Heinz P. Bloch, P.E.
Consulting Engineer, Process Machinery Consulting
Michael Mancini
Consultant and Trainer, Mancini Consulting Services
Lisa Roe
Business Development Manager, Wastewater Pumps Xylem Inc.: Flygt
Robert G. Havrin
Director of Technology, Centrisys Corporation
John M. Roach
Engineering Manager for New Product Development Trebor International, Inc.: A Unit of IDEX
Greg Towsley
Director of Regulatory and Technical Affairs, Grundfos
Todd Loudin
President, Flowrox Inc.
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 specically 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 jay@ modernpumpingtoday.com. For address changes, please contact Lindey Scott: lindey@highlandspublications.com
INDUSTRY news
HI AND FSA LEADERS SUMMIT MT. KATAHDIN, MAINE
The challenging climb was led by Henri Azibert, chief technology officer of A.W. Chesterton Company and VP of the Fluid Sealing Association with Robert Asdal, Executive Director of the Hydraulic Institute and Henris friend Bob Quinn, Esq. Summiting the highest mountain in Maine, at 5268 feet (1606 meters), by crossing the Knife Edge, took HI and FSA leaders to new heightsliterally speaking. Named Katahdin by the Penobscot Indians, the term means the greatest mountain. While this was strictly social adventure, new business opportunities between FSA and HI were explored. The next major educational event being held jointly by FSA and HI is the Fundamentals of Mechanical Seals course. This fourpart webinar series was released September 5 and features instructions by experts from four leading seal manufacturers (FSA and HI members), including Henri. Registration details can be found on the HI/Pump Systems Matter website: www.PumpSystemsMatter.org. seven-story, former warehouse designed to house water-related technology development facilities for universities, established businesses and start-ups. The centers opening ceremony took place September 12. The Water Center will allow Grundfos to leverage key relationships with original equipment manufacturers such as Veolia and Siemens, which maintain a presence in the Great Lakes region. "We view the Great Lakes region as an emerging and increasingly vital hub for the water industry," says Jay Stellmacher, business unit director for Grundfos USA Water Treatment. "Our new office in Milwaukee will allow us to continue to grow our presence in the area." The $22 million 98,000-square-foot building features a lecture hall, exhibition space for new prototypes, high-tech core facilities and a state-of-the-art water flow lab. The open, collaborative concept is critical to supporting water research and product development. Tenants include a mix of industry, academia and government expertise. "The Global Water Center gives us the unique opportunity to harness the economic talent and technology development of industry and academia under one roof," says Dean Amhaus, president and CEO of the Water Council. "Grundfos expertise as a global leader in water technology helps us truly position Milwaukee as a world water hub." Milwaukees proximity to Lake Michigan, which provides approximately 1 billion gallons of fresh drinking water each day, makes it the ideal location for freshwater research and development. Grundfos recently opened its North American
GRUNDFOS JOINS MILWAUKEES GLOBAL WATER CENTER
To promote its brand among the water community and collaborate with partners across all business sectors, Grundfos has leased an office in Milwaukees Global Water Center, a
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INDUSTRY news
headquarters about 100 miles south of Milwaukee in the Chicagoland area, another region along Lake Michigans shore. Grundfos also operates a manufacturing and service facility in the Chicago metropolitan area. Danfoss, a leading manufacturer of high efficiency electronic and mechanical components and controls for HVAC, industry and water, joined with the Alliance to Save Energy and the Water Environment Federation to host a The Imperative for a Sustainable Infrastructurea briefing on Capitol Hill to discuss water and energy efficiency. The briefing, which drew attendance from regulatory agencies, congressional staff, advocacy organizations and industry, addressed existing technologies, best practices and various policies and financing mechanisms that can be applied to improve water and energy efficiency in water and wastewater treatment plants. According to the experts testimony, improving efficiency in all sectors is critical to boosting the U.S. economy, preserving the environment, and increasing energy security. The briefing highlighted two existing technologies that could improve the energy use of wastewater treatment plants: anaerobic digestion and cogeneration. John Masters, Danfosss vice president of
DANFOSS CO-HOSTS CAPITOL HILL BRIEFING, URGES REDUCED ENERGY USE IN WATER AND WASTEWATER SECTORS
Orbeco-Hellige has received ISO 9001:2008 certification, an internationally recognized standard issued to organizations with a quality management system. The certification was authorized by TVRheinland, a global provider of independent testing and certification services. Orbeco-Hellige is extremely pleased with this certification, as we take great pride in the quality of services and products we provide to meet our customer's needs. This certificate illustrates our philosophy of continual improvement, attention to detail and companywide commitment to excellence. ISO 9001:2008 provides a set of requirements that must be in place to have a quality management system, regardless of the organizations size, product or service line, or public or private status. Certification to the standard is voluntary, and organizations must complete a rigorous auditing process by a third-party registrar. Located in Sarasota, Florida, Orbeco-Hellige serves as the North American headquarters for the Tintometer Group of Companies. They specialize in the manufacturing of products for the water quality and color measurement industries. For more information, contact Orbeco-Hellige at 800.922.5242 (941.756.6410), via email at service@orbeco.com or on the web at www.orbeco.com.
ORBECO-HELLIGES SARASOTA FACILITY NOW ISO 9001:2008 CERTIFIED
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INDUSTRY news
sales for water, demonstrated the energy saving potential of variable frequency drives (VFDs), a readily-available and proven technology.
TOSHIBA INTERNATIONAL CORPORATION ANNOUNCES TOSHIBA INDUSTRIAL PRODUCTS CANADA
goals for TIC, which includes growing its core motor products, further globalizing TICs operations, and expanding its revenue base, says Mike Ayers, senior vice president and general manager of TICs Industrial Division. We are confident that TIPCAs product offerings will complement all of TICs goals as well as bolster Toshiba Corporations motor line-up.
Toshiba International Corporation (TIC) announces the completion of its acquisition of Elettra Technology Incorporated (ETI). The new business will be named Toshiba Industrial Products Canada (TIPCA) and will operate as a wholly owned subsidiary of TIC. The acquisition of ETI is a strategic move for TIC to add to its strength in the electric motor marketplace and support the growth of TICs industrial and infrastructure business. This represents Toshibas first-ever motor acquisition in its 138 years of operations in the motors market. TIPCA is relocating ETIs operations to a recently renovated, state-of-the-art 58,000 square feet manufacturing plant in the Hamilton area with an additional 5,000 square feet of office space. The added space and crane capacity will provide TIPCA with the ability to manufacture larger motors and motors that fill complex and special application requirements, which will further enhance TICs business portfolio of large electric motors in the Canadian and global marketplace. By keeping TIPCAs operations in the Hamilton area, this allows TIC to continue to employ ETIs entire highly-skilled workforce and begin strategies to further grow its staff and operations. Well beyond the immediate financial and synergistic contributions, this acquisition will promote significant strategic
IRISS RELEASES CAP 4-INCH INFRARED WINDOWS TO MEET MARKETPLACE DEMAND
IRISS, a leader in the industrial infrared (IR) window market for electrical safety, is pleased to announce their addition of the CAP 4-inch IR windows protected by their Unconditional Lifetime Warranty. We pride ourselves in offering our customers IR windows to fit their needs and applications, says CEO Martin Robinson. The demand we have seen for this size IR window resulted in us adding this to our standard product line offering, continues Robinson. Now IRISS has over fifty standard IR window designs making them the only IR window manufacturer with standard options for customers to fit their needs. Additionally, for customers needing exceedingly unique IR windows, IRISS offers Custom Solutions. The IRISS CAP 4-inch is available with either transparent or opaque polymer both complying with all mandatory impact, load and flammability requirements. It features an increase in the field of view when compared to traditional round IR windows. Several major OEMs throughout the United States and Canada are among the first to adopt the IRISS CAP 4-inch IR windows.
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TRADE SHOW profile
WEFTEC 2013
The largest water quality event in the world expands again
EFTEC 2013the Water Environment Federations (WEF) 86th Annual Technical Exhibition and Conferencelooks to maintain its leading position as the foremost event in the worldwide water industry. This years conference will feature more than 140 technical sessions, 27 workshops, numerous events, and the largest exhibition in WEFTEC history. In partnership with BlueTech Research and Imagine H2O, WEF will once again present the Innovation Pavilion, one component of the broader Showcase. The Showcase will feature a host of companies offering cutting-edge products and services, as well programming structured around innovative themes that will occur throughout the week in the Innovation Pavilion Theater. Innovation shifts the water industrys business-asusual thinking to something different and better. The WEFTEC 2013 Innovation Showcase will help water professionals think outside of the box by putting a spotlight on water sector innovation and providing access to the leaders and technologies that are making it happen.
INNOVATION PAVILION
THE CONFERENCE WITHIN A CONFERENCE
WEFTEC 2013 will debut the inaugural Stormwater Congress. Featuring an extensive line-up of stormwater programming, world-class speakers and dedicated exhibit space, this new event offers attendees the best of both worlds. Following WEFs very successful Stormwater Symposium in 2012, this conference-within-a-conference was developed to maximize networking opportunities for stormwater professionals and facilitate participation in high quality programming dedicated to stormwater-related
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issues. Featuring seventeen technical sessions and more than seventy worldclass speakers, the events technical programming will include cutting-edge issues such as changing regulations and policies, climate change impacts, stream restoration, flow-based TMDLs, stormwater financing strategies, and more.
water, underscore the importance of the water profession, and demonstrate to the community about how to get started with clean water initiatives. Now in its sixth year, the annual WEF Community Service Project supports grassroots solutions and environmental stewardship on a local level while promoting WEFs overall mission to
preserve and enhance the global water environment. Local and WEF leadership are expected to attend the opening ceremony to share their vision for environmental protection and community involvement and service. By investing in tomorrows leaders as well as todays professionals, WEFTEC looks to have a future as promising as its reputation.
THE WORLDS FINEST
A distinguished panel of national and international water leaders will examine how communities of all sizes can best prepare for future water demands and related challenges during the second annual Water Leaders Session. As one of the most highly anticipated events of WEFTEC 2013, The Future of Cities and Water: Insights from Great Water Cities will be held Monday, October 7. Addressing this important topic will be a panel that includes senior executives from iconic and diverse water cities who will share their experiences and discuss innovative approaches to sustainable water management. Facilitated by G. Tracy Mehan III, a former U.S. EPA assistant administrator for water and a Principal in the Environmental Science and Policy Division for the Cadmus Group in Arlington, Virginia, the distinguished panel will include Harlan Kelly, Jr., general manager, San Francisco Public Utilities Commission Heiner Markhoff, president and CEO, GE Water & Process Technologies Chew Men Leong, chief executive, PUB Singapore Sue Murphy, chief executive officer, Water Corporation of Western Australia
LEADING THROUGH SERVICE
To help promote environmental stewardship and raise awareness of the value of water among Chicagos youth, the WEF Students and Young Professionals Committee (SYPC) has organized the sixth annual WEF Community Service Project, Reading, Writing , and Rain Gardens. During the event, conference volunteers will replace concrete with green infrastructure on the playground at Haines Elementary School in Chicagos Chinatown neighborhood. The trees and rain garden will help relieve runoff from urban flooding and reduce heat island effect in a critical public space for students. Locating the project at a local school gives WEF the opportunity to inspire area students to the cause of clean
SEPTEMBER 2013
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CASE Studies
On TOPS
T
hroughout his fourteen years with Valley Rural Utilities (VRU), Floyd Ogden has confronted numerous deficiencies with the aging wastewater collection system serving Hidden Lake, a lakeside residential development located in Dearborn County outside of Lawrenceville, Indiana. Recurring pump station failures and I and I have been among issues at the top of the list. He attributes the problems to the systems age and deterioration, clog-prone pumps, shoddy original construction, and capacity shortfalls caused by higher density development than the collection systems original design for two hundred homesites.
of the
By Steve London, Steven London Associates
World
Prefabricated lift stations deliver faster fix for private sewer utility
Fiberglass basin about to be inserted into hole adjacent to existing pump stations.
HIDDEN IN PLAIN SIGHT
We experienced overflows and up to six pump outages a month that cost us at least $250 per incident, Ogden recollects. The failures drew customer complaints and were sapping our budgets until we recently qualified for a $13 million federal loan through the USDA Rural Development that will underwrite an extensive multi-phase improvement program.
Two-man team sets one of the basins into the excavation.
About The Author

Steve London is president of Steven London Associates, Lansdale, Pennsylvania. Steve has extensive background as a writer and editor specific to municipal water treatment technologies. For the past eighteen years, the company has been involved in the development of application stories that highlight various solutions for water management professionals. He can be contacted at slondon2@verizon.net or 215.361.3630.
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Among the numerous problems we identified in a preliminary engineering study were eight of our twelve duplex lift stations had reached the end of their life expectancy. Their replacement became a high priority. VRU acquired the Hidden Lake service area in 1995 from the homeowners association that had assumed control of the sewage system from the subdivisions developer. The private utility serves a total of 1945 customers in a service area near the state line with Ohio and anticipates projected growth will add another 1000 connections. The Hidden Lake infrastructure is defined by fifteen sections with 230,000 linear feet (70,104 meters) of line and 850 manholes that include twelve lift stations. The lines are predominantly 8-inch (203.2 millimeters) clay that feed into larger trunk lines, some as large as 15 inches (381 millimeters), and a one-million-gallon (3,785,410 liters) equalization basin that acts as a backstop for handling wet weather events. Treatment occurs downstream at the South Dearborn Regional District Wastewater Treatment Plant in Lawrenceburg, Indiana. Replacing the 110 to 660 gallons per minute (6.94 to 41.64 liters per second) pump stations was complicated by their locations. Several of them are located 100 feet (30.48 meters) off the road, with steep topography, and unavoidable intrusions into customer homesites would be a necessity. Like most utility managers, Ogden needed access across legitimate easements with mature landscaping whose disruptions could spark an expected firestorm of customer protests. Completing the replacements as fast as possible while the existing stations remained active further shaped the project management plan.
Basins have a sloped bottom to churn solids into the Flygt N pump.
TOPS prefabricated station shown being set in place.
Crew spreading stable infill around the unit now in place and ready for connections.
SEPTEMBER 2013
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CASE Studies
AN INNOVATIVE SOLUTION
HREZO Engineering Inc., VRUs consultants, officed in Greendale, IN worked with the utility to devise a more practical alternative than demolition and rebuilds of the eight precast concrete facilities. Instead, the amended operating plan called for the original precast concrete stations to have their pumps removed and the wetwells converted to junction basins that would continue to collect the sewage from their original service lines. The collected wastewater would then flow by gravity through a single discharge outlet into an adjacent, prefabricated lift station from where it would be pumped downstream for eventual treatment at the South Dearborn Regional Sewer District WWTP in Lawrenceburg. Preserving the original service connections at the precast stations kept the penetrations in the prefabricated fiberglass wetwells to single inlet and discharge outlets at each location. The adjacent prefabricated wetwells are but half of a two-part lift station package designed specifically to complement the performance of a new generation of submersibleand uniquely clog-resistant pump. The combined package, manufactured by Flygt, a brand within Xylem Water Solutions, Inc., presented a remarkably simple and faster installation for the tandem replacements assuming the pumping mission. Following success with the two-part lift station and control panel at one installation, the utility had HREZO Engineering undertake engineering and design to apply the same units at the remaining stations. The prefabricated TOPS units (The Optimal Pump Station) are each equipped with a recently introduced Flygt Adaptive N-Pump. The complete package, including control panels and a Flygt AquaView SCADA management software system, were procured directly from the manufacturer. The single source for the integrated system included the prefabricated wetwells, pumps, easy access split aluminum access covers, sealed wall penetrations, along with the required fittings, mounting hardware, cover, vent pipe, level and pump station controls. One station was also equipped with an optional Mix- Flush valve to clear the wetwell of any built up sludge. The installation contract
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was awarded to C & H Excavating, based in Milan, IN following competitive bids. The schedule calls for completing the installations by the end of this summer.
FEATURES COMPLEMENT PERFORMANCE
The TOPS concept also simplified procurement because a single source supplies the fiberglass wetwells, pumps, sealed wall penetrations, and required fittings, mounting hardware, vent pipe, level and pump station controls. The aluminum access cover utilizes an integral Safe-Hatch design, which provides fall through protection that completes the package. The innovative, self-cleaning wetwell bottom directs solids and debris to the inlet of the Flygt Adaptive N Pumps where they can be pumped from the station. The combined design features optimize the fluid handling of a lift station, especially those facilities with high solids and debris in their flows. The twofold design features inherently eliminate dead zones where sludge can build up in non-agitated areas of traditional flat-bottom wetwells. One of the new stations also received a Mix-Flush Valve whose 15-second blast of recirculated wastewater flushes and helps remove settled solids at the bottom of the wetwell during startup of each pump cycle. The hydraulics of the Adaptive N-Pump delivers another Flygt innovation in fluids handling to the utility equipment market. The self-cleaning impeller is the primary feature of the N-technology that delivers unrivaled clog-free performance. The Water Environment Federation recognized the Adaptive N-hydraulics by naming the enhanced N-Pump technology The 2011 Most Innovative Product. The improved pumps clog resistance benefits from an impeller designed to move axially upwards when encountering most bulky rags, cleaning and personal hygiene wipes, or the toughest other debris so it passes through smoothly. The 6-foot (1.83 meters) diameter fiberglass stations are installed in fresh excavations, 14 to 16 feet (4.27 to 4.88 meters) deep, adjacent to the existing precast concrete stations that entered service in the 1970s. The added volume of the
TOPS prefabricated wetwells provide the capacity increase to gain the needed efficiency and to handle the past growth in connections. Furthermore, the more clog-resistant Adaptive N-pumps are acclaimed for eliminating built up material on their impellers that induces drag and compromise energy efficiency.
Our first station entered service two years ago and has used less than half the electricity of the old pumps, Ogden says. He expects the work at the eight stations to be completed later this year when he can turn his attention to other issues affecting the collection system.
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CASE Studies
Life in the Fast Lane

Five-axis water jet cutting system eliminates taper, cuts 3D parts
By Nancy Lauseng, Jet Edge, Inc.
ompeting in the NASCAR Sprint Cup Series requires more than just a fast car and a steady driver. For every race, every lap, countless hours go into ensuring the car and its crew have the right materials in place to succeed. This includes dozens and dozens of specialized parts that have to be precision made. Teams that can find efficient and reliable ways to keep their cars on the track gain a competitive edge, and thats what has led to a productive partnership between Michael Waltrip Racing and Jet Edge precision water jet cutting systems.
MWR chief technical officer Tom German (left) with Michael Waltrip.
waterjet machine, MWR selected Jet Edges new Edge X-5 five-axis waterjet cutting system, which is capable of cutting beveled and taper-free parts from virtually any material. The machine is powered by a 100 horsepower Jet Edge iP55-100 hydraulic intensifier pump that pressurizes water to 55,000 psi and features IGEMS CAD/CAM/ Nesting software. This new multi-axis water jet system complements MWRs existing threeaxis 90,000 psi 100 horsepower High Rail Gantry system, installed in 2008.
NO TIME TO WAIT
This is not the first collaboration between the race crew and Jet Edge. Michael Waltrip Racing (MWR) has installed a second Jet Edge precision water jet cutting system at its fabrication shop in Cornelius, North Carolina. For its second
The Edge X-5 five-axis waterjet system.
Jet Edges Edge X-5 five-axis waterjet system cuts precise taper-free parts from virtually any material. The system is capable of cutting sophisticated 3D parts such as impellers and bevels up to 50 degrees and is designed to provide years of dependable
FROM THE RACE TRACK
About The Author

Nancy Lauseng is marketing manager for Jet Edge, a leading manufacturer of ultra-high pressure waterjet technology. For more information about Jet Edge, visit www.jetedge.com or call 800.JET.EDGE or 763.497.8700. For more information about Michael Waltrip Racing, visit www.michaelwaltripracing.com .
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service in harsh industrial environments. Its sturdy design separates the motion system from the catcher tank, eliminating vibration and ensuring maximum part quality. The Edge X-5 utilizes an industrial PC controller. It is ball-screw driven for optimal precision and features direct-couple AC brushless digital servo motors and single or double carriages. Critical bearing components are protected with heavy metal covers with brush seals and positive air pressure. The Jet Edge Edge X-5 waterjet machine is available in many sizes, from 5 inch by 5 inch (127 millimeter by 127 millimeter) to 24 inch by 13 inch (609.6 millimeter by 330.2 millimeter). An optional second cutting head can be added to double productivity. MWR uses its Jet Edge waterjets to cut more than 1000 parts for each of its
The Edge X-5 features patented Permalign cutting technology.
NASCAR Sprint Cup cars. It builds about fifty-six cars per year, including the #55 Aarons Dream Machine Toyota Camry driven by Michael Waltrip, Mark Martin and Brian Vickers, the #56 NAPA Auto Parts Toyota Camry driven by Martin Truex Jr., and the #15 5-Hour Energy Toyota Camry driven by Clint Bowyer. Our engineering department is very excited to have this powerful new tool, says Tom German, MWR chief technical officer. The Jet Edge Edge X-5 is taking our fabricating capabilities to a whole new level. In fact, weve already taken design improvements to the track and Victory Lane.
TO THE FLOOR SHOW

MWR has a lot at stake when it comes to the performance and reliability of its manufacturing
This header flange was one of the first parts MWR cut with their Edge X-5.
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CASE Studies
Precision controls allow operators to supply MWR with the right part each time.
equipment, Jet Edge president Jude Lague says. Were very proud that weve earned their confidence and that they chose Jet Edge for their second system. Jet Edge will introduce the Edge X-5 five-axis waterjet cutting system for the general public at FABTECH 2013, November 18 through 21 in Chicago, where representatives will conduct live five-axis water jet cutting demonstrations on its premiere 90KSI Edge X-5 waterjet system. The company also will exhibit several ultra-high pressure waterjet pumps, including its 90KSI X-Stream hydraulic intensifier pumps and the eco-friendly and budget-friendly Eco-Jet direct drive pump.
JUST THE BEGINNING
Jet Edge offers the widest range of waterjet pumps in the industry. Its pumps include hydraulic intensifier pumps and direct drive pumps. 36KSI (2500 bar), 60KSI (4100 bar) and 90KSI (6200 bar) models are available from 30 to 280 horsepower in both electric and diesel models. X-Stream Waterjet Intensifier Pump Jet Edges 100 horsepower, 90KSI (75 kilowatt, 6200 bar), X-Stream xP90-100 waterjet intensifier pump is capable of producing 90KSI (6200 bar) and supports 75KSI (5200 bar) continuous operating pressure. The X-Stream achieves much faster cutting speeds and drastically lowers operating costs compared to traditional 60KSI (4100 bar) water jet pumps, enabling users to increase productivity and reduce part costs. The X-Stream produces 50 percent more pressure than a 60KSI (4100 bar) intensifier pump, resulting in a 40 to 50 percent increase in productivity for many materials. Compared to a 60KSI (4100 bar) pump, typical operating pressures of 75KSI (5200 bar) use 30 percent less water, 30 percent less power, and up to 50 percent less abrasive, resulting in a 40 percent reduction in operating costs. The xP90-100 is capable of producing flow rates of 1.45 gallons per minute (5.49 liters per minute) and supports up to a 0.017 inches (0.43 millimeter) orifice. Fittings and tubing are rated for 100KSI (6900 bar). The X-Stream is backed by nearly 10 years of extensive research and development in hyper-pressure technology. The X-Stream also is available in a 50 horsepower (37 kilowatt) model. Eco-Jet Direct Drive Waterjet Pump Eco-friendly and budget-friendly, the 30 horsepower, 55KSI (22 kilowatt, 3800 bar) Jet Edge Eco-Jet waterjet pump features an efficient direct drive pump design that consumes up to 40 percent less electricity than a 50 horsepower (37 kilowatt) hydraulic intensifier pump, but produces the same output. The Eco-Jet produces up to 1 gallon per minute (3.78 liters per minute) of 55KSI (3800 bar) ultra-high pressure (UHP) water for precision cutting, cleaning and surface preparation applications. It runs a 0.015 inches (0.38 millimeters) waterjet orifice and can power most manufacturers waterjet cutting systems and waterjet tools.
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CASE Studies
Landia pumps and mixers provide long-term solutions from East to West
By Thorkild Maagaard, Landia Pumps
o anticipate the changing needs of pump users, manufacturers need to build closer relationships with their clientseven if they seem a world away. At Landia, two recent cases illustrate how one of the top pump and mixer manufacturers in Europe has expanded its reach both east and west in order to better see the needs of todays industrial pump users.
GO EAST
and performance of twenty Landia flowmakers that have served Guilin since 1995. Landias proven POPL-I flowmakers will be installed in the aeration, anoxic, and anaerobic zones at Guilin, where their low rotations provide unrivalled flexibility for wastewater treatment. POP-I mixers from Landia, which are designed for harsh conditions, will also agitate, homogenize, and keep solids in suspension.
Guilin, the pearl of Chinas emerging tourist industry, has chosen Landias flowmakers, mixers, and recirculation pumps for two new wastewater treatment plants that are being built in the city famed for its magical land formations. The order, for a total of seventy-eight Landia flowmakers, mixers and recirculation pumps was based on the ultra-reliability
GO WITH THE FLOW
The expansion demonstrates that forward-thinking customers recognize and appreciate the operational and financial benefits that can be gained from investing in top quality equipment. For product longevity and reliability, Landias reputation in China and the Far East goes from strength to
strength. The flowmaker POP-I series is planetary gear driven, available in 1.8 to 12.2 horsepower and can be found in various applications: for flow creation and mixing of liquids at water plants, wastewater treatment plants, in industrial applications, and food processing. Operation is often continuous, which requires high efficiency and thereby a low energy consumption. This is achieved through a low speed. The low speed minimizes turbulence on the surface, whereby oxidation is avoided in the anoxic phase. Low propeller revolutions grant soft effluent treatment in activated sludge processes. Flocculation is promoted with the gentle mixing and disturbance of the biological balance is avoided. Meanwhile, Landias AXP-I pumps, which recirculate large volumes of
About The Author

Thorkild Maagaard is Landias export sales director. For more information on Landias range of pumps, visit www.landiaworld.com .
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water at low head but without creating excessive energy bills, will recirculate activated sludge from the Aeration Zone into the Anoxic Zone at Guilin. These recirculation pumps have a propeller designed for high efficiency pumping and a triple shaft sealing system. The planetary gear system gives the impeller ideal speed and efficiency. The AXP-I series comes with pressure tested waterproof motor casing, IP 68 rated, and is available with an explosion proof motor.
GO GROCONTINENTAL
Landia has continued its recent run of work in Shropshire with the introduction of a new pumping station for its neighbor Grocontinental, one of the United Kingdoms leading international storage and distribution companies. Working in
close conjunction with Chalcroft Construction who carried out the installation as part of a new 43,055.6 square feet (4000 square meters) warehouse for Grocontinental, Landias pumping station will handle wastewater and yard run-off at the prestigious Whitchurch site. David Grocott, joint managing director at Grocontinental, comments, Chalcroft Construction has proved to be a proactive, reliable long term partnerand we are also very pleased
to be working with our close neighbors Landia who are an equally reputable and quality-conscious company. The new installation at Grocontinental follows the successful work carried out by Landia at the nearby Dearnford visitor attraction and at The White House School, where raw unscreened sewage is pumped from a 9.84 feet (3 meters) deep sump 1312.34 feet (400 meters), via 3.94 inches (100 millimeters) of pipework to the sewer main by a 4 kilowatt 1500 rpm Landia DG Chopper Pump, which uses a unique knife system to reduce the risk of clogs developing in the line and ensures comminution of coarse solid parts making the pump especially suited for the pumping of heavily contaminated and thickened liquids with a high dry matter content.
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WATER & WASTEWATER solutions
Tuning the Accuracy of Lift Station Flow Rates

By Gary L. Kerr, Maid Labs Technologies, Inc.
PA RT 1
OF
o tune means to adjust for optimal or improved performance. Musical tuning entails adjusting an instrument to achieve a perfect pitch. Depending on the instrument, this continual process requires one to consider many fluctuating variableschanges in temperature, for example, or the varying acoustics of physical spaces. But much relies on intuition. Accurately determining lift station volumetric flow rates requires tuned precision, but on a more sophisticated scale. As wastewater collection systems age it becomes important to accurately monitor inflow and infiltration at lift stations; engineers and utility managers rely heavily on flow-data accuracy in making sound decisions to improve and maintain their systems efficiency. But, as the EPA acknowledges, todays wastewater utilities find themselves faced with increasingly tight budgets, and utilities search for cost-effective ways to monitor and record lift station flow ratesdata that has never been easy to calculate.
PRE-SCADA METHODS OF MEASUREMENT
Before the advent of SCADA (supervisory control and data acquisition) or telemetry systems, the municipal industry had two ways to measure flow rates in collection systems. Utilities could install a magnetic flow meter in the effluent line or use several types of metering devices in the influent pipe of the lift station. These techniques included volumetric, open channel, and closed conduit flow measurements. Implementing these flow techniques have myriad cost variables associated with them: installation,
About The Author

Gary L. Kerr is the national product manager for Maid Labs and brings with him over twenty years of experience in product performance and monitoring of wastewater pump station. For more information, visit www.maidlabs.com .
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manpower, site preparation, and accuracy verification. However, in the Science and Ecosystem Support Divisions Operating Procedure entitled Wastewater Flow Measurement made effective on August 12, 2011, the EPA clearly states that volumetric flow measurement techniques are among the simplest and most accurate methods for measuring flow. But calculating volumetric lift station pumping capacities to produce influent flow rates may be misleading. Pump capacities constantly change due to the applied head pressure and pumping conditions. Only tuning/updating pump curves while reacting to these changing conditions can improve volumetric flow accuracies. Using this tuning method, Maid Labs, the creator of the MerMaid system, has achieved true volumetric accuracies.
PAST APPROACHES AND DIFFICULTIES IN MEASURING LIFT STATION FLOW RATES
A magnetic flow meter provides the most accurate measurement for flow data. Some manufacturers offer an overall accuracy of 0.15 percent with 0.25 percent as the standard for these meters. A typical meter would be installed on the effluent side of a lift station. From there, it accurately monitors flow output from the pump(s) and totalizes the volumes. The downside rests with the expense to install a magnetic flow meter, and the fact that few lift stations have the required 100 percent full-pipe flow. Today, a magnetic flow meter can cost as much as ten to twenty thousand dollars, and many utilities only have 10 to 20 percent of their lift stations that even qualify for these meters. While this is the ideal system to monitor flow rates, its not practical or cost effective to install at most lift stations. The second type flow monitoring takes place on the influent line/pipe approaching, or at, the lift station. If the influent piping at the lift station is submerged, or could become submerged, a suitable location upstream becomes necessary to monitor the flows traveling to the station. This often requires several meters to monitor the flows to one lift station. This method also requires various types of primary devices such as V notch weirs or level/flow-measuring devices which use the Manning Equation. The problem, however, resides with the overall accuracy of these devices: as the conditions change, accuracy erodes quickly. The logistics to provide this type of technology alone requires large amounts manpower. Additional workers would be needed for the installation, removal, physical maintenance, and relocation of these meters, but also for
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WATER & WASTEWATER solutions

data collection and troubleshooting problems. Considering the number of additional employees, most utilities generally cannot afford to continuously monitor lift station flow rateseven if the DEP or the EPA mandates this monitoring. The first SCADA and telemetry systems aimed to solve the cost and practical application issues; these systems had the capability to monitor all the lift stations within the municipality on a continual basis. Telemetry systems communicated this data to the host through an assortment of methods primarily using radio or phone networks. This new method used the pump capacities supplied by the pump manufacturers or a drawdown test to set a capacity for each pump in the lift station. By recording the amount of time each pump was active and multiplying its capacity, these systems could produce a derived flow and totals for each lift station. The HMI could then report the flow data, display those totals, and store the information for future use in historical or modeling programs.
Only tuning/updating pump curves while reacting to changing conditions can improve volumetric flow accuracies.
THE SEARCH FOR MORE ACCURATE MEASUREMENT
The majority of municipalities today still use this derived-flow method to record flow rates, but even this system presents a problem: limited accuracy. To derive means to deduce by reasoning or an assumed conclusion. When it comes to monitoring flow rates, deduction can never equal solid calculation, reasoning becomes little more than guesswork. A calculation based on assumption, this method derives flow rates with an overall accuracy of only 10 to 15 percent of the actual flow in a lift station. This method scores points for cost effectiveness; the system does not require additional manpower other than the maintenance on the telemetry system. The telemetry system also adds value to the utilities by providing critical data for their lift stations maintenance divisions. However, many engineering consultants are skeptical of the utilities flowdata accuracy and some municipalities are uncertain of their recorded datas accuracy. In the August 2011 Wastewater Flow Measurement Operating Procedure, the EPA further stated that any continuous flow measurement system that cannot measure the wastewater flow within 10 percent of the actual flow is considered unacceptable for use in measuring wastewater flow. The problem here is certain: a system based on the derived-flow method is just not precise enough for the task at hand. To meet todays EPA standards wastewater utilities require improved methods to provide lift station flow accuracies greater than the derived 10 to 15 percent. In part two of this article, we will explore the development, difficulties, and solutions presented by tuned flow lift station monitoring.
REFERENCES
Salguero, Louis. (August, 12 2011). Wastewater Flow Measurement (SESD Publication No. SESSPROC-109-R3). Athens, GA: U.S. Environmental Protection Agency Science and Ecosystem Support Division. 1-16. Stoner, Nancy and Cynthia Giles. (October 27, 2011). Memorandum: Achieving Water Quality Through Integrated Municipal Stormwater and Wastewater Plans. United States Environmental Protection Agency. Washington, D.C: Government Printing Office. 28 | SEPTEMBER 2013 www.modernpumpingtoday.com
MAINTENANCE solutions
MAXIMIZE IZE
Pump Life
By Robert Matthews, Royal Purple
Pump Rebuild Protection to Help
vapor phase added might slightly change the viscosity, so it is recommended that you check with your lubrication supplier first. Pumps without lubricating oil should be filled with vapor phase oil and then reduce the volume to 10 percent cavity capacity for best effect. Circulating systems of any size are generally filled with the appropriate lubricating oil and 10 percent by volume of vapor phase concentrate oil. This will provide protection for pumps that run only intermittently as well as pumps in storage. A best practice to reduce false brinelling is to rotate stored equipment by hand every six weeks to two months. Brinnelling occurs when there is contact stress where hard metal presses into a less hard metal. The result is dented surfaces. Many bearing rolling elements are harder than the races they track in, damaging the race and leaving dents similar to small pot holes. Brinelling in rolling element bearings occurs when loads exceed the elastic limits of the race metal and visible indents are found.
BRINELLING
umps are major investments for any company, and the practice of rebuild over replacement not only yields cost savings, but often lessens the amount of down time the equipment is not in use. The question is, during the rebuild, are all the right steps being taken to protect the pump to ultimately maximize the pumps life, yielding more for your overall investment?
PUMP STORAGE
Figure 1
One of the most important factors in preserving a new or repaired pump is storage. Most manufacturers have storage recommendations that are often ignored. By industry best practices, rebuilt pumps should come from the clean room and be stored in a humidity controlled storeroom. Pump storage procedures are not the same for outdoor and indoor pumps, or for long and short term. Consider the conditions because inside and outside storage locations have frequency differences on changing out the preservative and coverings like tarps. Outside storing procedures can be costly and are usually more than what is needed for indoor stored equipment. When storing the pump outside, caution should be taken to keep water from entering the volute. This can corrode the casing, and in the winter a freeze might cause the water to expand and crack the casing. All of these are factors to consider when determining the location of the pump or maintenance needs and associated costs. For splash cavity systems the use of an assembly lubricant on unprotected steel bearings will reduce false brinelling and provide short term rust protection. If the pump contains lubricating oil during storage, add 10 percent by volume vapor phase concentrate to the housings. Note that some
The bearings and cooler from an API pump stored for less than six months without protection. Assembly lubricant or vapor phase oil would have prevented this damage.
False brinelling is when the dents are made from vibration and the pump is not running. These false brinelled dents are small and are not visible to the naked eye in most cases. To protect from brinelling and rust, assembly lubricants formulated specifically for industrial applications should be used in rolling element bearings. Assembly lubricants
About The Author

Robert Matthews is the reliability manager at Royal Purple, a manufacturer of synthetic premium industrial and consumer lubricants. Matthews travels to industrial plants and sites providing reliability education and recommendations for a wide variety of industries. For more information about Royal Purple industrial products for your pump or industrial equipment, visit www.royalpurpleindustrial.com .
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give greater wear protection, reduce operating temperatures and can extend equipment life. These robust oil molecules and additives adhere to metal surfaces to carry not only load, but displace moisture as well. Any pump mechanic or millwright who utilizes an assembly lube for the first time will feel the difference and will incorporate the practice in future unprotected rebuilds.
VAPOR PHASE OIL
Vapor phase oil is recommended to prevent rust and corrosion in pumps, engines, gearboxes and other closed systems that will be stored for one or more years. Vapor phase oil will fill any closed space with vapor to protect the surfaces not directly in contact with oil. The length of time the protection lasts is dependent upon the sealing of the housings. A completely sealed housing is usually one with magnetic contact seals on the shaft, breathers removed and all ports plugged. Some labyrinth seals can seal the bearing housing completely and can be confirmed with a simple test. To test the housing, place a small hose
nipple at the breather port and attach a balloon filled with air to it. If the balloon deflates, the housing is not sealed. Equipment stored inside and protected from the elements can remain for up to two years without additional treatment. Pump lubricating oils that meet OEM specifications can provide safe lubrication for bearings for up to six months when using a mineral oil based product and up to two years when using a synthetic oil based product. Always verify safe drain intervals with the pump OEM. If vapor phase protection is required in a pump already containing lubrication seek a vapor phase concentrate that can be safely added to the lubricant. No company can afford loss of productivity due to a piece of machinery that is inoperable. A few hours of preventative maintenance are less costly than days of shutdown or full equipment replacement. Taking the time to review the manufacturers maintenance and storage recommendations coupled with using quality industrial lubricants will extend the life of your equipment and protect your investment.
Figure 2
Careful transportation of equipment will reduce friction that may cause brinelling.
Figure 3
A bearing race was dented before being placed into service; brinelling damage is visible.
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PUMP solutions
Highest Precision
in the
Laboratory
By Bettine Kuhnert, for LEWA GmbH
Newly Developed Diaphragm Pump Delivers Micro-flow Metering in High-pressure Laboratories

or metering tasks in high-pressure laboratories, the highest of precision when conveying defined quantities of substances is a must. Plunger pumps used for this purpose can withstand the high pressure, but they inherently leak. If the fluids in question are hazardous substances of which no droplet may escape to the outside, that can be a problem. Upscaling can also be less accurate under some circumstances. To address this problem, LEWA GmbH has developed the Intellilab, a hermetically sealed high pressure micro-metering pump. With the integrated motion control system the Intellilab is a mechatronic design in total.
angular velocity so that, in combination with different control structures, the fluid kinematics can be specifically targeted to the needs of the process. In the table housing there is a pump head built-in that permits use of the servo motor to generate low-pulsation volume flows. The metered flow over time can also be modeled nearly arbitrarily. For example, the stroke volume can be quickly filled with the medium to be conveyed, which is then metered slowly and continuously.
The principle of the hydraulically coupled metal diaphragm HIGHLY DYNAMIC represents the latest The objective of this technical state of the art, development is the use for especially for low flow metering and conveying rates. Leakage to the LEWA Intellilab is a hermetically sealed high pressure micro-metering pump with integrated tasks for up to 500 bar, outside and contact of drive and control systems. It is particularly designed for applications in high pressure especially in high-pressure the metered fluid with air laboratories in which new process technologies are developed and verified at small scales. laboratories, in which are impossible because new process technologies the impermeable metal at small scale are carried out. The Intellilab's predecessors, the diaphragm seals the fluid hermetically against the atmosphere K3 and K5 micro-metering pumps that have been in use for and the hydraulic displacer system. Since the displacement decades, were already developed by LEWA. Now the Leonberg system is based on wear-free, maintenance-free hydraulic diaphragm pump specialist has revisited the existing solution oil, stuffing box problems are eliminated. The rigid hydraulic from a technical standpoint. linkage also keeps the influence of the pressure on the metering The mature pump technology was retained, and equipped flow to a minimum. with the latest in drive and control technology, the Intellidrive. The Intellilab is, therefore, primarily used for exact, This permits highly dynamic regulation of the drive sides reproducible metering in the processes of high pressure
RELIABLE METERING AND INTUITIVE OPERATION
About The Author

Bettine Kuhnert is a freelance journalist from Munich specializing in process technology and plant engineering. LEWA GmbH is the world's leading manufacturer of metering and process diaphragm pumps as well as complete metering systems for process technology. For more infomation, visit www.lewa-inc.com .
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flows profiles can be parameterized and later executed. Visualization using a colored touchpad contributes to intuitive operation and simpler evaluation. It is always possible to extend the Intellilab so that multiple devices can be synchronized seamlessly. Field tests with customers should provide additional options for improvement by the end of
the year. Series production and market introduction are planned for 2014. The precise results produced by the high pressure micro-metering pump would never have been possible using plunger pumps. For labortories working with high pressure synthesis or high pressure hydration applications, the Intellilab is the intelligent solution.
The high pressure micro-metering pump can provide significantly more precise results under realistic conditions than would be possible with plunger pumps, and is therefore used among other applications for exact, reproducible metering in the processes of high pressure synthesis and high pressure hydration.
synthesis and high pressure hydration. Its use would also be possible in the context of mini-plants. The use of the smallest possible experimental structures with correspondingly small metering quantities, particularly in research, also significantly reduces the consumption of materials deposited.
USER-FRIENDLY
There is also a new, user-friendly interface adapted to the special needs of high pressure laboratories. For example, a timer function and ramp control are supported, and metered
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PUMP solutions
PUMP RELIABILITY
PART 2 OF A 3-PART CHECKLIST OF IMPROVEMENT OPTIONS AND CONSIDERATIONS
By Heinz einz P. Bloch, Process Machinery Consulting
Best Practices for
n part 1 of our three-part checklist, we began our introduction to pump reliability practices by making a few very important points: Centrifugal pumps in U.S. oil refineries and petrochemical plants typically reach meantimes-between failures (MTBFs) ranging from barely 3 years to as much as 10 years. Theres therefore room for improvement at many plants. The average pump reliability improvement implementation costs only about 20 percent of the pumps original cost. Pumps are probably responsible for one fire per 1,000 pump
repair events. Factoring the imputed value of fire avoidance into ones upgrade cost justification makes sense. Our checklist of implementation items lists things to consider when pursuing reliability improvement. All are certainly known to Best Practices performers and further descriptions can be found in the listed reference books and other literature. Part 2 of this 3-part comprehensive checklist starts with lubrication issues (items 18 through 40) and concludes with mechanical seal issues (items 41 through 49).
About The Author

Heinz P. Bloch, P.E., is one of the world's most recognized experts in machine reliability and has served as a founding member of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME, in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at heinzpbloch@gmail.com.
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LUBRICATION ISSUES
18. On sump-lubricated pumps, do not permit oil levels higher than through the center of rolling elements at the 6 oclock position. 19. On pumps with dn-values (d = mean bearing diameter, mm; n = shaft rpm) in excess of 160,000, allowing lube oil to reach even this position may result in excessive heat generation. For these, the oil level may have to be lowered further and oil rings or flinger discs may have to be chosen by the user or pump manufacturer. 20. Except for moderate load applications in relatively cool ambient environments, ISO Grade 32 mineral oils and lighter lubricants are not suitable for rolling element bearings in centrifugal pumps. A thicker ISO Grade 68 lubricant will perform better in the majority of rolling element bearings in pumps. Unfortunately, it will not always work in pumps equipped with oil rings! 21. Bearing housing cooling may still be needed in pumps equipped with sleeve
bearings. The majority of these pumps require ISO Grade 32 lubricants. Close viscosity control may have to be maintained for satisfactory long-term lubrication. 22. Observe required ISO viscosity grades in moderate climates (Europe, the Americas, Pacific Rim, Australia): rolling element bearingsISO 68, synthesized hydrocarbon optional; sleeve bearingsISO 32, synthesized hydrocarbon optional; combining both bearing types in the same housingISO 32 PAO or dibasic ester synthesized hydrocarbon mandatory for extended life. 23. In bearing housings with both rolling element bearings (preferred lube viscosity ISO 68) and sleeve bearings (which may require ISO Grade 32 lubricants), consider satisfying both needs by using ISO Grade 32 or 46 PAO or diester-based synthesized hydrocarbon oils. 24. Next to oil-jet lubrication, dry-sump oil mist applied in through-flow fashion per AP- 610 (8th and later editions)
represents the most effective and technically viable lubrication and bearing protection method used by reliability-focused industry. 25. Be aware of upgrade and conversion options whereby a simple and economical inductive pump (a small pump with a free piston as its only moving part) can serve as the source of a continuous stream of pressurized lube oil. Used in conjunction with a spinon filter, the resulting clean stream of lubricant can be directed at the bearing rolling elements for optimum effect. 26. Certain grease formulations cannot be mixed with other grease types. Incompatible greases often enter into a chemical reaction that renders them unserviceable in less than one year. 27. Over-greasing of electric motor bearings is responsible for more bearing failures than grease deprivation. Know where the spent grease ends uphopefully not in the motor windings. Practicing proper re-greasing procedures is essential for long bearing life.
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PUMP solutions
28. Lifetime-lubricated (sealed) bearings will last only as long as enough grease remains in serviceable condition within the sealed cavity. Whenever the product of bearing bore (mm) times shaft rotational speed (rpm) exceeds 80,000, reliabilityfocused plants consider it no longer economical to use lifetime-lubricated bearings in continuously operating industrial machinery. 29. Grease replenishing intervals depend on bearing inner ring bore dimension and shaft rotational speed. Reliabilityfocused user plants consider dn = 300,000 the maximum for grease lubrication of electric motors and other machines in continuous service. It has been reasoned that beyond this dn-value (d = bearing bore, mm; n = shaft rotational speed, rpm), grease replenishing intervals become excessively frequent and oil lubrication would be more economical. 30. Realize that oil ring lubrication very rarely represent state-of-art. Oil rings are alignment-sensitive and tend not to perform dependably if one or more of the following requirements are not observed: Unless the shaft system is absolutely horizontal, oil rings tend to run downhill and make contact with stationary components. Ring movement will be erratic and ring edges will undergo abrasive wear. The oil will become contaminated. The product of shaft diameter (inches) and shaft speed (rpm) should be kept below 8000. Thus, a 3-inch (75 millimeters) shaft operating at 3600 rpm (DN =~10,800) would not meet the lowrisk criteria. Operation in lubricants that are either too viscous or not viscous enough will not give optimized ring performance and may jeopardize bearing life. The depth of immersion is closely controlled, the bore finish is 16 RMS or better, and the ring eccentricity does not exceed 0.002 inches (0.05 millimeters). 31. Solid metal flinger spools or flinger discs fastened to pump shafts often perform well for decades. When using retrofit flingers made with metal hubs/cores to which flexible elastomeric discs are firmly fused or attached, realize that the flex-parts have limited life. 32. If use of oil rings is unavoidable, be aware that a 30-degree angle between the contact point at the top of a shaft and points of entry into the oil represents proper depth of immersion. Too much immersion depth will cause rings to slow down, whereas insufficient depth tends to deprive bearings of lubricant. 33. Oil rings with circumferentially
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machined grooves will provide increased oil flow. 34. Consider buying true state-of-art bearing housing seals to preclude ingress of atmospheric contaminants and egress of lubricating oil. Install bulls-eye sight glasses on pump bearing housings so sealed. 35. On grease-lubricated couplings, verify that only approved coupling greases are used. Most motor bearing greases will centrifuge apart at the couplings peripheral speed! 36. Do not allow coupling greases to be used in electric motor bearings. Most motor bearings will fail prematurely unless a premium grade EM grease is used. 37. All purpose greases are not suitable for electric motor driver bearings in reliability-focused plants. 38. Fully consider vulnerabilities of unbalanced constant level lubricators. If you must use constant level lubricators, use pressure-balanced models (such as TRICO Optomatic Closed System II) only. 39. Mount constant level lubricators on the correct side of the bearing housing. Observe up-arrow provided by manufacturer of constant level lubricator. Incorrect mounting will lead to greater disturbances around the air/oil interface in the surge chamber of constant level lubricators. Correct mounting reduces the height difference between uppermost and lowermost oil levels. In other words, it ensures a more limited level variation. 40. Verify that re-lubrication and grease replenishment procedures take into account that: Mixing of incompatible greases will typically cause bearing failures within one year. Attempted re-lubrication without removing grease drain plugs will cause the grease cavity to be pressurized. Over-greasing will cause excessive temperatures. On shielded bearings, cavity pressurization tends to push the shield into contact with rolling elements or bearing cage, causing extreme heat and wear.
MECHANICAL SEAL ISSUES
It is generally acknowledged that most pump failure incidents involve mechanical seal distress. While this is true at many facilities, it is also true that a major refinery has documented an average mechanical seal life in excess of ten years (see reference 1). Using the right selection and installation procedures can markedly improve seal life and reduce pump failure incidents. Items 41 through 49 are of interest here. 41. Select mechanical seal types, configurations, materials, balance ratios, p-v values and flush plans certified to represent proven experience in identical services, or under verified-to-be-comparable service and operating conditions. Only these can guarantee to give extended seal life. 42. Except for gas seals (dry seals), mechanical seals must be operated so as to preclude liquid vaporization between faces. However, using cooling water in a jacketed seal chamber cannot effectively cool the seal environment. External flush cooling is far more effective.
43. Mechanical seals with quench steam provisions are prone to fail rapidly if quench steam flow rates or pressures are not kept sufficiently low. The installation of small diameter fixed orifices is very often needed to limit excessive steam quench rates. 44. Select the optimum seal housing geometry and dimensional envelope to improve seal life. Recognize that slurry pumps generally benefit from steeply tapered seal housing bores. The traditional concentrically bored stuffing box environment does not usually represent the optimum configuration for slurry pumps. 45. Avoid inefficient pumping rings on tandem seals. Consider using far more effective tapered pumping rings instead. 46. On hot service pumps, follow approved warm-up procedures. Verify that seal regions are seeing throughflow of warm-up fluid, i.e. are not dead-ended. 47. Understand the difference between conventional mechanical seals
(seals where the flexing portion rotates) and stationary seals (where the flexing part is stationary). Maximum allowable speeds and permissible shaft run-outs are lower for conventional seals and higher for stationary seals. 48. Flush plans routing liquid from stuffing box back to suction are reliable only if the pressure difference exceeds 25 psi (172 kPa). 49. Fluid temperatures in seal cavity must be low enough to prevent fluid vaporization occurring in sea faces. Part 3 (next issue) will delve into hydraulic and installation issues. There, too, we will grapple with misunderstandings and oversights. REFERENCES
1. Bloch, Heinz P., and Allan Budris. Pump Users Handbook: Life Extension, Second Edition (2006), Fairmont Publishing Company: Lilburn, GA (ISBN 0-88173-517-5). 2. Bloch, Heinz P. Machinery Reliability Improvement, Third Edition (1998), Gulf Publishing Company: Houston, TX (ISBN 0-88415-661-3).
A LOOK AHEAD
SEPTEMBER 2013
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DEWATERING solutions
R API D RE S ULT S
Bedford Pumps power slalom for Pinkston
By Lucy Ogden, Bedford Pumps
hen high-power pumps are applied to dewatering uses, many times the need is serious. In some cases, whether it is unsafe water levels in a mine or on-board flooding at sea, moving water quickly from Point A to Point B can have a life-saving urgency. However, Bedford Pumps recently undertook a unique application that will both save lives and provide hours of recreation for years to come. The renowned manufacturers of large submersible and conventional pumps to the water and waste water industries have extended their market with the contract for an exciting new project to create white-water for kayakingat a facility capable of both entertaining first-time ammeters and training emergency responders.
A UNIQUE OPPORTUNITY
Bedford Pumps SA.80.04.10 pump sets as used in Pinkston.
Kayaking is currently the United Kingdoms fastest growing water sport, and the new Pinkston Water Sports Centre will be Glasgows first competition standard, purpose built, paddle sports centre aiming to attract 25,000 visitors per year. The Pinkston Water Sports Centre will accommodate many types of users, from family rafts and personal tubes to more competitively minded kayakers who want to test their skill on a slalom course. Especially important, however, is the courses role in rescue training. The Pinkston Water Sports Centre provides a controlled environment for emergency personnel to simulate rescue situations, review what works and what needs improvement, and
About The Author

Lucy Ogden is the marketing manager for Bedford Pumps Ltd. For further information, email her at lucyo@bedfordpumps.co.uk, call 01234.852071, or visit the Bedford Pumps website at www.bedfordpumps.co.uk.
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experiment with new techniques. The overall benefit of these practice drills will save the lives of countless kayakers.
pole motor, will provide a capacity of 37,000 gallons per minute (2333 liters per second).
BUILDING THE RAPIDS
Bedford Pumps will be supplying three of their submersible axial pump sets to be installed in a cascade canister arrangement in the submersible pumping station within the water sports channel. The pumps will generate total flows of up to 110,000 gallons per minute (7000 liters per second) to create an exhilarating and challenging course. The slalom will include a circular loop with the pumps lifting the water 4.9 feet (1.5 meters) to create a static head. From here an adjustable gate controls flows to either of the two separate channels. The outer channel provides 295 feet (90 meters) of rapids suitable for beginners, intermediates and for canoe slalom training and national ranking competition. The side entry gate allows the easy entry of items to facilitate enhanced Swift water rescue training. Around the outer loop rafting and inflatables can be used by complete beginners in a safe environment. With the pumps switched off the control gate can be quickly and easily reconfigured to direct the water down a shorter and steeper channel. Within the confines of a shorter and steeper channel a significant hydraulic feature can be formed and tuned to appeal to paddlesport experts and advanced rescue training activities. The adjustment of the feature will keep experts interested in repeat visits and also for competitions and events. Within the loop there will be canoe slalom training and competition, whitewater kayaking and coaching and Swift water rescue training for the emergency services.
A MODEL FOR THE FUTURE
Bedford Pumps are delighted to be working with Rapid Water Courses Ltd, providers of the whitewater course, and assisting in the Glasgow
Canal Regeneration Project by giving Glasgow a white water course of national importance. This project is a life changing project for the community in North Glasgow and a significant breakthrough in community based paddlesport activities, which is sure to be replicated elsewhere around the United Kingdom and wider afield.
PUMPS WITH POWER
The pumps are to be manufactured with a cast iron pump casing and shroud and a gunmetal impeller. Each pump will be supplied with Bedford Pumps unique Pump Condition Monitor, designed to provide local operators with the status of various protection devices and performance indicators fitted into all modern submersible pumps. The pumps will be installed into a Scotchkoted steel canister also designed and supplied by Bedford Pumps. Each pumpset, powered by a 95 kilowatt 10
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MOTOR solutions
Driven Toward Innovation

Dual drive pumps and compressors for the water works industry
By Morgan Hendry, SSS Clutch
erdinand Porsche is best known today for the sports cars that bear his name, but, among other engineering breakthroughs, he also built the first hybrid automobile, which he displayed at the Paris Worlds Fair in 1900. Now it was nearly a century before Toyota released the Prius and other car manufacturers (including Porsche) followed suit with their hybrid models, but in the meantime hybrid drive technologies had caught on in a large number of other industries including marine propulsion, trains, pipeline compression, and steel plants.
CLUTCHED HYBRID SYSTEMS
Some hybrid designs, such as those used in trains and ships, use fossil or nuclear fuel to power an engine that drives a generator, and the electricity produced then drives the motors. For pumps and compressors, however, a better arrangement is to use clutches to connect both a motor/generator and an engine to the workload. In such a case the operator can then decide whether to run the engine, the motor or both at the same time, depending on the price and availability of fuel and electricity. This approach not only reduces energy costs, but also lowers capital costs, improves reliability and availability, and makes it easier to schedule maintenance. Currently there are several thousand such clutched hybrid systems in use at power plants, on natural gas pipeline compressors, in marine propulsion systems and at water pumping stations. But the municipal water and sewage treatment industry has lagged behind others with only a few plants so far achieving the benefits of such hybrid systems, mostly due to unfamiliarity with the technology. To remedy that, here is a description of how dual drive systems work and how they can benefit utilities.
elements of the equipment train, including the engine, motor/ generator and the load, whether a pump or a compressor. This allows the components to work independently or in unison so as to achieve the most economical and efficient operation. A freewheel or overrunning clutch is a one-way clutch that allows the transmission of torque in one direction from one rotating shaft to another. The clutch mechanically engages when the driving shaft speed attempts to overtake the speed of the driven shaft and disengages when the torque reverses on the driving shaft or the driving shaft speed decreases below that of the driven shaft. The condition of freewheeling occurs in most bicycles when the rider stops pedaling and the bicycle coasts. Without a free-wheel, the rear wheel would drive the pedals around. Overrunning clutches are not friction clutches and cannot force the speed of one shaft system to match the other.
LOW POWER OVERRUNNING CLUTCHES
TYPES OF OVERRUNNING CLUTCHES
The key to making hybrid systems work are the clutches that allow a plant operator to engage or disengage each of the
Low power overrunning clutches up to a few hundred horsepower rating include ramp-and-roller and sprag-type clutches. Both of these synchronize and transmit torque by wedging loose parts between inner and outer cylinders within the clutch. Ramp-and-roller clutches have a series of ramps on the inner cylinder. When the inner cylinder moves in one direction at a speed equal to or greater than that of the outer cylinder, the ramps wedge the rollers against the outer cylinder, transmitting the torque. Sprag clutches use figure-eight shaped rollers called sprags which allow the unit to freely spin in one direction, but when the direction is reversed, wedge between the inner and outer cylinders. These types of clutches are generally limited to low power services below 3600 revolutions per minute. The clutch components can deform or brinellparticularly under high stress and if there is some accompanying machinery vibration and are sensitive to shocks, sudden torque overloads and the
About The Author

Morgan Hendry is the president of SSS Clutch. Since its formation more than forty years ago SSS has concentrated solely on the marketing, development and production of SSS Clutches, primarily for high power and high speed applications. For more information, visit www.sssclutch.com .
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cleanliness of lubricating oil. That said, they are still well suited for many low-power service applications.
Figure 1: How an SSS clutch works
HIGH POWER OVERRUNNING CLUTCHES (GEAR TOOTH TYPE)
For high-horsepower, critical-service applications, an automatic overrunning clutch, such as a Synchro-Self-Shifting (SSS) Overrunning Clutch, is normally utilized. These clutches transmit torque through multiple gear teeth and separate the synchronizing function from the torque carrying components. With such clutches, small pawls are used to mate with ratchet teeth to align and then shift the clutch teeth into engagement along helical splines (see figure 1). The teeth are engaged automatically at synchronism at any speed from rest to full operating speed. The pawls and ratchets are inactive except during the short engagement process. Once engaged, torque is transmitted through the surface contact of concentric involute shaped teeth. An internal oil dashpot, between the input and output components, cushions the engagement of the clutch. High power overrunning clutches can be completely supported by the shafting and engineered to either act as a solid coupling when engaged and transmitting torque or designed to accept axial and offset misalignment. Alternatively, overrunning clutches can be mounted in an oil-tight housing which can be foot mounted or connected to the casing of the driving or driven machine.
Key: A Pawl B Main driving teeth C Helical Sliding Component D Helical Spline E Input Component F Output Component G Ratchet Teeth
DUAL-DRIVEN TRAINS
A dual-driven equipment train with an overrunning clutch enables one driver to be disconnected from the train and
SEPTEMBER 2013
45
MOTOR solutions
Figure 2: Schematic of dual-driven pump
Exhaust
Optional Heat Recovery System Clutch (A) Clutch (B)
Gas or Diesel Engine
Synchronous Motor Generator
Pump
To Switch Gear
stopped, while the second driver continues to power the driven machine. It also allows the driven equipment to begin operation with one of the drivers when the second driver is not available due to process, maintenance or other constraints, and to start and engage this driver with the already running train when the constraint no longer exists. For example, there are over a hundred dual-driven compressors used in natural gas pipeline applications with powers ranging from 1000 to 7000 horsepower. These trains use electric motors and gas engines as the dual drivers. The dual drivers allow the choice of power source depending on the real time cost advantages of one power source versus the other. Engine maintenance can take place while the train continues to operate using the motor driver. With two clutches in place, the drive train can also be used as an electrical generating source. When compression is not required, the engine can disconnect from the compressor and drive only the motor/generator, exporting power to the grid. Or with both clutches engaged and the power requirement of the compressor less than the engine rating, the extra power can be used to generate very efficient power for export since the full load engine fuel rate is significantly better than the part load rate.
DUAL-DRIVEN EQUIPMENT IN WATER WORKS
This same dual-drive concept could be applied to both compressors and pumps used by the water works industry. First, lets look at compressors. In a sewage treatment plant there is typically an engine burning digester gas as fuel
46 | SEPTEMBER 2013
that drives a generator and on a separate foundation there is a motor that drives an air compressor supplying the oxygen required by the digester. Using the dual drive concept, the engine, compressor and motor/generator would be combined in one train on a single foundation thus requiring only one motor/generator versus a separate motor and generator in a conventional arrangement. In addition, only one set of switchgear and cabling is required. Pumps would use a different dual drive configuration. Many pumping stations, both water and wastewater, require standby power to provide pumping during electric power disruptions. Often this is handled by installing an engine-driven pump alongside a motor driven pump, using the engine-driven pump when electric power is not available. This means that the investment for the engine driven pump (engine, pump, foundation, piping, etc.) is rarely used. In other cases a standby generator set is installed to operate the electric driven pump during power outages. In this case the engine must be sized considerably larger in power than the pump being driven by the generator in order to provide the torque required during the acceleration of the motor driven pump. The generator, which is very similar to the pump motor, needs its own set of switchgear and cabling. By dual driving the pump with both an engine and motor as shown in figure 2, only a single motor/generator is required with only one set of switchgear and cabling. In addition the engine size is reduced considerably when direct driving the pump. Only one foundation
Figure 3: Operating modes of dual-driven pumps

MODE Off peak pumping On-peak pumping with motor load shedded or reduced for demand response Emergency pumping Emergency power generation
Note: If emergency power generation alone is not a requirement, then Clutch B is not required
CLUTCH A Disengaged over-running Engaged Engaged Engaged
CLUTCH B Engaged
ENGINE Shut down
MOTOR GENERATOR Running as motor Spinning with breaker open, or breaker closed and running at part load as motor Spinning with breaker open Running as generator
PUMP Running
Engaged Engaged Disengaged locked-out with hydraulic servo
Running Running Running
Running Running Shut down
Emergency pumping and power generation (or on-peak pumping plus additional demand response by generating electric power to further reduce total facility demand)
Engaged
Engaged
Running
Running as generator
Running
is required. Total footprint is reduced. During a power outage the engine starts and the clutch automatically engages driving the pump through the motor with the motor breaker open. Using a transfer switch, and selecting a synchronous motor (rather than an induction type), the motor operates as a generator to provide station power.
motor generator and with the breakers open so it can provide electricity. Emergency Pumping and Power Generation In this case, both clutches are engaged, with the engine providing the torque necessary to run the pump and to generate electricity. In addition to the flexibility offered by these five operating modes, only dual-drive gives engineers the opportunity to shut down either their engine or their motor for maintenance, without interrupting service.
METHODS OF OPERATION
Using a dual-drive configuration for pumps and compressors gives utilities greater flexibility in operating their equipment to minimize costs and improve reliability. Here are five different scenarios that can be used for pump operations, and similar options can be used with compressors. These modes of operation are summarized in figure 3. Off-Peak Pumping During off peak hours when electricity prices are low, the engine is shut down and the clutch between the engine and motor generator is disengaged. The motor is using power from the grid to run the pump. On-Peak with Load Shedding In many areas electric utilities or grid operators have demand response programs offering as much as $100,000 per year to shed 1000 kilowatt of load a few times a year. Or the utility will charge much higher rates during peak demand periods, making it more economical to use the engine than to purchase electricity. In either case, the engine would be started and used to spin the motor and the pump. Depending on the economics, the breaker would be open with the engine providing all the power, or the motor could be drawing a reduced amount of electricity from the grid to supplement what the engine was providing. Emergency Pumping When electricity is not available, the engine will kick in and keep the pump running. The motor will be spinning, but will not be drawing or generating any current. Emergency Power Generation There may be emergency scenarios where pumping is not needed, but electricity is. In such a case, the clutch between the motor and the pump is disengaged. The engine drives the
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POWER GENERATION solutions
High Temperature Bearings

for Oil Field Flares
By Eric Ford, Graphite Metallizing Corporation
raphite Metallizing Corporation of Yonkers, New York, has been solving tough bearing problems for over one hundred years. The company began in 1913 when two engineers developed a method for putting molten metal into carbon to create a new material called Graphalloy , a graphite/metal alloy. Used in the manufacture of bushings, bearings, and other components for machinery and process equipment, Graphalloy materials are selflubricating, impervious to temperature extremes from -400 to 750 degrees Fahrenheit (-240 to 400 degrees Celsius) and thrive in harsh environments where other bearings fail. Special grades provide reliable service up to 1000 degrees Fahrenheit (535 degrees Celsius) and higher in non-oxidizing atmospheres.
Graphalloy bearings thrive in harsh environments.
LUBRICATION FAILURES
High temperature, self-lubricating Graphalloy bearing materials are uniquely suited to help control volatile gas burn-off flares at oil and natural gas production sites. This innovative development resulted from
a customer requirement to overcome design problems in a control linkage. The high heat of these flares caused bushing lubrication failures and this, in turn, caused flare control systems to fail. These repeated failures resulted in unacceptable maintenance and replacement costs. EPA regulations require that oil field flares destroy the volatile organic compounds emitted into the atmosphere in an environmentally friendly manner. To meet these requirements, oil field operators must use flares at their production sites that provide a clean burn. These flares must operate reliably at remote sites under all conditions.
PROVIDING CLEAN BURNS
Given the loss of lubrication within the faulty linkage, it became obvious
About The Author

Eric Ford is the vice president of sales and marketing at Graphite Metallizing Corporation. He can be reached at eric.ford@graphalloy.com or 914.968.8400. For more information, visit www.graphalloy.com .
48 | SEPTEMBER 2013
that flare controls and gas burn-offs were not meeting EPA regulations nor providing clean burns. The flare manufacturer tested other bearing materials. None met the challenge until Graphalloys high temperature self-lubricating graphite/metal alloy material was tested, approved, and put to work. Result? The custom produced bearings were retrofitted to thousands of existing flares and are now standard on new systems. Today, the bearings operate successfullyno stoppages!
specifications. FDA accepted grades of Graphalloy are available for food contact equipment. NSF International has certified two grades of material for use in municipal well pumps and water treatment plant applications. In some applications, Graphalloy bearings have operated for up to twenty years without maintenance.
Standard designs are available but most products are custom designed to the unique requirements of the specific application. ISO 9001:2008 certified as well as NSF/ANSI 61 certified, the company serves a broad range of industries with standard and custom quality bearings, bushings, and related products.
Other industrial applications have experienced success with Graphalloy in high temperatures. A mill reclaiming metals such as titanium feeds metal powders into a drum heated to 1500 degrees Fahrenheit (816 degrees Celsius). The drive shaft spinning the drum is supported by two Graphalloy Pillow Blocks. In addition, Graphalloy Bushings are in the twelve wheels that support the drum as well as the worm gear. This application demonstrates the ability of the bushings to perform in extreme temperatures. Also, a Midwestern steel mill was using these bushings for the horizontal rollers in their cooling beds. The bushings were thriving under severe heat and water spray conditions. Because of the success with the horizontal rollers, the mill wanted to consider Graphalloy Flange Bearings for another application: the vertical guide rollers along the sides of the cooling beds used to keep the hot steel from running off the sides. Guide rollers remain static until a piece of hot steel slams up against them, at which time they are expected to turn instantly to guide the steel back onto the cooling bed. This mill had been using conventional greased rolling element bearings in the vertical guides that were lasting only a few months. Based on the success with the vertical rollers, the mill has since retro-fitted additional lines with Graphalloy.
HIGH EXPECTATIONS IN HIGH TEMPERATURES
GRAPHALLOY PASSES THE TEST
Graphalloy can be the solution to the toughest bearing, bushing, thrust washer, cam follower, or pillow block bearing design problem. It is available in over one hundred grades with specific properties that meet a wide range of engineering solutions and
SEPTEMBER 2013
49
Recipe for Success

Danfoss VLT Drives are secret ingredient for artisan cheese maker
PROCESSING solutions
By Patrick Appleby, Danfoss

ecipes for cheese are thousands of years old, passed down through generations and crossing continents like the Swiss cheese recipes used by Shep Ysselstein, owner and grand fromage of Gunns Hill Cheese in Woodstock, Ontario, Canada.
Located in the green-grass dairyland of Oxford County, two hours west of Toronto, Gunns Hill Artisan Cheese is known for handcrafted, Swiss-style soft, semi-hard and hard cheeses. They are made from recipes that Ysselstein brought back from a one-year study of cheese making in Switzerland. But that Old World recipe is now a New World reality thanks to a secret ingredient: Danfoss VLT variable frequency drives. Cheese making involves processing a lot of fluids, explains Ysselstein. Were pumping thousands of gallons of milk in and out of different vats, stirring in different ingredients, maintaining precise temperatures in a clean environment and lifting and transporting wheels of cheese
NEW WORLD TECHNOLOGY FOR OLD WORLD TECHNIQUES
up to 55 pounds. We depend on Danfoss drives to make this operation move. Having earned a business degree several years earlier, Ysselstein opened the small, family-owned enterprise in October 2011. He sells cheese in a retail shop attached to the factory as well as through wholesale operations. A family dairy farmFriesvale Farmslocated next door to the factory, supplies milk. Oxford County is famous for being the dairy capital of Canada, says Ysselstein. Our family farm has been in business for over sixty years. The quality of the milk comes through in the cheese, especially in the curds. They are immensely rich in flavor and their squeak can be enjoyed during a great snack. Each of Ysselsteins three varieties of washed rind cows milk cheeses uses slightly different processes. The soft cheese is modeled after a little known Swiss recipe called Mutchli. This mild, creamy cheese is excellent for serving or melting, developing a buttery flavor after just four weeks of aging. The semi-hard recipe combines traits from Gouda and another
Thousands of gallons of milk pass through different vats at Gunn's Hill.
Using VLT drives has given Gunn's Hill greater control of their process.
About The Author

Patrick Appleby is the vice president of industry for Danfoss, a world leader within energy-efficient and climate-friendly solutions for selected industries. For more information, visit www.danfoss.com .
52 | SEPTEMBER 2013
overnight, depending on the desired hardness of the cheese. The round wheel of cheese is then immersed into salt brine for two days. Finally, the cheese is lifted from the brine onto racks where it is aged to develop flavor. The aging room is kept at 54 degrees Fahrenheit (12 degrees Celsius) and 90 percent relative
humidity. The cheese is turned every other day and washed with a salt water solution. The outside surface turns an orange color from natural microbes, unlike the dyes used by other cheese makers. After the proper aging time, the cheese is ready to eatthe result of hand craftsmanship and advanced technology.
VLT Micro Drives are up to 40 percent smaller than drives with comparable power.
Swiss variety called Appenzeller. Its creamy, rich flavor has sweet overtones with distinctive eyes in the body of the cheese. The mild version is aged five months and the semi-hard version, twelve months. Finally, the hard variety is a Swiss mountain-style cheese with rich, dry, nutty overtones aged one year. An extra-aged style will be available in two to three years.
FLUID AND MOTION CONTROL CHALLENGES
The fluid and motion control required in the process can be seen in the many steps involved in making semi-hard cheeses. Whole Holstein milk is pumped into a cheese vat, where it is pasteurized at 145 degrees Fahrenheit (63 degrees Celsius) for one-half hour. Then, starter culture is stirred into the milk to turn the lactose into lactic acid. An hour later, rennit is added to thicken the milk into a mass, like gelatin. When the milk is at the right thickness, it is cut into small pieces known as curds. For semi-hard cheeses, the cut pieces are the size of a kernel. The curds are heated by adding hot water. The hotter the water, the drier will be the cheese as the curds shrink and separate from the liquid whey. The curds are then transferred from the vat to the drain table. Then the whey is removed, while the curds form a mass at the bottom. Six hours after the milk was first pumped in, the curds are cut into squares and pressed into a round plastic mold, which squeezes out more whey. Pressing can take twenty minutes or
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PROCESSING solutions
Throughout the operation, a series of Danfoss VLT Micro Drives are used to provide pumping and mixing capabilities. Using VLT variable frequency drives was recommended by my HVACR contractor, Ben Kungl, of Oxford Energy Solutions, explains Ysselstein. The drives operate our AC pump motors, letting us dial the right speed for a given task. Actually, there are about fifteen VLT drives used in the plant for a wide range of jobs, notes Kungl. He himself grew up on an Oxford County dairy farm. After getting technicians training at a local technical college and working for the award-winning Performance Dairy Centre, he started his own businesses: Oxford Energy Solutions and Oxford Refrigeration. There are a lot of old-school ideas about using fixed-speed pumps and motors in dairy processing equipment, says Kungl. But in this day and age, you have to be as efficient as you can be.
Kungl was able to improve efficiency and control with Danfoss VLT drives in three areas: fluid pumps, ventilation system and cooling compressor. He applied three Danfoss VLT Micro Drives to drive the pumps used to off-load milk from the truck into the raw tank, transfer milk into vats and for washing. I can set three different speeds without damaging the motors, says Kungl. These drives are so easy to program. Pump control can be done either from the drive pad or a PLC.
INGREDIENTS FOR IMPROVING ENERGY EFFICIENCY
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Plus, they convert single phase household AC current to 3-phase, he adds. That means we didnt need to rewire to supply 3-phase current for the heavy commercial motors. For example, Kungl applied a VLT drive to control the hoist motor that lifts cheese trays from the brine. Another VLT drive is used for ventilation. Regulations require that a food plant have a positive air pressure inside to keep contaminants outside. So a VLT Micro Drive was applied to the reverse pressurized air handler that supplies the entire facility with 100 percent fresh air. It was easy to wire the drive into a pressure transducer, explains Kungl. That way, the air handler only needs to supply the make-up air to maintain positive pressure. You can get a small amount of inlet air using 30 horsepower, compared to an old-school fan system using 60 horsepower. That takes a lot of energy, considering you can do the same amount of useful work, get better results and use one-half the horsepower compared to a balanced system with fixed supply and exhaust fan systems. Finally, Kungl applied a Danfoss VLT AutomationDrive FC 302 in a NEMA 12 enclosure to modulate the compressor in the outdoor chiller. The drive serves a dual purpose: to save cost and give the customer a wide range of adaptability. The chiller modulates between the process cooling for the building and direct cooling for the product after it has been pasteurized and needs to be cooled back down. The FC 302 drive controls the scroll compressor speed and capacity, while two more VLT Micro Drives control the condenser fan motors for a fully modulating system. These types of condensing units/chillers are a very common product made by Oxford Energy Solutions and have become very popular in food processing and bio-fuel sectors.
units use algorithms dedicated for flow applications. That simplifies implementation. There are a lot of builtin featuresfrom process PI controller to a Smart Logic Controller that often make a PLC unnecessary. Plus, they can handle up to 122 degrees Fahrenheit ambient temperatures (50 degrees Celsius) without derating, so no special ventilation is needed.
But basically on a general all-around dairy operation like this one, I simply took advantage of the VLT drive familys versatility. For efficiency and reliability, Danfoss VLT drives can give Gunns Hill Artisan Cheese all the flavors of pump and motion control they need. Ysselstein agrees: Without Danfoss drives, I wouldnt be making good cheese.
The VLT industrial drive family has an outstanding history of reliability in our company," states Kungl. They have a large DC BUS that gives them a very large voltage tolerance. This is why the Danfoss drive product has become one of our companys flagship product lines. Danfoss VLT drives are also built in the U.S.A. in nearby Milwaukee, Wisconsin, adds Kungl. Unlike other variable frequency drives, these
SEPTEMBER 2013
DEPENDABILITY RUNS IN THE VLT DRIVE FAMILY
55
VALVES & CONTROLS solutions
Side-by-side microphone tests come through loud and clear for PCB Piezotronics
By Tito Rodriguez, PCB Piezotronics
CB Piezotronicsa global supplier of microphones, vibration, pressure, force, and torque sensorsannounces that it has received the published results of a competitive side-by-side test of 1/2 inch (XX millimeter) free-field prepolarized condenser microphones from PCB, B&K, G.R.A.S., and BSWA. The test was performed by SP Technical Research Institute of Sweden, an internationally accredited test house. This instrumentation is used for test, measurement, monitoring, and control requirements in automotive, aerospace, industrial, R&D, military, educational, commercial, OEM applications, and more.
LEADING EDGE COMPETENCE AND TECHNICAL REACH
whom half are graduates and about 290 are research scientists, the groups personnel constitute an important knowledge resource. National Laboratories are designated by the Swedish Government according to the ACT (2011:791) and Decree (2011:811) concerning testing and metrology. SP operates under ISO 17025, supervised by SWEDAC. SP is a government owned research institute that performed extensive performance and environmental testing on microphones from the industrys leading providers, says David Rizzo, director of sales and marketing for acoustics. The results confirmed what we have always known about PCBs microphone quality and performance so we are excited to share this with the market.
The SP Group is a Swedish National Laboratory that consists of the parent company and subsidiaries CBI, Glafo, SIK, SMP, YKI, and JTI. Together, they create a powerful group of research and development institutes aimed at innovation and sustainable development of industry and society. The groups laboratory resources are nationally and internationally competitive. With a staff of over 1100, of
TESTING PARAMETERS
The inch (12.7 millimeter) free-field microphone was chosen because it is the most popular model and size for test and measurement applications. The tests compared PCBs 378B02 against its competitors over a number of critical areas to determine if the microphones met both
About The Author

Tito Rodriguez is the director of corporate marketing for PCB Piezotronics and can be reached at 716.684.0002, trodriguez@pcb.com, or media@pcb.com. For more information, visit www.pcb.com/comparemics.
56 | SEPTEMBER 2013
the IEC standards and the vendors published specification. The areas tested included: Sensitivity Temperature Coefficient Dynamic Range Humidity Coefficient Frequency Response Low Frequency Limit
and traditional externally polarized condenser, array, probe, lowprofile surface, and special purpose microphones. PCBs Acoustic Team participates in both the Acoustical Society of America (ASA) and IEC Standards Board and is a Vendor Liaison to
Penn States Center for Acoustics and Vibration. PCB is accredited by the American Association for Laboratory Accreditation (A2LA) and a signatory to the International Laboratory Accreditation Cooperation (ILAC) Mutual Recognition Arrangement (MRA).
In the past few months we have taken several steps to position ourselves for rapid growth in the acoustic test and measurement space including the formation of a dedicated microphone team, introduction of new products, aggressive pricing and now third party test data validating our products quality and performance, says Rizzo. Combine these with our best-in-class delivery and support and we feel there is no reason why PCB should be anything other than the microphone vendor of choice. The report can be viewed or downloaded from PCBs website. The 378B02 is a complete system (microphone and preamplifier), which is ideally suited for product testing in anechoic chambers or environmental testing. The SP Group test results are in line with PCB Piezotronics commitment to providing its customers with reliable instrumentation that meets or exceeds the industry standard for microphones, vibration, pressure, force, torque, load, and strain sensors. In addition to being the pioneer of ICP technology, PCB boasts a customer support team of more than thirty customer service representatives and application engineers, including a twenty-four-hour SensorLine, a global distribution network, and the industrys only commitment to Total Customer Satisfaction.
LISTENING TO CUSTOMERS
A HISTORY OF SUCCESS
PCB provides precision microphones and accessories for a wide range of acoustic test and measurement applications. Leveraging state-ofthe-art equipment and facilities, a dedicated team of acoustic, mechanical and electrical engineers, including several PhDs, have built an extensive portfolio of products including modern prepolarized
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SEALING solutions
Maximize Your Filtration with High-Capacity Pleated Cartridges

By Dan Morosky, Rosedale Filtration Products
epending on your application, highcapacity pleated cartridges can have many advantages: One 7 by 36 inch (177.8 by 914.4 millimeter) high-capacity pleated cartridge can replace as many as forty 2 1/2 by 10 inch (63.5 by 254 millimeter) string-wound cartridges. Disposal costs are lower because of the high dirt capacity. A high-surfacearea cartridge may only have to be changed out two or three times a year compared to possible weekly change-outs when using standard cartridges. Cartridges can be used in vertical or horizontal housings. If downtime cannot be tolerated, parallel filters sized to handle the total flow rate can be used.
Elements are manufactured in a unique Y pleat arrangement that optimizes its physical size and maximizes effective surface area. A low fluid flux rate (gallons per minute per square feet of surface area) maximizes dirt containment. This means element life is extended and productivity is increased, resulting in fewer cartridge change-outs, less labor, and lower replacement costs. This design uses only the highest quality materials and most advanced manufacturing processes. The end caps are heat sealed for high efficiency performance. The o-ring seal insures sealing and eliminates bypass.
Cartridge filter housings using an ultra high capacity filter eliminates maintenance by providing high dirt removal.
High capacity cartridges are made from several types of filter media and pore sizes in order to maximize dirt-holding capacity. Available filter media materials are; polyester, polypropylene, cellulose and fiber glass. This
allows for a compatibility with a wide variety of fluids at various temperatures. Absolute-rated filter cartridges offer maximum dirt holding capacity coupled with micron retention ratings to 0.5 at beta 5000 or 99.98 percent efficiency.
A filter with a Beta Rating of 5000 means that it has an efficiency rating of 99.98 percent at the specified micron rating. This means the contaminant reduction ratio is 5000 to 1. In contrast, a 99 percent efficiency filter has a beta ratio of 100. A beta 100 filter will pass 1 in 100 particles at the given micron rating. Beta ratings are an indication of the filter performance throughout the life of the filter. Beta ratings are established
THE IMPORTANCE OF BETA RATINGS
About The Author

Dan Morosky is the vice president of sales and marketing of Rosedale Filtration Products. For more information, call 800.821.5373, email filters@rosedaleproducts.com, or visit www.rosedaleproducts.com .
58 | SEPTEMBER 2013
THIS SECTION SPONSORED BY
WWW.SALEM-REPUBLIC.COM
NITS INSTALLED IN VERTICAL OR HORIZONTAL HOUSING

100 square feet (9.29 square meters) of surface area maximum Up to 20 pounds (9.07 kilograms) (approx.) of dirt carrying capacity Rated 0.5 micron to 70 micron @ 5000 or 99.98 percent efficiency Flow rates to 100 gallons per minute (6.31 liters per second) 6.25-inch (158.75 millimeter) diameter and 35-inch (889 millimeter) length
14.0 12.0 10.0 P PSID 8.0 6.0 4.0 2.0 20 40 60 80 Flow GPM (Water)
Flow Rate Vs.
P
.5-2 5 10 20-40 70 100
Model 24 multi housing with six elements
150 square feet (13.94 square meters) of surface area maximum Up to 40 pounds (18.14 kilograms) (approx.) of dirt carrying capacity Rated 0.5 micron to 70 micron @ 5000 or 99.98 percent efficiency Flow rates to 200 gallons per minute (12.62 liters per second) 6.25-inch (158.75 millimeter) diameter and 60-inch (1524 millimeter) length
14.0 12.0 10.0 P PSID 8.0 6.0 4.0 2.0
Flow Rate Vs.
P
.5-2 5 10 20-40 70
40 80 120 160 Flow GPM (Water)
200
Model 18 high flow housing with three elements
SEPTEMBER 2013
59
SEALING solutions
UNITS INSTALLED IN VERTICAL HOUSING
400 square feet (37.16 square meters) of surface area maximum Up to 100 pounds (45.36 kilograms) (approx.) of dirt carrying capacity Rated 0.5 micron to 70 micron @ 5000 or 99.98 percent efficiency Flow rates to 400 gallons per minute (25.24 liters per second) 13-inch (330.2 millimeter) diameter and 40-inch (1016 millimeter) length
Flow Rate Vs. P
.5-2 5-10 20-40 70 100 200 300 Flow GPM (Water) 400
10.0 P PSID 8.0 6.0 4.0 2.0
1150 square feet (106.84 square meters) of surface area maximum Up to 250 pounds (113.4 kilograms) (approx.) of dirt carrying capacity Rated 0.5 micron to 70 micron @ 5000 or 99.98 percent efficiency Flow rates to 600 gallons per minute (37.85 liters per second) 20-inch (508 millimeter) diameter and 40-inch (1016 millimeter) length
10.0 P PSID 8.0 6.0 4.0 2.0
Flow Rate Vs.
P
.5-2 5-10 20-40 70
150 300 450 Flow GPM (Water)
600
Platinum housing with element hoist
60 | SEPTEMBER 2013
THIS SECTION SPONSORED BY

during testing by averaging the performance values at intervals of 2PSID differential pressure until the filter is dirty. The range is typically from initial pressure drop to terminal pressure drop at 30 PSID. The Beta Ratio () at a given particle size can be correlated to the filter efficiency at that particle size according to the following formula:
WWW.SALEM-REPUBLIC.COM
Horizontal or vertical mount Housings available in carbon steel, 304 or 316 stainless steel and polypropylene Pressure ratings in 100, 125, and 150 psi ASME code stamp available on selected models Flanged or threaded connection sizes from 2-inch (50.8 millimeter) through 12-inch (304.8 millimeter) Covers are o-ring sealed and easy to remove Leg assembly (excludes CR8) Clean and dirty/gage port connections O-ring seals: Buna, Ethylene Propylene, Viton, and Teflon Encapsulated Viton The benefits are a decrease in cartridge use, reduced labor, inventory, worker exposure and disposal costs. A single cartridge holds as much as 20 pounds (9.07 kilograms) of contaminant with flows to 100 gallons per minute (6.31 liters per second). Because of the plug in design, the laborintensive v-posts and spring seals associated with smaller cartridges are eliminated. The cartridges are easily removed, requiring no special tools. The large diameter 13 by 40 inches (330.2 by 1016 millimeters) and 20 by 40 inches (508 by 1016 millimeters) cartridge housing are equipped with a removal cable and hoist assembly. Cartridges are designed to fit all standard housings, and multi-housings. Typical cartridge size specifications and flow rates are detailed in this articles diagrams. For most users, high capacity cartridges unit will outperform standard wound or pleated cartridges and reduce maintenance time and cost.
Filter Efficiency (%) = [(b-1)/b] x 100% Beta Ratio () Filter Efficiency (%) 100 99.00 1000 99.90 5000 99.98
Each filter element will have a different Beta Ratio for every specified particle size. The determination of a variety of Beta values for the same filter provides a filter efficiency profile commonly referred to as a Beta Curve. Beta Ratings allow the user to select the performance that the individual application requires.
CHANGING THE CHANGE-OUT
These new cartridge housings are designed to end the high cost of cartridge change-out. They are offered in single cartridge and multi-cartridge housings. Standard features include From 1 to 38 cartridges Multi-cartridge units are offered in the low profile design, for quick and easy cartridge removal
SEPTEMBER 2013
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MODERN PUMPING products

AIRMASTER AERATOR
Turbo X-Treme Magnum Water Cannon
The Turbo X-Treme Magnum Water Cannon is Airmasters high-efficiency, 50 horsepower floating/surface aerator, which can pump up to 12.5 million gallons of water per day and has been upgraded with the addition of the new rotating water cannon. In operation, the water cannon (powered by a separate 7.5 horsepower grinder pump) rotates 360 degrees in 1 minute 35 seconds, spraying out over 100 gallons of water per minute in an approximate 230 feet diameter, achieving foam suppression, aeration, evaporation, and cooling. The aerator is ideal for a wide variety of applications, including municipal, industrial, agricultural, and disaster recoveryand performs especially well in high-foam applications. For more information, contact Dean Caldwell at 888.813.3680, deanc@airmasteraerator.com, or visit www.airmasteraerator.com.
FRANKLIN CONTROL SYSTEMS

Intelligent Pump Starter
Integrated Tru-Power sensing protects pumps from dry pump, dead head, burnout, and jammed impeller conditions. Comprehensive wide range electronic motor protection includes over/under voltage and ground fault detection. HMI with LCD display allows for programming of protective functions and quick viewing of faults. Optional fault logging with date and time stamping allows for recording up to 100 events. Controls 1/3 to 300 horsepower motors. Learn more about the IPS at www.franklin-controls.com or by calling 800.962.3787.
M20 Shaft Power Monitor
H2FLOW CONTROLS, INC.

By detecting abnormal conditions, the M20 Shaft Power Monitor is able to drastically reduce downtime and eliminate equipment failure before they occur. The M20 uses a patented algorithm, so that unlike amp / current monitors, the M20 achieves a linear and precise reading of true shaft horsepower. This allows the M20 to reliably protect motor driven equipment from abnormal process conditions such as pump dry run, dead head, closed valve, and cavitation. In addition to providing inexpensive overload and underload protection, the M20 is also compact and DIN-rail mountable, so that it may fit within any electrical cabinet. For more information, contact Russ Weiss at 513.702.4449 or visit www.h2flow.net.
SC450 Series Single Parameter Colorimeters

The SC450 Series of Single Parameter Colorimeters is a versatile line instruments for water quality analysis. Able to test for a wide range of water quality parameters, these colorimeters are ideal for use in the field or laboratory. Using Orbeco-Helliges Open Reagent System (which uses Powder Pack, stable tablets and liquid reagents) many of the instruments offer users a choice of multiple ranges and/ or reagent style platforms. Orbeco-Hellige manufactures a full range of water quality instruments, reagents and accessories for testing over 100 parameters. Our products cover a broad range of applications including drinking water, wastewater, and industrial water. For more information, call 800.922.5242 or 941.756.6410, email service@orbeco.com, or visit www.orbeco.com.
ORBECO-HELLIGE
62 | SEPTEMBER 2013
SEPTEMBER 2013
63
PUMPING trends
OF PANDAS, PENGUINS, BLACK HATS

arlier this year, Googles search algorithm changed some of the fundamental methods it relies on to filter and rank its users search results. Understanding these changes, says Brad Miller, director of marketing for Shanley Pump and Equipment, is crucial for OEMs and distributors looking to maintain their marketing and sales position in the eyes of customers. Brad Miller sat down with Modern Pumping Today to provide an overview of these changes and how they could affect many business owners without their even knowing it. Modern Pumping Today: More and more industrial businesses are relying on their websites to generate new sales. However, youre saying that companies need to educate themselves with how new customers can find them? Brad Miller: Many companies have noticed a precipitous drop-off in site traffic from Google in the past few months. In some cases between 50 to 85 percent of a sites traffic has been removed because Google has moved the goalposts for the sites placement online thanks to the Panda and Penguin updates for the Google search algorithmthe first in a longseries of changes Google will make in how search results are displayed from now on.
Shanley Pump and Equipments Brad Miller previews the new frontier of search engine optimization
links to point at a particular domain name. It requires little to no effort and most CEOs didnt care about what happened to their site, just that the site rankings and traffic remained high and leads continued to come in. MPT: But now Googles changed how they approach these listings? Brad Miller: At the end of May, Google updated their Panda and Penguin search algorithms specifically to target these SEO tactics online and penalize the sites using them. The results have been staggering: companies that held top-10 placements have been kicked ten pages deep or worse and not recovered. If your sites performance has taken a large hit recently, more than likely you are a victim of either a Panda/Penguin update or a negative SEO attackanother Black-Hat SEO programmer tactic used to lower your search result rankings, rather than increase it. If you have several hundred thousand links pointing to you from sites that have nothing to do with your business or industry, the end result will be new customers simply wont be able to find you in a search. Most companies dont even know this is happening. Now more than ever, paying attention to whats going on online for your site is a critical business task. Owners and managers need to start paying serious attention and educating themselves about how the web, especially Google, works. There is no longer an easy way for ranking in the internet, and if you try to cheat the penalty might be your presence online.
AND
MPT: What are Panda and Penguin, and how have they changed the way Google organizes its users search results? Brad Miller: Both updates are responsible for how a website ranks in the search results or even if a site shows up in the search results. As a business owner, you may have held top positions in searches for yearsyou may be a large multimillion dollar industry leader with top brand recognition and a world-wide distribution chain and thousands of employeesbut in the eyes of Google, you are simply another website. MPT: So how do Google and other search engines prioritize different sites, and how did these companies get into this predicament online? Brad Miller: When a webpage is submitted there are over 200 determining factors that Google looks for how each page is placed in the search results. Everything from keyword density to background coding to sentence structure and internal links are considered. One of the current major factors in how Google determines who winds up with Top-10 positioning is who links to you. Its true, if you have a ton of links pointing towards your site, Google will think your site offers more value to a relevant search and, therefore, you will get a better placement. Many site owners relied on companies who used Black-Hat search engine optimization (SEO) tricksa quick performance boost from SEO programmers who use overseas search engines and literally buy thousands of
64 | SEPTEMBER 2013

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