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MODERN

TODAY
PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MARCH 2015

NATURAL GAS-POWERED
FACILITY A MODEL
OF EFFICIENCY

BELL & GOSSETT


TURN UP
THE HEAT
TOMORROW'S
DEWATERING
PUMP TODAY
PACKAGED
PUMP SYSTEMS
TO THE RESCUE

CONTENTS
4
10

MARCH 2015

Industry news
trade show ProfIle
Case studIes

12 Warming Up a Newport Mansion

Bell & Gossett pumps power a state-of-the-art heating system

14 Mine to Double Productivity with Waterjet Cutting System


DRC Copper Mine installs Jet Edge 5-Axis waterjet

12

water & wastewater solutIons

18 STEP: Another Alternative to Alternative Sewers


22 The Pursuit of a Green Carbon Steel Corrosion Inhibitor
Part 3 in a 4-part series

MaIntenanCe solutIons

26 Electronic Water-Conditioner Keeps Boilers Scale Free

Scalewatcher saves San Antonio housing agency the cost of replacing boilers every six months

PuMP solutIons

28 Packaged Pump System Improves Quality of Life

18

City of Southside, Alabama, selects EBARA for emergency lift station upgrade

34 Digester Mixing on Track

Biogas Energy brings Landias GasMix system and chopper pumps to


North State Rendering

dewaterIng solutIons

38 A Pump System for the Future

Boskalis invests in a new, environmentally friendly high flow pump unit

Motor solutIons

40 The Need for Speed

One-minute V-belt changes with energysaving Tenso-set motor base

38

www.modernpumpingtoday.com

P.O. Box 660197 | Birmingham, Alabama 35266


@ModPumpMag

Power generatIon solutIons

42 Fast, Efficient, and Environmentally Friendly

Rubart Station, Caterpillars largest natural gas-powered facility, is a model of efficiency

ProCessIng solutIons

46 Offshore Opportunities Continue for Pumping Professionals

ValVes & Controls


solutIons

JEFF FLETCHER Associate Publisher


jeff@modernpumpingtoday.com
RANDY ARMISTEAD Associate Publisher
randy@modernpumpingtoday.com
J. CAMPBELL Editor
jay@modernpumpingtoday.com
DONNA CAMPBELL Editorial Director
donna@modernpumpingtoday.com
SCOTT GORDON Art Director
scott@modernpumpingtoday.com

48 Say Good-Bye to Inaccurate Chlorine Readings


New analyzer measures near zero levels of chlorine for repeatable accuracy

LISA AVERY Assistant Art Director


lisa@modernpumpingtoday.com
JAMIE WILLETT Circulation Consultant
INGRID BERKY Administrative Assistant
TONYA BROWNING Account Executive

sealIng solutIons

JERRY DICHIARA Account Executive


DAVID MARLOW Account Executive

50 Strategic Mechanical Seal Partnerships

SANDY HAYS Account Executive

Building owner-manufacturer relationships that benefit all parties


Part 2 in a 2-part series

54

Modern PuMPIng ProduCts


Featured Product Release: BALDOR ELECTRIC COMPANY NXR High Voltage Rib-Cooled Motor

www.highlandspublications.com

PuMPIng trends

312 Lorna Square | Birmingham, Alabama 35216


T: 866.251.1777 | F: 205.824.9796

56 Going the Distance

DIGI International's Aaron McNally on the new reach for industrial wireless communication

TIM GARMON
CEO/President
RUSSELL HADDOCK
COO/Publisher

CHRIS GARMON
General Manager

EDITORIAL ADVISORY BOARD


Terry Bell

Drives and Motion Solution Engineer


Baldor Electric Company

Heinz P. Bloch, P.E.

Consulting Engineer,
Process Machinery Consulting

Robert G. Havrin
Director of Technology,
Centrisys Corporation

Michael Mancini

Consultant and Trainer,


Mancini Consulting Services

John M. Roach

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

Lisa Riles

Business Development Manager,


Wastewater Pumps
Xylem Inc.: Flygt

Greg Towsley

Director of Regulatory and


Technical Affairs, Grundfos

Trey Walters, P.E.

President, Applied Flow Technology

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


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

INDUSTRY news
ACEEE INTELLIGENT EFFICIENCY
CONFERENCE SETS DATE

The second annual ACEEE Intelligent Efficiency Conference has


announced it will be held on December 6-8, 2015, in Boston,
Massachusetts. The ACEEE Intelligent Efficiency Conference
brings together energy efficiency and technology innovators
and thought leaders to discuss evolving markets, to work on
new policies and efficiency program strategies, and to explore
new opportunities for energy savings. This is the event where
the IT, telecom and energy sectors convene to determine the
future of energy efficiency.
The ACEEE Intelligent Efficiency Conference is designed
specifically for:

Energy efficiency program developers and administrators


State and local government policymakers, staff, and
associations
Chief technology officers and chief information officers
Service providers
Investors
Entrepreneurs
Hardware and software developers
ICT solution providers
Building automation providers
Smart manufacturing, smart transportation, smart
buildings, and smart cities leaders

Speaking roles at the conference are by invitation only.


Interested parties who would like to share topic ideas, speaker

4 | MARCH 2015

suggestions, or learn about sponsorship opportunities, can


e-mail the Intelligent Efficiency program team or visit the IE
web page: www.aceee.org/conferences/2015/ie.

VINYL SAVES LIVES PROJECT AT THE


INTERNATIONAL PLASTICS SHOWCASE

The vinyl (PVC) industry and its leaders have selected American
Red Cross International Services to benefit from a week-long
special Vinyl Saves Lives project and demonstration during
NPE2015: The International Plastics Showcase, one of the
worlds largest trade shows, being held March 23-37, 2015, at
the Orange County Convention Center in Orlando, Florida.
The project will ask the showcases 60,000 attendees to
support American Red Cross in the fight against Ebola (i.e.,
all proceeds will be designated to American Red Cross
International Services), and demonstrate to an international
audience that vinyl is a critical component in the manufacture
of hundreds of medical products and therefore plays a key role
in Africa and elsewhere helping to save lives.
The Vinyl Saves Lives project will utilize a 40-foot-wide
booth to maximize exposure to showcase attendees and offer
special demonstrations of dozens of medical products used
in the treatment and isolation of Ebola. Included in the booth
display will be an actual patient isolation bed field unit and
several medical personnel protective garments as broadcast
internationally during the Ebola crisis in Africa, plus a chance
for attendees to learn how vinyl/PVC, the second mostused plastic materials, have been used to help save lives for
decades.

www.modernpumpingtoday.com

INDUSTRY news
The American Red Cross has raised nearly $5.6 million
to support Ebola relief efforts in the affected West African
countries, and 100 percent of donations collected by the Vinyl
Saves Lives project sponsors will be designated to support
American Red Cross International Services. Sponsors and
participants recognize that nearly 24,000 people have been
victims in the last year, and the Red Cross plays a vital role
in the fight against Ebola with more than 6,000 volunteers
leading disease prevention, education and awareness efforts,
having reached 39 million people, in addition to providing
psychosocial support and assisting in management of the
deceased.

MANUFACTURING DAY LAUNCHES NEW WEBSITE

The partners responsible for producing Manufacturing Day at


the national level announced today the refresh of its website,
MFGDAY.com. The upgraded site boasts more resources for
sponsors, companies, supporters and volunteers, making it
easier than ever to participate in this years annual celebration of
manufacturing, which is scheduled for Friday, October 2, 2015.
Users can now sign up to host events, find MFG DAY events
in their areas, and learn more about sponsorship opportunities
through the newly updated interactive site. With user-friendly
links to social media channels, scholarships, and success stories,
potential participants, manufacturers, educators and students
can better collaborate and access important industry resources.
For three years, Manufacturing Day has celebrated the world
of modern manufacturing. The annual event is meant to inspire
the next generation of manufacturers across the North American

6 | MARCH 2015

continent. In 2014, more than 1650 companies, educational


institutions and associations in all 50 states, Canada and Puerto
Rico participated by holding Manufacturing Day events attended
by 360,000 people. With the launch of this new site is hoping
to increase participation and further educate the public about
the benefits of manufacturing. For more information, visit
www.mfgday.com.

B&W SUBSIDIARY AWARDED $220 MILLION


CONTRACT FOR U.K. POWER PLANT

The Babcock & Wilcox Company (B&W) announced today that


its Denmark-based subsidiary, Babcock & Wilcox Vlund A/S,
has been awarded contracts totaling more than $220 million
to design, manufacture and operate a biomass power plant in
Rotherham, South Yorkshire, England.
B&W Vlunds consortium partner, Interserve Strategic
Projects, will construct the plant for the developer, Copenhagen
Infrastructure Partners.
The Rotherham Biomass Plant will feature a B&W Vlunddesigned multi-fuel boiler with a DynaGrate fuel combustion
system, a dry flue gas desulfurization system (dry FGD) and will
burn waste wood to generate approximately 40 megawatts of
electricity.
The contracts also call for B&W Vlund to provide operations
and maintenance services for an initial term of fifteen years
once the plant is commissioned.
We greatly appreciate the confidence Copenhagen
Infrastructure Partners has shown in B&W and this consortium
and look forward to executing this project, said Paul Scavuzzo,

www.modernpumpingtoday.com

INDUSTRY news
B&W senior vice president and general manager, global power
division. The market for biomass power and waste-to-energy
technologies in Europe continues to be strong, and B&W is
well-positioned to meet the demand for reliable, clean energy
solutions. This is B&Ws fourth major renewable energy project
announced in the European market in the last seven months.
The project was booked in the first quarter of 2015 and B&W
Vlund has received a full notice to proceed with its work. Plant
completion is scheduled for third quarter of 2017.

FLOWROX TO PARTICIPATE AT THE PHOSPHATES 2015


INTERNATIONAL CONFERENCE AND EXHIBITION

Flowrox, a global leader in heavy-duty industrial valve


manufacturing and services, will exhibit at the Phosphates 2015
International Conference & Exhibition to be held at the Marriott
Tampa Waterside Hotel in Tampa, Florida, on March 23-25.
Currently in its eighth edition, the Phosphates International
Conference presents a global point of convergence for
networking and trading in the fertilizer, industrial and feed
phosphate industries; all of great interest to Flowrox, given their
use of slurry pipelines to process phosphate salts.
Understanding slurry dynamics was instrumental in Flowroxs
development of its Scaling Watch and SKW Heavy Duty Slurry
Knife, a pair of products designed to help phosphate processing
operators monitor and control the flow of phosphate slurries.
The Flowrox Scaling Watch is actively used in industries
such as oil and gas, pulp and paper, metallurgy and minerals
mining to proactively detect buildup that can lead to scaling that
reduces the flow of materials.

Complementing the Scaling Watch is the SKW Heavy Duty


Slurry Knife, designed to control the flow of fluidsan industrial
need in high demand by the mining industry given the coarse
nature of its slurry and the potential for clogging or jamming.
Anthony Clark, Flowrox vice president of sales, will
be delivering a presentation during the event focused on
the Flowrox Scaling Watch and the use of a tomographic
instrumentation to monitor scaling in phosphate production and
processing.
The aforementioned sensor allows producers to utilize a nonintrusive instrument to accurate display real-time scale growth;
thus providing the user with useful data to help them minimize
anti-scaling chemicals, validate the effectiveness of anti-scaling
chemicals and minimize lost production, equipment failures,
and costly maintenance caused by scaling.
Any decrease in fluid movement is often tied to a loss
of revenue in an industry that depends on optimal pipeline
performance, said Todd Loudin, president of Flowrox. Our
products have been engineered to keep our customers pipelines
operational and profitable.
Flowrox will be showcasing the Scaling Watch and SKW
Heavy Duty Slurry Knife as viable solutions to help those in the
phosphate industry achieve operational excellence using devices
that reduce the effects of transporting minerals.
The 2015 Phosphates International Conference will bring
together over 400 delegates from more than 40 countries who
represent producers, service providers, technology companies,
traders, and executives who seek to network, learn and engage
in new business relationships.

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8 | MARCH 2015

www.modernpumpingtoday.com

TRADE SHOW profile

OFFSHORE TECHNOLOGY
CONFERENCE 2015
OTC is where energy professionals
meet the future

ndorsed by technical
societies that cover all
aspects of the energy
industry, the Offshore
Technology Conference prides
itself on being the best event to
gain technical knowledge and
make valuable contacts. OTC
ranks among the largest 100
tradeshows held annually in the
United States and is among the
ten largest meetings in terms of
attendance. The 2014 version
of OTC saw record attendance
numbers, and this years event
promises to be even bigger.

SPOTLIGHT ON NEW
TECHNOLOGY

The Spotlight on New


Technology Awardsa program
for OTC exhibitorsshowcase
the latest and most advanced
hardware and software
technologies that are leading
the industry into the future.
Seventeen technologies will
receive the prestigious award,
and winning technologies were
selected based on the following
five criteria:

New: less than two years old


Innovative: original,
groundbreaking, and
capable of revolutionizing
the offshore E&P industry
Proven: through full-scale
application or successful
prototype testing
Broad Interest: broad appeal
for the industry
Significant Impact: provides
significant benefits beyond
existing technologies

In support and recognition of


innovative technologies being
developed by small businesses,
OTC has created a new
Spotlight on New Technology
Small Business Award in 2015.
10 | MARCH 2015

The small business applications


were evaluated using the same
five criteria above, but also
were required to have fewer
than 300 employees.
Our Spotlight Award winners
embrace OTCs mission to
advance technical knowledge
of offshore developments and
environmental matters, said
Spotlight Award Committee
Chair Steve Balint. And
with the creation of the
Small Business Awards, we
are recognizing the fact that
companies both big and small
are developing innovative
technologies and creative
solutions to meet the worlds
energy demands.

RESEARCH AND
DEVELOPMENT SHOWCASE

The OTC University R&D


Showcase provides universities
the opportunity to share with
attendees their current and
planned R&D projects that are
relevant to offshore technology.
Participating universities include
the University of Houston, Penn
State University, Rice, Texas
A&M, among others. All will
showcase their R&D projects
during one of the four days of
the conference.

PROGRAM FOR YOUNG


PROFESSIONALS

The changing environment


of exploration, production,
refining, and operations
demands leadership from the
next generation to reach these
new frontiers, both domestic
and worldwide. With the oil
and gas industry entering
these new environments the
career opportunities for young
professionals are endless.
The Next Wave 2015 program
will offer insight from industry

leaders into the challenges ahead


and how to face these as a young
professional while recognizing
the increased interconnectivity
of the global industry. Speakers
with technological, operational,
academic, and political
backgrounds will be the guides
for the discussion and share
their valuable experience and
advice on what lies ahead. The
discussion will address how
technological advancements
in operations are expanding
opportunities, while taking
into consideration the political
aspects surrounding these new
frontiers and the knowledge
young professionals will need to
tackle their careers.
This program will investigate
how the industrys global
contribution, in this highly
connected world, will have an
impact far beyond the office.
The panel will discuss many
aspects of working in some of
the most challenging and new
environments and explain the
benefits of having a diverse
outlook. Ultimately, attendees
will hear what is needed to
obtain a job in these new
markets and how to become a
driving force for the future of
the industry.
www.modernpumpingtoday.com

CASE Studies

Warming Up a Newport Mansion


Bell & Gossett pumps power
a state-of-the-art heating system
By Mark Handzel, Bell & Gossett

rom the outside, the 1920s villa in the seaside community of


Newport, Rhode Island, appears as any other stately historic home
in the neighborhood. But inside the 15,000-square-foot house,
the heating system is state-of-the-artcomplete with Wi-Fi and remote
programming capabilitiespowered by a Bell & Gossett (B&G) pump
system.
This Newport, Rhode Island, 1920s villa contains a state-of-the-art heating
system powered by a Bell & Gossett pump system.

UPDATING THE PAST

The old cast-iron steam boiler was obsolete and expensive to run, costing
the homeowners $20,000 a year in oil alone. Property caretaker Jeff
Ward started investigating options to convert the system from steam to
hot water, downloading manufacturers manuals to compare and contrast
pumps for the system. He set up a beta test in the house to find the most
effective and energy-efficient model by measuring output through an amp
meter.
B&Gs ecocirc vario circulator pump met Wards criteria, most notably
because of its electronically commutated permanent magnet motor
designed specifically for hydronic systems. In Wards test, the ecocirc
heated the room while operating at just of an amp and maintained
consistent pressure.

ECOCIRC: A CLOSER LOOK


The 15,000-square-foot historic home requires a heating system that is
both dependable and efficient.

Compared to its competitors in the field, the ecocirc has numerous


advantages. First, it uses less wattage at maximum speed 60 watts
versus 85 watts resulting in roughly a 30 percent savings in energy.
In addition, its variable speed capabilities allow it to adjust to demand
instead of running at maximum speed at all times, resulting in less energy
use.
While proper pressure within the system was a primary consideration,
the ecocirc also proved it could handle the long heat runs in the 20-room
house for just pennies a day in electricity costs, another priority for Ward.

MIXING OLD AND NEW

The ecocirc vario allows for step-less speed control to set the pump
performance to meet individual system requirements.

Steve Graham of local B&G representative Fluid Industrial Associates Inc.


(FIA), helped marry the new circulator technology with the homes existing
radiators sixty-seven in all. It was a challenge to reuse the radiators
and run new piping without it becoming a major construction project,
said FIA Vice President George Carey. But aesthetically the radiators fit
the look of the house and the homeowners wanted to keep them.
The process of disassembling and cleaning all of the radiators took
two years. Crews had to work around some of the complicated plumbing
features of the house, such as two of the radiators being located behind
built-in bookcases. Specialized tubing connects the radiators and the 25

About The Author


Mark Handzel is the vice president of product regulatory affairs and director of HVAC commercial buildings for Bell
& Gossett, a Xylem brand. Bell & Gossett is the world leader in energy efficient pumps. For more information, visit
www.bellgossett.com.

12 | MARCH 2015

www.modernpumpingtoday.com

Celsius) on a 10-degree Fahrenheit


(-12.2 degrees Celsius) day but only
needs to be heated to 110 degrees
Fahrenheit (43.3 degrees Celsius) on
a 50-degree Fahrenheit (10 degrees
Celsius) day.

RESULTS YOU CAN SEE

The new system is already paying

dividends, with fuel costs plunging


about 80 percent in just a few months.
This is the fastest payoff ever, Ward
said. We dont need oil anymore.
Contrast that with the carriage house
on the property, which is still fueled by
an outdated system, costing about four
times as much to heat than the main
house now does.

The ecocirc vario circulators were designed with highly


efficient electronically commutated permanent magnet
motor (ECM/PM technology) specifically for hydronic
systems.

With the radiator adapted to new system, the historic


homes heating will be more effective and efficient.

ecocirc pumps, now in a centralized


location in the house, to the new
modulating gas boiler.

A THOROUGH JOB

The ancient boiler was only part of the


homes heating problem. Previously,
there were only two zones to control
the temperature in the house. Installed
by Steve Antoch of A&L Plumbing and
Heating, the new system features thirtyfour zones, and has Wi-Fi capability.
Now, while the homeowners are out,
they can send a text to Ward, who can
program the system remotely so they
arrive to comfortable temperatures
inside the house.
Another key feature of the system is its
outdoor reset, which takes into account
the outdoor temperature when heating
the water. For example, water is heated
to 180 degrees Fahrenheit (82.2 degrees
www.modernpumpingtoday.com

MARCH 2015 | 13

CASE Studies

Mine to Double
Productivity with
Waterjet Cutting System

DRC Copper Mine


installs Jet Edge
5-Axis waterjet

By Nancy Lauseng,
Jet Edge
Jet Edge's Edge X-5 5-axis waterjet cuts precise 3D parts from virtually any material.

ased in Johannesburg, South Africa, Jetstream Cutting


Solutions represents Jet Edge waterjets in several Southern
African nations and carries Jet Edges full line of waterjet
cutting and surface preparation equipment, including waterjet
cutting machines, waterjet intensifier pumps and portable
waterjetting systems. In addition to Jet Edge waterjets, Jetstream
also sells, installs and services other 3-axis waterjet systems and
UHP pumps. With Jetstream Cutting Solutions help, operators
of a remote copper mine in the Democratic Republic of Congo

(DRC) are planning to double the mines productivity with the


use of a new Jet Edge Edge X-5 5-axis waterjet.
The DRC mine operation, which is at least a three weeks
drive from Johannesburg, South Africa, plans to use the Jet
Edge waterjet system to speed up the completion of a copper
processing plant. The Jet Edge machine is the mines second
waterjet system. In 2012, they installed a new Jetstream 3-axis
waterjet, powered by a 90,000 psi (6200 bar) 50hp Jet Edge
X-stream xP90-50 hydraulic intensifier pump.

About The Author


Nancy Lauseng is the marketing manager for Jet Edge. For more information about Jet Edge, visit www.jetedge.com
or call 800.JET.EDGE (538.3343) or 763.497.8700. For information about Jetstream Cutting Solutions CC, visit
www.jetstreamcutting.co.za, and for information about Mobile Digital Solutions, visit www.mobiledigitalsolutions.com.au.

14 | MARCH 2015

www.modernpumpingtoday.com

RELIABILITY IN ACTION

They run their first machine


24/7, says Jetstream Cutting
Solutions director Malcolm
Cruickshank. The Jet Edge
X-Stream pump was key
to the success of the first
machine because they could
utilize the higher pressure to
increase productivity.
For their second
waterjet system, the mine
operators selected Jet
Edges premiere 90,000 psi
(6200 bar) Edge X-5 system
with dual independently
programmable 5-axis cutting
heads and laser plate
mapping system, Aquavision
Di industrial PC controller,
and 5-axis waterjet cutting
software.
Cruickshank notes that
the mine officials chose a
Jet Edge system for their
second machine based on
the reliability of their first Jet
Edge pump, and Jet Edges
ability to quickly supply
spare parts when needed.

Jetstream Cutting Solutions director Malcolm Cruickshank (right) and subcontractor Jake Hall travelled to a remote copper mine in
Africa's Democratic Republic of Congo to install a premier Jet Edge 5-axis waterjet system.

www.modernpumpingtoday.com

MARCH 2015 | 15

CASE Studies

Mine officials plan to double productivity with help of their latest Jet Edge waterjet.

The Jet Edge Edge X-5 work envelope can accommodate very large plates.

Reliability is very important to them due to the remoteness


of the mine, he says. They appreciate the speed with which Jet
Edge can supply spares.

reliable. The software is great. It solves a lot of the problems of


other CAD/CAM software. Its been specifically designed with
waterjetting in mind. Lead ins and outs are easy and its easy
to nest multiple parts. Most importantly, youre not stuck to a
certain order. With some software, if you miss one step, you
have to start all over again. Jet Edges software is flexible and
its not labor intensive. The library of materials is good and the
speed control is good.
Hall added that he has been very impressed with Jet Edges
X-Stream intensifier pumps, service and training.
The X-Stream pump is bullet-proof, he says. We feel
comfortable that we have a good support network and that we
can call Jet Edge any time, day or night.

INTUITIVE AND EASY

Jake Hall, a Jetstream subcontractor and director of Mobile


Digital Solutions of Sylvania, Australia, oversaw the installation
of the Jet Edge system and trained the mines waterjet operators
how to use the new 5-axis machine.
The Edge X-5 is a good system, Hall notes. Its intuitive
and easy to operate. Ive seen lots of systems in my eleven years
working with waterjets and it seems to do the job very well
and is easy to teach. The Aquavision Di controller is extremely

16 | MARCH 2015

www.modernpumpingtoday.com

WATER & WASTEWATER solutions

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Sew

The easy-pull-cleaning swab handle is used to maintain the exterior and


flush out the angled slots.

By Jennifer Cisneros, Bio-Microbics, Inc.

hat kind of options does a neighborhood


developer have to easily manage and monitor
the wastewater generated from the homes
of cluster developments or a small community

About The Author

Jennifer Cisneros is the manager of marketing and multimedia for Bio-Microbics, Inc. Bio-Microbics has developed a number
of innovative products, some of which have revolutionized methods of dealing with the treatment of sewage on sites where
infrastructure and drainage was and is not available. For more information, visit www.biomicrobics.com.

18 | MARCH 2015

www.modernpumpingtoday.com

THIS SECTION SPONSORED BY

hen there are more options


than to hook-up to
a municipal plant and
pay exorbitant connection fees, a
community developer looks into
alternative methods to handle water and
wastewater issues for each/equivalent
residential unit (ERU) on the property
for development. Options include sump,
sewage, grinder, gravity feed effluent,
and filtered pump vaults commonly
referred to as STEP (Septic Tank Effluent
Pump).

WWW.ADEDGETECHNOLOGIES.COM

a holding tank for sewage, a screen


chamber, and a small, high-pressure
pump within the tank. The STEP system
pump is controlled by a system of floats
within your tank. The floats activate an
alarm in the electrical (alarm) box when
the fluid level in the tank gets too high
or too low. The liquid waste is pumped
through a small pressure line into sewer
lines.

THE PATH TO RESPONSIBLE


WATER USE

STEP units encourage responsible


water use and disposal practices by the
homeowner. As a cost effective solution
for transporting effluent in a wastewater
collection and treatment system, STEP
effluent quality (average TSS 29, BOD5
129) is much better than sewage,
reducing the biological load. The quality

THE NEW FACE


OF WATER UTILITIES

As part of a progressive replacement


program, municipalities will continue
to develop and install innovative
technology, prescreening / pretreatment
systems and better maintenance
procedures. The challenge many strong
industries within the economy face
are to understand what technologies
are available and will they work on
their site to improve their wastewater
treatment facilities. The investment
seems high upfront, but the payoff
is significant overtime with reduced
maintenance and operation costs.
The water utility business model
is changing. Historically, water and
wastewater utilities have functioned as
monopolies without competition. As the
price of water services rises, the cost of
new technology drops, and concern for
securing a water supply increases, we
are likely to see a rise in use of these
"disruptive" technologies, which can
undermine the monopolistic nature of
the water utility.
Now technological advances are
allowing more options for water
efficiency, water re-use, and water
harvest.

WHAT TO DO?

Small municipalities can explore the


option of updating their wastewater
facilities. And those public/private
that do not have the resources for a
large infusion of cash to update these
facilities might consider outsourcing to
treatment facilities that already have this
technology in place.
A STEP system prescreens wastewater
from large solids and inorganic clogging
debris; and is a form of pressure
sewer that has several advantages over
traditional gravity collection systems.
As an ideal conveyance method where
gravity collection systems are not
possible, the STEP system includes
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MARCH 2015 | 19

WATER & WASTEWATER solutions

BioSTEPs standard design incorporates a superior 3/4 inch (19.05 millimeter) solids handling sewage pump and a
comprehensive control system.

Provides flexible, uniform installation options for most tank, manhole, and riser
configurations.

Installation of adjustable footing to handle weight of the


submersible pump.

of effluent from STEP Units allows the collection system to


be designed the same way as a water system. Small diameter
PVC pipe is laid in shallow trenches. Infiltration problems
are eliminated, and hence, treatment plants can be smaller;
lift stations and manholes are not required. Maintenance and
operating costs are the same as, or less than, conventional
sewers. Per -unit costs can be much lower, especially in areas
with dispersed dwellings, hilly terrain, high water table or
rock. The on-site costs can be deferred until occupancy.
Available from Bio-Microbics, Inc., the BioSTEP (Septic
Tank Effluent Pumping) Systems are ideally suited for all
onsite wastewater pumping applications, from single family
residential to small diameter collection systems. These
effluent pumping systems filter out solids so that only liquid
from the "clear zone" between the tank's scum and sludge
layers is pumped. This reduces biological loading and
clogging of downstream components, extending drainfield
life. All systems are pre-assembled with corrosion resistant,
durable components, ensuring reliability. All BioSTEP Systems
are available as individual components or preassembled in
ready-to-install System Packages. Our Filtered Pump Vaults
provide your pump with critical protection from solids larger
than 1/16 inches (1.59 millimeters) Each vault incorporates
slotted filter screens into easily removable panels, allowing
for an easy and quick servicing.

COSTS, INSTALLATION, OPERATION


AND MAINTENANCE

Once installed, BioSTEP STEP/STEG devices are designed to be cleaned in placeno


removal of any components.

20 | MARCH 2015

The cost of a STEP/STEG system can be divided into two


major components: The on-lot cost and the collection
network cost. On-lot installation costs include the pump,
tank, controls, building sewer, and electrical service. A
STEG system would not have the pump, controls and electric
service costs. The initial on-lot costs are usually paid by
the lot owner. The installer must follow the guidelines
established by the utility for the selection and placement
of components. Depending on the style of pump and tank
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selected by the utility, and the STEP
pressure requirements needed to inject
sewage into the network, the on-lot
costs are estimated to be $3500 to
$5000 for a single-family home. The
electrical cost would be about thirty
dollars per year.
Licensing requirements for personnel
who install STEP/STEG systems varies,
but they must typically be licensed
by the state or region in which they
work. Like all other alternative
collection systems STEP collection
network require minimum excavation.
The required depth of the pipeline
is minimal and can generally follow
the terrain. The collection network is
installed either through trenching or
horizontal directional drilling (HDD).
HDD reduces or eliminates the need
for large, deep trenches that disrupt
existing utilities, landscaping, roads and
driveways. STEG systems must maintain
an overall slope toward a lift station
or treatment facility. However, since
there are no heavy sewage solids to be
transported, slope can be significantly
reduced or eliminated. In all cases,
slope and sewage velocity requirements
are less than a conventional gravity
sewer. Many small communities have
both STEP and STEG within the same
cluster of sources.

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replacement costs are reduced. System


components should be standardized
as much as possible to facilitate easy
maintenance. Some wastewater sources
may need more powerful pumps if they
are located at lower elevations or at
distant sites. When these special pumps
fail, they must be replaced with pumps
of similar capacity.

Typically, preventive maintenance


visits are required for the on-lot
components as well as the communal
collection components. Historically,
STEP unit service callouts are
overwhelmingly related to electrical/
control issues. With STEG systems,
effluent screens should be checked
annually and cleaned as needed.

DESIGN, CONSTRUCTION,
AND INSPECTION

Effective operation of a STEP/STEG


system begins with proper design and
construction, but regular inspection
of system components is critical.
Leaky tanks or pipe connections are
a potential source of groundwater
infiltration that can overload the
systems capacity. Tank residuals
must be pumped out on a requisite
basis (ideally, when solids are 25 to
33 percent of the liquid depth of the
tank) and effluent screens (in STEG
tanks) must be inspected annually and
cleaned as needed. Service providers
must be properly trained and have
knowledge and skills related to effluent
screens, electrical connections and
controls and other sewer appurtenance
technologies. They must know
and observe the associated safety
precautions. Operators must have
proper training and may be subject to
certification requirements depending
upon jurisdiction.
If pumps in STEP configurations
are installed with quick-disconnect
fittings, maintenance is facilitated and
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MARCH 2015 | 21

WATER & WASTEWATER solutions

The Pursuit
of a Green
Carbon Steel
Corrosion Inhibitor
Part 3 of 4
By Matthew LaBrosse and Donovan Erickson, U.S. Water Services, Inc.

any inhibitors considered for use in an


environmentally friendly corrosion inhibitor
program are organic in nature and may be subject
to oxidation. This paper aims to expand on previous studies
to determine acceptable green corrosion inhibitors for use
in open system cooling waters by examining the effect of
oxidizing biocide on their performance. Pilot-scale corrosion
testing is used to generate results from corrosion coupons
and corrator electrodes under chlorinated synthetic water
conditions. Several carbon steel corrosion inhibitors are
examined and their performance monitored under conditions
of continuous chlorination over five days. The results are
used to further validate and select the most appropriate and
cost effective product for use as a green corrosion inhibitor.

OXIDATION OF INHIBITORS
AND THEIR PERFORMANCE

Organic and inorganic corrosion inhibitors and combinations


thereof have been used for many years to reduce corrosion
of mild steel in industrial heat exchange equipment.
It is important that the inhibitors used for mild steel
corrosion protection be as safe to use as possible and be
environmentally friendly. In previous work, the pursuit of a
green carbon steel corrosion inhibitor led to examination
of several commercially available inhibitors under synthetic
laboratory conditions (see reference 1). This paper is a
continuation of that quest by concentrating on many of these
same inhibitors and the effect of oxidizing biocide, such as
sodium hypochlorite, on their performance.

About The Authors


Matthew LaBrosse, PhD, is an engineer in research and development at U.S. Water Services, Inc. in St. Michael, Minnesota, and
can be reached at mlabrosse@uswaterservices.com. Donovan Erickson is a certified water technologist for U.S. Water Services,
Inc. The authors wish to thank the Association of Water Technologies for allowing this series to be presented and to U.S. Water
Services for the resources necessary to conduct the research. For more information, visit www.uswaterservices.com.

22 | MARCH 2015

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It is known that oxidation of
inhibitors can affect their performance.
For instance, reversion of some
phosphonates to orthophosphate is
quite common under the right oxidation
conditions.2 Some manufacturers have
suggested that their phosphorous based
organic inhibitors be protected with
amine to prevent this phenomenon
(see reference 2). It is thought that
combined chlorine (e.g. chloramines)
is less destructive of inhibitor structures
than free chlorine. Another example of
a performance issue for inhibitors is the
oxidation of azoles and the resultant
increase in yellow metal corrosion if
too much azole is lost in the affected
system. This can lead to a serious
secondary problem of increased mild
steel corrosion caused by plating of the
copper onto the mild steel (see reference
3). Some water technology providers
have recognized this serious problem
and used various methods to combat the
loss of azole due to oxidizing biocides
(see reference 4).
Oxidizing biocides like sodium
hypochlorite are used to reduce
biological problems in cooling systems.
They also minimize loss of heat
transfer and minimize health related
issues like Legionella pneumophila.
Biological slimes can lead to underdeposit corrosion and efficiency loss
due to a combination of organic and
inorganic scale deposits (see reference
5). Legionella is a serious health
concern and has even lead to the death
of affected individuals (see reference
6). Aside from possible negative health
consequences, poor biological control
can also be a great liability to facilities
and management for unprotected
systems. Although oxidizing biocides
perform the very necessary function of
minimization of biological problems,
they are also known to reduce the
efficiency of some scale and corrosion
inhibitors as previously mentioned. One
of the main purposes of this current
research is to identify green inhibitors
that are least affected by oxidation. The
relationship between inhibitor choice,
mild steel corrosion rates, and copper
corrosion rates was also investigated in
this work.

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low ecological toxicity, favorable NPDES


status, minimal heavy metals, good
safety profile, and status as a drinking
water additive. Certain inhibitors were
identified to be more favorably green
than others, including: aspartic acid
polymer (AAP), phosphono-carboxylic
acid mixture (PCM), hydroxyphosphonic
acid (HPA), polyamino-phosphonate
(PAP), and stannous chloride. Corrosion

inhibition mechanisms of these


inhibitors are discussed in more detail
in previous work (see reference 1).
This work concentrates on testing the
organic inhibitors and their possible
reaction with an oxidizing biocide such
as sodium hypochlorite. An enhanced
phosphono-carboxylate (EPOC) has been
added to the list of organic inhibitors
investigated in this work while stannous

METHODOLOGY

As was the case in previous work, the


goal is to be as green as possible while
performing adequately for the purpose
intended. In the first paper, green criteria
were identified as high biodegradability,
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MARCH 2015 | 23

CONTROLLER

ORP RELAY

WATER & WASTEWATER solutions


ORP

pH

SUMP
HOCI

COND

CORROSION RACK

Figure 5: Corrosion testing circulation loop

chloride has been omitted from the


testing because it is inorganic.

EXPERIMENTAL PROCEDURE

The conditions of the test were identical


to those found in our previous work,
except for the automatic addition of a
bleach solution based on an ORP probe.
After twenty-four hours of a test run, the
ORP set point was increased by 100 mV.
The free and total chlorine levels were
intentionally high at 0.51.5 and 1.0

2.5, respectively, to simulate a system


that did not have good control, as can
be commonly found in field conditions.
This also provided circumstances that
were conducive to comparing inhibitors
to a control. Test runs were five days
long during which mild steel and
copper corrator data was collected.
Appearance of corrosion coupons was
also observed. Most of the tests were
run using a synthetic water that was
both corrosive and scaling, shown in

Table 6. Later tests runs were done


using a water that would be considered
low hardness to simulate a soft water
system, shown in Table 7.

TEST APPARATUS

Figure 5 shows the test apparatus,


consisting of a circulation loop with
the return water line aerated before
returning to the sump. This provided
the necessary oxygen to simulate
cooling tower water. The flow rate was
7.0 gallon (26.5 liters) per minute in
1 inch (25.4 millimeters) clear PVC
piping for ease of visual inspection.
This corresponds to a linear velocity
of 3.2 feet (0.98 meters) per second,
which is in the range of accepted flow
rates for corrosion coupon racks (see
reference 7). The temperature for each
run was maintained at 95 degrees
Fahrenheit (35 degrees Celsius); the heat
was provided by the circulation pump.
Oxidizing biocide was also added to
the sump using an ORP monitor and
relay set-point. This feature allowed for
automatic oxidant addition for the five
day test runs.

A LOOK AHEAD

In next months conclusion to this


series, we will examine the testing
results in terms of corrosion coupons
of carbon steel and corrator analysis
for both hard water and soft water. We
will also present visual representations
for corrosion rates and imbalance rates
for organic inhibitors and combined
inhibitors, as well as corrosion rates for
combined inhibitors. By the conclusion
of this series, readers should see,
after careful inspection of the test
results, that it is possible to design a
greener solution that does not sacrifice
performance or increase usage cost.
24 | MARCH 2015

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Item

Concentration

Unit (ppm)

Item

Concentration

Unit (ppm)

Ca

543

CaCO3

Ca

80

CaCO3

Mg

140

CaCO3

Mg

50

CaCO3

HCO3

328

CaCO3

HCO3

110

CaCO3

Cl

114

Cl

Cl

180

Cl

SO4

505

SO4

SO4

60

SO4

Polymaleic Acid

8.5

Active

PBTC

1.9

Active

Copolymer

Active

Copolymer

8.1

Active

Tolyltriazole

Active

Tolyltriazole

3.1

Active

Table 6: High hardness synthetic water conditions

Table 7: Low hardness synthetic water conditions

REFERENCES
1. M. LaBrosse and D. Erickson, The Pursuit of a Green Carbon Steel
Corrosion Inhibitor, The Analyst Technology Supplement, Fall (2012).

Legionnaires Disease: Risk Factors for Morbidity and Mortality,


Archives of Internal Medicine, 154, 2417-2422 (1994).

2. Association of Water Technologies Technical Reference and Training


Manual, 2nd ed., chapter 4, section 5.10.6 (2009).

7. B.P. Boffardi, Corrosion and Fouling Monitoring of Water Systems,


The Analyst Technology Supplement, Spring (2010).

3. H. Van Droffelear and J.T.N. Atkinson, Corrosion and Its Control: An


Introduction to the Subject, 2nd ed., chapter 2, page 25-26 (1995).

8. Association of Water Technologies Technical Reference and Training


Manual, 2nd ed., chapter 4, section 5.10.1 (2009).

4. K.M. Given, R.C. May, and C.C. Pierce, A New Halogen Resistant
Azole (HRA) for Copper Corrosion Inhibition, Conference on
Industrial Water, Paper IWC-98-60 (1990).

9. H. Van Droffelear and J.T.N. Atkinson, Corrosion and Its Control: An


Introduction to the Subject, 2nd ed., chapter 2, page 33-35 (1995).

5. H. Van Droffelear and J.T.N. Atkinson, Corrosion and Its Control: An


Introduction to the Subject, 2nd ed., chapter 6, page 98-100 (1995).
6. B.J. Marston, H.B. Lipman, and R.F. Breiman, Surveillance for

www.modernpumpingtoday.com

10. D.L. Hjeresen, Green Chemistry and the Global Water Crisis, Pure
and Applied Chemistry, 73, 1237-1241 (2001).
11. Rohrback Cosasco Systems, Inc., Model 9020 &9020-OEM Corrater
Transmitter User Manual, November (2004).

MARCH 2015 | 25

MAINTENANCE solutions

Electronic Water-Conditioner
Keeps Boilers Scale Free
SCALEWATCHER SAVES SAN ANTONIO HOUSING AGENCY
THE COST OF REPLACING BOILERS EVERY SIX MONTHS
By Jan de Baat Doelman,
Scalewatcher North America Inc.

an Antonio Housing Agency (SAHA) is saving thousands


of dollars a year at its Woodhill Apartments on
expensive maintenance and replacement boilers every
six to nine months following
the installation of the patented,
award-winning Scalewatcher
computerized, electronic waterconditioner from Scalewatcher
North America. Purchased
following a successful four
month trial at the apartments,
the Scalewatcher has
successfully kept all four boilers
scale free since it was installed.

MEETING AN
IMPORTANT NEED

KEEPING WATCH ON THE BOILERS

A Scalewatcher unit was installed on to the pipes in the


boiler room to treat all four boilers. However, SAHAs
Project Manager, Neville Blair
decided that the newest boiler
would be the control boiler for
the purpose of the test. After 64
days a section of copper pipe
was removed for inspection and
it was observed that there was
no scale at the bottom of the
boiler.
After 180 days the heater tank
was valved off and drained.
It was noted that there was
soft sand- like deposit on
the bottom of the tank and
the copper coils were clean.
Previously, scale would have
formed a hard crust on the
copper coils and at the bottom
of the tank. The new boiler at
this stage would be halfway
A closer look at the patented Scalewatcher computerized electronic
through its useful life.
water conditioner.

SAHA provides housing


assistance to over 70,000
children, adults and seniors
through its Public Housing,
Section 8 Housing Choice
Voucher and Mixed-Income
housing programs. The Agency
owns and manages 6254 public
housing units at seventy-one properties, employs more
than five hundred individuals, has an annual operating
budget of $172 million and real estate assets valued at
over $500 million.
The Agency chose the Woodhill apartments as the BETA
site because in spite of attempts at water treatment, it had a
consistent history of domestic hot water boiler failure due to
scaling. At the site a 100 gallon boiler typically had a life
span of six to nine months. With four boilers in the boiler
room the cost of replacing each boiler was $3,590.

THE IMPORTANCE OF PREVENTATIVE MAINTENANCE


We had no hestiation in buying the Scalewatcher, said
Neville Blair. Previously we had used a liquid water
treatment that had cost $200 per month and had been
ineffective. Since Scalewatcher has been installed we have
had to replace just one boiler, which we believe was due to
age and not scale.
Twelve months following the Scalewatcher installation,
the bottom of the heater was once again inspected and
the copper coils were found to be clean. The sand-like

About The Author


Jan de Baat Doelman is president of Scalewatcher North America Inc. The Scalewatcher is an environmentally friendly alternative to
chemical and mechanical descaling. Launched in the 1980s it has successfully treated hard water problems for industrial manufacturers
as well as water companies, oil producers, farmers, horticulturists, shipping companies, shopping centers, school, universities and
government establishments. For more information, call 610.932.6888, email sales@scalewatcher.com, or visit www.scalewatcher.com.

26 | MARCH 2015

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deposits on the bottom of the tank are
removed from time to time as part of a
Preventative Maintenance program.

FIT AND FORGET

Scalewatcher North America has a


range of environmentally friendly
units that will combat the effects of
hard water limescale without the use
of chemicals or salt. A fit and forget
system, Scalewatcher is easy to install
and requires no plumbing, maintenance
or chemicals. Using modern, integrated
circuitry the Scalewatcher emits an

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electronically applied force field,


induced by a coil wrapped around the
outside of the pipe work, which keeps
the minerals in suspension and thus
prevents limescale forming. The unit
can be attached to all types of pipework
material, regardless of size.
Scalewatcher models are based on
continuous research and over twentyfive years experience and expertise

as market leaders in electronic scale


control with countless units sold
worldwide. The patented Scalewatcher
systems start at $248.00 USD and are
capable of treating pipe sizes from
1 to 120 inches (25.4 millimeters to
3 meters). All Scalewatcher systems
come with a full performance
guarantee and are shipped throughout
North America.

Agents / Reps
Wanted
Sims Pump, a fast growing
structural composite pump,
pump parts, and mechanical seal
manufacturer is seeking ambitious,
aggressive, and self-motivated
representatives of both the
marine and industrial markets
around the world. Sims focuses on
sales to customers with corrosive
environments, such as marine,
cruise, power generation, public
utility, wastewater, oil and gas, as
well as chemical. A background in
pumps, mechanical seals, or any
rotating equipment is required.

Please fax your resume to


1-201-792-4803 or email to
Simsite1@aol.com

Custom-engineering pumps to meet your specific requirements


Since 1919

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MARCH 2015 | 27

PUMP solutions

Packaged Pump
System Improves
Quality of Life
City of
Southside,
Alabama,
selects
EBARA for
emergency
lift station
upgrade
By Regina T.
Marsden Crupe,
EBARA Fluid
Handling

he city of Southside, Alabama, has experienced


tremendous growth over the last decade. Located on the
banks of the Coosa River, Southside is a relatively small,
but progressive city and is always looking for ways to improve
the quality of life for its residents. Just as so many other
municipalities face aging infrastructure challenges, Southside
determined a need to upgrade and replace one of its main lift
stations that had become troublesome and costly for many
years.

SCOPE OF CHALLENGE

The traditional suction lift station located on Highway 77 is one


of Southsides main lift stations and has been in service since
1991. The station had experienced several problems over the
last few years including multiple failures due to the age and
strain on the system. As a result of these failures, the high costs
for repairs and the encroaching seasonal inclement weather,
the situation was quickly considered an emergency installation.
A quick turnaround was very critical in order to meet the needs

About The Author


Regina T. Marsden Crupe is the marketing communications manager for EBARA Fluid Handling, the U.S. sales and service
subsidiary of EBARA Corporation, Japan, and provides engineered pump, pump products and related services for the water,
wastewater, commercial, municipal, energy and power industries offering reliable product knowledge, application expertise
and responsive support including aftermarket replacement parts services. For more information, visit www.pumpsebara.com.

28 | MARCH 2015

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of the flows coming into the system and
the system not being out of service for a
very long time.

THE SOLUTION

CDG Engineers & Associates worked


with The Eshelman Company to select
and install an EBARA EP1 duplex
packaged pump system to replace the

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existing self-priming system that failed.
Two, 30 horsepower submersible model
DLKFU pumps each rated to deliver 150
gallons (567.81 liters) per minute at 145
feet (44.2 meters) TDH were specified
as part of the system to accommodate
the current conditions and allow for
the anticipated expansion the system
faces. The K Series design was specified

to reduce clogging from fibrous waste


(non-dispersibles) and thereby reduce
maintenance and increase efficiency of
operation.
The old station was removed and
the 20 feet (6.1 meters) deep wet
well cleaned and epoxy coated prior
to installation. The EBARA packaged
system is pre-assembled at the factory

PROJECT AT A GLANCE
Client: Southside Water Works
and Sewer Board, Southside,
Alabama
Industry: Municipal
wastewater, sewage
Problem: Emergency lift station
rehabilitation
Result: Cost effective,
expedited and simplified
installation
Products Installed: EBARA
Model EP1 Duplex Packaged
Pump System
Highlights:

Factory pre-assembled and


sole source responsibility
for complete station
provided

Two, 30 horsepower model


DLFU submersible cast
iron wastewater, sewage
pumps

Pumps rated to deliver 150


gallons (567.81 liters) per
minute at 145 feet (44.2
meters) TDH with K-series
impeller design to reduce
clogging

R7 insulated fiberglass
enclosure with large doors

Pre-cast reinforced
polymer concrete base
provide resistance to H2S
corrosion

Six-inch liquid filled


pressure gauge protected
from wastewater by
pressure isolator ring

Standard check valves

Emergency by-pass
connection

Thern portable hoist

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MARCH 2015 | 29

PUMP solutions
and shipped directly
to the site ready to be
installed.
EBARAs standard
package design includes
a corrosion resistant,
steel reinforced,
polymer concrete
base. Wet-well access
covers are pre-cast
into the base frame
providing durability and
sturdiness. All discharge
piping, valves and
controls are protected
inside an R7 insulated,
weatherproof fiberglass
enclosure. Large doors
on both sides of the
enclosure provide
easy access to system
components.
Safety grates protect
personnel from falling
into the wet well when
the access doors are
open. Penetrations for
the piping and cables
are sealed from the
wet well to prevent

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harmful gases from entering the enclosure. Dedicated pressure


gauges and sensing piping for each pump are standard on the
EBARA system. Pressure sensor rings isolate the gauges from
the pumped wastewater to eliminate clogging of pressure gauge
lines and ensure accurate, repeatable pressure readings.
Everything is at head and hand level, explained Jeff
Harrison, PE, CDG Engineers & Associates. This eases
maintenance and removes the need to send personnel into
dangerous confined spaces present in traditional below ground
valve vaults.

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MARCH 2015 | 31

PUMP solutions

The station runs on 460/3/60, and is


designed with a float switch level control
system with reduced voltage soft starters
to limit inrush current to the station.
This station was loaded with
optional features, including individual
board mounted discharge gauges, an
emergency bypass connection and a
(Thern) portable hoist; these options
making regular maintenance more
manageable and efficient.

THE RESULT

The installation concluded with a


clean-water (accommodated by the

32 | MARCH 2015

City of Southsides Fire and Rescue


Department) start-up and testing with
minimal onsite adjustments made to the
controls and floats to ensure optimal
performance.
Once the EBARA EP1 packaged
station arrived on site, it was installed
and on line at the end of the second
day. It was a very quick retrofit, which
kept downtime and bypass pumping
to a minimum and was delivered
and installed well within the city of
Southsides capital budget.
What would have taken two months
to install a new system, the city of

Southside was able to complete in two


days due to the refurbishment of the
existing wet well and the selection of
the single-source and complete EBARA
packaged pump system.
The package station concept
incorporates all the necessary equipment
in one factory built unit with a company
that has decades of experience providing
reliable sewage pumps, said Ed Moore,
vice president, The Eshelman Company.
We feel confident the EBARA packaged
system is going to be a cost effective
solution for any city looking to put in a
replacementor newlift station.

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MARCH 2015 | 33

PUMP solutions

DIGESTER

MIXING

By Soren Rasmussen, Landia, Inc.

ONTRACK

Biogas Energy brings Landias GasMix system and chopper pumps to North State Rendering

he rendering business is not known for its glamour


or its cutting edge technology, but in North
Americas first project of its kind, thats all about to
change for an industry that is positioned for growth.

SMART DECISIONS, GREEN TECHNOLOGY

Biogas Energy have built an anaerobic digestion (AD)


facility at North State Rendering in Oroville, California
that is already paying dividends, with uninterrupted
biogas generating electricity, fuelling trucks, and running
boilers. The economics seriously stack upnot to
mention the massive reduction in carbon footprint.
For a rendering plant, biogas is a natural fit, says
Brian Gannon of Biogas Energy. North State Rendering
were looking for ways to cut costs, secure new waste
supply contracts, and improve wastewater treatment,
so creating their own on-site biogas facility was a wise
move. Fuel and energy are a significant operational
cost for the business, so investing in technology that
eliminates electricity bills, slashes diesel costs and
reduces natural gas imports all makes sense. Modifying
the anaerobic digestion process to integrate with a
rendering plant took some fine tuning, including a very
positive modification to the digesters mixing system, but
now, we see how we got it right.

North State Rendering where Landia's GasMix digester system is installed.

WASTE RECEPTION AND PRE-PROCESSING

Grease trap waste and food waste from kitchens,


restaurants, and food manufacturers is expensive to
render, so by diverting this material to the digester, North
State Rendering reduces costs and frees up rendering
capacity for higher-value materials.
The waste reception equipment prepares high-solids
feedstocks for the digester, whilst a grease trap reception
system separates out contaminants such as plastic and
metals.
With this flexible reception facility configuration,
the digester can process a wide variety of materials,
from food and yard waste to high-liquid grease trap
material. Wastewater from the rendering process is

Landia's externally mounted GasMix at North State Rendering.

About The Author


Soren Rasmussen is the director of Landia, Inc. For more information about Landias range of applications, call
919.466.0603, email info@landiainc.com, or visit www.landiainc.com. For more information about Biogas Energy, visit
www.biogas-energy.com.

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also added to the mix. North


State Rendering can also add
dead stock to the digester
during warmer months
when rendering can become
problematic due to extreme
degradation of the material.

ANAEROBIC DIGESTER
TANKS

From the reception area, the


material is pumped into two
tanks (40 feet [12.2 meters]
diameter by 24 feet [7.3
Biogas digester at North State Rendering.
meters] high), where the first
acid-forming phase of the
biogas production process
needs. One of the main issues with
takes place.
These heated tanks contain bacteria
submersible digester mixing systems is
that the equipment is inside the tank,
that break down the material and
which from a maintenance point of view
prepare it for the main digester tank,
is a nightmare. The downtime caused
which stands 64 feet (19.5 meters) tall.
by having to open the digester to lift the
When the material is ready, it is pumped
mixers out for repairs and maintenance
into the main digester where biogascaused serious process interruptions and
producing bacteria get to work.
safety issues.
Brian Gannon continues: We had
We now have a Landia digester
been using submersible propeller mixers
mixing system, which is mounted
inside our main digester, but with our
externally, so maintenance is much
re-design of the tank, we switched
easier. Even during commissioning
to a new system that meets all of our

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when the AD biology was at a


delicate stage, we were able to
carry out some tweaks without
any interruption whatsoever to
the biogas production process.
With submersible mixers we
would have had to start over
again, which would have been
very expensive and used up a
ton of manpower.

POWER IN THE PUMP

In addition to its ease of


maintenance, Brian also points
to the Landia (patent-pending)
GasMix System being able to
agitate the entire digester tank
(especially one 64-feet high!), whereas
other units often cannot prevent a crust
from forming on the top level of the
tanks contents.
The anaerobic digestion facility is
designed to process a very wide range
of feedstock, he says, so its pumps
and mixers have to cope. The Landia
chopper pumps, which form part of the
GasMix system, are absolute troopers.
They just keep on working. We wouldnt
be achieving what we are now without
them.

MARCH 2015 | 35

PUMP solutions
Comprising two 30-horsepower
chopper pumps and a self-aspirating
system that reduces solids to
produce more methane in a much
shorter time period, Landias
GasMix (designed specifically for
AD/biogas) is easy to regulate and
also offers significant energy savings
because it only has to run for a

maximum of 30 percent of the installed


capacity.
Brian also explained that the
anaerobic digester is not only producing
biogas, but processing wastewater to
improve water quality. The bacteria
creating biogas digest is the material
that causes elevated COD in wastewater.
Hence, the digester also acts as a small

wastewater treatment plant, improving


the quality of wastewater and enabling
reductions in discharge fees.
We generate enough electricity to
power the entire North State Rendering
plant, adds Brian. Heat from the
generator is also used to heat the
digesters, so were able to optimize
energy efficiency.

ENERGY AND FUEL PRODUCTION

Biogas Energy estimates that North State


Rendering will reduce diesel costs by 75
percent by introducing a gas-cleaning
skid to create a pipeline-quality
biomethane that is then compressed in
a CNG fueling station.
As the biogas-to-CNG upgrade system
produces pipeline-quality natural gas,
producers can inject the gas into the
pipeline to sell to other customers.
Finally, any surplus biogas is fed to a
boiler at the rendering plant to reduce
the need to purchase natural gas. With
a diverse use for the biogas, North
State Rendering will maximize revenue
and hedge against price increases in
electricity, diesel, and natural gas.

SOURCES OF FACILITY FUNDING

For its new anaerobic digester, North


State Rendering was able to take
advantage of grants from the California
Energy Commissions Alternative and
Renewable Fuel Vehicle Technology
Program.
State and federal inducements can
also include tax incentives, sales tax
exemption, grants for renewable energy
project and truck conversion costs,
and incentivized electricity production
pricing.
Brian Gannon concludes: Renderers
have a big head-start over other
companies trying to develop new
waste-to-energy facilities. Unlike
newcomers, renderers already have the
necessary permits in place to process
waste material. They also have the
trucks to collect waste, and the energy
consumption that biogas facilities can
help fuel.
As energy and fuel prices climb and
wastewater discharge fees escalate,
waste processors can turn waste into
an asset. For Biogas Energy, our
experience at North State Rendering
and the introduction of Landias
GasMix digester mixing system means
that we can help our clients generate
renewable energy with a system that
maximizes production while facilitating
operations and maintenance.
36 | MARCH 2015

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MARCH 2015 | 37

DEWATERING solutions

a pump system
for the future
Boskalis invests in a
new, environmentally
friendly high flow
pump unit

By Henno Schothorst, BBA Pumps

oskalis Nederland is a part of Royal Boskalis


Westminster N.V. Boskalis was established in
1910 and has expanded from a local dredging
contractor to a leading global maritime services
company with over 11.000 employees. Originally,
dredging and earth moving were the core activities
of the company. They are now additionally active in
the dredging and inland infra, and offshore energy
sectors.

THE CHALLENGE

Boskalis Technical Service Nederland in Capelle


aan den IJssel manages several mobile pump units
with high and ultra high flows and clearly prefers
environmentally friendly equipment and has very
specific requirements from their pumps which
include

The pump must have a minimum capacity of


over 20,000 gallons (75,708 liters) per minute
and a pressure in excess of 3 bar;
Competitive excellent suction capacity
capabilities (NPSHr) and suitable for use as a
dewatering pump;
High fuel efficiency combined with the lowest
exhaust emissions;

About The Author


Henno Schothorst is product manager at BBA Pumps and can be reached at hschothorst@bbapumps.com. For more
information, visit www.bbapumps.us.

38 | MARCH 2015

www.modernpumpingtoday.com

The pump unit should fit into a 20 foot (6.1 meter)


container for easy transport;
The maximum weight should be no more than 26455
pounds (12,000 kilograms).

Exhaust gas is treated using AdBlue.


It is fully equipped with the newly developed, extremely silent
and light weight canopy and its dimensions ensure that it fits
into a 20 foot (6.1 meter) container without any problems. The
total weight of the pump unit is just 23,800 pounds (10,795.5
kilograms)!

Boskalis has a number of widely divergent projects around


the globe. This makes multi-functionality and ease of logistic
handling important factors in the purchase of new equipment.
THE RESULT
In addition, durability and corporate social responsibility are
The new BA-C500S11 has now been deployed in a first project
central to the companys values.
in Muiden. The A1 highway is being widened and partially
As an example Bas van den Brand, a technical inspector with
rerouted. The Boskalis Nederland employees on location are
Boskalis Nederland, mentions the
very impressed with the pumping
topic of weight: For a pump system
performance, especially with regards to
of this size, 26,000 pounds (11,793.4
the low noise emissions.
kilograms) is usually the maximum
Upon commissioning positive
permissible due to limitations in
feedback abounded:
handling on site. Also, the soil layers
This pump unit only has to work
1129 Cainhoy Road, Unit C
Wando, SC 29492
can be substantially compacted and
half throttle to do the jobat 1250
843.849.3676
cannot always carry the weight.
revolutions per minute it provides as
info@bbapumps.com
much capacity as the old one at 2000
www.bbapumps.us
revolutions per minute.
THE SOLUTION
Incredible, theres not even any
Early in October 2014, Boskalis
smoke from the exhaust at start-up.
Nederland officially commissioned
Its amazingly quiet.
the delivery of a BBA high flow pump unit of the type BAThe former pump unit regularly clogged up due to solid
C500S11 D711 with a very attractive efficiency of 86 percent.
materials as a result of the vertical drainage hose we use here
The auto prime pump provides a capacity of over 24,200 gallons
fortunately the BA-C500S11 can just pump it.
(91,607 liters) per minute (max. head 122 feet (37.19 meters))
BBA Pumps has decided to include this pump unit in its
and is driven by a modern Stage IV Volvo Penta diesel engine;
the TAD1374VE.This provides a power of 510 horsepower
standard product range. This technology cant be ignored any
and delivers the lowest specific fuel consumption in its class.
longer.

www.modernpumpingtoday.com

MARCH 2015 | 39

MOTOR solutions

The ed for
Ne

P
S

D
EE

One-minute V-belt changes with energysaving Tenso-set motor base

By Don Sullivan, Regal Power Transmission Solutions

t the most recent AHR Expo, Browning


introduced an expanded range of sizes at
for its self-tensioning Tenso-set motor
base in a hands-on, informative, and fun
way. Attending technicians were provided
training and one speedy volunteer
was awarded an iPad Air to the
winner of a belt-change speed
contest at the booth. Browning
demonstrated side-by-side
identical belt drives with
an industry-standard
base and another
with the Tensoset quickrelease base,
and also
ran beltchange speed
contests on
this setup to
give technicians
hands-on
experience and
a chance to see
what a life-changer
a one-minute belt change can
be. The expanded product range for the
energy-saving Tenso-set base includes up to NEMA
447 and equivalent IEC motor frame sizes. At AHR, the
Tenso-set base with its quick-release (QR) optionavailable
for NEMA frame sizes up to 286was matched against a
standard base of equal size in a belt-change run-off called
the Tenso-set Challenge. Product enhancements for the
quick-release models will also be highlighted at the show.

IMPROVING
SPEED AND SAFETY

Enhancements on the Tenso-set base


include features that improve the speed and safety of belt

About The Author


Don Sullivan is the Browning director of marketing for Regal Beloit America / Power Transmission Solutions. Regal Beloit
America provides automation and power generation technologies and services to a wide range of industries. For more
information visit www.powertransmissionsolutions.com.

40 | MARCH 2015

www.modernpumpingtoday.com

changes. Browning added a jam nut on the adjusting rod


to hold tension on the spring system before releasing belt
tension with the adjusting nut on the rod. The technician
simply spins the jam nut forward against the carriage, gives
it a turn or two to compress the spring further, and this
relieves tension on the adjusting nut so it's easier to loosen.
With the quick-release Tenso-set model, technicians are
able to change belts on a 20-horsepower motor in about a
minute with this improved designaround one-sixth the
normal time.

BENEFITS AT A GLANCE
Significantly reduces time required to change
v-belts

Promotes greater efficiency by constantly


maintaining v-belt tension

Tube rail and one-piece carriage design


promotes and maintains superior drive
alignment

Improved safety. No need to cut off belts or roll


them onto sheaves

DROP-IN REPLACEMENT

The Tenso-set base is a drop-in replacement for most


standard motor bases, and utilizes the same jackscrew
design to adjust and hold tension on the belt. However,
the Tenso-set base includes a coil spring inside the screw
housing that pushes against the carriage to maintain tension
as the belt naturally breaks-in and seats itself further into the
sheave groove due to loss of mass.
The Tenso-set design helps eliminate the need for frequent
belt re-tensioning, including during the first 24 hours of
run time, which saves the maintenance staff at least one
service call. More important for the building owner, it
better maintains the drive's energy efficiency by preventing
the normal tension loss that occurs over time. Some of
the largest commercial buildings in the United States are
already testing this base to determine return on investment.

QR: QUICK RELEASE

The QR option for the base allows release of all belt tension

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after just a few turns of the tensioning screw. The QR base


has a patent-pending sliding gate that covers a cutout in the
motor frame. This allows the head of the tensioning screw to
pass through the base, so the carriage easily slides forward
to slacken the belts. After belt installation, the carriage can
be moved back and the sliding gate closed to retain the
head of the jackscrew for tensioning.
Browning also offers free mobile apps for efficiency
calculation, belt selection, troubleshooting and GPS
locating of stocking distributors. These can be accessed
through iTunes and Android websites.

MARCH 2015 | 41

POWER GENERATION solutions

Fast, Efficient, and


Environmentally
Friendly
By Cinthia Hertel,
Mid-Kansas Electric Company

Rubart Station,
Caterpillars largest
natural gas-powered facility,
is a model of efficiency

n 1957, six western Kansas rural electric distribution


cooperatives created Sunflower Electric Power Corporation
to purchase and develop a reliable, long-term power
supply. In 2007, members of Sunflower formed Mid-Kansas
Electric Company, an affiliated generation and transmission
company, to support a business acquisition. Today, MidKansas, which is governed by a democratically elected board
of directors, provides wholesale services to its six members
serving electric consumers across thirty-three counties in
central and western Kansas.

POWER NEED

Mid-Kansas has a power generation portfolio made up of


coal, natural gas, wind resources and transmission line assets
that include more than 1000 miles (1609 kilometers) of
high-voltage lines ranging from 115 to 230 kilovolts. This
diversified portfolio allows Mid-Kansas to provide reliable
energy and transmission service at the lowest possible cost to
its members.
In 2012, the Mid-Kansas team began formal planning for
ways to meet the growing demand for electricity and provide

voltage support in the area. Also at issue were southwest


Kansas highly intermittent wind resources, which result
in a constantly shifting generation production due to wind
fluctuations at any given time. These factors gave rise to
the need for a highly flexible power generation system to
accommodate such rapid system changes.

SOLUTION

The Mid-Kansas team spent months visiting reciprocating


engine-based generating facilities to learn about the
technology and configurations of different facilities.
A technology selection study completed by Burns and
McDonnell, a full-service engineering, architecture and
construction firm, identified that reciprocating internal
combustion engines (RICE) could provide flexible and costeffective generation.
This benefits Mid-Kansas members in the Integrated Market,
which includes a day-ahead look at potential load generation
to determine the most reliable and economical combination
of generation resources, by serving the load and dispatch
generation to meet real-time load across a nine-state footprint.

About The Author


Cinthia Hertel is a communications manager with Mid-Kansas Electric Company. For more information about Caterpillar
Energy Solutions, visit www.catpowerplants.com.

42 | MARCH 2015

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After Caterpillars new 20-cylinder


RICE units became the technology of
choice, Mid-Kansas partnered with
Caterpillar and Burns and McDonnell
to construct a new generation facility,
Rubart Stationnamed after Perry
Rubart, long-time Pioneer Electric
Cooperative trustee. Construction
began in February 2013, and the
facility was completed nineteen months
later.
Located just 13 miles (20.9
kilometers) east of Ulysses, Kansas,
Rubart Station is powered by twelve
Cat G20CM34 natural gas RICE units
and has a nominal 110 megawatt
output capability. The efficiency and
fast-start feature of the G20CM34 allow
a quick response to the Integrated
Markets conditions, often affected
by the massive wind penetration in
southwest Kansas.
Its easy to see the benefits of
Caterpillars RICE technology when
we analyze the fast start time, quick
response to changing load demands
and high-efficiency performance, said
Steve Ricard, executive manager of
generation at Mid-Kansas. If needed,
we could run at full loadthats 110

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Were blessed with an abundance of


wind. However, just because a wind
turbine is spinning doesnt necessarily
mean full power is being generated. The
reality is that varied production, which
naturally occurs with wind resources,
requires other controllable generating resources to balance
the input with the output for a stable power supply

~ Kyle Nelson
Senior Vice President and Chief Operating Officer at Mid-Kansas

megawatts of power in less than nine


minutes. Thats pretty impressive.
The availability of resources in the
area and environmental impact were
also critical to Mid-Kansas choice
of technology. For example, the

proximity of Rubart Station to natural


gas pipelines and low fuel costs make
the G20CM34 an economical and
clean-burning choice for the facility.
A concern for water conservation in
an area of Kansas often plagued by

MARCH 2015 | 43

POWER GENERATION solutions

Rubart Station is powered by twelve Cat G20CM34 natural gas RICE units and has a nominal 110 megawatt output capability.

Rubart Station has become the most efficient installation in the Mid-Kansas portfolio and Caterpillars largest natural gas-powered facility in the world.

drought was another consideration.


Rubart Station utilizes a closed-loop
cooling system, which reduces water
use by recycling cooling water rather
than using an open-loop, evaporative
cooling process.
44 | MARCH 2015

Moreover, Rubart Station was


permitted under the U.S. Environmental
Protection Agencys Prevention of
Significant Deterioration (PSD) permit
program, which is designed to prevent
significant environmental impact

from large sources of air pollution.


Rubart Stations major source PSD
permit allows for unlimited hours of
operation, which provides tremendous
operational capability to this highly
flexible generating asset.
www.modernpumpingtoday.com

Reciprocating engine facilities have


a unique capability for maintaining
a very flat efficiency curve across
a wide load range, Nelson said.
Rubart Station adds high efficiency,
low emissions and virtually no
water consumption to our portfolio,
which cannot be achieved with any
other Mid-Kansas asset. The facility
can produce 10 megawatts, 110
megawatts, or anything in between
without losing efficiency, and thats an
enormous advantage for us.
In addition to cutting-edge
Caterpillar technology, Rubart Station
includes forward-looking building
design. No detail was too small,
as stairwell placement, cable tray
layout, module spacing, convenience
of access points, forklift mobility
and overhead hoist width were all
thoroughly considered. Even the
smallest details helped build a strong
foundation for Rubart Station, which
supports the Mid-Kansas generation
portfolio in multiple ways.
We had a very robust due diligence
process when planning and designing
Rubart Station, said Paul Reynolds,
senior manager of generation
engineering and environment at
Mid-Kansas. While we applied some
features that worked for others, we also
tried to learn from their experience.
Rubart Station was built from the
ground up, so we had the opportunity
to control many facets of the design,
and we listened to and learned from
the experiences of others.
We like to think of Rubart Station
as the Swiss Army knife of our power
generation portfolio because its
capabilities are so diverse and the
project execution was excellent, said
Nelson.

team works very, very hard to provide


everything we need.
While Rubart Station has become the
most efficient installation in the MidKansas portfolio, it is also Caterpillars
largest natural gas-powered facility in
the world to date.
Caterpillars mission and goals
line up with what were trying to

achieve here through reciprocating


engine technology, said Derek
Seacat, project manager at Rubart
Station. Rubart Station is fast,
efficient and environmentally
friendly, which couldnt have
been achieved without Caterpillar.
Theyve gone above and beyond
for us.

RESULTS

Rubart Station is also permitted


for an additional 110 megawatts
of Caterpillar engines. Burns &
McDonnell developed a site plan
incorporating enough space to install
twelve more engines, if the need
arises. Caterpillar technicians and
engineers continue to serve Rubart
Station with parts and maintenance
support.
Caterpillar was very dedicated to
the success of this project, and any
challenges we had along the way were
met head on, said Tom Dinkel, project
supervisor at Rubart Station. The Cat
products are very reliable, and the
www.modernpumpingtoday.com

MARCH 2015 | 45

PROCESSING solutions

Offshore
Opportunities
Continue
for
Pumping Professionals
By Monica Gomez

Trained welders find work on offshore oilrigs


across U.S. waters and around the globe.

rained pipefitters and welders come across


opportunities to work on offshore oilrigs across U.S.
waters and around the globe. They are responsible
for ensuring that machinery and pumps continue to
operate effectively. In addition to traveling to the offshore
work-site, these professionals receive a high level of
compensation, a flexible work schedule, and plenty of
recreational activities to stay active while at sea.

water, have a tendency to weaken and must be consistently


repaired throughout the course of operation. An offshore
pumping professional or welder will be responsible for
ensuring the pipes maintain their purpose while watching
over the stability of the structure of the rig itself. If you
would like to weld beneath the waves, you will need a
diving certification in addition to your welding training.

WHAT IS OFFSHORE PUMPING AND WELDING?

According to the Offshore Welding Jobs website, entrylevel welders often start out making between $66,000
and $80,000 per year. The decline in oil prices in
2014 have led to many oilrigs freezing their hiring for
the first quarter of 2015. However, oil refineries have

Every facet of an offshore oilrig revolves around a


synchronous movement to pull oil from beneath the ocean
floor. This task comes with a caveat: salt water is corrosive
to metal. As a result, the pipes, including those above

WHAT ARE THE CAREER PROSPECTS?

About The Author


Monica Gomez writes on professional issues facing the upstream pumping and oil processing markets. She can be reached at
gomezmonica53@gmail.com.

46 | MARCH 2015

www.modernpumpingtoday.com

transitioned to producing summerblends of oil products, and offshore


oilrigs will need to produce larger
quantities of crude oil to meet this
demand. In addition, Tulsa Welding
School reports that the industry is
desperately seeking skilled pipeline
workers, as a large portion of the
current workforce is set to retire
in the upcoming years. Current
offshore programs will be difficult
to complete without the adequate
personnel. This demand for young
talent will likely not be met soon.

WHAT IS THE WORK


SCHEDULE LIKE?

Since offshore welders travel to


and from the rig to land by way of
helicopter or boat, they typically
work on a rotation schedule. Many
offshore pumping professionals work
two to four weeks at the rig and then
have a two- to four-week time period
off. However, each oil company may
have its own schedule, and you may
be able to have longer lengths at sea
if you prefer. Depending on the need
to bring new oilrigs on line, you may
be sent to multiple rigs for several
days, rather than weeks, before
having a few days off.

WHAT ARE THE


CAREER PROSPECTS?
www.offshoreunderwaterweldingjobs.com
Hosts online hiring posts as well as
common employment requirements
for many companies.
Includes Featured Employers
section and a free newsletter.

TULSA WELDING
SCHOOL
www.weldingschool.com
Founded in 1949 by two welders,
Tulsa Welding School instructs its students
in skills for welding, pipefitting, and electromechanical careers. With three campuses in
Tulsa, Oklahoma; Jacksonville, Florida; and
Houston, Texas, programs are largely hands-on
and include classroom and lab instruction.

WHAT CAN YOU DO


IN YOUR SPARE TIME AT SEA?

When you think about working on


an oilrig, far from the entertainment
and variety you would find on land,
you probably associate solitude
and boredom with the job. Yet, in
reality, you will have many different
recreational opportunities. Modern
oilrigs often have advanced living
quarters, outdoor sporting courts,
movie rooms, and Internet access,
keeping you active and entertained
during your off-hours. Moreover,
with Internet access you will be able
to stay in contact with your family
and friends while at sea.
As the demand for energy
continues to grow, more trained
pumping professionals will be
needed to maintain and operate
offshore drilling sites throughout
2015 and beyond. Because of its
lucrative pay, flexible schedule, short
training required, and recreational
opportunities, a career on an
offshore drilling rig is one of the
most promising career opportunities
for skilled professional pumping
specialists in 2015.
www.modernpumpingtoday.com

MARCH 2015 | 47

VALVES & CONTROLS solutions

Say Good-Bye to
Inaccurate Chlorine Readings
NEW ANALYZER MEASURES NEAR ZERO LEVELS
OF CHLORINE FOR REPEATABLE ACCURACY
By Joe Bradley, Electro-Chemical Devices

unicipal water system and


industrial process engineers
in search of an analyzer that
accurately measures near zero levels of
chlorine will want to learn more about
the plug-n-play DC80 De-Chlorination
Analyzer from Electro-Chemical
Devices (ECD), which utilizes a zeroshift method to ensure stable and
reliable chlorine measurement.

GOOD-BYE TO INACCURATE
AND INCONSISTENT READINGS

Conventional amperometric chlorine


sensors are unstable when measuring
near zero amounts of chlorine,
which can lead to inaccurate and
inconsistent readings. The DC80
De-Chlorination Analyzer utilizes a
zero-shift methodology to provide
accurate measurement and to protect
total chlorine sensors from damage,
which naturally occurs when the water
samples measured contains near zero
or zero levels of chlorine.
For example in wastewater treatment
when monitoring for chlorine just
before outfall, there can be no chlorine
present and yet measurement is still
necessary. If there is no chlorine
present then the electrode becomes

DC80

FEATURES AND BENEFITS

Total residual
measurement

Zero shift strategy

Optimize sulfite addition

Panel mounted

Automatic pH
compensation

Automatic flow control

unstable and finally unresponsive.


Therefore the very process of
measuring de-chlorination becomes
problematic. If all of the chlorine is
removed then the sensor will provide
an inaccurate reading after a few hours
and fail after a few days still reporting
zero chlorine.

THE ZERO SHIFT SOLUTION

The DC80 De-Chlorination Analyzer


solves this problem: It is a total
chlorine analyzer that uses the zero

shift strategy to monitor near zero


amounts of total chlorine. Chlorine
is metered into the sample shifting
the zero from a near zero chlorine
concentration to a measurable value.
The analyzers offset feature allows the
metered value to be subtracted from
the measurement.
The DC-80 De-Chlorination
Analyzer monitors chlorine in drinking
water, wastewater, cooling water and
other de-chlorination applications
from 0.05 to 20 parts per million.
Its mounted system includes built-in
flow control, which eliminates the
need for complicated plug-and-play
design installs quickly right out of
the box. The DC80s advanced panel
pressure regulators and rotometers.
Built-in automatic pH compensation
for samples between 4 and 12 pH
also eliminates the need for expensive
reagents to reduce maintenance and
life-cycle costs.

STABLE AND RELIABLE


READINGS

The analyzers total chlorine sensor is


a three electrode amperometric sensor
with a gold cathode, silver halide
anode, and 304 stainless steel counter

About The Author


Joe Bradley is the director of sales and service for Electro-Chemical Devices (ECD), a manufacturer of liquid analytical
process instrumentation. For more information, call 800.729.1333, email sales@ecdi.com, or visit www.ecdi.com.

48 | MARCH 2015

www.modernpumpingtoday.com

electrode. The counter electrode


provides a stable base potential
that minimizes drift for superior
accuracy. The total chlorine sensor
has a micro-porous membrane that
allows ions to diffuse in and out of
the sensor.
The analyzers pH sensor provides
accurate compensation for samples
between 4 and 12 pH, which
eliminates the need for a sample
conditioning system. The total
chlorine sensor graphically displays
both the total chlorine and pH levels
for easy trend analysis.

MULTIPLE POWER OPTIONS

The DC80 Analyzer is available


with either 110-240 VAC or 24 VDC
power. The standard configuration
features dual measurements, two
4-20 mA outputs and three alarm
relays. The user friendly DC80 also
is available with an auto clean
option that includes a solenoid
actuated spray cleaner using either
30 psi process water or air. An
easily adjusted timer controls the
period and duration of the cleaning
cycle.

www.modernpumpingtoday.com

DC80 De-Chlorination Analyzer is ideal for de-chlorination applications including


municipal water systems and industrial cooling water.

MARCH 2015 | 49

SEALING solutions

Strategic Mechanical
Seal Partnerships
Building owner-manufacturer
relationships that benefit all parties

Part 2 of 2

By Heinz P. Bloch, Process Machinery Consulting

OBLIGATIONS AND
RESPONSIBILITIES OF
THE PARTIES

It was not the intention of this article


to suggest or prescribe iron-clad
stipulations, obligations, or the exact
wording chosen here. Suffice it to say
that all mature relationships are anchored
in communication, cooperation, and
consideration. While specifics can
be fine-tuned, these three Cs are
principles to be upheld. That said, a
cooperative owner must communicate
the following to the supplier:

n last months installment, we outlined


a few of the unforeseen consequences
that stem from the decision to singlesource reliability-critical components
and explained why global single-source
procurement strategies for reliabilitycritical components rarely (if ever)
meet a buyers overall objectives and

expectations. Below, well lay out


our suggestions for the roadmap to
optimized seal selection, which will
include common-sense obligations and
responsibilities for equitable ownermanufacturer partnerships as well
guidelines for oversight, compensation,
and other terms.

Accurate data on maintenance


history and parts consumption of
the equipment population covered
by the agreement. To the extent
it is determined that insufficient
history does not allow suppliers
to accurately estimate their cost
of meeting obligations under the
terms set forth in an agreement,
the supplier should be allowed an
adjustment of the fees to be paid
to them, or delete the equipment
from the population covered by
the agreement.
Timely implementation of
recommended and mutually
agreed-to upgrades or
improvements necessary to achieve

About The Author


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

50 | MARCH 2015

www.modernpumpingtoday.com

the goals and/or objectives of the


agreement. If the improvements
are not made in a timely and
agreed-upon manner, the same
remedies should be available to
the supplier as stated above.
Suitable access to plant and
working space is needed.
Access for training must be
granted, at least annually, during
normal working hours and at no
cost to the supplier. The training
should be extended to such
operations and maintenance
personnel as have a direct
impact on the reliability and
performance of the equipment
covered by the agreement.
Adequately decontaminated
equipment, or the knowledge and
facilities allowing the supplier to
adequately decontaminate any
equipment or device that is to be
handled by supplier.
Material safety data sheets and
related documentation.
Payment, net thirty days and
with surcharges of 1.5 percent
per month of unpaid balance
thereafter.

www.modernpumpingtoday.com

COMMUNICATION,
COOPERATION
CONSIDERATION
All mature relationships
are anchored in
communication,
cooperation, and
consideration.
While specifics can be
fine-tuned, these
three Cs
are principles to be upheld.

The supplier should provide the


products and services covered by
this agreement, barring labor strife,
catastrophes, shutdowns, etc.,
in which case equitable pro-rata
separation of responsibilities would
have to be made.

SUCCESS OVERSIGHT
COMMITTEE AND ARBITRATOR

Each party should appoint at least


two (but no more than three)
individuals to a committee charged
with overseeing the timely and
successful implementation of
the agreement at each plant site.
This committee should convene
periodically, but no less frequent than
every sixty days.
In plants with two or more sites, an
executive committee should monitor
the overall progress. The committee
should have at least one member from
each side with sufficient authority to
resolve disputes and direct corrective
steps to resolve deficiencies in their
companys performance under the
terms of this agreement.
Disputes that cannot be resolved
by the committee(s) should be

MARCH 2015 | 51

SEALING solutions

Figure 1: A highly effective tapered, bi-directional, pumping ring (Innovative Vendor).

Figure 2: Cog-style pumping rings associated with relatively inefficient flowrate and heat removal capability
(Vendor B).

submitted to an independent thirdparty arbitrator who will be designated


by mutual agreement at the inception
of this agreement and whose fees
should be paid equally by both
supplier and owner.

COMPENSATION, TERMS AND


TERMINATION

The base fee should be set by mutual


agreement based on prior yearly seal
consumption (equipment MTBR), as
well as historic expenditures for such
related outlays as seal failure induced
52 | MARCH 2015

collateral damage, production losses,


and so on.
In addition, the supplier should
earn a mutually agreed-to success
fee equivalent to one third of the
overall savings generated by the
enhancements and to the extent that
these exceed the predetermined goals
of the program. Savings are defined as
direct and measurable savings in labor,
parts, energy, incremental production,
and so on.
A typical agreement should
cover a five-year period, and early

termination of the contract without


cause will cause monetary damage
to both parties. Therefore, the party
terminating without cause should
agree to pay the other party damages
equivalent to twelve months base fee
and an annualized success or, as the
case may be, non-realized success
fee based on the results achieved
(or, as the case may be, forfeited)
because of early termination.
Of course, the article
merely represents a basic
proposal for an equitable
agreement that serves
both parties. While it may
not be considered
complete, it
should form the
cornerstone of
your partnership
agreement with
a seal supplier. A
number of action steps
will be involved in carrying
the agreement forward:
1. Identify Mechanical Seal
Manufacturers A, B, C, and D.
2. Provide e-mail with invitation to
reply by a deadline date (typically
one week).
3. Request experience data
disclosing seal type and average
life attained.
4. Request feedback on applicability
of gas lubricated seals.
5. Provide the four manufacturers
with tabulation of data needed for
comparison and/or evaluation:

Materials of construction
stationary faces versus rotating
faces

Springs or bellows

Gaskets or O-rings

Balance ratios inboard set


versus outboard face set
6. Request manufacturer's comment
on available seal cavity
dimension.
7. Request feedback on seal cavity
modification options.
8. Request data from CPRS
(highly experienced pump repair
shops with full competence in
pump upgrading).
9. Compare against product flush
lost into pumpage (contractor/
consultant calculation) to
determine incremental savings.
10. API Flush Plan Number.
11. Heat removal rate of cooler
(if a cooler is used).
www.modernpumpingtoday.com

THE ROADMAP TO OPTIMIZED


SEAL SELECTION

In the final analysis, we believe that


structuring mutually beneficial alliance
partnerships is possible. Mechanical
seals for process pumps rank highest
on the list, but other component or
services alliances are also feasible.
The issue of single-sourcing deserves
attention but should not be applied
to all conceivable components or
subassemblies. A manufacturer of
process pumps may well elect to
provideand thus single-source
pump shaft, casing, bearing housing,
base plate, and so on. In like manner
the mechanical seal manufacturer may
decide to be the sole provider of all the
parts which he then assembles into a
mechanical seal cartridge.
At issue for reliability-focused
users are technology updates and
the grooming or nurturing of future
generations of professionals. The needs
of these long-range activities will
not be met by removing from other
competent providers the incentive
to participate in presenting best
technology. Including one or two
presumed second tier (size-wise) seal
manufacturers in your plans will be
the best possible assurance for a user
company to become familiar with
innovation and quality of service. These
are rarely available from the largest
size/largest volume manufacturersjust
look at the automobile industry.
Give serious consideration to
inviting Vendors B through D if the
opportunity presents itself. Ask them
to propose all mechanical seals for a
certain add-on project or process unit.
Make your plant an 80 / 20 percent
plant and reap benefits far in excess
of a mere percentage reduction in the
cost of mechanical seals originating
from a single source. The value of
using best available technology and
long-term effective training by different
innovative parties must be factored-in
as we try to list all the benefits of an
engineering approach.
And heres an update on training
via lunch-and-learn meetings: That
type of training is very much on the
decline. Until relatively recently,
component manufacturers allocated
some of their marketing money for
lunch-and-learn sessions at select EPC
and user locations. The frequency
of such in-office or in-plant sessions
has notably lessened wherever global
supply agreements are firmly in place.
www.modernpumpingtoday.com

Money spent on lunch-and-learn


sessions for the non-empowered and
for employees intent only on grabbing
a free lunch is considered money
wasted. The situation will change only
if total received value is shifted toward
the positive. A shift in value will be
perceived when technology updates
are again provided through responsible
teaching and mentoring by innovators.

Look back to the first installment


of this series. If mechanical seal
consumers are unaware with where,
when and why the assembly in figure
1 exceeds the value of the assembly in
figure 2, Vendor C would be pleased
to explain. Without having the answers,
an owner-users exposure to potential
cost and risk will be much greater than
it needs to be.

MARCH 2015 | 53

MODERN PUMPING products


BALDOR
ELECTRIC COMPANY

NXR High Voltage Rib-Cooled Motor

Featured Product Release

Baldor Electric Company offers ABBs expanded line of high


voltage rib-cooled motor platform, type NXR, with higher
power ranges and increased ingress protection. With higher
power ranges and optional ingress protection up to IP66,
these motors fit more industries and applications, providing
more reliability and easier maintenance. The new NXR high
voltage rib-cooled motor platform is based on the wellestablished and successful HXR range.
The NXR motor platform is now available in frame sizes 355
450 and in the power range of 100 1250 kW. The entire
power range is enhanced with optional increased protection
ratings up to IP66. Higher protection is especially important
for applications where dust is present, such as in the mining
and cement industries. IP66 means that the enclosure is
completely dust tight and will withstand powerful water jets.

For more information, contact Brad Chrudimsky, marketing


communications electrical, at brad.chrudimsky@baldor.abb.com
or 479.788.8532, or visit www.baldor.com.

FLUID COMPONENTS
INTERNATIONAL

FS10A Analyzer Flow Switch/Monitor


The advanced Model FS10A Analyzer Flow Switch/Monitor represents the bestin-class solution for continuously verifying flows within liquid or gas process
analyzer sampling systems. It is a small, lightweight instrument featuring superior
low flow sensitivity, a relay alarm trip point, an analog output and an RS232
interface. The FS10As advanced electronics and thermal dispersion flow sensing
technology provide an accurate, repeatable overall solution for sampling system
flow assurance. The FS10A Analyzer Flow Switch/Monitor ensures continuous
reliability and requires virtually no maintenance, featuring a precision flow
sensor element with no moving parts to foul, clog or maintain. Unlike alternative
technologies, such as magnetic floats, capillary bypass or rotameters, the
FS10A has no cavities, orifices or dead-legs that can trap fluids and lead to
contaminated samples, which preserves sample integrity and provides faster system sampling times. The instruments wetted parts are
corrosion-resistant 316L stainless steel with Hastelloy-C22 sensor tips. For more information, visit www.fluidcomponents.com.

COMAU

Racer 999
Passion and beauty come together to deliver efficiency and technological
excellence. In addition to the base of the robot, which has been designed
to assure maximum stability, Racer 999 can count on E-motion software
to optimize movements and increase their fluidity in order to reduce cycle
times by up to 25 percent compared to the previous-generation robot. The
reduced dimensions of the robot and the controller also provide lower energy
consumption thanks to the installed energy reduction system in accordance
with the eComau Energy Management System principles. For more
information, visit www.comau.com.

54 | MARCH 2015

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BJM PUMPS

XP-KZN Series, Heavy Duty Submersible Slurry Pumps


The new XP-KZN heavy duty submersible pumps are designed for tough conditions where
explosion-proof, FM, C/US approved (Class I, Division 1, Group C & D) are needed. Features a top
discharge, slim-line design with agitator to suspend heavy slurries coal, ash, sand or gravel. The
impeller, wear plate and agitator are made of abrasive resistant 28 percent chrome iron (600 Brinell,
57 Rockwell C). The replaceable wear plates hardened surface on the suction side prevents erosion,
ensuring optimum performance. Protected by Class H motor insulation and built in amperage ( FLA )
and temperature overload protection. Features double silicon carbide mechanical seals in a separate
oil filled seal chamber and a heavy duty lip seal. Pumps a sump or pit down to within inches of the
bottom. For more information, visit www.bjmpumps.com or call 860.399.5937.

NEPTUNE CHEMICAL PUMP CO.

Series 500 Pump with Base and Chemigation System


Neptune Chemical Pump Co., part of PSG and a leading manufacturer of chemical
metering pumps, announces that its Series 500 hydraulic diaphragm metering pumps
improve the accuracy and reliability of drip and center-pivot irrigation systems by applying
fertilizers and chemicals in the most precise, timely and cost-effective manner. Neptune
Fertigation and Chemigation systems have been designed for the application of fertilizers,
herbicides, fungicides, insecticides and other strong chemicals. The chemical tanks have a
sloped bottom for complete drainage and ease of cleaning. All tanks larger than 55 gallons
are fitted into double-wall containment and with double wall injection lines to protect the
environment. A cover shields the pump, piping and electrical controls from the elements
and excludes rain and debris, which allows 100 percent reclaim of uncontaminated
chemical in the event of a spill or broken line. For more information, contact the Neptune
Agricultural Service Center at 970.848.2550 or neptunepump@plains.net.

BLACKMER

Ebsray AutoGas Products


Blackmer is offering the Ebsray
RC20 and RC25 Regenerative
Turbine Pump models for use in
Autogas-handling applications
that require long pump life,
quiet operation and the ability
to handle high differential
pressures. In side-by-side
tests with competitive
models, the Ebsray pumps
were proven to be 30 percent
more efficient in terms of
energy use. To complement
these pumps for Autogashandling operations,
Blackmer is also offering
the Ebsray Model RV18
Bypass Valve, which
enables regenerative
turbine pumps to
offer full pump flow
while maintaining
controlled, preset
maximum pressures. The
RV18 bypass valves are
constructed of ASTM A395
ductile iron with steel springs.
They have been hydrostatically tested to 1000 psi
(70 bar) and are UL-listed for LPG/Autogas service.
For more information, visit www.blackmer.com.

www.modernpumpingtoday.com

KOCH MEMBRANE SYSTEMS


Puron MP Hollow Fiber
Ultrafiltration Products

Koch Membrane Systems, Inc. (KMS), a world-class developer and


manufacturer of innovative membranes and membrane filtration
systems, announced today its Puron MP hollow fiber product line.
This Puron MP ultrafiltration cartridge is designed for high-solids
water and wastewater applications, including surface water treatment,
reverse osmosis (RO) pretreatment, and tertiary wastewater treatment.
Puron MP simplifies operation, eliminates clarifier pretreatment in
many applications, minimizes downtime, and reduces chemical usage
to provide a lower total cost of ownership. The Puron MP ultrafiltration
system features a unique single-potting cartridge design that allows air
scouring to penetrate the fiber bundle more completely and release
accumulated solids to the bottom where they are easily drained
away. The cartridge uses the same virtually unbreakable reinforced
fiber made popular by other products in the companys proven Puron
submerged hollow fiber product line. For more information, visit
www.kochmembrane.com.

MARCH 2015 | 55

PUMPING trends

G o i n g

the

D i s t a n c e

DIGI INTERNATIONALS AARON MCNALLY ON


THE NEW REACH FOR INDUSTRIAL WIRELESS
COMMUNICATION

s industrial communication has shifted from wired


Ethernet to wireless RF and broadband connections,
Digi International has led the way in addressing the
technical hurdles many companies face in this new arena.
Aaron McNally, a market development manager at Digi
International, spoke with Modern Pumping Today about
the challenges, changes, and advantages of wireless
industrial communication systems.
Modern Pumping Today: At many remote
sites, users are looking to send huge amounts
of field data over long distances. How do
wireless data transmitters like Digis XLR
PROTM help fill that need?
Aaron McNally: First, any time you have a wired line
especially out in the middle of, for example, an oil field in
remote parts of Texas or North Dakotathere is a risk of an
electrical overload travelling. Often these remote sites do not
have many trees in the vicinity, and oil field equipment will be
frequently hit by lightning strikes. If the site is using copper, those
lines will carry that electrical charge between products, and
mobile systems and sensors that are connected could all blow
out. By going wireless, users can eliminate that issue. Theres
nothing for lightning to travel through.
Also, most of these systems are not transmitting gigabytes
of data per second. Industrial data is made of small bits and
pieces of data coming in from a number of devices, collecting
at a central point, and then being transmitted back to a remote
location. In total, these systems collect and use a tremendous
amount of data but these devices themselves are not producing
a lot.
MPT: How does the Digi XLR PRO compare with typical radios,
such as those using frequency-hopping spread spectrum (FHSS)?
Aaron McNally: Many systems in the field today are frequencyhopping spread spectrum. In fact, Digi offers frequency-hopping
models in the 900 megahertz range and on other wireless
devices, but the XLR PRO uses chirp spread spectrum, which is
a different frequency modulation than frequency-hopping. For
frequency-hopping spread spectrum devices, as data is being
transmitted across a range of frequencies, the device is detecting
interference and literally hops that data transmission across
these various channels to make sure nothing is lost by avoiding
that interference and noise.
However, instead of hopping across frequencies, chirp
spread spectrum sweeps its transmissions across frequency
bands to send its data. Its the XLR PROs Punch2 Technology
that leverages the chirp sequence to the whole spectrum of
frequencies available in the unlicensed 900 MHz ISM band,
broadcasting a signal that breaks through the noise, filtering and
suppressing it away, and reliably delivers its data.
56 | MARCH 2015

MPT: How does the XLR PROs Punch2 Technology


overcome noise-saturated RF environments?
Aaron McNally: Punch2 is the magic that sits on top of
this chirp spread spectrum technology. It improves receiver
sensitivity and interference immunity, but it also improves
multi-path recovery when a signal has physical obstacles in
the way of transmission bouncing signals at different
angles and sending them back.
The XLR PRO has a much better recovery
potential than other types of systems. Users can
also turn up or turn down the transmission from
9600 baud to 3 megabytes, and as they turn
down from 3 megabytes they will improve their
signal-to-noise ratio and interference immunities
go up.
MPT: What can users in the oil and gas exploration/
production industries expect from the XLR PRO?
Aaron McNally: The true story I give comes from an oil and gas
company who set up a bunch of wells in an area with a series of
frequency-hopping 900 megahertz radio systems, but not soon
afterward a competing company set up one well with another
900 megahertz radio system nearby. Initially, the signal had
some degradation but nothing too bad. But as their competitors
added more wells, the environment became so noisy that both
companies were having trouble sending and receiving signals.
That leaves only one practical solution: buying space in
the privately licensed range from the FCCalong with the
generally more expensive equipment that comes with it.
However, the XLR PROs Punch2 Technology filters out that
noise in these frequency-saturated environments allowing
for more consistent data transmission while maintaining high
performance levels in the unlicensed 900 megahertz band.
MPT: How well is it suited for use in utilities?
Aaron McNally: With utilities, the problem is not just noise
but distance. XLR is shorthand for extra-long range, and it is
phenomenal technology. For example, I have worked with a
family farm in southern Minnesota and their substation is in the
middle of nowhere. Cellular coverage is often spotty at best and
data may need to be transmitted to the next town or further for
remote access to these systems.
Getting signal to these remote locations is key, and there is
outstanding distance offered by the XLR PROupwards of 150
miles (241 kilometers) distance in between line of sight. Many
of our engineers are based in Utah, where they conducted a
mountaintop-to-mountaintop test achieving over 1 megabyte
of throughput in excess of 100 miles. Ive worked with wireless
technology for twenty years and this is one of the best solutions
Ive ever seen.
www.modernpumpingtoday.com