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Providing SolutionS for the WorldWide PumP induStry

february 2014


Maintenance and Monitoring


Fea e Be
on tur ll &
pa ed G
ge Pro os
52 duc set
t R t's



february 2014

industry news
trade Show Profile
Case Studies

14 Keep it Clean

Bedford Pumps provide triple protection for the Yorkshire Coastline

16 Wastewater treatment facility

improves visibility
LED lighting reduces energy consumption by more than 50 percent for Santa Cruz

Water & Wastewater



18 a new approach to accurate

Water flow measurement

maintenance Solutions

22 equipment maintenance and monitoring

best Practices
IR windows improve profitability, uptime, and safety

Pump Solutions

24 the Power of e


Part 2 of a 3-part series

Efficiency Islands: What are they? How do they result in operating benefits?

30 Working Smarter, Working together

Grundfos, U.S. Boiler Company collaborate to provide ultra-efficient boiler-pump package

dewatering Solutions

34 Cultec Chambers Solve infiltration issues

for business Center

motor Solutions

36 browning turns up the heat

EPDM-formulated belts have heat advantage over polychloroprene belts



P.O. Box 660197 | Birmingham, Alabama 35266

Power generation

38 Power (and Savings) to the People

Large and fast-track solution for combined cycle power plant

Processing Solutions

40 Qatar relies on a flexible Choice of fuels


JEFF FLETCHER Associate Publisher
RaNDY aRMISTEaD Associate Publisher
J. CaMPBELL Editor

New triplex pump drive unit will also power natural gas tankers with LNG in the future

DONNa CaMPBELL Editorial Director


valves & Controls


SCOTT gORDON Art Director


44 actuators aid Pump Station

Pressure Surge Solution

Sealing Solutions

50 Wear Components Perfect

for high Performance
Zeon Technologies introduce new material to outperform thermoplastics



LISa aVERY Assistant Art Director

CHRIS gaRMON General Manager
LINDEY SCOTT Circulation Manager
JaMIE WILLETT Circulation Consultant
INgRID BERKY Administrative Assistant
NaNCY MaLONE National Sales Manager
RaNDY MOON Account Executive

modern Pumping
Featured Product Release: BELL & GOSSETT Ecocirc XL

Pumping trends

56 the time is now

The Equipment Leasing & Finance Foundation finds confidence is rising for industrial equipment

editorial adviSory board

Terry Bell

Michael Mancini

Drives and Motion Solution Engineer

Baldor Electric Company

Consultant and Trainer,

Mancini Consulting Services

Heinz P. Bloch, P.E.

John M. Roach

Consulting Engineer,
Process Machinery Consulting

Robert G. Havrin
Director of Technology,
Centrisys Corporation

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


312 Lorna Square | Birmingham, Alabama 35216

T: 866.251.1777 | F: 205.824.9796
Vice President

Vice President

Lisa Roe

Business Development Manager,

Wastewater Pumps
Xylem Inc.: Flygt

Greg Towsley

Director of Regulatory and

Technical Affairs, Grundfos

Trey Walters, P.E.

President, Applied Flow Technology

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

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


Smith & Loveless Inc. president Frank J. Rebori has been

appointed to the Board of Directors of the Hydraulic Institute
(HI), the largest association of pump manufacturers and
suppliers to the pump industry in North America, and the
global authority on pumps and pumping systems. Rebori was
formally introduced at HIs 97th Annual Meeting, February 6
through 11, in Litchfield Park, Arizona.
Reboris appointment yields an industry distinction as
well as a strategic one. He concurrently serves on the
Executive Committee of the Board of Directors for the
Water & Wastewater Equipment Manufacturers Association
(WWEMA), recently tabbed as Chairman-Elect in 2014. His
dual board participation in both HI and WWEMA is believed
to be an industry first, and it promises to foster enhanced
dialogue and technical exchange between the two long-time
Rebori was named just the sixth president in Smith
& Lovelesss 65-plus year history in 2008. Under his
leadership, Smith & Loveless Inc. has significantly expanded
its wastewater equipment system offerings and global
distribution, while establishing even higher standards for
manufacturing quality and technical output.



Power usage effectiveness (PUE) has become the industrypreferred and globally adopted metric for measuring the

4 | february 2014

energy efficiency of data centers. In response to this demand,

ASHRAE and The Green Grid have published PUE: A
Comprehensive Examination of the Metric.
This is the eleventh book in the Datacom Series of
publications from ASHRAE Technical Committee (TC) 9.9,
Mission Critical Facilities, Data Centers, Technology Spaces
and Electronic Equipment. ASHRAE TC 9.9 collaborated with
The Green Grid on the book.
Our primary goal is to provide the data center industry
with unbiased, vendor neutral data in an understandable and
actionable way and this latest publication on the PUE metric
does exactly that, Don Beaty, publication subcommittee
chair of TC 9.9, says. We want to ensure that data center
designers, owners and operators have access to information
that enables them to make informed and educated decisions
based on their business needs and value systems.
For this book, all previously published material related to
PUE was consolidated and augmented with new material.
The content includes detailed information on procedures for
calculating, reporting and analyzing PUE measurements, plus
quick references to other resources in print and online. The
intention is that a broad audiencefrom those implementing
and reporting data center metrics seeking in-depth
application knowledge and resources to executives hoping
to gain a higher level of understanding of the concepts
surrounding PUEcan easily grasp the guidance offered.
"Data centers are complex systems for which power
and cooling remain key issues facing IT organizations
today, John Tuccillo, chairman of the board for The Green
Grid Association, says. The Green Grid Association's


PUE metric has been instrumental in helping data center
owners and operators better understand and improve the
energy efficiency of their existing data centers, as well as
helping them make better decisions on new data center



As the original inventor of the Rotamat centerfeed drum

screen, Huber Technology continually develops innovations
of the Rotamat screen to address increased equipment
protection requirements. Huber recently unveiled their latest
design, the Rotamat RPPS STAR. The design utilizes a 1 or 2
millimeter patented pleated perforated plate geometry. This
increases throughput by 25 percent allowing for a smaller
footprint. This results in a reduced capital expenditure for the
screen and structure. The fold provides additional stiffness
critical to larger drum designs.
Two-dimensional perforated plate screens achieve a high
removal of hairs and fibres, i.e. two to four times the amount
of solids are removed than one-dimensional screens are able
to separate. The significantly increased separation efficiency
is accompanied by a high level of screen surface blinding and
requires larger dimensioning of the fine screens compared to
other commonly known wedge wire screens. Conventionally,
a screen basket with bigger external dimensions is used to
achieve larger dimensioning with the result of significantly
increased investment costs and even building costs as a
bigger channel is required. The perforated plate of the screen
basket is folded in axial direction like an accordion. The zig-

6 | february 2014

zag folds form the star-shaped screen basket (RPPS-Star). This

increases the screen basket surface by about 30 percent with
still the same nominal diameter.


Bioscience, Inc. is now offering a free workshop presentation

titled "The Biological Process in Wastewater Treatment" for
all wastewater professionals including consulting engineers,
wastewater treatment plant managers, superintendents and
operators, and collection systems personnel. The focus of the
presentation is on the "Bio" part of the plant or collection
system and details how to evaluate, analyze and promote
good biological activity and plant stability. Implementation of
simple laboratory procedures for evaluating treatment plant
performance is introduced, as well as, bioaugmentation for
overcoming common treatment plant and collection systems
problems. Visit the Bioscience website for an outline of the
presentation. Call 484.245.5232 for more information.



TURBOdesign Volute introduces a novel approach to volute

design for compressible and incompressible flows which
allows for more practical and faster volute design cycles,
eliminating most of the traditional CAD volute design work.
The two-session webinar on February 26 will be presented
by Mehrdad Zangeneh, who is professor of thermofluids
at University College London and founding director of
Advanced Design Technology, Ltd. His research has resulted
in important breakthroughs in turbomachinery and marine


propulsor design. He has been granted six international
patents. In 2000, he was awarded the Japans Turbomachinery
Societys Gold Medal and in 2003 he was awarded the
Donald Julius Grone Prize by the Institution of Mechanical
Engineers in UK.
The code allows designers to approach volute design within
either a traditional 1D approach, or via a novel 2D approach
where the volute area distribution is calculated subject to
a specified non-uniform inlet velocity distribution from the
impeller. The code allows the designer to specify various
cross section shapes and outputs a clean IGES Surface file.
The demonstration will provide detailed flow analysis
and performance comparison for volutes designed by
TURBOdesign Volute compared to conventional 1D methods.
The webinar will conclude on ease of 3D CAD geometry
generation directly from TURBOdesign Volute for immediate
meshing in CFD codes. To register, visit the ADT website at


IRISS unveils their new Safety and Maintenance Academy of

Reliability Technologies training website featuring online,
electrical safety training courses available in English and
French for both electrical and non-electrical personnel:
Electrical safety is at the heart of everything we do and
it is essential to stay sharp with continual education for
both electrical and non-electrical personnel, explains
Martin Robinson, CEO of IRISS Group. Expanding our
hands-on training with this supplemental online training

8 | FEBRUARY 2014

helps reinforces the practices and principles essential for

establishing a safe work environment for electrical workers.
The Electrical Safety Training System (ESTS) focuses on
workplace electrical safety and the application of industry
accepted best practice consensus based standards to
effectively manage the electrical hazards of arc flash and
shock. ESTS was developed with content consistent with
industry adopted electrical safety standards, CSA Z462 and
NFPA 70E and provides due-diligence for OH&S Regulation
in Canada (CSA Z462) and OSHA in the United States
(NFPA 70E).
Risk is inherent to all electrical work and almost every
worksite today presents some form of potential electrical
hazard. This makes it critical that anyone required to work
on or near energized electrical equipment knows how to
safely work with and around it. ESTS is about understanding
the hazards of electricity and learning how to mitigate
them. Students will be guided through a Virtual Electrical
Workplace (VEW) to illustrate the electrical hazards and
safety concepts needed to be aware of when working with
By the end of the online training program, students will
have a good understanding of the electrical hazards they face
at work, the most effective ways to address them and how to
plan electrical work tasks safely, how to operate within OSHA
regulatory obligations and apply the tools from the NFPA
70E Standard for Electrical Safety in the Workplace, how to
use electrical specific PPE/tools/equipment, what needs to be
considered for emergency response and electrical incident


TRADE SHOW profile

IFPE 2014

Where all the solutions come together

and connections are made

he International Fluid Power Exposition, better known

as IFPE, is the leading international exposition and
technical conference dedicated to the integration of
fluid power with other technologies for power transmission
and motion control applications. Held every three years,
the next IFPE is set for March 4 through March 8, 2014, at
the Las Vegas Convention Center in Las Vegas, Nevada. IFPE
2014 is co-located with CONEXPO-CON/AGG 2014, one of
the worlds largest gatherings for the construction industries,
so this is a unique opportunity to network across a range of
industries and technological pursuits.
IFPE attracts design engineers and other decision-makers
from the fields of construction, mining, agriculture, fluid
power/power transmission products, instruments/controls,
material handling, manufacturing/production automation
(including chemical, petroleum, metal, plastics, and rubber
processing), and a vast assortment of engineering services.
The exhibits showcase the latest technologies and innovations
in equipment, products, and services for fluid power/motion
control/power transmission and also feature product-focused
exhibit pavilions and international exhibit pavilions.


The 95-plus official 2014 show supporting organizations come

from the United States, Canada, and sixteen other countries
worldwide. They bring qualified buyer groups to the events,
and many help develop direction and content of the education
programs to ensure they meet industry needs. Leading industry
organizations from around the world participate as supporting
organizations, and leading industry publications/media
worldwide participate as supporting publications/media.
IFPE is owned by National Fluid Power Association (NFPA),
Association of Equipment Manufacturers (AEM), National
Ready Mixed Concrete Association (NRMCA), and National
Stone, Sand and Gravel Association (NSSGA). AEM is show


IFPE 2014 education provides both application-based

and research-driven sessions, targeted to several levels of
expertise and interest, with the latest information crucial for
engineers and others involved in the design and manufacturing
processes. IFPE offers extensive educational programming,
including the prestigious National Conference on Fluid
Power (NCFP), which emphasizes new technologies and
methods related to improved analysis, design, manufacture,
and performance of fluid power components and systems for
mobile and industrial markets.
The IFPE Technical Conference features the latest research
developments in the fluid power industry. Special keynote
presentations are included. One registration allows access to
more than eighty presentations and the keynotes and includes
a flash drive with conference Proceedings. IFPE College-Level
Courses are half-day sessions focused on hands-on technical
knowledge on fluid power and hydraulics, with four to be
offered: overview of fluid power systems, sizing a hydrostatic
transmission using calculations, condition monitoring of
hydraulic fluids, and design of hybrid systems.
10 | february 2014


CASE Studies

Keep It Clean
Bedford Pumps
provide triple
protection for
the Yorkshire

Suspended bowl pump

for Toll House SPS at
Bedford Pumps works.

by lucy ogden, bedford Pumps

ituated on the North Sea coast of North Yorkshire, England,

the beautiful town of Scarborough has been welcoming
tourists and holiday travellers for over three centuries.
Established as the first seaside spa resort along the Yorkshire
coastline, the town has two designated beaches for public use:
North Bay and South Bay. The quality of the water at these
beaches differs. While North Bay already boasts the very highest
standard under the current European Union water directive,
the waters of South Bay have been playing catch up to earn the
designationearning the area a Blue Flag label, a reference
to the EU-style pictograms noting clean water on popular public

Scarborough North Bay and South Bay eligible for Blue Flags in
the future.
Bedford Pumps Ltd has been a vital partner in these efforts
and has now completed installation on the first of Yorkshire
Waters pivotal pumping stations situated on the picturesque
coastline of Yorkshire. The works are part of an 110 million
($182 million US) investment by Yorkshire Water to ensure
that Yorkshires beaches and bathing water are among the best
in Europe. A new European Bathing Water Directive is due to
come into force in 2015 and this investment should ensure an
excellent standard for water quality with the ability to secure
some coveted Blue Flags for Yorkshires beaches.



For the past three years, Yorkshire Water has been investing
millions to improve local wastewater pumping, storage, and
treatment facilities in Scarborough to meet the requirements of
the European revised Bathing Water Directive. The goal is to
reduce the chance of untreated water entering the sea during
times of heavy rainfall. The work should ensure Scarboroughs
beaches are even cleaner. By making these improvements
Yorkshire Water can play a huge part in securing the highest
standards of water quality for the townhelping make both

Toll House Sewage Pumping Station in Scarborough is the first

to benefit from Bedford Pumps expertise with three suspended
bowl pumps for pumping storm water. Toll House SPS is located
on Scarboroughs peninsula in an extremely challenging
location, and as such is Yorkshire Waters most significant
project in Scarborough, costing the company approximately
10 million ($16.5 million US) at this site alone. The pumping
station will encompass a new storm water storage tank capable
of holding 1.05 million gallons (4000 cubic meters) of storm

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.

14 | february 2014


Bridlington Wastewater Treatment Works,

which will require four suspended
wet well bowl pumps for storm water
protection. The construction will be
similar to the Toll House units and
designed for a duty of 39,625 gallons
per minute (2500 liters per second) at 26
feet (8 meters) head and driven by 288
kilowatt 12 pole motors.


Bedford Pumps is looking forward to be

working once again in collaboration with
civil contractor Morgan Sindall Grontmij
(MGJV). In the near future, they will be
providing Yorkshire Water with three
pumping station upgrades to ensure that
the beautiful Yorkshire coastline remains
exactly that.

Pump being installed at Toll House SPS on

Scarboroughs seafront.

water, which will minimise the risk of

any untreated water entering the sea
during heavy rainfall. Bedford Pumps
have manufactured three colossal storm
transfer pumps which will discharge the
excess storm water from the storage tank
out to sea.
Bedfords three storm water pumpsets
(one duty, one assist and one standby)
are of a mixed-flow bowl design with
steel rising mains, support plates and
motor stools. As Toll House pumping
station is situated on the coastline, the
open, mixed-flow impellers have been
manufactured in bronze to address the
potential corrosion problems associated
with the saline environment. Each pump
is designed to discharge at 54525 gallons
per minute (3440 liters per second) at
33.1 feet (10.1 meters) head with a BEP
of 86 percent, and driven by a 12 pole
450 kilowatt motor.


Bedford Pumps will shortly commence

the second of the trio of pumping station
upgrades for Yorkshire Water. Scalby
Mills Pumping Station, also situated in
Scarborough, will be supplied with four
wet well submersible volute pumpsets
for handling raw/screened sewage.
The order offered Bedford Pumps a
challenging design criteria requiring the
pumping of solids and stringy material
whilst discharging at high heads with
low vibration levels. The pumps will
deliver a duty of 7021 gallons per minute
(443 liters per second) each at a head of
221.8 feet (67.6 meters), making Scalby
Mills probably the largest submersible
sewage station in the region in terms of
The third and final pumping station to
benefit from Bedford Pumps expertise is

february 2014 | 15

CASE Studies

treatment Facility
improves visibility

LED lighting reduces energy

consumption by more than
50 percent for Santa Cruz
by dialight

he city of Santa Cruz, California,

wastewater treatment facility
processes an average daily flow
of 10 million gallons (3.7 billion liters)
per day, providing regional wastewater
treatment and disposal for both the
city and Santa Cruz County Sanitation
District, including the communities of
Live Oak, Capitola, Soquel, and Aptos.
In operation since 1928, the facility has
undergone numerous expansion projects
to accommodate growth in the region
and now boasts a rated design capacity
of 17 million gallons (6.4 billion liters)
per day.
Aiming to achieve better visibility
and reduce energy consumption, the
facility recently modernized its exterior
area and site lighting, upgrading
from high-pressure sodium (HPS) and
mercury vapor (MV) fixtures to new
Dialight DuroSite LED fixtures in

several areas. As a result, the plant

has reduced lighting energy usage and
cost by more 50 percent, significantly
lowered CO2 emissions, and realized
a dramatic improvement in visibility
that contributes to more robust security
throughout the facility. With fixtures that
are expected to last more than ten years,
the project will pay for itself in just a
third of that time.


With hundreds of fixtures to light

its exterior structures twelve hours
a day, seven days a week, the Santa
Cruz treatment facility previously
used a combination of high pressure
sodium units ranging from 70W to
400W and mercury vapor fixtures in
175W to 400W models. For safety and
security purposes, the entire facility
is under 24/7 closed-circuit television

surveillance, yet the poor quality of

light emitted by the antiquated fixtures
hindered visibility and reduced the
image clarity of the closed-circuit
In addition, the HPS and MV fixtures
required constant maintenance to
change bulbs and ballasts, costing
the plant both money and valuable
personnel time. Not to mention, the cost
of hazardous material disposal for the
bulbs added to the ongoing maintenance
expense and the environmental impact.


As part of a citywide Climate Action

Program to reduce energy consumption
and to resolve its lighting challenges,
the facility experimented with several
LED lighting solutions, including one
from Dialight. Impressed with the way
the Dialight fixture outperformed the

for more information

With a high-specification range of products Dialight is uniquely positioned for a number of long-term global growth trends,
many of which are driven by government regulations and environmental initiatives. These include the current global
infrastructure build-out, and the need for improvements to the efficiency, reliability, and productivity of the electrical grid.
For more information, visit www.dialight.com.

16 | february 2014


Exterior lighting at wastewater treatment facility
82 high-pressure sodium and mercury vapor fixtures with:
- Low Bays
19 - 14K lumen High Bays
30 - 12K lumen High Bays

Complete installation in just 5 days

Energy rate: $0.15/kWh
12/7 lighting with photocells and timers
$5000 rebate
~3 year payback

others, the facility ultimately chose

Dialight to replace eighty-two fixtures
in its solids dewatering building,
pre-aeration and trickling filters with
the companys DuroSite LED fixtures,
including thirty-three Low Bays specially
designed for areas of low clearance, and
forty-nine High Baysnineteen with
14,000 lumen output and thirty with
12,000 lumen output.
The entire changeout took just five
daysabout thirty to sixty minutes per


fixture. The 12/7 lighting was outfitted

with a combination of photocells and
timers, taking advantage of the Dialight
LEDs instant-on capabilities.


LED fixtures typically draw less than

half the wattage of high pressure sodium
and mercury vapor (on average). With
the new fixtures, the Santa Cruz facility
reduced its lighting energy usage
and cost by more than 50 percent,

significantly lowered its CO2 emissions

and realized a dramatic improvement in
visibility that contributes to more robust
security throughout the facility.
With each fixture expected to last up
to ten years, the retrofit has reduced
lighting maintenance and costs for
the next decade. A rebate was also
approved through a local incentive
program, based on energy savings, and
the entire project will pay for itself
within three years.

february 2014 | 17


A New ApproAch
to AccurAte
wAter Flow
by nicholas voss, mcCrometer inc.

lectromagnetic flow meters, or mag meters, are

the most widely used meter technology to measure
the flow of water in the world today. As populations
expand, water measurement and management is becoming
increasingly critical to preserve our water resources. To
complicate the equation further, many existing water
treatment and distribution systems that need to upgrade
their technology cannot shut down or stop service to the
communities they serve. The result is unmetered lines or
inaccurately metered systems which leads to costly water loss.
In 2011, McCrometer Inc., an innovator in flow
measurement technology for over fifty-five years introduced
the FPI MagTM electromagnetic flow meter. The FPI Mag
promised to give the same specified accuracy of traditional
full bore or flanged mag meters but with the ease of
installation of insertion type meters. In addition, the FPI Mag
promised to be hot tapped or installed while the system was
running at normal capacity, preventing costly shut downs and
the loss of service. While the hot tapped feature of the meter
has been proven and documented in customer experiences,
the third party proven testing had not previously been
published. This paper will examine the accuracy claims for the
FPI Mag and present testing performed. All testing presented
in this paper was done at an independent third party test lab.


The claimed accuracy for a calibrated FPI Mag meter is as

+/- 0.5 percent for Velocity 1 foot (0.3 meters) per second
to 32 feet (9.8 meters) per second
+/- 1.0 percent from 0.3 feet (0.1 meters) per second to 1
foot (0.3 meters) per second

Testing was done at Utah

State Water Research Laboratory
(USWRL) in Logan, Utah. USWRL
was chosen to perform these tests
because they are a well-known,
reputable water lab and because
they have a very large range of
line sizes and flow rates they can
McCrometer chose to test
the accuracy of a 30 inch (750
millimeter) FPI Mag at USWRL. This
size was chosen instead of a smaller
size due to the sheer volume of water
a 30 inch (750 millimeter) line carries.
In service, accuracy matters more in
larger pipe sizes: in a smaller line in the
4 to 10 inch range, if the measurement is
off by 1 percent at high flows, the meter
would be off by a few hundred gallons,
which represents a low cost in lost revenue. In a 30 inch
line or larger, the amount of water flowing is much greater,
so a 1 percent error can mean thousands of gallons of water
unaccounted for, leading to significantly more lost revenue to
the plant or district.
Testing was done over a wide 22:1 turndown with 23D
upstream piping and 14D downstream piping. The long
upstream and downstream pipe lengths simulate an infinite
straight pipe section to establish the baseline performance
of the meter without obstructions. Flow rates reported by the
FPI Mag were compared against the flow rates reported by a
20 inch (508 millimeter) master Venturi flow meter owned by
USWRL for the moderate and high flows. Flow rates reported

about the author

Nicholas Voss is the product manager for the FPI Mag electromagnetic flow meter. McCrometers products and systems are
found in thousands of installations worldwide and meet many of the worlds most demanding industrial, safety, and quality
standards. For more information, visit www.mccrometer.com.

18 | february 2014


table 1: fPi mag test Protocol Parameters

FPI Size

Min Flow
Rate (gpm)

Max Flow Rate


Min Velocity

Max Velocity


Upstream Pipe

Pipe Diameters









FPI Mag compared against the master flow meter is better

than +/-1.0 percent for velocities between 0.3 feet (91
millimeters) per second to 1 foot (304.8 millimeters) per
second. Tested accuracy above that was better than +/0.5 percent within uncertainty of the system. For the test
point at 5.2 feet per second, the tested FPI Mag accuracy
best summarized in the accuracy
was 0.66 percent. This is less than the total accuracy
of measurement of
0.71 percent for the
figure 1: 30 inch (750 millimeter) fPi mag error Plot
combined system.
Results of the 30 inch
(750 millimeter) FPI
Mag test prove the FPI
Mag meets the accuracy
claims. The measured
error of the 30 inch (750
millimeter) meter was
equal to or better than
the specified accuracies
for a wide range of flow.
Not only was the meter
accurate at low flow
Velocity (ft/s)
rates where accuracy is


The results of the tests are

plot below. The accuracy
is expressed as the
difference in the reading
reported by the FPI Mag
compared against the
actual flow rate. The
actual flow rate was
established by the Venturi
and full bore mag meter
as described in figure 1.
The orange bars represent
the accuracy of the
complete measurement
Tested accuracy of the
30 inch (750 millimeter)

% error

by the FPI Mag were compared against a traditional 12 inch

(304.8 millimeter) full bore mag master meter owned by
USWRL for the low flow rates.
The complete detail of the accuracy test is found in table 1.


february 2014 | 19


often difficult to achieve, but it was
also very accurate at high flow rates
where inaccuracy equals lost revenue.
We should highlight that two
reference meters were necessary to
measure the reference flow rate of one
FPI Mag meter. In addition, one of the
pipe systems had to be reduced from
30 inches (750 millimeters) inches to
20 inches (508 millimeters) to employ

the Venturi, and again reduced to 12

inches (304.8 millimeters) to employ
the full bore mag. Not only did the
FPI Mag measure the full range of the
Venturi and full bore mag, it did so
without needing to reduce or change
the pipe system. The FPI Mag allows
operators to put the meter where they
need it without making modifications
to the piping system.


When evaluating the accuracy of a flow

meter, we must take into account the
uncertainty of both the test meter and
the system determining the actual flow
rate. For the moderate and high flow
rates of the 30 inch (750 millimeter) FPI
Mag, the reported flow was compared
against the flow rate of a USWRL
Master Venturi flow meter. Venturi flow
meters are a differential pressure type
flow meter. Differential pressure (DP)
type flow meters use a pressure drop
across the primary element to determine
a volumetric flow rate. The stated
uncertainty of the Venturi master flow
meter is +/-0.25 percent of flow rate
For the low flows, the 30 inch (750
millimeter) FPI Mag was compared
against the flow rate of a traditional full
bore mag meter. The stated accuracy of
the full bore mag is +/-0.15 percent of
flow rate.



Furthermore, the FPI Mag

electromagnetic flow meter is easier
than ever to install and set-up for
use. With its precision multi-point
flow sensing technology and efficient
hot tap installation method, which
eliminates the need for extra labor,
heavy equipment, or line shut down,
this next generation mag meter delivers
superior performance, convenience
and installation cost savings of up to 45

Now available with Quick Connect

cabling, the FPI Mag flow meters set
up process is simplified even further.
The detachable Quick Connect Cable
can be sent to the plant ahead of the
sensor to allow for advance completion
of wiring assembly work prior to sensor
installation. Once the prep work is
20 | february 2014


table 2: 30 inch (750 millimeter)

fPi mag test System uncertainty
Device Uncertainty

0.3 to 1 ft/s

> 1 ft/s

Full Bore Mag

+/- 0.15%

--+/- 0.25%




+/- 1.0%

+/- 0.5%

Total Test Uncertainty

+/- 1.12%

+/- 0.71%

include effluent treatment and

For industrial processes, the
FPI Mag flow meters applications
include: intake water, feed
water, chilled water, cooling
water, fire water, water recycling
and effluent discharge. Such
applications are found in diverse
industries: chemical, electric

power, food/beverage, oil/

gas refining, metals/mining,
pulp/paper and more, as well
as chilled water and HVAC
applications in large campus
facilities. Given the ease of
installation and the testing
presented here, the FPI Mag
meter is the next generation in
water flow measurement.

done, technicians can quickly install the

sensing element without having to carry
or manipulate extended lengths of heavy
cable. Disconnect is also easy should
the cable need to be removed from the
sensor for maintenance or any reason.
The Quick Connect Cable for the
FPI Mag flow meter is compliant with
the International Electrotechnical
Commissions (IEC) IP68 standard. That
means McCrometer customers can be
assured the meters cable connection
meets international requirements with
regard to protection from both solid
particles and liquid ingress. The durable
cable connection is resistant to dust and
water-tight to a depth of 3 feet (1 meter).
Unlike all other insertion mag
meters, which only have a single point
of measurement, the FPI Mag flow
meters advanced multi-electrode sensor
compensates for variable flow profiles
including swirl and turbulent conditions.
The electrodes, which are placed across
the entire sensor body, continuously
measure and report the average flow
rate across the full diameter of the pipe,
delivering accuracy comparable to theperformance of a full-bore mag meter.
Multi-point sensing technology
makes the FPI Mag flow meter ideal
in cramped plant retrofit equipment
layouts or in confined space areas with
limited straight pipe run availability. The
sensor's body also is hermetically sealed
and protected by NSF certified 3M
fusion-bonded epoxy coating.
Available for forward-flow only or
a bi-directional measurement, the FPI
Mag flow meter supports line sizes from
4 to 138 inches (101.6 millimeters to
3.5 meters). The flow sensor comes
pre-calibrated from McCrometers NIST
traceable Calibration Lab and requires
no recalibration in the field.
The FPI Mag flow meter supports
liquid flow measurement requirements
in municipal water plant applications,
including: distribution, wells and
booster stations, disinfection dosing,
filter balancing and backwash and
effluent. Wastewater applications

february 2014 | 21


Equipment Maintenance and

Monitoring Best Practices

IR windows improve
profitability, uptime,
and safety
by martin robinson, iriSS, inc.

umping machinery is continually

subjected to wear and tear and
therefore is vulnerable to failure.
Correct operation, timely maintenance,
and upkeep of pumping station
machinery ensures uninterrupted
operation and extends the life of the
equipment. Sudden failures can be
avoided by timely inspections, follow
up actions, and planned periodical
Equipment reliability is critical
in any production environment,
especially when it comes to pumps.
There are several diagnostic
methods that are very helpful in
monitoring equipment health. Well-

implemented programs can often

recognize degradation in the initial
stage. In some cases, a root cause of
the problem can be identified and
mitigated before further damage is
done. In others, developing problems
can be monitored carefully and
trended, allowing preventive or
corrective action to be initiated in
planned environment instead of
having to address failures that cause
unplanned outages.


Lack of preventative, timely, or poor

maintenance can cause undue wear

and tear leading to premature failure

of equipment. Condition based
maintenance (CBM) techniques are
invaluable for keeping pump reliability
high and life-cycle costs low.
Diagnostic monitoring of electrical
distribution systems during pump
operation includes the use of electrical
maintenance safety devices (EMSDs)
such as infrared windows that help to
reveal early signs of trouble.
Infrared (IR) windows can help
detect unusual heat in electrical
controls, motors, and bearing that
is undetectable by ordinary means.
Using IR windows on electrical and
mechanical components helps to

about the author

Martin Robinson is the chief executive officer of IRISS, Inc. IRISS stands for Infrared (IR) Inspection Support Solutions and
is committed to universally mitigate the risk for electrocution and arc blast during the inspection of energized electrical
equipment. For more information, visit www.iriss.com.

22 | february 2014


quickly detect temperature differences

on mechanical equipment via nondestructive, non-contact temperature
measurements. Using IR windows is a
very fast and efficient method to scan
pieces of equipment quickly, searching
for thermal anomalies. With baseline
scan records, trend analysis of motors,
and bearings provide early warning of
impending problems.
IRISS IR windows utilize infrared
transmissive polymers. These material
are unaffected by mechanical stress,
moisture, humidity, seawater, and a
broad spectrum of acids and alkalis
so are ideally suited for any type
of pumping equipment. Another
significant advantage of polymer based
IR windows is they can be any size and
shape. IRISS customized IR windows
can even be designed in a curved
or rainbow shape to fit around a
mechanical guard or pumping device.


The use of electrical maintenance

safety devices is growing as companies
strive to improve profitability, uptime,
and safety. They allow the testing
of fully energized electrical systems
and pumping equipment without
risk to personnel. Those who are
implementing EMSD based programs
are reaping significant benefits in
terms of efficiency gains, cost control
and fire prevention. Because lower
PPE levels are required, inspections are
One of the tasks that need to be
completed on pumping equipment
while it is energized and under load
is infrared (IR) scanning. To allow the
inspections to be completed under
load, we use an IR window, which is
an EMSD that allows an IR camera to
see the energized loaded connections
through a special lens materials in
the IR windows. Much of the recent
acceptance of IR windows has
coincided with the increase in level of
awareness regarding electrical safety
and risk reduction. Organizations such
as the IEEE have been at the vanguard
of this movement with its Safer by
Design campaign.

Voltage detection (EMSD - external

voltage detection ports)
Motor current analysis (EMSD
voltage tap off connections)
Other EMSD strategies include the
use of online monitoring systems that
transmit data back directly to the client
utilizing either wired or wireless sensor
systems. These systems include:
Temperature measurement (contact
and non-contact systems)
Vibration analysis (rotating UPS
and generator systems)
Power quality (online and fixed
data collection systems)
Partial discharge (online and fixed
data collection systems)


The benefit of using EMSDs is that they

standardize the inspection routes as
they become data collection points for
the test equipment. They also ensure
that all the inspection parameters
are fixed and that all collected data
is standardized ensuring that any
trend analysis data is accurate. Other
benefits include:

Remove risk of electrocution and

possible triggers of an arc flash
Removal of high risk behaviors
Conduct valuable, fully loaded
online inspections
Access Inaccessible equipment
inspections require less
inspections require lower Personal
Protection Equipment (PPE) levels
inspections are faster and more
More inspections are completed
due to ease of operation
It is significant that most electrical
maintenance and safety standards
value the use of condition based
maintenance (CBM) inspections such
as IR surveys, ultrasound inspections,
vibration analysis, MCA, and partial
discharge testing as a critical part of
an electrical preventative maintenance
program. EMSDs provide a way
for companies to comply with
recommendations for inspection and
safety standards/guidelines while also
protecting their personnel, equipment,
and profits.


Other tasks where EMSDs are used

Airborne ultrasound (EMSD ultrasound ports)

february 2014 | 23

PUMP solutions

the Power of

Efficiency Islands : What are they?

How do they result in operating benefits?

Part 2 of a 3-Part sErIEs

by Christopher S. Johnson,
Xylem applied Water Systems

n the first part of this series, we

introduced the term Efficiency
Island, a graphical representation of
the improvements available to the best
operating performance in a centrifugal

pump. In this article, we will continue

to examine how Efficiency Islands can,
from a system perspective, address
new system efficiencies or lead to the
retrofit and improvement of existing

systemsespecially for the designers

and operators of HVAC systems for
buildings and facilities, whose systems
have substantial load variations (flow
rates) depending on the load profile.

about the author

Christopher S. Johnson is the global engineering manager for centrifugal pumps in Xylem Applied Water Systems in the
commercial building and HVAC business unit, while also supporting the other business units with crossover products. He has
held leadership roles in sales, application engineering, product management, global sourcing, global product development, and

24 | february 2014


figure 6
Efficiency vs Flow Rate as % of BEP
Product A vs Product B
Maximum and Reduced (90%) Impeller Diameter @ 1750 RPM



Product A
Product A
(8.5 inch, 90%)
Product B


Product B
(8.6 inch, 90%)












figure 7
Efficiency vs Flow Rate as % of BEP
Product A vs Product C
Maximum and Reduced (92%) Impeller Diameter @ 1750 RPM



Product A


Figures 6 and 7 compare efficiency

at maximum and for Products A and
B. In figures 6 and 7 the maximum
diameter efficiency is shown as the
solid line for the two products and
the reduced diameter in the dotted
line of the same color. A historical
specification requirement limiting
the impeller diameter to 90 percent
of the maximum impeller diameter
is used for this illustration. Note the
efficiency of the reduced impeller
diameter (figure 6) for Product A
exceeds even the maximum impeller
diameter efficiency of Product B,
a clear illustration of improved
efficiency at cut down impeller
diameters and enhanced Efficiency
Figure 7 shows a similar example.
Again, Product A efficiency at the
cut down diameter is better than
the maximum impeller diameter
efficiency of Product C.
A comparison of the ANSI/HI POR
(70 percent to 120 percent of BEP) for
each of the pump sizes just examined
is provided in figure 8. The maximum
impeller flow range is shown along
with the reduced impeller diameter
flow range. Each line indicates data
points for the 70 percent flow, the
BEP flow and the 120 percent flow
A more traditional view of flow
versus TDH with efficiency is also
provided in the next illustrations.
Figure 9 shows Product A (in red)
compared to Product B (in blue).
There is very little difference in TDH
versus flow rate for each unit. There
is a sizable advantage to Product
A when efficiency is compared at
BEP and, more importantly, as one
operates to the left or right of BEP.




Part 1 concluded with a

comparison of maximum diameter
efficiencies is done using percent of
BEP flow, specifically the Hydraulic
Institute (HI) Preferred Operating
Range (designated POR) of 70 to 120
percent of BEP flow rate to ensure a
consistent comparison is made among
pumps with somewhat differing BEP
flow rates. In part 2 of this series, we
will continue our look at efficiency
comparisons, this time beginning
with reduced diameter impellers and
their effect on Efficiency Islands.

Product A
(8.5 inch, 90%)
Product C


Product C
(8.5 inch, 92%)













figure 8
HI Preferred Operating Range (POR) Flow Rates
Maximum and Reduced Diameter Impellers
Products A, B and C at 1770 RPM

6 - Product A (Max)
5 - Product A (90%)

4 - Product B (Max)
3 - Product B (90%)

2 - Product C (Max)
1 - Product C (92.5%)









february 2014 | 25

PUMP solutions
figure 9
Product A (4 x 5 - 9.5) vs. Product B (4 x 5 - 9.5)
Maximum Impeller at 1770 RPM
Flow - Head - Efficiency


TDH, ft



Product A Efficiency in Red
Product B Efficiency in Blue

Product A (9.5 in Dia)

Product B (9.6 in Dia)










figure 10
Product A (4 x 5 - 9.5) vs. Product C (4 x 5 - 9.25)
Maximum Impeller at 1770 RPM
Flow - Head - Efficiency

TDH, ft


Product A (9.5 in Dia)

Product A Efficiency in Red

Product c Efficiency in Green


Product C (9.25 in Dia)









Figure 10 shows Product A (in

red) compared to Product C (in
green). There is some difference
in TDH capabilities versus flow
rate for each unit. Again, there is
a sizable advantage to Product A
when efficiency is compared at
BEP and as one operates to the
left of BEP. The different shape of
the head capacity curve and the
slightly different BEP design point
are aspects of pump comparison
which make it difficult to have a
completely uniform comparison of
26 | february 2014

Figure 11 shows Product A

(in red) compared to Product B
(in blue) for a reduced diameter
impeller (90 percent). The TDH
variation is nominal versus flow rate
for each unit. There is a substantial
advantage to Product A when
efficiency is compared at BEP and
more importantly as one operates to
the left or right of BEP.
Figure 12 compares Product A
(in red) to Product C (in green). The
H-Q differences reflect different
design approaches. The efficiency
clearly reflects the advantage of

figure 11
Product A (4 x 5 - 9.5) vs. Product B (4 x 5 - 9.5)
90% of Maximum Impeller at 1770 RPM
Flow - Head - Efficiency



TDH, ft




Product A Efficiency in Red
Product B Efficiency in Blue

Product A (8.5 in Dia)

Product B (8.6 in Dia)













figure 12
Product A (4 x 5 - 9.5) vs. Product C (4 x 5 - 9.25)
90% of Maximum Impeller at 1770 RPM
Flow - Head - Efficiency

Product A. Retaining high efficiency

levels as the impeller diameter is
reduced provides several advantages
in addition to energy cost savings.
With the higher efficiency levels it
is sometimes possible to use smaller
motors for non-overloading motor
size requirements for either the
constant speed or variable speed
drive situations. Noise levels and
mechanical loads are also reduced as
the impeller diameter is reduced.
From another viewpoint, the
following comparisons are examples
of the wider Efficiency Islands (with
respect to flow rate) and deeper
Efficiency Islands (with respect to
sustained efficiency at reduced
Impeller diameters). Refer to figure 2
in part 1 of this series.
In the conclusion to this series, we
will end by looking at control curves
and variable speed operation, as well
as an operating cost comparison for
our three test cases. These comparisons
reveal where the benefits of Efficiency
Islands leave the testing areas and
affect the bottom line.

TDH, ft





1. ASHRAE 90.1 2010 Energy Standard for

2. ANSI/Hydraulic Institute Standard 9.6.3
2012, Guideline for Allowable Operating



3. Simplified Analysis of Flow in Closed Loop

Hydronic Systems, Bell & Gossett Technical
Brochure TEH-802P, August 2001

Product A Efficiency in Red
Product c Efficiency in Green

Product A (8.5 in Dia)

4. Variable Primary Flow Systems, Bell &

Gossett Technical Brochure TEH-910, 2010

Product C (8.3 in Dia)













Max Impeller Efficiency Island

Product A
9.5" (max)
Product B
9.6" (max)
Product C
9.25" (max)

Product A
Product B
Product C

E, %

Deep Efficiency Islands

Impeller (max to 90% )
9.5" (max) Z 8.5"
9.6" (max) Z 8.6"
9.25" (max) Z 8.25"

Efficiency at Max and Min

Max Impeller
Product A
Product B
Product C


Flow Width (GPM Range)

120 GPM (650-770 GPM)
60 GPM (715-775 GPM)
180 GPM (690-870 GPM)

E, %
85% Z 84%
83% Z 80%
84/83% Z 80%

Min Impeller

Peak Efficiency Island, % (at Max )


Impeller Depth (Cut )

8.75" (3/4" cut, 92% of max )
9.54" (1/16" cut, very shallow)
9.125" (1/8" cut, 98.5% of max )

Flow Width (GPM Range)

135 GPM (540-675 GPM)
155 GPM (575-730 GPM)
120 GPM (620-740 GPM)

Impeller Depth (Cut )


february 2014 | 27

PUMP solutions

Working Smarter,
Working Together
Grundfos, U.S. Boiler Company collaborate to
provide ultra-efficient boiler-pump package
by helen mubarak, grundfos north america

rundfos recently celebrated its fortieth

anniversary in the United States, a
note-worthy marker as it indicates
a full generation of commitments between
the company and its domestic
customers. Its a relationship that
extends in both directions. Across
North America, Grundfos employs
more than 1600 people1300 in
Grundfos ALPHA saves up to 85 percent more energy than conventional
the United States aloneand is
circulators, helping U.S. Boiler Company boost product efficiency. U.S. Boiler
continually expanding its regional
Company, Inc., headquartered in Lancaster, Pennsylvania, is the manufacturer
expertise. For example, a recent
of Burnham brand products. As the industry leader in North America, U.S.
partnership between Grundfos and
Boiler Company products provides high efficiency boilers for residential space
Pennsylvania-bases U.S. Boiler
heating and domestic hot water. Residential boilers are available either gas or
Company highlights the benefits
oil-fired for water and steam heating systems. Along with the best hydronic
of shared expertiseboth for
engineering capabilities available anywhere, U.S. Boiler Company delivers
manufacturers and for end uses.
world-class marketing, technical sales, and sales support.
At the 2014 Air-Conditioning,
With an annual production of more than 16 million pumps, Grundfos is
Heating and Refrigerating Exposition
the global leader in advanced pump solutions and a trendsetter in water
(AHR Expo) in New York City,
technology, specializing in circulator pumps for heating and air conditioning
Grundfos and U.S. Boiler Company
as well as centrifugal pumps for industrial applications, fire protection, water
announced an agreement to pair
supply, wastewater, and water treatment.
Grundfoss ultra-efficient ALPHATM
circulators as options on most U.S.

about the author

Helen Mubarak is the public affairs coordinator for Grundfos North America. In addition to pumps, Grundfos produces
standard and submersible motors as well as state-of-the-art electronics for monitoring and controlling pumps. For more
information, visit www.grundfos.us.

30 | february 2014


ALPHA Pump with AUTOAdapt
Flow range: 0 to 21 gallons per minute (0 to 1.3 liters per second)
Head range: 0 to 19 feet (5.8 meters)
Motor: 1X115V
Min. fluid temperature: 36 degrees Fahrenheit (2 degrees Celsius)
Max. fluid temperature: 230 degrees Fahrenheit (110 degrees Celsius)
Max. working pressure: 150 PSI
Watts: 5-45
Amps: 0.65

Boiler gas cast-iron heating products. The combined product leverages

both companies individual competencies in the industry and provides
a market-leading solution for highly efficient heating in residential and
light commercial applications.
We know that the price of energy is a growing concern for many
Americans. Grundfoss collaboration with U.S. Boiler Company will
allow us to deliver the total package for saving energya best-in-class
boiler paired with an ultra-efficient pump, says Barry Nauss, director
of HVAC OEM Sales for Grundfos USA.
Made in the United States, the package will feature the ALPHA, a
Grundfos pump designed for circulating liquids in light commercial and
residential heating systems. This pump features patented AUTOAdaptTM


february 2014 | 31

PUMP solutions
With its permanent magnet motor design,
this energy efficient circulator reduces power
consumption by 50 percent or more. The unique
patented AUTOAdapt feature controls pump
performance automatically within defined
performance range, ensuring lowest possible energy
consumption without sacrificing comfort.

32 | february 2014

technology, which
For installation, you also have
analyzes the needs
the flexibility to use either
of the system
our unique ALPHA Plug with
and then adjusts
line cord or the ALPHA with
operation to changes
terminal box for conduit
in demand. By
connection applications. The
learning the patterns
choice is yours.
of consumption,
the pump can save
end users up to 85
percent in energy
costs when compared to a conventional
circulator, ensuring the lowest possible
consumption without sacrificing comfort.
Dan Cork, vice president of sales and
marketing for U.S. Boiler Company adds,
We are pleased to offer this combination
of leading-edge products. The Grundfos
ALPHA pump is an advanced solution
that many of our contractors have
asked for, and its a great match with
our industry-leading, technically
advanced boilers. Its always about
giving customers the opportunity to use
products that offer the most value to the
complete system.
Together with U.S. Boilers top-quality
product, the competitively priced boilerpump package will achieve new levels of
complete energy efficiency. In addition
to guaranteeing energy savings for end
users, the combined product will also
ease the installation process, making it a
win-win for both parties.
Grundfos is the global leader in pump
solutions for boiler manufacturers,
Nauss says. We are confident that this


Performance Curve
3 Fixed Speeds

3 Constant Pressures

new collaboration with the U.S.

Boiler Company will strengthen our
share of the American market and
help us achieve our long-term goal
to reach $1 billion in annual sales.
The package is currently available
from Venco Sales, U.S. Boiler, and
Grundfos wholesalers in the New York
High on the Grundfoss corporate
agenda is an active commitment



to improving the environment,

and the company contributes to
global sustainability by pioneering
technologies that improve quality
of life for people and care for
the planet. Partnerships that
emphasize shared benefits and
increased efficiency, like the one
between Grundfos and U.S. Boiler
Company, will be the standard going

FEBRUARY 2014 | 33

DEWATERING solutions

Cultec Chambers Solve

Infiltration Issues for
Business Center
by Cultec technical staff

early three decades ago, Cultec introduced its

Contactor and Recharger HDPE septic and
stormwater chambers and helped begin a revolution
toward the use of plastic construction products. Since then,
several product developments and strategic alliances have
made Cultec a cutting-edge research-and-development-based
manufacturer. Today, Cultec chambers can be seen in projects
being used as subsurface retention or detention systems and as
replacements for ponds, concrete structures, or pipe and stone
installations. In the following case study, a business centers
infiltration issues presented a challenge tailor-made for Cultecs
technical staff.


Upper Macungie Township in Lehigh County, Pennsylvania,

is located in the corridor between Philadelphia and New
York City, with quick and easy access to both of these major
metropolitan areas. Since Lehigh County neighbors the East
Coast's major markets, regular commuters have realized
the ultimate convenience of the countys central location.
Therefore, it became the ideal location for Compass Business
Center, LLC to build eleven flex-office, warehouse-type
buildings of varying configuration.
The facilities, which are arranged in nine groups of two,
one group of four and one group of five, are situated on
approximately four-and-a-half acres of land which was
previously an open field. The development is designed in a
loop, and a road separates the North and South units. The rest
of the site is surrounded by an existing industrial park.
While planning for this new development, engineers from
Base Engineering, located in Allentown, Penn., coordinated
with contractors from Saylorsburg-based A. Scott Enterprises
to install a stormwater management system that would provide
detention and infiltration to the site.


The team faced a number of challenges during this project,

including the infiltration potential of the soil itself. The
infiltration rate turned out to be very slow, so the site needed
to be over-excavated in order to replace the existing soil with a
two-foot layer of engineered fill.
This special fill is a combination of 80 percent sand and 20
percent compost, which allows water to soak into the ground
at a rate that is neither too fast nor too slow. This amended soil
comes with a certain pre-established infiltration rate which had

to be assumed. Once the fill was in place, the engineers were

required to recheck the in-place infiltration rate to be sure it
either matched or exceeded the rate that was assumed, which
was a condition of the permit when it was issued.
The use of Cultec chambers was very useful in this instance
because engineered fill cannot be compressed or it nullifies the
infiltration capacity and capability, says Amit Mukherjee, MS,
P.E., Base Engineering. The chambers are rigid, which helped
to even out the load distribution so the fill placed directly
beneath them was not compacted.
The site consists of two separate systems, North and South,
and Cultecs Recharger 280HD was chosen for the project
because the model would provide the 43,560 cubic feet
(12,33.48 cubic meters) of total storage required within the
smallest footprint while accommodating the site parameters.
Each unit is 47 inches (1.2 meters) wide, 26.5 inches (0.7
meters) high and offers a bare chamber capacity of 6.08 cubic

for more information

For more information about Cultec stormwater management chambers and other products, call 203.775.4416 or visit

34 | february 2014


feet (0.17 cubic meters) per linear foot

of storage capacity. It is designed to
retain water until the soil is no longer
saturated and is suitable for infiltration
back into the ground.
The North system contains 18
rows and 369 chambers while the
South system has eight rows with 231
chambers. The 600 chambers combined
with a layer of stone provide 44,249
cubic feet (1253 cubic meters) of storage
for the site.

to the U.S. Green Building Council's

credits, under the LEED rating system,
when the project is designed per LEED


The design plans for the Compass

Business Center were reviewed by the
township engineer, Keystone Consulting,
to verify Cultecs products satisfied a

number of Department of Environmental

Protection requirements, specifically the
infiltration rate could not be less than
1.02 inches [25.9 millimeters] per hour,
says Frank Daddona, estimator and
project manager for A. Scott Enterprises.
Since CULTECs system passed this
inspection, and they were competitively
priced they were chosen over a number
of other brands.


A second challenge was encountered by

contractors when they were installing
the chambers in the South basin. A
utility pole and guide wire, which
prevents the pole from leaning, was
anchored in concrete directly in the
middle of the infiltration basin. In order
to progress on the site, the contractors
installed chambers up to the guide wire
and then skipped approximately 15
to 20 feet (4.57 to 6.1 meters) while a
utility company moved the wire and
pole. Once the pole and wire were
safely relocated, the contractors were
able to return to the South basin and
complete the middle section, effectively
joining all of the chambers together.
Cultec manufactures several chamber
sizes ranging from 8.5 to 48 inches (0.2
to 1.2 meters) to accommodate almost
any site parameter. The chambers
perforated sidewalls and fully open
bottoms promote maximum infiltration
capability and allow for the transfer of
high volumes of water at a low velocity.
The units can be installed singularly or
in series in single- or multi-layer beds.
In addition, CULTEC developed
its own in-line side portal manifold
system, which eliminates the need for
a conventional pipe header system,
and water quality unit for maintaining
CULTEC chamber systems. CULTEC
products are currently modeled in
HydroCAD, Bentley Systems, Inc.s
PondPack V8i, Autodesks Storm &
Sanitary Analysis in Civil 3D, and
Streamline Technologies' ICPR.



Cultecs technical staff offers free

design assistance including preliminary
calculations and job-specific CAD
details. A free Cultec StormGenie
AutoCAD Plug-In for designing systems
and a free HydroCAD custom edition
are also available from the company. In
addition, Cultec products can contribute

february 2014 | 35

MOTOR solutions

Browning Turns Up
the Heat

EPDM-formulated belts have heat

advantage over polychloroprene belts

by don Sullivan, emerson industrial automation

ased in St. Louis, Missouri,

Emerson has been bringing
technology and engineering
together to provide solutions
for customers in industrial,
commercial, and consumer markets
around the world for decades.
The companys five business
segments (Process Management,
Industrial Automation, Network
Power, Climate Technologies,
and Commercial and Residential
Solutions) represent a wide range
of resources and ideas that provide
a foundation for innovations across
a range of industries. Emersons
Browning brand has made the latest
contribution, introduced at last
months AHR Expo, which improves
the heat rating and durability for
V-beltseven beyond what many
technicians in the HVAC field
thought was possible.


Browning introduced EPDM's heatresistance and durability advantages

to all its raw-edge, notched V-belts
at Januarys AHR Expo, bringing an
expanded temperature rating of -60
to 250 degrees Fahrenheit (-51 to
121 degrees Celsius) to AX, BX, CX,
3VX, 5VX and 8VX Gripnotch belts,
some of the most commonly used
V-belt cross sections in the HVAC
industry. The EPDM formulated
belts have a 110 degrees Fahrenheit

The image on bottom is a wrapped belt. It's the same drive, running
for same amount of time in each image. The cooler running notched
belt is 2 to 3 percent more energy efficient than the wrapped design.
The wrapped belt runs hotter, less efficiently, due to increased friction
as it wedges itself into the sheave. Polychloroprene belts in normal
conditions operate close to their maximum allowable temperature in
any ambient environment and, thus, have less safety margin as ambient
temps increase.

(43 degrees Celsius) higher heat

tolerance than industry-standard
polychloroprene belts, making
them ideal for rooftop blower
units, commercial kitchen, or
industrial process exhaust systems.
These belts will set a new
standard for the industry, says
Don Sullivan, marketing manager
for Browning.
Many technicians fail to
account for the fact that a belt
may reach 110 to 115 degrees
Fahrenheit (43 to 46 degrees
Celsius) while simply running
in the sheaves at 72 degrees
Fahrenheit (22 degrees Celsius)
ambient temperature. If this heat
is concentrated under a solid
metal guard and the ambient
temperature rises, it does not
take long to approach the 140
degrees Fahrenheit (60 degrees
Celsius) limit for common
polychloroprene belts, Sullivan
adds. On a rooftop in summer,
even in northern climates, a
V-belt drive can easily reach
this critical temperature. Our
EPDM formulation gives a much
wider temperature window than
polychloroprene 79 percent
wider. We originally introduced a
limited offering of EPDM belts and
due to popularity we expanded
the offering to all notched
belts and further developed the

about the author

Don Sullivan is the marketing manager for Emerson Industrial AutomationPower Transmission Solutions. He can be reached
at don.sullivan@emerson.com. Emerson Industrial Automation, a business of Emerson, provides automation and power
generation technologies and services to a wide range of industries. With its global capabilities and deep industry expertise,
Emerson Industrial Automation is a trusted partner for products and solutions that increase machine performance, efficiency,
reliability, and availability. For more information, visit www.emersonmovingconversations.com.

36 | february 2014


temperature range to 250 degrees Fahrenheit (121 degrees

Celsius). This heat rating will be valuable in all applications and
industries, but particularly in warmer climates.


tolerances right off the shelf and are static dissipating, as well as
oil and heat resistant. Coupled with the precision-ground edge
for smooth, quiet operation, these raw-edge belts demonstrate
how twenty-first century engineering and manufacturing can
revolutionize a time-proven
concept like the V-belt.

Browning's notched V-belt

styles can also improve
drive efficiency 2 to 3
percent over wrapped
In addition to innovative
technical details, Browning
style V-belts, saving
about $300 per year on a
is also bringing new ways
for technicians to gather
drive at $0.12 per kilowattand use data. Browning
hour. U.S. Department
offers free mobile apps
for efficiency calculation,
of Energy DOE/GO102005-2060 makes this
selection, troubleshooting,
EPDM (ethylene propylene
recommendation, because in a typical
and GPS locating of belt distributors.
diene monomer) is a synthetic
commercial application with twenty
This spring, Browning will provide its
rubber compound formulated
identical air handling units of this size,
HVAC Drive Kit Manager for iPhone
for superior strength, flexibility
and Android devices, a new feature
a 3 percent energy savings at $0.12 per
and resistance to heat, decay,
of the Browning Toolbox Technician
kilowatt-hour is about $6000 per year,
ozone, oxidation and humidity.
Sullivan explains.
app, which allows users to access
All these belts utilize a proprietary
product information, track maintenance
design that includes high fiber loading
information from a phone or desktop,
for long life, multiple plies of a unique
schedule future maintenance reminders,
tubular-woven knit fabric in the overcords for maximum
and share information between HVAC mechanical contractors
flexibility, and wider notch spacing to increase rigidity and
and building owners. These features will utilize existing
stability for lower stress at the cord line. They meet RMA
Browning belt drive kit labels on many HVAC unit control
(Rubber Manufacturers Association) standards for matched
panels, so users should have a very small learning curve.


february 2014 | 37


(and Savings)
to the People

Large and fast-track

solution for combined
cycle power plant

by bill rose, abb

about the author

Bill Rose is the media relations manager for ABB Inc.a leader in power and automation technologies that enable
utility and industry customers to improve their performance while lowering environmental impact. He can be reached at
bill.rose@us.abb.com. For more information about ABB, visit www.abb.com.

38 | february 2014


BB has supplied highly complex electrical systems and grid

connections for a mega power generation and water desalination
project in Qatar. The combined cycle power plant in the industrial
city of Ras Laffan, Qatar, has a generating capacity of 2730 megawatts,
and can produce more than 8.4 million cubic feet (238,000 cubic meters)
of potable water daily. This equates to 20 percent of Qatar's water
consumption and 30 percent of its electricity generation.


ABB's German and Swiss operations provided the design, supply,

installation, and commissioning of the plant's electrical systems,
including substations rated at 400 kilovolts (kV), 220 kV and 132 kV;
two 800 megavolt ampere MVA interbus transformers; eight generator
circuit breakers for the gas turbines; the isolated phase ducts, the direct
current (DC) supply and uninterruptable power supply (UPS); transformer
protection system, seventy-five medium- and low-voltage switchgears, and
cable systems with a total length of more than 620 miles (1000 kilometers).
ABB was responsible for complete engineering services, construction
supervision, and commissioning of the electrical systems, as well
as for staff training. A consortium comprising Suez Energy
International, Mitsui, Ras Girtas Power Company, and
Qatar Petroleum developed the plant, which sells water
and electricity to the local utility, Kahramaa.


Very early in the tendering stage the EPC

Hyundai Engineering and Construction
supported by Suez/Mitsui signed a
cooperation agreement with ABB, due to
the highly complex nature of the electrical
systems in the project. This was to limit their
risk and was a direct result of ABBs excellent
track record in Qatar with Kahramaa. Ras
Laffan was the third large project ABB has
successfully completed in the country, after
Ras Abu Fontas B2 in 2008 and Quatalum in
ABB products make up 71 percent of the
hardware scope of supply, and ABB resources
constitute 67 percent of the services. Total
investment for the power and desalination
plant amounts to $3.7 billion. ABB's project
management was based in Mannheim
(Germany), which during the engineering
phase had to coordinate design offices in Abu
Dhabi, Kosice (Slovakia), Baden (Switzerland)
and the general basic design with offices in
Seoul (Korea). A total of forty-one factory
acceptance tests held in the span of ninetyfour days were successfully completed.
Logistical challenges included 308,924
square feet (28,700 square meters) of freight
managed in some sixty-one shipments.


ABB's Swiss operations supplied some of the

largest substations in the Middle East region
for this project, including thirty-one bays
of 400 kV gas-insulated switchgear (GIS),
twelve bays of 220 kV GIS and twelve bays
of 132 kV GIS, as well as associated systems,
such as IEC 61850 substation automation,
control, protection, telecommunication and
auxiliary systems. ABB and its subcontractors
performed 200,000 man-hours of work
within the three years between go-ahead and
ABB engineers and technicians from
around the globe, including Germany,
Switzerland, the United States, Canada, the
Philippines and Korea helped complete this
demanding project.
Following the hand-over, Hyundai project
management commented: Hyundai and
ABB have pulled together to achieve the
common targets for this project. Most of our
plans have been completed successfully.
We have mastered difficult and serious risks
with the help of our strong cooperation
and proper coordination, in spite of many
unexpected obstacles and interruptions from
the start-up until now, the finish. We are
grateful to ABB and ABB staff for the positive
cooperation and assistance, which proves
ABBs reputation and capability as a highly
qualified company in the field of power
systems worldwide.

february 2014 | 39

PROCESSING solutions

Qatar Relies on
a Flexible Choice
of Fuels

New triplex pump drive unit

will also power natural
gas tankers with LNG
in the future

by thomas bkenbrink, lewa gmbh

The triplex G3M drive unit is a special-order production of the Leonberg-headquartered system builder Lewa. This is a robust,
low-maintenance intermediate size specifically designed for long-term operation on natural gas tankers.

ighly poisonous heavy

oil, a waste product of
petroleum refineries, is
still blown through the funnels of
tankers into the air without being
filtered. To reduce the burden on
the environment, especially near
the coast, while being able to
react better to price fluctuations,
Qatar wants to arrange the future
operation of its entire LNG fleet
on a flexible basis. The dualfuel engines that MAN Diesel &
Turbo developed for this purpose
can optionally be operated with
heavy oil or with the liquefied
natural gas in the hold. To do this,

Cryostar has the know-how

needed for working with
cryogenic gases, while Lewa
supplies the robust and lowmaintenance technology in the
newly developed drive unit that
will be needed for long-term
operation on board.

the boil-off gases are reliquefied

under high pressure and injected
into the ship's engine. Since
ships are always operating and
only brought into dry dock
for maintenance once in five
years, the high-performance
pumps used for this purpose
must be extremely robust and
temperature-resistant. One of
the favorites for the supply of
these high-performance pumps
is Cryostar SAS, a specialist in
cryogenic gases. As a partner of
this French manufacturer, Lewa
GmbH was entrusted with the
development of a new drive unit

about the author

Thomas Bkenbrink is a product manager for Lewa GmbH, the world's leading manufacturer of metering and process
diaphragm pumps as well as complete metering systems for process technology. The company, headquartered in Leonberg,
Germany, has developed over just a few decades into an international group, and its position in the world market was further
strengthened by its integration into the Japanese Nikkiso Co. Ltd. in 2009. For more information, visit www.lewa.com.

40 | february 2014


The perfect phase offset between the three pistons is achieved by using a single, massive crankshaft
with three crank bends. All components are designed for long-term load, making trouble-free
operation of over 40,000 hours possible.

that meets the strict requirements for

this application.
Heavy oil is easily obtained,
difficult to burn, and can be fed into
the engine at low pressure. When the
large transport ships of the Q-flex and

The French technology company Cryostar

SAS was founded in 1966 and is a world
leading manufacturer of cryogenic and
refrigeration systems. The hundredpercent subsidiary of the Linde Group
specializes in equipment and provision
of technical knowledge in the areas of
industrial gas, liquefied natural gas (LNG),
hydrocarbons, and environmentally
friendly energy. Cryostar supplies pumps,
turbines, compressors, heat exchangers,
filling stations, natural gas liquefaction
and natural gas regasification systems and
power plants to international customers
with the strictest of requirements. The
company employs about 450 people and
had turnover of about $272 million (200
million Euros) at last report, 90 percent of
which were in export business.

Q-max LNG fleet were built nine years

ago, the decision was therefore made
to use slow-running diesel engines,
since these are also thermally more
efficient than steam turbines and burn
less fuel. But it is foreseeable that

tankers like those in Qatar will have to

convert to other fuels in the future for
environmental reasonsat least near
the coast. Transport ships with dual-fuel
engines like the ones the Emirate wants
to use, however, are new territory for

When it comes to check
valves, Check-All is king.
Our spring loaded check valves
are assembled to your exact
needs, ensuring absolute
precision and reliability. They
work like they should. Thats
what makes Check-All the only
choice. Plus, most lead times
are less than one week.
Count on the king.

Get me a Check-All.
Check-All_CheckMateAd_921.indd 1


SINCE 1958

Manufactured in West Des Moines, Iowa, USA 515-224-2301 www.checkall.com

9/21/12 9:13 AM

february 2014 | 41

PROCESSING solutions
everyone involved. Many shipowners found the technical risk too
high, since LNG can be transported
safely in the liquid state only at very
low temperatures. However, the
option of using on-board natural
gas as a fuel is also becoming more
attractive because engine efficiency
is improved in comparison with
heavy oil.


The challenge for the ships is that

liquefied gas warms up during
travel, partly converting back into
its gaseous state, meaning that its
volume grows by a factor of 600
and the pressure in the storage tanks
rises. Venting these boil-off gases
harms the environment and reduces
the profits of both the producers
and the charter companies. Instead,
in the Q-flex and Q-max LNG
fleet, they are therefore reliquefied.
This yielded the idea of making
the gas available to operate the
ship. Additional equipment will
therefore be provided to make
the fleet flexible in its choice of
fuel. This allows a reaction to
the current prices in the specific
export country: If gas is trading
high there, it's better to sell it than
to burn it in the ships engine.
But in the opposite case, it pays
to operate the ship with LNG. But
since the gas is extremely explosive,
absolutely tight special equipment
is needed that can withstand both
the temperatures and the high


As a researching and productive

company, LEWA develops technologies
and works out solutions for a wide
variety of its customers' applications.
Products are primarily used in the
oil and gas industry, in the area
of gas odorization, refineries, and
petrochemistry, but also in the
manufacture of plastics, detergents, and
cleaning agents. Additional application
areas can be found in chemistry, the
cosmetics industry, in pharmaceutical
and biotechnology, in the food and
beverage sector, and in power supply.
LEWA currently has approximately 840
employees and has sixteen subsidiaries
worldwide as well as representatives and
sales offices in over eighty countries.
42 | february 2014

The G3M and its sister models

have a wide range of processing
applications, for example
the injection of methanol or

The three-piston design relies on a

single crankshaft.

With the Triplex pumps that Cryostar

and Lewa developed together, both
companies are ideally prepared for this
new application. The French company is
a pioneer in this area and developed the
pump heads to meet the requirements
for cryogenic liquefied gases. The
corresponding G3M triplex drive unit
is a special-order production of the
Leonberg-headquartered system builder.
Cryostar has the know-how needed
to work with cryogenic gases at
temperatures ranging from -256 to -328
degrees Fahrenheit (-160 to -200 degrees
Celsius), while Lewa has the robust,
low-maintenance drive unit technology
needed for long-term operation, which
explains the synergy between the two
companies. With a rod force of 125

kN, the G3M transforms the rotary

movement into an oscillating movement,
achieving a maximum power of 160 kW.
The development also closes a gap in
the manufacturer's portfolio. This is an
intermediate size with a 4.72 inch (120
millimeter) stroke length, and we see
additional market potential for it.
The first prototype from Cryostar and
Lewa is currently in the testing phase.
If the results of these tests and the first
trips under load come out positive,
the system will be tested on a ship
under real conditions. The costs for the
retooling are estimated to be about $15
million per ship, with the total order
volume for all forty-five ships in the
Q-flex and Q-max fleet coming to $700


by david buchwald, Pipestone equipment,

and Steffen Koehler, SiPoS aktorik

ver since they were invented, control valves have been

on the move. As an integral and essential element
of pumping applications, the issue of managing the
performance of these valves has been the driving force
behind the development of new generation actuators and
actuation solutions. Pipestone equipment, which has adopted
SIPOSs Variable Speed Actuator (VSA) technology in a
number of pump station installations, provides technical
data and illustrations to support the following report. A
supplier of municipal and industrial water products providing
comprehensive support including system design, Pipestones

services include hydraulic analyses as well as the engineering

element of the plant incorporating directly linked control
valves, other shut-off valves and air valves or surge tanks.


With a hundred year historyoriginally as part of the Siemens

organizationSIPOS supplies both standard and Variable
Speed Actuators. The company, which has been established as
SIPOS Aktorik for over a decade, launched the SIPOS 5 VSA in
1998. Introducing an integrated frequency converter to valve
actuation, and pairing with intelligent controls, gave SIPOS
A Pipestone Equipment pump station installation
featuring SIPOS Aktoriks Variable Speed Actuators.

about the authors

David Buchwald is the president of Pipestone Equipment and a member of the American Water Works Association (AWWA)
and Colorado Renewable Energy Society (CRES). Steffen Koehler has worked as an international sales manager for SIPOS
Aktorik for fourteen years and has extensive experience of global business and electric actuation projects/applications.

44 | february 2014


the ability to facilitate the smooth

control of valves in both an open and
closed loop. Additionally, functional
reliability was provided, which could
be monitored in the interests of
efficient process operation. The product
development initiative also meant that
the actuators output speed could be
changed at any time, depending on
valve/process requirements.
The automation experts at Pipestone
Equipment confirm that, for modern
pumps, which are combined with
valves to ensure controlled and reliable
flow rates, minimizing the risk of
pressure surges is essential, and this can
be achieved by using Variable Speed
Actuators. Avoiding water hammer is of
particular interest, as this is a very real
potential danger for plants and pipeline
With their variable speed
functionality directly integrated into
the firmware, SIPOSs VSAs have been
identified by Pipestone as the optimum
solution for minimizing, or avoiding,
water hammer using intelligent control
of pump or pressure compensation

torques if the valve is blocked between

the end positions. The voltage for each
of the many available speed/cut-off
torque combinations is pre-selected
so that the cut-off torque setting
corresponds to the stalling torque of the
In other words, if a VSA is used, the
massive current peaks experienced

when the motor starts are eliminated

and, even an unscheduled stop, does
not result in torque damage.
The alternative to VSAs is to fit an
external frequency converter: this is
not an aesthetically pleasing option
and, more importantly, workers on site
are required to program and maintain
highly complex converter software.


A key area that the VSAs have

addressed is the highly damaging
impact of water hammer. High pressure
build up culminates in shock waves
and, in the worst case scenarios,
pipelines can break. Vacuum can also
be created that causes pipes to collapse
or implode. The topic of pressure
surge reduction is, therefore, a key
consideration for pump station projects
and an issue that requires considerable
engineering work to facilitate solutions.
SIPOS invested heavily in R&D to
address the issue of soft starting or
caressing. The reason that the valve
needs caressing can be explained by
drawing a parallel with the motion of
a lift. To avoid impact on both the lift,
and the people using it, a soft start (and
stop) is required. The lift should ease
gently into its movement, gradually
gather momentum and slow to a stop at
its selected end point.
The same principle applies to water
flow needs to caressed to avoid the
build-up and pressure peaks associated
with water hammer, which have been
known to rupture pipes. SIPOSs
integrated VSA frequency converter
ensures that motor speed is reduced
automatically in the end positions.
Therefore, there are no magnification

february 2014 | 45


figure 1


46 | february 2014







Position %-OPEN

Figure 1 shows the flow capacity curve for a ball valve and waterline used in a pump station
application managed by Pipestone Equipment. The graph illustrates the throughput curve of a
typical ball valve and waterline. Note that, when just 6 percent open, the throughput rate is
already 50 percent.

figure 2a
Curve: CLOSE < _> OPEN
Position (% OPEN)

Free selection of output

speed is the basis of
SIPOS technology. This
is achieved using an
integrated frequency
converter for control.
Intelligent software
within the actuator
not only controls
the motor but also
provides a special
travel-positioning time
Actuators are
historically selected to
open or close within a
specified time, which
defines the output
speed. Typical water
industry pump control
ball valves have very
high flow capacities (Cv)
and, when combined
within a waterline,
have non-linear flow
capacity curves whereby
relatively small opening
percentages (i.e. 10
percent) result in
capacities of greater
than 50 percent and
full flow rates can be
achieved at openings
in the one third range.
As such, constant speed
actuation only provides
flow rate control over
roughly the first third
of the operating time.
Additionally, the control
provided is non-linear
and is determined by the
valve characteristics, not
the actuator.
Ball valves have a
rugged, simple design
and a high volume
throughput which
minimizes headloss
during pumping
operation and saves
energy cost. When
the high capacity ball
valve is combined
with a waterline and
pump station, the flow
capacity of the waterline
quickly becomes a
limiting factor. Effective
valve control is therefore
essential for maximizing
the benefits of ball












Positioning Time (s)

Figure 2a: Example of a travel-positioning time function for the SIPOS 5 actuator. The
parameterized curve compensates for the curve of a ball valve and pipeline. Rapid operation
within the OPEN range, from approx. half the closing time is indicated with considerably reduced
output speed.

figure 2b
Flow linearized via positioning time (16 ball valve)







Position time in s
Figure 2b shows the resulting linearized curve of the ball valve and pipeline from the figure 1.

control valves, while

minimizing transients
within the system.
Ideal pump station
start-up and shutdown sequences
would accelerate
and decelerate water
within the pipeline at a
constant rate or linearly.
Due to the complex
between pump curve,
ball valve Cv curve and
pipeline configuration,
achieving linear flow
rate changes has been
difficult to achieve over
the years. However, if
the rotational speed of
the valve shaft during
the opening and closing
sequences could be
varied, linearization
becomes possible.
With this ability,
computations could
be made to determine
valve shaft rotational
speed at various points
during operation
and a valve could
be programmed to
essentially be a linear
control valve for that
specific installation
site. This theory applies
to any type of valve or
gate, any water source
and any type of fluid
control system.
Bridging the gap
between theory
and reality is the
SIPOS 5 actuator. By
defining up to ten
value pairs (position;
positioning time); the
required parameters
may be set directly
within the actuator
according to the system
characteristics. Once
programmed, the SIPOS
actuator will operate
the valve as required
to achieve optimized
and linearized flow
rate changes. For
first-time input based
on manufacturer
curves, use of COMSIPOS actuator


president of
include an
MSME in fluid
dynamics and
a BSME in

parameterization software is highly recommended. Separate

operation curves for opening or closing the valve can be
specified. COM-SIPOS presents the entered values on a chart


enabling quick verification of figures (see figures 2a and 2b).

For the operator, the result is a practical linear relation of run
time and throughput (see figure 2b).

february 2014 | 47


figure 3


48 | february 2014

Pressure curve conventional compared to control via

SIPOS stroke-time function
Pressure in bar

Pressure surges are often caused

by valves opening quickly with
excessive pressure variation in front
of and after the valve. Pressure
peaks, due to simultaneous closing of
several valves within closed systems,
are also known. The flowing medium
suddenly halts and kinetic energy is
turned into pressure.
Another reason may be the quick
start of a powerful pump. The
overpressures and low pressures,
also called water hammer, can be
reduced by combining a pump with
additional start-up control and a ball
valve with a Variable Speed Actuator.
Pressure relief valves and/or bladder
surge vessels can also be used to aid
pressure surge reduction and system
Pump failure, e.g. in case of power
failure has major impact. Pipeline
breaks may also generate pressure
surges and cause further damage to
the entire system.
Every day, companies like
Pipestone Equipment address the
challenges of pressure surges and
water hammer. Central competences


Pressure curve with conventional control


Pressure curve utilizing the SIPOS stroke-time function


Pump starts slowing and ball valves closes

Ball valve
fully open

10 Pump startup,

Pump off

pump discharge

8 ball valve opens

Pump discharge ball valve

fully closed







Time in s

Figure 3: Pressure curve measured at the pump or after the pump valve (ball valve) for starting up or shutting down at
a pump station project. The blue curve clearly shows the reduction of pressure surges when using the SIPOS 5 travel
positioning time function.


include detailed examination of the

behavior of systems which comprise
pumps, shut-off valves and pipelines
with water. The starting point for all
considerations is often measurements and
simulations, such as the pressure curve
shown in red on figure 3.
The amplitude at measuring point 2
after the pump ball valve shows significant
pressure surges. As an alternative, or
in addition to reduced mechanical and
hydraulic measures, pressure waves can
also be remedied by means of intelligent
control of the pump valve. The blue curve
clearly shows softer pressure variations
when using the SIPOS 5 travel-positioning
time function.
In conclusion, SIPOS stresses the
importance of controlling water hammer
in pump stations and, although actuation
devices look quite innocuous to most
people, anyone working in the front
line dealing with the aftermath of pipe
ruptures will reinforce the importance of
valve control technology. The experts at
Pipestone Equipment can confirm, the
control of pressure surges are all important
and advancements such as VSAs play a
significant role in enhancing automation


SIPOS actuators address water hammer.

february 2014 | 49

SEALING solutions

by roman nykyforuk, Zeon technologies

or years, the pump

industry has been
challenged. The need
for a new wear material
product, providing
better performance,
dimensional stability
at high temperature,
and longevity at a
lower cost, has always
been the dream. Zeon
Technologies, a resin
and molding compound
manufacturer, has made
this dream a reality. The
company has introduced
a new material used to
produce wear-rings and
bushings for the pump industry made
from carbon fiber-ceramic or kevlarceramic.



kevlar-ceramic. Randy
Lewis, an engineer for
Zeon Technologies,
recently said, Parts from
these composites can
be easily molded and
machined. Field use
of nearly five years has
shown no measurable
wear on pump shafts,
wear-rings, or bushings.


In five years in the field, no

measurable wear has been
found on either the wear
components or the pump
shaft on which they ride.

Before Zeon Technologies,

the industry responded with
thermoplastics that worked but still
had challenges of high temperature as
well as high pricing. Recently Zeon
Technologies developed a unique
thermoset composite that fulfills the
basic needs of many wear parts used
in the pump industry. The North Carolina based company
offers these specially formulated compounds in a variety
of fiber and mineral fillers such as carbon fiber-ceramic or

Positive feedback from

field operations praises
the performance of these
parts in water pumps and
in dry run operations.
High temperature resistance is also
an outstanding feature of these
composite materials. In addition
to exceptional performances,
the materials are also very cost
competitive in comparison to the
high priced thermoplastics currently
used in the market place. In five years
in the field, no measurable wear
has been found on either the wear
components or the pump shaft on
which they ride.


While change is hard to accept, proactive maintenance

engineers and proactive new product designers have taken
Zeon Technologies materials and tested these composites in

about the author

Roman Nykyforuk is a consultant for Zeon Technologies of Salisbury, North Carolina. Zeon Technologies offers ideal materials
to replace or create new products for the pump industry. For more information, call 704.680.9160 or visit www.zeontech.net.

50 | february 2014


todays pump market

applications. There
are no one product
fits all solutions, but
serious attention is
being given to Zeon
materials as they are
establishing themselves
as unique materials
for rather common
pump solutions. Only
with forward thinking
can new products
be incorporated
into traditional
applications which
are hard to change.
Every application is
unique and requires
the utmost attention to
implement materials
that are best suited
for pump operations.
Thus, such materials
offer the industry a new
outlet for obtaining
high performance, low
maintenance, and cost
effective materials for
todays and future use.


Sample Product Data: ZeMC 3858 A

Carbon Fiber Filled Bulk Molding Compound Lubricated with Graphite
Rod Stock (+) 55 mm diameter x (+) 130 mm length
ROD Stock molded from ZeMC 3858 A, which is a carbon fiber filled BMC
lubricated with graphite designed primarily for use in the manufacture of wear
bushings. Its phenomenal wear resistance is coupled with thermal conductivity,
allowing heat transfer through the part reducing thermal retention and degradations of
the product.
Typical Cured Physical Properties
Specific Gravity




Mold Shrinkage In/In

mm/mm, in/in

<0.001 mm/mm

<0.001 in/in

Water Absorption 24hr/23 C

ASTM D 955

<0.04 %

< 0.04 %

Flexural Strength

ASTM D 790

90.08 MPa

13,065 PSI

Compressive Strength


290 MPa

42,000 PSI

Izod Impact, UN Notched

ASTM D 256

11.9 NM

8.55 FT LB

Electrical Resistance

Fluke Meter

4.4 ohms @ 0.38mm

4.4 ohms @0.150

Coefficient of thermal
Expansion (Post Baked)


2.27 E-05 mm/mmC

Typical Thermal Properties

Glass Transition, Tg

Un Post Baked

220.9 C


february 2014 | 51


bell & goSSett
ecocirc Xl

Featuring an easy-to-use digital interface that provides

the user with real-time pump performance information
through proactive self-monitoring, the ecocirc XL
significantly reduces system downtime for maximum
operational efficiency. This intuitive human machine
interface (HMI) keeps users informed of key pump
settings, such as operating or fault modes, flow
control and set point, further decreasing setup and
installation time. Additional settings and access to indepth historical pump data can be obtained through a
laptop, or an optional Wi-Fi module and standard Wi-Fi
enabled device (i.e., tablet or smartphone). Advanced
control options, including Modbus or BACnet access,
provide dynamic system management. Effective system
sizing and selection to realize even greater system
efficiencies can
be accomplished
through Bell &
Gossett ESP-System
Syzer software
or the mobile
Featured Product Release
application for

For more information on the ecocirc XL, visit power-of-e.com.

To contact a Bell & Gossett representative, go to www.bellgossett.com/sales-service/.

gouldS Water teChnology

Series e-Sv Pump

The Series e-SV stainless steel vertical multistage pump by Goulds Water Technology,
a Xylem brand, is offered in eleven models with flow rates of up to 800 gallons per
minute and heads up to 1150 feet, ensuring a precise fit for a variety of commercial and
industrial applications. The e-SV features standard National Electrical Manufacturers
Association (NEMA) meters that support 0.5 to 75 horsepower and have a temperature
range of -20 to 250 degrees Fahrenheit, adding to the pumps versatility. Easy to maintain,
the pumps design enables the removal of the mechanical seal without having to detach
the motor, reducing repair time by up to 50 percent. To learn more about the Series e-SV,
visit www.goulds.com/centrifugal-pumps-boosters/multi-stage-end-suction/e-sv-series/.


Conditioning monitoring Pod (CmP)

Lunetas Condition Monitoring Pod (CMP) is a new multi-parameter

inspection device designed to modernize and expand daily lubricant
inspections. This offering is part of a larger plan to roll out a series of
inspection-related products in the next few years. The CMP is a visible
inspection window revealing critical health conditions of the lubricant
and machine. Ideal applications include gearboxes, bearing oil sumps,
hydraulic reservoirs, compressor oil reservoirs, turbine-generator main
oil tanks, and paper machine central reservoirs. For more information
visit www.luneta.com or call 888.742.2021.

52 | february 2014


Wilden PumPS
Pro-flo Shift

The new Wilden Pro-Flo SHIFT represents a significant breakthrough in energy efficiency
within the AODD pump category. Due to its revolutionary design, the patent-pending ProFlo SHIFT Air Distribution System (ADS) allows Wilden AODD pumps to achieve up to a 60
percent savings in air consumption over all competitive AODD pump technologies, while
providing more product yield per standard cubic foot per minute (SCFM). While the Wilden
Pro-Flo SHIFT dramatically improves energy efficiency, it also costs 50 percent less than an
electronically actuated ADS, is submersible, and features plug-and-play operation. Its robust
design makes the Pro-Flo SHIFT ideal for use in harsh operating environments and includes
ATEX compliance for use in potentially explosive atmospheres. The Pro-Flo SHIFT has
fewer operating parts, which equates to less downtime and simple maintenance. For more
information about the Pro-Flo SHIFT, visit www.profloshift.com.

SolCon uSa

rvS-dn Combo Soft Starters

SOLCON USA offers heavy duty RVS-DN combo soft starters with built in circuit breaker
and ATL rated bypass in NEMA12/3R cabinets. Designed for in-plant use or for outdoor
applications, SOLCON soft starters ensure smooth, step-less acceleration and deceleration
of AC induction motors, eliminating high inrush currents and mechanical shocks to the
motor and the load. These UL listed soft starters are ideal for pump duty, crusher duty, mine
duty, and even marine duty application (ABS and other marine certifications available).
For more information, contact Karen Alberts, vice president of sales and marketing, at
724.473.1301 ext. 102 or karen.a@solcon.com, or visit www.solcon.com.


ultra-Compact Pressure
The Ashcroft GC51
and GC52 gauge and
differential pressure
transmitters offer the
ideal economical
alternative to
network process
when a digital
protocol is not
required. The
features an
measuring only
2.65 inches in diameter.
Stainless steel wetted parts
accommodate either wet or dry media. The GC51 is
available in ranges up to 0-7500 psig and the GC52 offers DP
ranges up to 400 inches of water. A built-in LCD display and
a 4-20mA output provide both local indication and remote
signaling. For more information, visit www.ashcroft.com or call


Krohne, inC.

h250 m40 f lowmeter

Krohne, Inc., a global technology leader in the
development, manufacture, and distribution of accurate,
reliable and cost effective level and flow measurement
products for the process industries, announces that Krohne
has received North American approval for use of the H250
M40 variable area flowmeter in hazardous areas. Since its
introduction in 2011, the H250 M40 has achieved more
than thirty approvals worldwide for hazardous gas and dust
areas, including usFMc for the United States and Canada,
CCOE. All available H250 M40 flowmeter indicator options
can be supplied with specific approvals, onsite, and without
interrupting the process. These purely mechanical flow
indicators can easily be upgraded with 1 or 2 limit switches
(NAMUR, transistor, or reed), a 4-20mA signal output with
HART, a graphical LCD with totalizer and pulse output, as
well as a digital, bus-powered communication interface
using FOUNDATION Fieldbus or the PROFIBUS (Process
Field Bus) PA standard. For more information, contact Sandy
Olley at 800.356.9464 or s.olley@krohne.com.

february 2014 | 53



utility air-Spade 4000

Air-Spade, a division of Guardair Corporation, announces the
availability of the Utility Air-Spade 4000 SERIES excavation tools.
These tools are safe, non-damaging alternatives to traditional
digging methods that often puncture sensitive underground
cables and pipes during soil-excavation applications. The Utility
Air-Spade 4000 is designed for safe excavation around buried
utilities. Electrically insulating materials as well as non-sparking
materials make excavating around high voltage power lines and
gas lines safe. The Utility Air-Spade comes in two sizesthe 105 cfm with 4-foot barrel and the 150 cfm with 4-foot barrel. They
feature patented supersonic nozzles that utilize compressed-air to produce high-speed laser-like jets that move at twice the speed of
sound for faster, more effective digging in the toughest soils. For use in utility locating and repair, keyholing, potholing, valve box
cleaning, and cable trenching. For more information, visit www.airspade.com or call 800.GUARDAIR (800.482.7324).

metroPolitan induStrieS

ion gateway monitoring and alarm System

Metropolitan Industries Inc. is a single source for quality pumps, control systems, and
ancillary equipment serving the residential, commercial, municipal and mechanical
markets and has just released a new product to its Ion Products line, the Ion Gateway,
Monitoring and Alarm System for use with wireless sensors. The Ion Gateway gives
customers the ability to monitor incidents such as power loss, temperature, high water,
and more. Using both the cellular gateway link and wireless sensors, the Ion Gateway
can send alarm notifications direct to your e-mail address or SMS text account. For more
information, call 815.886.9200, fax 815.886.6932, email pr@metropolitanind.com, or visit

emerSon induStrial automation

browning v-belts

Browning introduced EPDM's heat-resistance and durability

advantages to all its raw-edge, notched V-belts at the AHR
Expo, bringing an expanded temperature rating of -60 to 250
degrees Fahrenheit (-51 to 121 degrees Celsius) to some of
the most commonly used V-belt cross sections in the HVAC
industry: AX, BX, CX, 3VX, 5VX, and 8VX Gripnotch belts.
See the full article describing the applications of this product
in this months Modern Pumping Today. For more information,
contact Jackie Catalano, corporate manager of global marketing
communications for Emerson Industrial AutomationPower
Transmission Solutions, at jackie.catalano@emerson.com or

oven induStrieS

model 5r7-350/347 temperature Controller

Oven Industries Model 5R7-350/347 is an economical thermal controller
especially designed to operate with thermoelectric (Peltier effect) modules.
Most of these modules may be operated in either a cooling mode or a heating
mode depending on current direction. The 5R7-350/347 thermal controller
may be field configured for either of these operating modes. These thermal
temperature controllers were designed with a proportional/integral control
algorithm to provide the best control at the most economical cost. Either a
fixed or adjustable proportional bandwidth and integral rate permits optimizing
individual thermal systems. Additional external heat sinking will permit
operating load currents in excess of 10 amperes. For more information, visit

54 | february 2014



eZstrip transfer Pump

EZstrip has revolutionized the way in which PC pumps and associated products are Maintain-In-Place
(MIP) reducing a day-long maintenance operation to a few hours. The EZstrip Transfer Pump provides a quick
and easy way to disassemble, de-rag, and maintain a PC pump in place, reducing maintenance time by
more than 93 percent for significant cost savings. Distinguished by a patented split coupling, EZstrip Transfer
Pump offers direct access to the wear parts and rotating assemblies without affecting the operational
parameters. Features include full drive train including rotor, stator, shaft, rod and seal can be
removed in minutes with no electrical disconnection required. The EZstrip Transfer Pump is
available in cast iron or stainless steel with a choice of rotor and stator materials to suit
individual applications. For more information, call 877.4UMOYNO,
fax 937.327.3177, or visit www.moyno.com.

hamilton CaSter

316l Stainless Steel inline Caster

What began as a simple inquiry for a wheel spawned into a new
Hamilton innovation. The end result was a custom engineered all
stainless inline caster for a major aerospace part supplier. The aerospace
company ordered two of these special casters designed for a clean room
environment and each with an impressive carrying capacity of 15,500
pounds. The caster stands 10-1/8 inches tall and 21 inches long equipped
with two 8 inch diameter by 2.2 inches inch wide double flanged track
wheels. Four 40 millimeter double sealed precision stainless steel ball
bearings were press fit into each wheel with 1-1/4 inch axles. The pivot
block used axles 1-1/2 inch in diameter. For more information, call
800.733.7655, fax 800.232.3733, visit www.hamiltoncaster.com, or
email info@hamiltoncaster.com.


f900 load rated Composite

access Covers
Fibrelite can now provide the perfect lightweight
alternative to traditionally used heavy concrete
and metal access covers for areas imposing
particularly high wheel loads such as aircraft
pavements, taxiways of civil airports and
dockyards. These lightweight composite access
covers can be used for a multitude of applications:
from ports and dockyards, industrial facilities,
airports, HGV loading areas and also power
stations for example. No other covering system
matches its easy lift, skid resistant or load carrying
properties. For more information, contact Jo Stott,
marketing director, at jostott@fibrelite.com or visit


february 2014 | 55

PUMPING trends

The Equipment Leasing & Finance Foundation finds

confidence is rising for industrial equipment

illiam G. Sutton,
CAE, is the president
and CEO of the
Equipment Leasing & Finance
Association and president of the
Equipment Leasing & Finance
Foundation. In January 2014,
the Foundation released its
Monthly Confidence Index for
the Equipment Finance Industry
(MCI-EFI), which reported the
highest confidence level in two
years, and nearly a ten point
jump from even the previous
month. Mr. Sutton joined Modern Pumping Today to look
closer at the numbers and what they mean for the industrial
equipment market.
Modern Pumping Today: What are some of the ground
level factors influencing this positive trend in the
equipment finance market?
William G. Sutton: There are a number of factors. One
is end-of-year optimism looking toward a year where
economists are projecting GDP growth of 3 percent, which
is the fastest weve seen since the recession. The economy
seems to be gaining some momentum, and the recent
budget agreement has taken some uncertainty off the table.
MPT: Is this a trend you expect to continue? Where do
most of your respondents see their first quarter for 2014
William G. Sutton: The respondents to our Foundations
January Monthly Confidence Index were very optimistic,
seeing growth in sectors such as transportation,
manufacturing and industrial. Overall, we expect positive
growth in 2014. The Equipment Leasing and Finance
Foundations 2014 Economic Outlook forecasts a progrowth direction, driven by a number of positive factors.
Specifically, a sustainable housing market recovery,

56 | february 2014

low natural gas prices, robust auto sales, record high

household wealth, steadily improving credit availability,
and improving employment gains. However, these positive
trends are counter-balanced by high oil prices, slow
international growth, moderating fiscal consolidation, and
the continued threat of political uncertainty.
MPT: How steady does the index project demand for
equipment leases and loans in the first part of 2014?
William G. Sutton: The Foundations Monthly Confidence
Index projects business conditions and expectations
for the next four months, so we expect Q1 to be solidly
in the steady category on range of demand. Some 94
percent of the respondents to our January MCI expected
business conditions in the first quarter to remain the same
or improve over the next four months, and 97 percent
expected demand for equipment to remain the same or
increase through the first quarter.
MPT: For your respondents, how does this increase in
confidence affect their business practices? Do they foresee
an increase in their business development activities or
their hiring practices?
William G. Sutton: Some 95 percent of executives
responding to our January MCI expected to spend the
same or more on business development; in fact, more
than half expected to increase their spending on business
development. Roughly 91 percent expected headcount to
remain the same or grow in the first quarter, with about a
third saying they planned to hire during the first quarter.
MPT: Do executives responding to your survey extend the
optimism they feel about the equipment finance market
into the U.S. economy overall?
William G. Sutton: Yes, they do. They are optimistic, but
that optimism is tempered by concerns over the political
uncertainty going forward, the regulatory environment and
slowing international growth.


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