Modern Pumping - 022015

MODERN
TODAY
PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY
FEBRUARY 2015
ELIMINATING
A WASTEWATER PLANTS
PIPE FAILURES
THE CRISIS
FACING
FRESHWATER
RESOURCES
SCREENING
SYSTEM STOPS
CLOGS
EXTEND
YOUR PUMP'S
OPERATING LIFE
CONTENTS
4
10
FEBRUARY 2015
Industry news
trade show ProfIle
Case studIes
12 Remotely Managing Pumps on the Farm
water & wastewater solutIons
16 The Pursuit of a Green Carbon Steel Corrosion Inhibitor

Part 2 in a 4-part series
22 How to Select the Most Effective Blower Technology
12
for Wastewater Applications

MaIntenanCe solutIons
26 Eliminating Pipe Failures from Pneumatic Conveying Line
The Smart Elbow stops lime spills and prevents dust cloud exposure for wastewater treatment plant
PuMP solutIons
30 Small and Simple
Watson-Marlow's 120 peristaltic pump answers customers' needs
32 So Fresh, So Clean
30
Hidrostal's pump cleans carrots for consumption
dewaterIng solutIons
34 Screening System Eliminates Clogging from Membrane Bioreactor

Retrofit cuts upgrade costs by one million dollars
Motor solutIons
36 New Bearing Designs Meet Demands for Extended Pump

Operating Life
Power generatIon solutIons
38 The Wind Is Blowing East
In South Korea and China, Alstom is providing power generation solutions
34
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266
ProCessIng solutIons
@ModPumpMag
40 Using Coriolis Mass Flow Meters
with Positive Displacement Sliding Vane Pumps

RANDY ARMISTEAD Associate Publisher

randy@modernpumpingtoday.com
ValVes & Controls

solutIons
J. CAMPBELL Editor
jay@modernpumpingtoday.com
44 Take the Knife to High Costs in Wastewater Treatment

Specialty AWWA C520-10 knife gate valve saves construction and operating costs
DONNA CAMPBELL Editorial Director

donna@modernpumpingtoday.com
SCOTT GORDON Art Director
scott@modernpumpingtoday.com
LISA AVERY Assistant Art Director
lisa@modernpumpingtoday.com
sealIng solutIons
JAMIE WILLETT Circulation Consultant
46 Strategic Mechanical Seal Partnerships
INGRID BERKY Administrative Assistant
Building owner-manufacturer relationships that benefit all parties

50
JEFF FLETCHER Associate Publisher

jeff@modernpumpingtoday.com
TONYA BROWNING Account Executive

JERRY DICHIARA Account Executive
Modern PuMPIng ProduCts

Featured Product Release: JWC ENVIRONMENTAL 10K Series Muffin
Monster
DAVID MARLOW Account Executive

SANDY HAYS Account Executive
Sewage Grinder
PuMPIng trends
52 Reuse, Repurpose, and Rethink
Dr. Lynn E. Broaddus on the crisis facing U.S. freshwater resources
www.highlandspublications.com
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TIM GARMON
CEO/President
EDITORIAL ADVISORY BOARD

Terry Bell
Drives and Motion Solution Engineer

Baldor Electric Company
Heinz P. Bloch, P.E.
Consulting Engineer,
Process Machinery Consulting
Robert G. Havrin
Director of Technology,
Centrisys Corporation
Michael Mancini
Consultant and Trainer,

Mancini Consulting Services
John M. Roach
Engineering Manager
for New Product Development,
Trebor International, Inc.:
A Unit of IDEX
RUSSELL HADDOCK
COO/Publisher
CHRIS GARMON
General Manager
Lisa Riles
Business Development Manager,

Wastewater Pumps
Xylem Inc.: Flygt
Director of Regulatory and
Technical Affairs, Grundfos
No part of this publication may be reproduced or transmitted in any form or by any

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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
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Trey Walters, P.E.
For address changes, please contact Lindey Scott:

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Greg Towsley
President, Applied Flow Technology
INDUSTRY news
EXONE NORTH AMERICAN PRODUCTION SERVICE
CENTERS CERTIFIED FOR ISO 9001:2008
The ExOne Company, a global provider of three-dimensional

printing machines and printed products to industrial
customers, today announced that its production service
centers (PSCs) in North Huntingdon, Pa. and Troy, Mich.
have been certified to ISO 9001:2008 as Industrial Additive
Manufacturers by DAS Certification. With the latest two
facility certifications, all five of ExOnes PSCs in North
America now have ISO certification, joining ExOnes other
PSCs in Auburn, Wash., Houston, Texas, and Las Vegas, Nev.
ISO 9001:2008 certification designates that the ExOne North
Huntingdon and Troy facilities quality management systems
conform to the specific requirements of the ISO (International
Organization for Standardization).
The ISO 9001:2008 standard is based on eight quality
management principles, including a strong customer focus,
commitment of top management, a process approach
and continuous improvement. Receiving ISO 9001:2008
certification helps ensure that ExOnes customers receive
consistently high quality products and services. To achieve
the certification, ExOne had to demonstrate its consistent
ability to provide products that meet customer and applicable
statutory/regulatory requirements, while enhancing customer
satisfaction through the effective application of the system.
This includes processes for continuous improvement and the
assurance of conformity to customer and statutory/regulatory
requirements.
Receiving ISO certification demonstrates that ExOnes
binder jetting 3D printing technology consistently meets
4 | FEBRUARY 2015
our customers expectations and product quality standards

for industrial usage, says Tim Pierce, ExOnes U.S. chief
operating officer. "By earning this certification at all of our
North American facilities, ExOne customers recognize that
they can achieve a high-level of service and quality regardless
of their business region or printing application."
HI/FSA LAUNCHES INTRODUCTION TO

MECHANICAL SEALS WEBINAR SERIES
Beginning Tuesday, March 10, 2015, the Hydraulic Institute

and the Fluid Sealing Association will launch a WEBINAR
SERIES Introduction to Mechanical Seals. This 4-part
webinar series is based on the Hydraulic Institute guidebook,
Mechanical Seals for Pumps: Application Guidelines
which was published in cooperation with the Fluid Sealing
Association. Session 1 will cover mechanical seal types and
operating principles. Mechanical Seal construction and design
will be the topic of discussion during session 2. Session
3 will examine mechanical seal installation, connections,
and commissioning. The final session will discuss seal
environment and failure analysis. More information can be
found at the Hydraulic Institutes website www.pumps.org.
SMITH & LOVELESS INC. ACQUIRES SCHLOSS

ENGINEERED EQUIPMENT INC.
Smith & Loveless Inc., the global leader in advanced grit

removal and handling technology, announces the asset
acquisition of longtime headworks equipment designer
Schloss Engineered Equipment Inc., Aurora, Colo. The parties
agreed not to disclose the terms of the acquisition.
INDUSTRY news
The acquisition supports Smith & Loveless strategy of
augmenting its market leadership in wastewater headworks
and separation technologies by expanding its offerings
for its industry partners and customers. Schloss designs a
comprehensive line of headworks screening, compacting,
conveying, washing and dewatering technologies, backed
by more than 100 years of operation.
The well-respected Schloss brand in screening
technology and headworks dewatering equipment
established by the technical ingenuity of the Schloss
familystands for robust design and engineering, and
remarkably complements Smith & Loveless marketleading grit removal equipment, says Smith & Loveless
President Frank J. Rebori. Our combined screening and grit
removal technologies enable Smith & Loveless to deliver
to our customers exceptional value and performance for
municipal headworks and industrial liquid-solids separation
applications.
Schloss Chief Executive Officer and President Kristy A.
Schloss commented on the significance of the acquisition:
Joining Smith & Loveless will accelerate the growth and
legacy of the Schloss equipment line, Schloss says. My
father Charles Schloss (P.E.) and I are excited for this next
chapter in the companys 116-year history, powered by
Smith & Loveless national and international distribution.
Schloss products will be incorporated into Smith
& Loveless Municipal, Industrial, After Market and
International Sales Division offerings, while the acquired
company will be re-launched as Schloss Environmental
Equipment Inc., a Smith & Loveless Company.
6 | FEBRUARY 2015
WATEREUSE SYMPOSIUM CALL FOR ABSTRACTS
The WateReuse Association is accepting abstracts for

presentations at the 30th Annual WateReuse Symposium to
be held September 13 through 16, 2015, at the Sheraton
Seattle in Seattle, Washington. The Annual WateReuse
Symposium is the worlds premier conference devoted to
helping communities build a safe and sustainable local water
supply.
To be considered for a place on the podium at the 30th
Annual WateReuse Symposium, submit an abstract of your
proposed presentation by Friday, February 27, 2015. Abstracts
may be submitted in the following categories: Individual
Presentation (a 30 minute speaking slot), Panel Discussion
(1.5 or 2 hours in length with a maximum of 3-5 speakers
total), and Full Organized Session (1.5 or 2 hours in length
with a maximum of 3-5 speakers total). For a full list of
topics, visit www.watereuse.org.
QUANTUMFLO UPGRADES NASCARS DAYTONA

INTERNATIONAL SPEEDWAY PUMP SYSTEMS
Award-winning pump technology leader, QuantumFlo, is

providing a facility upgrade to the water pump system at
NASCARs Daytona International Speedway. The three 2400
GPM triplex booster systems were completed in the third and
fourth quarters of 2014, and by the end of February 2015 all
three will be commissioned and ready to serve the domestic
water requirements in support of The Great American Race,
the Daytona 500.
Chief Executive Officer, Dave Carrier, is excited to
bring the energy efficient and cost-saving technology
INDUSTRY news
of QuantumFlos products to the Daytona International
Speedway. Water requirements for large-scale events, like
the Daytona 500, demand tremendous power and reliability.
QuantumFlo goes beyond that demand with greater energy
efficiency and performance through our intelligent software
and design.
QuantumFlo has applied its cutting-edge pump technology
on past NASCAR facility projects with great success. Because
of their superior technology and experience on these past
projects, NASCAR, the general contractor, Barton Malow,
and the plumbing contractor, Nash Plumbing Inc., selected
QuantumFlo to contribute to this great improvement to the
Daytona International Speedway.
NASCAR recognized QuantumFlos drive for innovation
and their successful pursuits towards being the worldwide
leader in variable speed pumping technology. The Daytona
International Speedway will now benefit from QuantumFlos
top-quality pre-packaged pump systems equipped with
advanced software to minimize the facilitys energy and water
consumption.
As a sponsor for a dragster racecar, QuantumFlo is no
stranger to the racing world and is proud to be able to make
such a great benefit and contribution to both their Volusia
County community and to what makes Daytona International
Speedway a world-class facility. Recognized as an industry
and business leader, QuantumFlo provides pre-packaged
pump systems for plumbing, HVAC, turf and irrigation and
more both locally, as a 2014 Florida Companies to Watch
award winner, and globally, as the VMA, Inc 2014 Exporter of
the Year.
8 | FEBRUARY 2015
ASHRAE, IAQA APPROVE CONSOLIDATION
A consolidation between ASHRAE and the Indoor

Air Quality Association has been finalized by both
organizations. The consolidation was approved by the
Boards of Directors for ASHRAE and IAQA at ASHRAEs
recent 2015 Winter Conference in Chicago.
We are excited about the opportunities presented by
this consolidation, ASHRAE President Tom Phoenix says.
It opens the door to alignment of ASHRAE and IAQA
programs to create high-impact resources for building
professionals around the globe.
This is an historic event for both associations and
has great promise for growth and development for both
organizations, IAQA President Kent Rawhouser says.
The opportunities and possibilities for members are only
limited by our own imaginations. IAQA and ASHRAE are
committed to growing and developing the IAQA brand.
The consolidation will open new avenues for programs
and benefits for our members.
In July, ASHRAE announced it had agreed in principle
to join forces with the IAQA, combining resources to
improve indoor air quality in the built environment.
Since August, the two groups have been undergoing a
period of due diligence. That diligence was completed
earlier in January.
Under the consolidation, IAQA will become a part
of the ASHRAE organization while maintaining its
own brand and Board of Directors. IAQA will operate
independently within ASHRAEs organizational
structure.
TRADE SHOW profile
WWETT SHOW 2015

New Name, Same Opportunity
ttended by over 4000 septic, sewer, and

drain businesses each year, the Water and
Wastewater Equipment Treatment and
Transport (WWETT) Showformerly the Pumper
and Cleaner Environmental Expo International
consists of the latest products and technologies
in the environmental service industry as well as
providing educational seminars taught by highly
skilled professionals.
VARIETY OF EXHIBITORS
For thirty-five years WWETT exhibitors have been

showcasing the newest and brightest technology in
the wastewater industry. The WWETT Show floor
is an ever-evolving marketplace where industry
professionals can secure the equipment and
knowledge they need to grow their businesses and
in turn create a better world in the environmental
service industry.
Attendees have access to over
500 exhibits, spanning more
than 500,000 square feet of the
convention center, displaying
everything from septic system
components and trailers to portable
sanitation units and industrial sewer
equipment. The WWETT Show has
grown significantly
over the last several
years, attracting
some 12,000
environmental
service
professionals
from forty-five
countries to discuss
onsite installation,
portable sanitation,
sewer cleaning,
utility location, and
much more.
Exhibitor and
show sponsor, Southland Tool is a featured brand
on the official WWETT pickup truck, which will be
given away as a Grand Prize during the convention.
EDUCATION SESSIONS
The WWETT Show places a premium on continuing

education, with opportunities for professionals to
earn CEUs in a variety of tracks. Available tracks
for the 2015 show include the National Onsite
Wastewater Recycling Association (NOWRA),
National Association of Wastewater Technicians
(NAWT), Water Jet Technology Association and
Industrial Municipal Cleaning Association (WJTA10 | FEBRUARY 2015
IMCA), Southern Section Collection Systems

Committee (SSCSC), National Association of
Sewer Service Companies (NASSCO), National
Environmental Health Association (NEHA), and
many more.
WORLD HEALTH
ORGANIZATION TALK
Given the recent news of a West

African Ebola virus outbreak,
wastewater industry professionals
are rightly concerned over the
possibility of other communicable
diseases to spread through the
pumping,
transport and
handling of
septage and
sludges containing
human waste.
WWETT attendees
will hear the latest
information on
this issue from
Dr. Adrianus
Vlugman,
World Health
Organization
senior adviser
on water, sanitation and environmental health,
who will provide a general overview covering the
survival and life expectancy of communicable
diseases in water and wastewater.
Dr. Vlugman will also address safety precautions
to consider when handling water and wastewater
in developing nations, the likelihood of
communicable diseases to be spread or passed
through both centralized wastewater plants and
decentralized onsite wastewater systems, and
whether there is a concern for the spread of
communicable diseases through land application
of properly treated sewage, biosolids or septage.
CASE Studies
REMOTELY MANAGING
PUMPS ON THE FARM
By Eddie DeSalle, Net Irrigate
ade Qualls has been farming in Lake

City, Arkansas, for nearly sixteen
years. Hes a third generation farmer
who produces grain, cotton, corn and
soybeans on his farm of 4000 acres. With
crops that cover about 30 to 40 miles (48.3
to 64.4 kilometers) of land, Qualls does a
substantial amount of watering. The process
can take place for up to twelve hours a day,
sometimes more, depending on the time of
year and environmental conditions. Right
now Qualls has several irrigation pumps
and center pivots on his property and
each of them are used quite heavily in this
prominent farming community.
THE PROBLEM
Qualls Farms produces grain, cotton, corn and soybeans on 4000 acres.
During watering season, irrigation happens

several days in a row. This has always
meant that Qualls must be present at the
farm at nearly all times to ensure that
nothing goes wrong (such as power loss or
equipment malfunction) with the pumps or
the pivots. If something happens while he is
away from the farm, it can lead to hundreds
of gallons of wasted water, crops being
over-watered, or crops not being watered at
all if a piece of equipment malfunctions. Its
a risk he cant take, so as a result, Qualls
would spend much of his time driving
across his 30 to 40 miles (48.3 to 64.4
kilometers) of land, checking on the pumps
and pivots throughout each day of watering.
While this is how the Qualls family has
run their farm for decadeschecking on
pumps and pivots throughout growing
seasonQualls hoped to find a more
convenient way to manage the equipment.
THE SOLUTION
One day in late spring of 2014, Qualls was

at his local John Deere dealership when
PumpProxys remote start and stop function will control the pump with a phone call or with the mobile app.
About The Author

Eddie DeSalle is the CEO and founder of Net Irrigate, a manufacturer of wireless irrigation monitoring technology for the agriculture
industry. The companys hardware and software solutions are designed to notify irrigators of costly events, and its products include
WireRat, PivotProxy and PumpProxy. DeSalle is an alumnus of the Kelley School of Business at Indiana University where he
received his MBA with a focus in new product marketing and management. For more info, visit www.netirrigate.com.
12 | FEBRUARY 2015
his dealer introduced him to the Net

Irrigate PumpProxy and PivotProxy.
These products allow irrigators to
manage pumps and pivots from the
convenience of their phone, through a
mobile app.
Net Irrigate estimates the use of
PumpProxy has the potential to
conserve approximately 5 percent of
gravity flow irrigation water per year,
or about 800 billion gallons (over
three trillion liters) of water per year
in the United States, as well as reduce
total energy pumping expenditures by
$96 million annually and automotive
fuel expenditures for field travel by
$22 million.
wire is cut. The technology has led to

more than 60 thieves being arrested,
and more than 200 being caught in the
act and scared away.
While Qualls has never had an
attempted copper wire theft on his
farms, he knows other farmers who
have. He says he was happy to have
the copper wire theft protection, but
was most attracted to the ability to

turn his pumps and pivots on and off
remotely.
What I liked about these products
is that I can be anywhere and use
them, says Qualls. I didnt have to
get up in the middle of the night, or
miss out on weekends with family in
order to stay back at the farm. I just
PumpProxy
PumpProxy allows irrigators to
remotely monitor, start and shut down
irrigation pumps. When used with
center pivots, it eliminates the need
for kill wires to associated irrigation
wells. Functionality includes a virtual
timer to set the pump to turn off at
a given time online or through the
mobile app. Its remote start and stop
function will control the pump with
a phone call or with the mobile app.
Also, the thermal overload/ power
failure notifications can alert up to
ten recipients of thermal overload or
other power failure via call, text, or
email, and its safety stop alerts provide
notifications when your pump starts or
stops.
PivotProxy
PivotProxy provides comprehensive
pivot monitoring and security. The
PivotProxy works seamlessly with all
brands of pivots. When a pivot stops,
the safety stop alerts function sends
text, voice or email notifications,
and the remote shut down function
can stop the pivot with a phone call,
online, or through the mobile app.
GPS allows operators to check the
heading of the pivot via web or phone,
and the virtual stop-in-slot can set
multiple check points and automatic
stops.
WireRat
In addition, both the PumpProxy and
PivotProxy were outfitted with Net
Irrigates WireRat technology, which
offers farmers the ability to better
protect the valuable copper wire on
their pivot and pump irrigation systems
by immediately sending alerts via
phone, email or text when a copper
FEBRUARY 2015 | 13
CASE Studies
have to pull out
my iPhone and
control them from
anywherethe
lake, St. Louis, it
doesnt matter.
Since purchasing
one PumpProxy
and one PivotProxy,
Qualls has been
accessing the
mobile apps 3-4
times a day during
watering season.
One instance in
which this has been
especially helpful
is when the power
goes out in the
area. It happened
a few times in the
summer of 2014.
Whether the power
goes out entirely,
or just flickers,
doesnt matterthe
pivots and pumps will turn off and
wont automatically re-start when the
power comes back on. In the past,
Qualls had to go out and check all
14 | FEBRUARY 2015
the pivots that were in use when this

happens and re-start them manually.
This was especially inconvenient
because sometimes outages would
only affect certain areas in his acreage,

but he wouldnt know which pump or
pivots had turned off. Qualls would
waste valuable watering time driving,
stopping and checking each one with

every electrical surge. Since investing
in the PumpProxy and PivotProxy, hes
been notified immediately of outages
and has been able to turn the pumps or
pivots back on remotely.
CONCLUSION
Since purchasing the Net Irrigate

products, Qualls says hes been able
to enjoy time away from the farm
more often, since he doesnt have
to wait around to manually turn a
pump or pivot on or off. He says he

is considering purchasing more of
these products possibly as soon as this
year. For Qualls, the additional free
time and peace of mind is more than
worth it.
FEBRUARY 2015 | 15
WATER & WASTEWATER solutions
The Pursuit of a Green Part 2 of 4

Carbon Steel Corrosion Inhibitor
By Matthew LaBrosse and Donovan Erickson, U.S. Water Services, Inc.
uilding on last months installment in this series,

New carbon steel coupons and corrator tips were used for
this article will detail the simulated cooling tower
each run. All coupons and tips were not passivated prior to
an experimental run. Each test consisted of a five day run at
water experiments test procedure for both a scaling
which time pictures were taken of the carbon steel coupon
and corrosive environment. Also, we will provide visual
and corrator data was graphed. A copper coupon was also
reference and figures illustrating general corrosion rates.
installed in the loop for each run to provide a source of
Later installments will build on these observations to
potential free copper to more closely simulate a mixed
determine acceptable green corrosion inhibitors for use
metallurgy cooling water system. Tolyltriazole was added to
in open system cooling waters by examining the effect of
the system to minimize corrosion of the copper coupon. This
oxidizing biocide on their performance and, finally, to select
was done to further mimic field
the most appropriate and cost
conditions. No other metallurgy
effective product for use as a
Item
Concentration
Unit (ppm)
was present in the system;
green corrosion inhibitor.
all fittings were schedule 80
Ca
543
CaCO3
PVC. The system was cleaned
EXPERIMENTAL
between runs with citric acid
PROCEDURE
Mg
140
CaCO3
and rinsed thoroughly. The
The test apparatus consisted
HCO3
328
CaCO3
rating of an inhibitor was
of a circulation loop with
determined by the appearance
the return water line aerated
Cl
114
Cl
of the coupon, the corrator
before entering the sump. This
505
SO4
SO4
graphs, the green status, and
provided the necessary oxygen
the use cost.
to simulate cooling tower
HEDP
3
Active
water. The flow rate was 7.0
RESULTS AND DISCUSSION
gallon (26.5 liter) per minute in
Copolymer
8
Active
1 inch (25.4 millimeter) clear
Coupon Analysis
Tolyltriazole
3
Active
PVC piping for ease of visual
Due to the shortened five day
inspection. This corresponds to
exposure time of each trial,
Table 2: Synthetic water quality used in all trials.
coupon analysis was limited
a linear velocity of 3.2 feet (1
meter) per second. This is in the
to qualitative observations.
range of accepted flow rates for corrosion coupon racks (see
The results, shown in Table 3, provide a visual comparison
reference 12). The temperature for each run was maintained
between corrosion inhibitors. Under the test conditions
at 95 degrees Fahrenheit (35 degrees Celsius); the heat was
outlined in the experimental procedure, the carbon steel
provided by the main circulation pump and booster pump.
inorganic inhibitor performance can be ranked as follows:
Synthetic water was used to simulate both a scaling and
corrosive environment. The synthetic water quality is shown
Sn PO4/Zn >> PO4/TKPP > MoO4.
in Table 2. Scale was controlled during each run by the
addition of active 1-hydroxyethane-1,1-diphosphonic acid
The relatively poor performance of the molybdate
(HEDP) and a phosphate/iron dispersant copolymer (AA/
and phosphate/polyphosphate could be attributed to an
AMPS). The active amounts of scale inhibitors are shown in
ineffective low dosage. It is also possible that the inhibitor
Table 2. The equilibrium pH for each run was 8.7 to 8.9. This
did not provide both anodic and cathodic protection under
was the natural result of the amount of synthetic bicarbonate
the test conditions. The molybdate coupon appeared worse
alkalinity added, the temperature, aeration, and test run
than the control coupon that had no adjunct corrosion
duration.
inhibitor added beyond what may have been provided by
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.
16 | FEBRUARY 2015
Treatment
Dosage
(ppm)
Treatment
Dosage
(ppm)
Control
Control
Mo
15.0
PAP
15.0
PO4/TKPP
3.0/1.0
HPA
15.0
PO4/ZN
5.0/1.0
AAP
30.0
Sn
3.0
PCA
15.0
Coffee
50.0
Carbon Steel Coupons
Table 3: Inorganic inhibitor corrosion coupon results.
the HEDP and copolymer shown in Table 2. The tolyltriazole

present in each trial may have also provided some minor
protection for carbon steel either by limiting free copper in
the system or as a complimentary carbon steel corrosion
inhibitor.
Table 4 shows corrosion coupons for the organic carbon
steel corrosion inhibitors. The qualitative performance under
the conditions tested can be ranked as follows:
HPA > PCA >> AAP PAP > Coffee.
Carbon Steel Coupons
Table 4: Organic inhibitor corrosion coupon results.
The HPA provides excellent carbon steel corrosion

protection under the conditions tested. There is no evidence
of general corrosion or pitting on the corrosion coupon.
The PCA run also provided excellent corrosion inhibition
of carbon steel. Another inhibitor tested was aspartic
acid polymer. AAP is not typically touted as carbon steel
corrosion inhibitor, but is known for its scale inhibition
properties. AAP provided some carbon steel protection in
the testing. The dosage for this inhibitor was intentionally
FEBRUARY 2015 | 17
HPA > PCA > Sn PO4/Zn > AAP PAP > Coffee
> PO4/TKPP > MoO4.
Control
Mo
24
48
PO4/Zn
Sn
PO4/TKPP
15
Corrosion Rate (mpy)
tested at twice the manufacturer recommended rate due to

the lack of documentation of using AAP as a carbon steel
corrosion inhibitor. Further testing is needed to observe
AAP performance at recommended dosage. The carbon
steel corrosion coupon from the coffee extract trial shows
a significant amount of surface corrosion. This inhibitor has
the poorest qualitative results of the organic inhibitors.
The appearance of the corrosion on the coupon run using
PAP was different than the appearance of the coupon tested
with AAP. The PAP coupon appeared to have more of pitting
type corrosion, although it was not severe. PAP results are
discussed more in depth with the evaluation of the corrator
results.
If the inorganic and organic inhibitor results are
combined, the carbon steel inhibitor performance under the
conditions tested based on corrosion coupon analysis was:
10
0
0
72
96
Exposure Time (hrs)
120
144
Figure 1: Inorganic inhibitor corrosion rate.
Corrator Analysis
This type of corrosion analysis yields graphical results
that provided a quantitative representation for the full five
day test run. The two-channel corrator output provided
continuous results on general corrosion and the pitting
potential, which is called the imbalance.12 As with the
coupons, the molybdate and phosphate/polyphosphate
inhibitors provided the least mild steel corrosion protection
under the conditions of the test and the inhibitor dosages
used, as can be seen in Figure 1. Tin exhibited similar
18 | FEBRUARY 2015
corrosion results to the phosphate/zinc inhibitor. They both

started with low carbon steel corrosion rates around 1.0
mpy, but the corrosion rates gradually increased over the
five day trial.
Figure 2 shows the corrosion imbalance for the
inorganic carbon steel corrosion inhibitors. The phosphate/
polyphosphate saw a large increase in the pitting corrosion
during the end of the test run. This trend was also observed
Control
Mo
PO4/Zn
Sn
Control
PO4/TKPP
PAP
HPA
AAP
PCA
Coffee
20
Corrosion Rate (mpy)
Corrosion Imbalance (mpy)
15
15
10
10
0
0
24
48
72
96
Exposure Time (hrs)
120
144
24
48
72
96
Exposure Time (hrs)
120
144
Figure 2: Inorganic inhibitor imbalance rate.
Figure 3: Organic inhibitor corrosion rate.
for phosphate/polyphosphate in Figure 1, indicating a poor

overall performance. The molybdate imbalance was high
during the initial part of the run but decreased toward the
end, indicating high pitting potential for the first twentyfour hours. The general corrosion was relatively high for
the duration of the run. This is consistent with the severe
general corrosion observed on the corrosion coupon
surface. Both the tin and phosphate/zinc trials produced
similar corrosion and imbalance results, but the phosphate/

zinc appeared to provide less pitting potential.
Figure 3 shows the general corrosion rate for the organic
carbon steel corrosion inhibitors. AAP provided corrosion
protection for carbon steel as compared to the control, but
the corrosion rate steadily increased over the five day trial.
PAP exhibited excellent general corrosion protection with
the rate staying at or below 2.0 mpy for the duration of the
FEBRUARY 2015 | 19
HPA > PCA > PO4/Zn Sn > AAP > PO4/

TKPP > MoO4 >> Coffee.
Based on the Green Chemistry criteria defined in this
research, aspartic acid polymer and coffee extract ranked
the most green, as can be seen in Table 1 and Table 3.
They are followed by tin, phosphonocarboxylic acid,
hydroxyphosphonic acid, and polyaminophosphonate.
Finally, orthophosphates, polyphosphates, molybdate, and
Control
PAP
HPA
AAP
PCA
Coffee
20
Corrosion Imbalance (mpy)
trial. The HPA shows superior general corrosion inhibition

as compared to all other inhibitors.
Figure 4 shows the imbalance for the organic corrosion
inhibitors. There is some pitting potential observed for the
AAP. As was the case with the general corrosion graph,
the HPA exhibits superior pitting inhibition over all the
inhibitors tested. The PAP corrator results provided an
interesting and definite contrast between the general
corrosion and imbalance rates. The PAP general corrosion
in Figure 3 was good, second only to the HPA, but the
pitting potential in Figure 4 appeared to be the worst of
all the inhibitors tested. The imbalance output steadily
increased until it exceeded the maximum measuring
limit of 20 mpy. This is consistent with the PAP carbon
steel corrosion coupon, which shows evidence of several
pitting corrosion sites on the surface. Additional testing is
required to determine the repeatability of that observation.
PAP may also require a co-inhibitor to provide better
overall anodic and cathodic protection for carbon steel.
The combined results of the inorganic and organic
inhibitors tested under the conditions tested based on
corrator analysis are listed below. The PAP was not ranked
in the corrator performance due to the unexplained
imbalance results and pending further testing.
15
10
0
0
24
48
72
96
Exposure Time (hrs)
120
144
Figure 4: Organic inhibitor imbalance rate.
zinc were considered the least green. If phosphate-free

status is mandatory then polyaspartic acid and tin would
be the green inhibitors of choice.
CONCLUSIONS
All inhibitors tested provided some level of carbon steel

corrosion protection. Under the experimental conditions,
HPA was the best carbon steel inhibitor tested as shown
by both the qualitative coupon results and quantitative
corrator analysis. The corrator results compare nicely with
the coupon results based on the ranking for each corrosion
analysis method. Comparison of the normalized use
Control Unit
Typical Dosage (ppm)
Normalized Use
Cost
Green Status
Molybdate
Mo
10
100
Fair
Zinc
Zn
Fair
Tin
Sn
24
Good
Orthophosphate
PO4
14
Good
Polyphosphate
TKPP
Good
Polyaminophosphate
PAP
15
30
Good
Hydroxyphosphate Acid
HPA
15
33
Good
Phosphonocarboxylic Acid
PCM
15
50
Good
Aspartic Acid Polymer
AAP
15
23
Excellent
Product
Excellent
PO4 / Zn
5/2
17
Fair
PO4 / TKPP
5/3
18
Good
Inhibitor
Coffee Extract
Phosphate/Zinc
Phosphate/Polyphosphate
Table 5: Comparison of corrosion inhibitor green status (from Table 1) to its use cost. The use cost has been normalized to an arbitrary value of 100.
20 | FEBRUARY 2015
cost of the inhibitors clearly shows

that molybdate is not an effective
inhibitor for mild steel at reasonable
cost when used alone in a cooling
tower. The inhibitors considered
most green and phosphate-free are
aspartic acid polymer and tin. Their
use cost is approximately 30 percent
higher than a normal phosphate/
zinc program. This makes them a
potentially acceptable choice in
the pursuit of a green carbon steel
corrosion inhibitor. Further testing
is required including field testing
to expand the scope of corrosion
inhibitors investigated and verify
pilot results in field trials. Further
testing is also necessary to examine
the effect of oxidation on the
corrosion inhibitors and explore
potential synergistic effects of
combining carbon steel corrosion
inhibitors.
9. W.E. Stapp and G. Westlund, Corrosion

Inhibition Compositions and Methods for
Using the Same, U.S. Patent 7,910,024,
issued March 22, 2011.
11. B.P. Boffardi, Corrosion and Fouling

Monitoring of Water Systems, The
Analyst Technology Supplement, spring
(2010).
10. V.V. Torres et al., Inhibitory Action of

Aqueous Coffee Ground Extracts on
the Corrosion of Carbon Steel in HCl
Solution, Corrosion Science, 53, 23852392 (2011).
12. Rohrback Cosasco Systems, Inc., Model

9020 &9020-OEM Corrater Transmitter
User Manual, November (2004).
REFERENCES
1. Report on Carcinogens, Twelfth
Edition, National Toxicology Program,
Department of Health and Human
Services, 2011. Web. May 17, 2012.
2. Qishlaqi and F. Moore, Statistical
Analysis of Accumulation and Sources of
Heavy Metals Occurrence in Agricultural
Soils of Khoshk River Banks, Shiraz,
Iran, American-Eurasian J. Agriculture
and Environmental Science, 2, 565-573
(2007).
3. J.T. Huber, N.O. Price, and R.W. Engel,
Response of Lactating Dairy Cows to
High Levels of Dietary Molybdenum,
Journal of Animal Science, 32, (1971).
4. B. Oram, Water Research Center, B. F.
Environmental Consultants Inc., 2012.
Web. May 17, 2012. Phosphates in the
Environment.
5. Association of Water Technologies
Technical Reference and Training
Manual, 2nd edition, chapter 5.10,
(2009).
6. P. Puckorius et al., Phosphonates-Part
II-Corrosion Control- Cooling Water,
A Practical Guide to Water Treatment
Chemicals Newsletter, Volume 2, Issue 1,
1st quarter (1998).
7. P. Howe, M. Wood, and P. Watts,
Tin and Inorganic Tin Compounds,
Concise International Chemical
Assessment Document, 65, World Health
Organization Geneva, (2005).
8. J. Fawell and R. Mascarenhas, Inorganic
Tin in Drinking-water, Background
document for development of WHO
Guidelines for Drinking-water Quality,
World Health Organization, (2004).
FEBRUARY 2015 | 21
How to Select the

Most Effective Blower Technology
for Wastewater Applications
By Aerzen USA
n the first part of this series, we

examined turbo, hybrid, and
combination blower technologies
and addressed the most effective
technology for particular applications.
In this article, we will take a closer
look at case studies illustrating these
three technologies and the results that
can be achieved by implementing
them in wastewater treatment plants.
After seeing the results in action, most
wastewater professionals feel more
confident in making their next blower
selection the right one to fit their
needs.
WASTEWATER TREATMENT PLANT

APPLICATION EXAMPLES
The following case studies illustrate
results that can be achieved by
implementing turbo, hybrid, and
combination blower technologies in
wastewater treatment plants.
Turbo Blower: Blue River Wastewater

Treatment Plant
Overview: Built in 1974, the
Blue River Wastewater Treatment
Plant in Silverthorne, Colorado,
provides wastewater services to the
communities of Silverthorne, Dillon,
Dillon Valley, Buffalo Mountain,
and Mesa Cortina. A conventional
activated sludge plant with extended
aeration capabilities and a design
capacity of 4 million gallons (15.1
million liters) per day, the Blue River
Wastewater Treatment Plant serves
resort communities with high variation
in usage, both seasonally and between
Aerzen TB100 turbo blowers at the Blue River

Wastewater Treatment Plant (Silverthorne, Colorado)
midweek and weekends during the

peak season.
Average demand ranges from
approximately 1.5 to 2 million gallons
(5.6 to 7.5 million liters) per day.
Given the variation in basin levels
and the limitations on turndown in
the multistage centrifugal blowers,
the plant operators were frequently
overaerating, resulting in energy
loss and lowered overall blower
efficiencies. Engineers experimented
with adding VFDs to the old blowers
to reduce energy consumption, but
it proved difficult to protect the
centrifugal blowers from surge.
Objective: Reduce rising energy
costs and replace the aging multistage
centrifugal blowers with new
technology that would reduce energy
consumption and provide steady and
reliable operation.
Results: The Silverthorne-Dillon
Joint Sewer Authority (JSA) selected
the Aerzen TB100, a 100-horsepower
PART 2 OF 2
turbo blower for its ability to meet
the plant's maximum design aeration
requirements of 1400 cubic feet
(39.6 cubic meters) per minute
at a pressure of 7.5 psi. The TB
100 runs on a permanent magnet
motor specifically designed for
the high frequency and high speed
requirements of a direct drive turbo
application.
An immediately apparent benefit
was the drastic reduction in noise,
eliminating the need for hearing
protection. The plant has averaged
20 percent greater energy efficiency
than with its predecessor blowers,
which translates to annual savings
of approximately $6500. Another
energy benefit is the heat recovery
from the blower's cooling system. The
warm air is used to heat the facility
during the cold winter months, and a
separate cooling air connection vents
the heat outdoors during the summer
months. Since the blowers use airfoil
bearings that are lubricated by air
instead of oil, the plant has also
reduced its maintenance costs.
Hybrid Blower: City of Anacortes
Wastewater Treatment Plant
Overview: The City of Anacortes
WWTP is located in the state of
Washington off the coast of Puget
Sound, which is home to a variety of
wildlife and aquatic life. Its WWTP
processes 2 million gallons (7.5
million liters) per day and was using
three 150 horsepower multistage
centrifugal blowers with a minimal
For More Information

Aerzen USA offers a wide array of positive displacement blowers, high-speed turbo blowers, screw compressors, rotary lobe
compressors, and vacuum pumps for various industries. For more information, visit www.aerzenusa.com.
22 | FEBRUARY 2015
overall design capacity of 30,000

Einwohnergleichwert (EGW,
or population equivalents)a
measurement of the total pollution
load divided by the individual
pollution load of one person.
Operating at approximately 29,000
EGW, the plant is nearing full
capacity, processing up to 105,944

cubic feet (3000 cubic meters)
of wastewater per day. However,
weekend turndown can result in
load fluctuation from 42,377 to
52,972 cubic feet (1200 to 1500
cubic meters). During the week, the
plant processes a nearly constant
The City of Anacortes replaced a 125 horsepower

multistage centrifugal blower with an Aerzen D 62S 75
horsepower hybrid blower
air flow rate of roughly 1750 standard

cubic feet (49.5 cubic meters) per
minutefar more than required to
maintain adequate dissolved oxygen
(DO) in the basin.
Objective: Improve efficiency of the
aeration system and reduce operating
costs and energy consumption/costs
by investing in more efficient blower
technology.
Results: After evaluating hybrid and
turbo technologies, the plant selected
the Aerzen Delta Hybrid model D
62S with a 75 horsepower motor for
two reasons: (1) lower initial and
operating costs and (2) broad range
of operating conditions, specifically
greater turndown capacity. The new
Delta Hybrid operates between
1450 standard cubic feet (41 cubic
meters) per minute at peak flow and
600 standard cubic feet (16.9 cubic
meters) per minute during the night,
for a power savings of 30 to 55kW.hr,
depending on the time of day.
The new blower also enabled
the plant to turn off two channel
air blowers, which alone saved
approximately $11,700 per year. All
told, the new aeration system saved
the city approximately $56,155 per
year in energy costs and demand
fees, which their utility provider
charges industrial customers based on
consumption. Payback was achieved
in twenty-two months. In addition,
the plant was able to use existing
maintenance staff to service the new
aeration blowers, eliminating the
potential costs associated with service
and maintenance agreements.
Combination Blower Technology:
Bremervrde Sewage Treatment Plant
Overview: The Bremervrde sewage
treatment plant in Germany has an
FEBRUARY 2015 | 23

52,972 cubic feet (1500
aeration blower technologies
cubic meters) per day using
and application concepts.
two existing Aerzen Delta PD
A thorough understanding
blowers. Approximately 75
of the overall process,
operating conditions, and
percent of the plant's energy
consumption goes toward
interplay of aeration and
generating process air, which
process controls is key to a
represented a significant
successful implementation.
operating cost reduction
Often, technologies are
opportunity.
misapplied due the promise
of high energy efficiency,
Objective: Optimize energy
use by implementing a fully
failing to consider operational
variables that will ultimately
automated blower system
that would meet process
cause the machine to run
air requirements within the
outside its intended range.
New concepts of applying
operating range of 50 to 100
established and more recent
percent.
Aerzen AT turbo blower and two PD blowers processing air at a Bremervrde,
technological advances
Results: The plant selected
Germany sewage treatment plant.
within the context of the
the Aerzen AT 100 turbo
entire wastewater treatment
blower. The new turbo
plant system have proven
blower serves as a base load
effective in maximizing the benefit
generator for process air, operating at
turbo blower resulted in cost savings
a capacity range from 1200 to 2800
of each technology. The result is
on the order of 20 to 25 percent.
an improvement in the overall
standard cubic feet (35 to 80 cubic
operating efficiency of the wastewater
meters) per minute. The two existing
SUMMARY AND CONCLUSION
PD blowers are connected to the new
treatment plants in terms of overall
Wastewater treatment plant managers
system and automatically start when
equipment effectiveness (OEE), energy
have more opportunities to optimize
needed to handle peak loads or serve
efficiency, and reduced operating and
energy efficiency and reduce
maintenance costs.
as redundant blowers. Adding the new
operating costs thanks to a variety of
24 | FEBRUARY 2015
MAINTENANCE solutions
Eliminating
Pipe Failures
from Pneumatic
Conveying Line
The Smart
Elbow stops
lime spills
and prevents
dust cloud
exposure for
wastewater
treatment
plant
By Miaja Marek, HammerTek
obert Forgione, P.E. and his team at the Upper

Occoquan Water Reclamation Plant in Centreville,
Virginia were wading through yet another dust cloud to
cleanup yet another pile of dry pebble lime and dust that had
leaked from a failed elbow in the conveying line. While the
hole measured a mere -inch (12.7 millimeter) across, it was
large enough to spew the abrasive powder billowing all over
the building until the high pressure conveying system could
be shut down. The elbow failure created a hazardous slip and
fall situation, threatened acceptable air quality levels, and
put sensitive electronic controls at risk. Although it would be
feasible to recover from a single leak like this one, Forgione
was responsible for elbows that failed and leaked every six
months. We had to fix this situation, says Forgione, the
director of the operations and maintenance division for the
Upper Occoquan Sewage Authority (UOSA).
HITTING A BRICK WALL
The wastewater treatment plant handles upwards of 30

million gallons (11.3 million liters) per day and provides
potable water to more than 300,000 people in portions of
Fairfax and Prince William Counties. Its chemical treatment
system relies on a non-stop supply of pebble lime for
raising the pH to levels where bacteria and phosphorous
can be efficiently removed. After off-loading, the lime was

pneumatically conveyed up to six silos but transporting this
huge volume of abrasive material with three to four percent
grit at high velocities proved far too demanding for every
type of elbow Forgione and his mechanics and engineers
could find. Schedule 80 steel sweep elbows had worn
through in a few months. So did the short radius welded steel
elbows. And, so did similar long radius steel elbows. Ductile
iron piping and elbows lasted nearly a year. Then longer 10foot (3.05 meter) radius steel sweep elbows were installed.
They lasted for a year and a half. None worked.
Every time there was a failure, the line had to be shut
down and its silo taken offline. Inspecting elbows became
a daily ritual while maintenance personnel became expert
at welding temporary patches to keep the seventeen elbows
intact. Eventually, these would also wear beyond repair and
each time an elbow had to be replaced, it consumed hours,
along with the expense. Its very difficult for us to replace
an elbow, says Forgione. Not technically, but the elbows at
ground level are not easily accessed and the ones on top of
the silos are four stories up. Its a safety concern as well as a
cost concern.
Meanwhile, operations personnel were being diverted from
their more formal responsibilities to help with the cleanups.
About The Author

Miaja Marek is the advertising and marketing director for HammerTek Corporation. HammerTek is the inventor and
manufacturer of the Smart Elbow . Having recognized a need for extremely wear resistant and space efficient elbows,
the designers created a revolutionary elbow that operates by deflection. For more information, call 800.505.9665, email
elbows@hammertek.com, or visit www.hammertek.com.
26 | FEBRUARY 2015
We needed to make the elbows

last longer and we needed it done
fast, says Forgione. As far as the
type of elbow or material, wed
hit a brick wall.
A DIFFERENT APPROACH
Then Forgione came across the

Smart Elbow from HammerTek
Corp., Landisville, Pennsylvania.
A completely different approach,
the Smart Elbow has been
installed in some of the worlds
largest facilities that handle
highly abrasive materials such
as ceramics, plastics, grains, and
mineralsall without fail. The
Smart Elbow had been installed
at a wastewater treatment plant
in Alexandria, Va. to solve an
identical lime handling problem.
Under Forgiones direction,
UOSA Process Control Engineer
Ivan Romero and Mechanical
Manager Larry Brown toured
the facility. They were very
happy and hadnt had a single
blowout since installing the Smart
Elbow, Romero said, also noting
the cleanliness of their facility.
This 90-degree Smart Elbow from HammerTek diverts the pebble lime
in the pneumatic conveying line into a silo for storage. The sharp turn that
had tormented many different types of elbows has not been a concern for
the Smart Elbow, nor for facility management.
The HammerLoy Series Smart Elbow from HammerTekis one of fourteen
such elbows installed at the Upper Occoquan Water Reclamation Plant in
Centreville, Virginia, to eliminate pipe failures in the conveying line. After
more than four years in operation, all of the Smart Elbows continue to
perform as specified without a single pipe failure.
FEBRUARY 2015 | 27
MAINTENANCE solutions
You could see they werent having
any of the problems with leaks that we
were having.
GOING WITH THE FLOW
The Smart Elbow is based on the

natural flow patterns of fluids. It
combines a rounded chamber on
a tight radius elbow in a single,
rugged unit. The conveyed particles

gather and swirl inside the chamber
in a slowly-rotating, selfrenewing
ball, absorbing new material while
gradually releasing it in a firstin, first-out progression. Incoming
particles deflect off of this rotating
ball of air and material and continue
to the silo. Rather than inviting the
material to collide with the elbow

wall, this elbow virtually eliminates
such wearing impact, instead causing
gentle deflections that promote
directional change without affecting
system pressure.
Forgione tested Smart Elbows
and after more than a year without
any signs of wear, let alone a leak
or blowout, he replaced all of the
elbows at his second installation.
With assistance in specifying the
elbows from Joe Cathey of Cathey
Prosolutions, Sykesville, Maryland
who had originally specified the
Smart Elbows in the Alexandria
facilityfive 45-degree, four-inch
(101.6 millimeter) elbows were
installed where the trucks offload their
lime and nine 90-degree, four-inch
elbows were installed at the tops of
the silos. With careful consideration
of the characteristics of the lime, the
length and velocity of the pneumatic
conveying system and other factors,
Cathey recommended the HammerLoy
Series Smart Elbows, which feature a
custom alloy with impressive hardness
proven in handling abrasives. This is
what we specified in Alexandria and it
has performed as anticipated, Cathey
says. Six years have gone by since
installation there and none of them
has needed to be replaced.
A LONG-TERM SOLUTION
Similarly, four years have elapsed

since their installation at Forgiones
UOSA facilities and there hasnt been
a single blowout. With the Smart
Elbow, weve eliminated the primary
source of lime dust along with the
hazardous conditions it creates,
Forgione says. Maintenance and
labor costs have been reduced, safety
and air quality have been upgraded,
the building is visibly cleaner and
according to Romero, management
is enjoying some well-earned peace
of mind. As an engineer, it doesnt
matter what I think, what matters are
results, Romero says. The fact is, the
Smart Elbow is working, were happy
with it and I would recommend it to
anyone involved in handling lime.
Forgione adds, Our experience
with HammerTek has been excellent,
the delivery was fast and our
mechanics were able to install it pretty
quickly without any complaints. If we
ever get wear in an elbow anywhere
in the plant, well replace it with the
Smart Elbow.
28 | FEBRUARY 2015
PUMP solutions
Small and Simple

Watson-Marlows
120 peristaltic pump
answers customers
needs
By Russell Merritt,
Watson-Marlow Fluid
Technology Group
esigning and
manufacturing
equipment for the
biopharm sector requires a
number of talented people with a
wealth of training and expertise.
However, it also means listening
to what customers ask for. In
response to customers seeking
a small and simple cased
peristaltic pump, Watson Marlow
has launched their 120 pumps,
which are perfectly suited to
single-use systems where no
contamination can be accepted.
Ultimately the 120 pumps have been developed to increase
the low-flow capabilities of the company's product range for
applications in the biopharm sector. The market need for the
120 range is well understood, with customers voicing their own
mantra, "keep it small, keep it simple. Accordingly, the new
120 pump is focused on size, performance, and ease-of-use.
EXTENSIVE FEEDBACK
With development based on extensive feedback from

customers, Watson-Marlow Pumps Group has launched its 120
cased peristaltic pump range. The 120 pumps are perfectly
suited to single-use systems where no contamination can be
accepted.
Eric W. Johnson at Novozymes Inc, who was one of the first
people to use the 120 pump comments: "I love simple and
this has a small footprint without a lot of bells and whistles.

Easy menu, short learning curve, improved performance,
and hopefully zero maintenance, have generally left me very
impressed and satisfied with this unit."
The biopharm sector embraces applications such as
fermenter feed, an upstream process important in both
production and research, where the growth of cell cultures
demands an accurate and repeatable process with no
contamination. Ultra-compact and stackable for multiple feeds
like pH control, antifoam, nutrient and buffer addition, the
120 offers the ideal combination of size and technology to
optimize the process. The pump will also be effective where
the validation of drug research experiments demands accurate
flow rate, easy monitoring of parameters and process control.
Biopharm processes require accurate and repeatable
pumping that is easy to validate. With an exceptional 2,000:1
About The Author

Russell Merritt is the marketing manager for Watson-Marlow Fluid Technology Group and can be reached at 978.988.5307 or
russell.merritt@wmftg.com. Watson-Marlow Fluid Technology group is the worlds largest manufacturer of peristaltic pumps,
Biopharmaceutical grade tubing, Flexicon liquid filling systems, and BioPure single-use flow path components. For more
information, visit www.watson-marlow.com.
30 | FEBRUARY 2015
speed range (speed accuracy 1

percent) and a selection of USP
Class VI tubes, the 120 delivers
the flexibility and purity so vital to
drug trials.
SIZE IS A PRIORITY
Pump size was a priority on the

120 enclosure design because
benchtop space is a premium
for biopharm companies. Pumps
measure just 4.3 inches (110
millimeters) in width which is
significantly smaller than most
pumps offering similar flow rates.
The 120 pumps also benefit from
an intuitive interface which makes
them quick and simple to set-up
and reduces the number of key
presses and potential errors.
Simplicity is also captured by
the new 114 pumphead, where
the spring-loaded flip-top track
secures repetitive flow and
pressure performance. The 114
pumphead provides error-free tube
changing in only seconds, with
tubing clamped and tensioned
automatically to ensure repeatable
performance.
Ultimately the 120 pumps have

been developed to increase
the low-flow capabilities
of the company's product
range for applications in the
biopharm sector. The market
need for the 120 range is well
understood, with customers
voicing their own mantra,
"keep it small, keep it simple."
As a result, Watson-Marlow
has produced a pump that is
focused on size, performance
and ease-of-use.
INSTALLATION AND
PERFORMANCE
The unit also has a hygienic enclosure

ideally suited to ethanol wipedown, while the smooth lines of the
enclosure eliminate bug traps and help
prevent the tearing of gloves.
The illuminated numeric speed
display provides easy recording of
operating parameters, giving customers
greater flexibility and repeatability
in their processes. A keypad lock
prevents accidental key presses,
offering process security. All 120
pumps are IP31 rated and carry a three
year warranty. Processes are boosted
further through the use of WatsonMarlow's high tolerance tubing,
which is designed specifically to give
optimum performance in its pumps.
Further benefiting the bottom line,
operating costs can be predicted
for the customer over the lifetime
of the pump because tubing is the
only consumable. The ultra-quiet
120 cased pump range is available
with three different models for fixed
speed, manual or remote auto control,
and five single and multi-channel
pumpheads.
FEBRUARY 2015 | 31
PUMP solutions
Hidrostals pump cleans carrots for consumption

By Gennaro Poli, Hidrostal Ltd.
idrostal Ltd.,
renowned
manufacturers
of pumping products
to the water industry
have provided
a leading fresh
vegetable grower and
supplier, Produce
World Group, with an
enhanced solution for
the cleaning of carrots
in the vegetable
processing operation.
BOOM WASH
SYSTEM
Produce World is
the largest grower
and supplier of
high quality fresh
vegetables in the
The pre-wash process at Yaxley
United Kingdom and
one of the largest
in Europe. It provides a wide range of conventional and
organic vegetables to the major supermarket chains. All
its produce is picked fresh from the fields and processed
without the addition of any chemical additives.
Hidrostal have supplied Produce World with an
immersible pump to aid it in the pre-wash process at its
Yaxley site which deals exclusively in organic vegetables
including carrots. Upon arrival at the plant the carrots are
off loaded from a truck and pre-washed using recycled
wash water.
Produce World
had previously
used an enclosed
web, open belt
conveyor method
in this process
but the pump that
Hidrostal have
supplied is part
of a new open
catchment design
with a sloping
bench arrangement
to the sump area.
The boom wash
system aids the
movement and
flushing of newly
arrived field carrots
off the truck at the
very start of the
process into the
sump. The wash
water is pumped using Hidrostals immersible pump to a
rotary screened drum where most of the solids are filtered
out before re-entering the boom wash system once more.
This process occurs each time a truck arrives with fresh
field carrots.
THE COST OF CLEANLINESS
The carrots from the field, when mixed with the water,
leave a very abrasive media consisting of flint, stones,
About The Author

Gennaro Poli is a key account manager at Hidrostal Ltd. With over thirty years of experience and having deployed thousands
of pumping systems, Hidrostal fully understands the needs and technical requirements of todays pump users. For more
information, email sales@hidrostal.co.uk or visit www.hidrostal.co.uk.
32 | FEBRUARY 2015
immersible pump with its 5.5kW 4

pole 3 phase motor has resulted in
reducing power consumption by 50
percent, a huge power saving from the
previous end suction style pump that
required an 11 kilowatt motor.
Kevin Lander, the lead engineer
for Produce World, has enthused:
I have been very pleased with the
performance of this pump over the last

eighteen months. It has gone beyond
our expectations outlasting previous
designs three times over.
Hidrostal Ltd. are delighted that
the pump is functioning so well for
Produce World and look forward
to further opportunities within this
sector.
A Hidrostal immersible pump, similar to the one

installed at Yaxley.
sand, soil, weed, and the occasional

carrot! The common approach to
pump selection in this type of arduous
application has always been to err on
the side of caution and to compromise
by sacrificing pump efficiency for the
sake of a pump which can handle
solids and fibrous material; the result
being a forgiving impeller design but
greater power absorption and energy
usage.
In all cases the largest cost is the
running cost, the cost of electricity
which is affected directly by pump
efficiency. Produce World Yaxley took
the decision to change from the norm
and choose Hidrostal.
SCREW CENTRIFUGAL
IMPELLER AT WORK
The Hidrostal Screw Centrifugal

impeller is a unique design, whereby
the single spiral vane impeller is
axially extended creating a large free
passage for solids but at the same time
maintaining an optimum hydraulic
design leading to high efficiencies, low
shear pumping, and low velocity at the
pump inlet.
The Hidrostal pump retained the
desired solids handling capabilities
and has provided longevity in its
operation. The Hidrostal pump
has also ensured a reduction in
maintenance costs, down-time and
operational spend associated with
the cleaning and maintenance of the
previous open belt conveyor method.
SAVING ENERGY
MEANS SAVING MONEY
In addition, in this case the Hidrostal

FEBRUARY 2015 | 33
DEWATERING solutions
Screening SyStem eliminateS clogging

from membrane
bioreactor
Retrofit cuts upgrade costs
by one million dollars
By Kevin Bates,
JWC Environmental
n order to keep up with the rising population, increased

demands and tougher regulatory requirements, the U.S.
Army Schofield Barracks, Hawaiis largest Army post,
recently upgraded its wastewater treatment facility. The result
was improved efficiency and water quality, and decreased
environmental impact on the region.
The project was spearheaded by Aqua Engineers of Kauai
following a contract with the Army to privatize the facility.
Key to the projects ultimate success was technology from
JWC Environmental, Costa Mesa, California, and GE Water
and Process Technologies, a unit of General Electric Company.
PROJECT GOALS
The goals for the facility upgrade were both specific and
challenging. The plant needed to go from R2 quality effluent
to R1 quality effluent suitable for reuse in agriculture and
irrigation applications, and the crew also needed to increase
plant capacity by roughly 30 percent from 3.2 to 4.2
million gallons (12.1 to 15.9 million liters) per day. Another
requirement was providing a surge capacity of 15 million
gallons (56.7 million liters) per day to handle Oahus frequent
rainstorms, which further increased the design challenge. On
top of that, the total project needed to be completed without
major capital expenditure.
SOLUTION AND RESULTS
Aqua Engineers recommended General Electrics ZeeWeed

Membrane Bioreactor (MBR) technology to achieve the R1
quality effluent desired. This advanced wastewater treatment
system uses rugged hollow-fiber, ultrafiltration membranes in

order to protect the system from clogging and damage.
JWC Environmental recognized that protecting the
membrane is critical in these types of MBR systems. The
Bandscreen Monster was used because it provides excellent
membrane protection, since the entire screening operation
is done on the inside of the screen. This prevents any debris
from passing through and getting to the membrane itself. If
that were to happen, the debris could go all the way through
the process and wrap itself around a membrane, causing it to
either plug or break.
Originally, the project design called for building a
completely new separate screening facility downstream from
the existing installation to accommodate the new screens.
However, in working with JWC, the need for a separate
screening structure was eliminated, enabling the facility crew
to replace the old 0.23 inch (2 millimeter) screens with the
new 0.07 inch (2 millimeter) ones in the same channel. This
significant design change saved about one million dollars in
infrastructure and screen costs.
MONSTER SCREENS AT WORK
While a number of screens were considered, Aqua Engineers

selected the Bandscreen Monster and Screenings Washing
Monster from JWC Environmental as the most suitable for
the project. The screens are well-equipped to handle the
15 million gallons (56.7 million liters) per day per screen
requirement for storm surge capacity and were priced less
than competitive screens. The stainless steel construction is
About The Author

Kevin Bates is the global marketing director for JWC Environmental based in Costa Mesa, California. JWC Environmental
is a world leader in solids reduction and removal for the wastewater industry with its Muffin Monster grinders and Monster
screening, compaction and washing systems. Bates has more than twenty year of experience working with global industrial
leaders to solve challenging technical problems spanning a wide range of markets including wastewater, construction and
mining. For more information, visit www.jwce.com.
34 | FEBRUARY 2015
also more desirable for the humid environment. However,

one of the largest benefits is the fact that the Monster screens
could fit the existing channel without modification, something
other competitors were not able to offer.
This retrofit aspect of the screen systems was key to the
installations success, as it was absolutely critical that the
screen fit into the existing envelope without making any
changes to the concrete or other structures. The equipment
arrived at the scheduled time, and the crew was able to put
it directly into the channel without any modifications. This
smooth transition also was a large time-saving benefit.
The Bandscreen Monster offers high capture rates and is
able to remove a wider variety of waste solids, particularly
small solids, like trash and hair, better than traditional
screens. The product is particularly specified to protect
high-tech Membrane Bioreactors so they can run more
efficiently and with less maintenance. Unwanted solids are
captured on the UHMW plastic panels with 0.07, 0.11, or
0.23 inch (2, 3 or 6 millimeter) openings and lifted to the
discharge level where a spray system washes solids into the
Screenings Washer Monster, used for washing, dewatering and
compacting.
Used in conjunction with the Bandscreen Monster, the
Screenings Washer Monster was also employed at the
Schofield Barracks wastewater treatment facility. This selfcontained, hopper-fed system grinds, washes, compacts
and dewaters screenings. The removed solids contain up to
50 percent dry solids, are 80 percent compacted and are
significantly lighter and cleaner than typically screened
solids. This unique process of grinding prior to solids
separation removes virtually all of the soft organics from the

discharged product, which reduces odors and landfill costs.
A THOROUGH UPGRADE
In comparison to the previous screens used prior to the

upgrade, which only dewatered the material, the combined
Monster systems collects, washes and grinds the screenings
to produce a product that is relatively dry and free of organic
products. Not only did the screens reduce the size of the
materials passing through from 0.23 to 0.07 inch (6 to 2
millimeter), they also eliminated the odor, resulting in a much
better quality of waste going to the landfill.
Using the latest water treatment technologies available from
GE and JWC Environmental, Aqua Engineers improved the
local water quality and made more than 1 billion gallons (3.7
billion liters) of high-quality, recycled water a year available
for non-potable uses.
The Schofield Barracks wastewater treatment plant upgrade
enabled the plant to provide premium quality recycled water
to irrigate lawns, golf courses, parks and other sites on base,
positively affecting the nearly 28,000 military personnel, their
families, and civilians who work on base and nearby.
The upgrade has turned the plant into the largest privately
owned R-1 facility in Hawaii, and enables the military to
conserve water, decrease pollution and contribute to the
sustainability goals of the facility. After the upgrade was
completed, the treatment facility was awarded a Global
Ecomagination Leadership award for employing the latest
technology to achieve significant environmental and operating
improvements to meet community needs.
FEBRUARY 2015 | 35
MOTOR solutions
New Bearing Designs Meet

Demands for Extended
Pump Operating Life
By Barry J. Blair, Waukesha Bearings
he pump industry, like many others in todays

economic landscape, is striving to extend
equipment operating life while putting greater
demands on that equipment. Developments toward
longer life and increased productivity are creating
a chain reaction of demands, innovations and
improvements.
The technological advances in steam assisted
gravity drainage (SAGD) that are facilitating the
extraction of oil shale deposits also demand that
electric submersible pumps (ESPs) operate in higher
temperatures, and sometimes at higher speeds. Given
the high cost of a wells downtime, equipment is expected
to continue to perform even in upset conditions such as
contamination.
In the subsea pump industry, multiphase pumps are in

greater demand to shift the separation of oil and water or gas
and water to central processing facilities and eliminate the
need for auxiliary equipment. This introduces a wide range
of fluids and fluid viscosities, as well as abrasives, to the
equipment operating conditions, adding to the continued
drive to increase durability, load capacity and operating life.
BEARING REQUIREMENTS AND DESIGNS
As the industry continues to push the limits for greater

efficiency, the pumps require higher quality bearings with
a greater operating range. High temperatures in ESPs place
increased demands on the thrust bearings in the motor and
seal/protector sections of the string, and there is some push
for bearings that can operate with abrasives, when sealing is
compromised. The subsea pump industry not only requires
process-lubricated bearings for multiphase pumps; it needs a
low-stress leveling system that can operate with abrasives and
prevent wear over time.
About The Author

Barry J. Blair is chief engineer at Waukesha Bearings, headquartered in Pewaukee, Wisconsin. Blair has responsibilities for
fluid film bearing research and development activities, including new products and the refinement of bearing design tools
and methods.
36 | FEBRUARY 2015
THIS SECTION SPONSORED BY

To meet these demands, investment
in research and testing are necessary to
evaluate the limits on durability and the
performance margins of existing and
new bearing designs.
Bearing engineers are also
making a significant investment in
testing a plethora of materials. Each
material is evaluated for its ability to
accommodate higher temperatures,
higher loads, higher speeds, abrasives
and a variety of fluids (e.g., light
oils, high temperature oils, water,
multiphase).
WWW.FUSIONBABBITTING.COM
well as low viscosity fluids and

abrasives. These bearing designs also
offer pivot mechanisms that eliminate
the possibility of pivot wear while
providing load-equalizing capabilities.
CONCLUSION
When seeking a bearing solution, pump

manufacturers and operators need to
look to advanced materials and designs

that can keep pace with the other
technological advances in the industry
to extend pump operating life. The ideal
bearing supplier is a partner that can
serve as a reliable, consistent resource
for product and technical information,
ensuring the quality of the bearings for
the individual operating conditions.
THE LATEST BEARING SOLUTIONS

Recent bearing developments for
traditional oil-lubricated pumps include
new bearing designs and materials
that provide higher load capacity.
The benefit is twofold: the ability to
handle higher loads also allows for a
reduction in bearing size, resulting in
lower power loss. If size reduction is
not required, the higher load capacity
provides a more durable bearing with
higher safety margins for a given size
and load.
A new solution within the ESP
market, specific to SAGD, is the
Hidrax HT thrust bearing from
Waukesha Bearings, which addresses
the demand for temperature capabilities
beyond the limits of traditional ESP
bearing materials. The Hidrax HT
ceramic/cermet bearing surfaces
retain their strength, hardness and
load capacity in oil bath temperatures
in excess of 572 degrees Fahrenheit
(300 degrees Celsius). In addition to
handling high temperatures, the Hidrax
HT bearing has the potential to handle
abrasives.
For the subsea market, ceramic/
cermet bearings are handling higher
loads and higher temperatures, as
FEBRUARY 2015 | 37
POWER GENERATION solutions
THE WIND IS
BLOWING EAST
In South Korea and China, Alstom is
providing power generation solutions
By Ccile Dodat, Alstom Renewable Power
leaner energy
the installation and
commissioning of
and pumped
storage
six units of the ECO
technology are in
110 Wind Turbines
increased demand
with 295 foot (90
throughout the
meter) towers, each
with an output of 3
globe, and nowhere
megawatts. When
is that demand
greater than in
operational, the
wind farm will have
the expanding
a capacity of 18
economies of
South Korea and
megawatts.
The ECO 110
China. Alstom has
is equipped with
positioned itself to
Alstom Pure
aid these markets
Torque technology,
in meeting their
which protects
power generation
the transmission
needs. Alstoms
chain by diverting
ECO 110 Wind
unwanted stresses
Turbines are helping
Alstoms ECO 110 Wind Turbines reside in 295 foot (90 meter) towers, each with an output of 3 megawatts.
from the wind to the
optimize wind farm
performance, and
turbines tower and
Alstoms pumped
thereby optimizing
storage electromechanical equipment is helping China share
performance. Exclusively developed by Alstom and deployed
throughout its entire range of wind turbines, this technology
resources across many power stations to reach ideal capacity.
increases the reliability and durability of each turbine. In
BUILDING A BETTER WIND FARM
addition, the nacelles specific design made up of three
independent elements and of large dimensions, facilitates
DaeMyoung Energy Corporation, subsidiary company of
maintenance operations and safety inside of the machine.
DaeMyoung GEC, a large engineering and construction
The Gowon wind farm, the second secured by Alstom in
services company in South Korea has asked Alstom to provide
Korea this year, will be fully operational by the end of 2015
wind turbines for Gowon wind farm. The wind farm is
located in Gangwon province approximately 105 miles (170
and is set to support Koreas aim to have renewable energy
account for 20 percent of total electricity generated by
kilometers) east of Seoul. Alstom will supply and supervise
About The Author

Ccile Dodat is the media relations and content senior manager for Alstom Renewable Power. She can be contacted
at cecile.dodat@alstom.com. Alstom is a global leader in the world of power generation, power transmission and rail
infrastructure and sets the benchmark for innovative and environmentally friendly technologies. For more information, visit
www.alstom.com.
38 | FEBRUARY 2015
2020. With a population exceeding 50

million and limited domestic energy
sources, coupled with huge demand,
South Korea relies on imported sources
for 96 percent of its energy supply.
The Gowon wind farm will be
operated by joint owners Eurus Energy
Holdings Corporation (Eurus Energy)
and DaeMyoung Energy Corporation.
Eurus Energy is a leading Independent
Power Producer in Japan with over
2000 megawatts in operating assets.
Alstom has supplied wind turbines
for Eurus Energys Satomi Wind Farm
and is currently supplying turbines to
Kawazu Wind Farm in Japan.
We are pleased to be a part of
Koreas dedication to increasing its
renewable energy footprint. This
opportunity is significant as it will
represent our continued presence for
wind power in Korea and also working
with our important customer Eurus
Energy, saya Yves Rannou, senior vice
president, wind.
Alstom has been present in South
Korea for over forty-five years having
supplied to over 34 percent of hydro
plants as well as the first TGV export
systems solution in the KTX Project and
the first High Voltage Direct Current
link between Haenam and Jeju, among
others. Alstom is currently supplying
wind turbines to Gimnyeong wind
farm.
Alstom was awarded a contract by the Hainan Pumped

Storage Power Generation Co. Ltd. to equip Hainan
Provinces first pumped storage power station.
water will later be reused to generate

electricity to cover temporary peaks.
As another successful cooperation
with CSG, Alstoms leading pumped
storage technology will enable

Hainan Qiongzhong pumped storage
power station to respond quickly to
fluctuating power demand and to
manage demand peaks.
This contract demonstrates our
customers confidence and trust for
the quality and excellent execution
capability of Alstom team, and further
reinforces our leading position on the
hydro pumped storage power market.
I strongly believe that our global
expertise and complete local value
chain will best position us to tap the
booming Chineses pumped storage
power market, says Fabio Nossaes,
General Manager of Alstom Hydro
China.
Pumped storage is the most
widespread energy storage system in
use on power networks, and today
there is over 127 gigawatts of pumped
storage in operation around the world.
Alstom has been providing unitsthat
is, pump turbines and generators
for over fifty years and has supplied
140 units to date, which represents a
market share of more than 39 percent
and positions Alstom as the leader in
this field.
ADVANCED PUMPED STORAGE

POWER EQUIPMENT IN CHINA
Invested by China Southern Power

Grid (CSG), Hainan Qiongzhong
pumped storage power station is an
important supporting facility for the
Hainan Changjiang nuclear station in
terms of peak load regulation. Alstoms
largest hydro power manufacturing
site in Tianjin, China, will provide
a comprehensive range of pumped
storage electromechanical equipment
including Alstoms pump turbine,
motor generator and balance-of-plant,
as well as handling the design, delivery
and installation supervision of the
project. Alstom will provide three
200 megawatt unitsincluding pump
turbine, motor generator with other
key equipmentto the 600 megawatt
new plant. The first unit is due to enter
commercial operation on December
2017.
During off-peak hours, pumped
storage uses the energy from other
power stations to transfer water to
a high storage reservoir. The stored
FEBRUARY 2015 | 39
PROCESSING solutions
Using
Coriolis Mass Flow Meters
with Positive Displacement
Sliding Vane Pumps PART 2 OF 2
By Jeff Sietsema and Richard E. Foster, Blackmer
n part one of this article, we offered

a detailed look at the theory of
operation for Coriolis flow meters,
also known as mass flow meters, for
applications requiring very precise
delivery of high-value liquid product. In
this concluding entry, well examine the
testing results as well as introduce some
valuable observations from the field.
FLOW PRECISION
A test was designed to demonstrate and

compare the accuracy of the Coriolis
mass flow meter and the positive

displacement meters historically used at
Blackmers Research and Development
Laboratory. To provide an alternate
method of measuring flow, a 300-gallon
(1135 liter) tank was placed on four
500-pound (226 kilogram) precision
NIST-traceable load cells. The load cells
and electronic instrumentation were
selected so that the precision of the
weight-flow measurement would have
a tighter tolerance than the mass flow
meter at some of the lower flow rates.
A pump and the test flow meter were

piped to another tank such that all the
flow moving from the supply tank was
metered as it entered the fill tank. The
test pump was operated at constant
speed with minimum back pressure (no
valve throttling) to obtain a constant flow
rate while emptying the supply tank. The
weight of the supply tank was recorded
every 0.1 seconds so that a mass flow
rate could be directly recorded. The
density of the water was measured with
an NIST-traceable hydrometer so the
About The Authors

Jeff Sietsema is the Research & Development Lab manager, and Richard E. Foster is director of engineering for Blackmer,
the leading global brand of innovative and high-quality rotary vane and centrifugal pump, and reciprocating compressor
technologies for the transfer of liquids and gasses. Part of PSG, a Dover Company, Blackmer pumps and compressors are
used in a multitude of applications in the process, energy, and military and marine markets. For more information, visit
www.blackmer.com.
40 | FEBRUARY 2015
Diagram 1
Supply Tank
Fill Tank
Coriolis or Positive
Displacement Flow
Meter
Pump
Load
Cells
Flow
Figure 5 : Characteristics of Flow Meters Used During Precision Test

FLOW METER
Characteristic
PD Meter
Coriolis Meter
Flow Range
10-150 gpm
8-800 gpm
Porting
2"
3"
Output Signal
Frequency
Frequency
Accuracy
.5 to 1% of FS
0.1 to 0.4% of actual flow reading
ACCURACY AT TESTED FLOW RATES

9 gpm
1.0 gpm
0.04 gpm
72 gpm
1.5 gpm
0.07 gpm
118 gpm
1.5 gpm
0.18 gpm
1 Based on water flow

rate - lower density
results in higher flow,
higher density results in
lower flow
2 Based on calibration
data for the meter
tested. Tighter precision
possible based on
meter selection
3 Lower accuracy
occurs at lower flow
rates and drops to
0.1% of reading at
approximately 15% of
maximum flow rate
mass flow rate (measured in pounds

per second) could be converted into a
gallons-per-minute flow rate. A drawing
of the test setup is depicted in Diagram
1, as well as a chart of the characteristics
of the flow meters tested (see figure 5).
Three basic flow rates were tested: 9,
72, and 118 gallons per minute. Data
was collected the entire time the pump
was in operation, recording flow-meter
readings and the weight of the supply
tank. About five seconds after pump
startup, flow became very consistent
until the supply tank was nearly
emptied. The data from the steady-state
flow intervals is shown in figures 6
through 11.
The graphs show the precision of
each test meter and the precision of the
weight method of flow measurement.
Precision of the flow meters is the
published calibration/ accuracy
specifications at the tested flow rates.
The weight-method precision is a
function of the accuracy of each load
cell, the amount of weight that was
moved during the measurement and
the amount of time required to move
the measured weight. The low flow
rate (9 gallons per minute; or 34 liters
FEBRUARY 2015 | 41
PROCESSING solutions
Figure 6:
Precision Chart for Nominal 9-gpm Flow Rate
12.0
11.0
Flow Rate (GPM)
10.0
9.0
8.0
7.0
Meter Lower Limit

Meter Upper Limit
Weight Method w/Precision
6.0
0
50
100
150
200
250
300
350
Time (Seconds)
Positive Displacement Meter
Figure 7:
Coriolis Meter
13.0
12.0
Flow Rate (GPM)
11.0
10.0
9.0
8.0
Meter Lower Limit
7.0
Meter Upper Limit

6.0
0
50
100
150
200
250
300
350
Time (Seconds)
Figure 8:
OBSERVATIONS FROM THE FIELD
82
80
78
Flow Rate (GPM)
76
74
72
70
Meter Lower Limit
68
Meter Upper Limit

66
0
10
20
30
40
Time (Seconds)
42 | FEBRUARY 2015
50
60
70
per minute) produced the most precise weight-measured

flow because more time was required to remove the
approximately 900 pounds (408 kilograms) of water. As flow
rate was increased, less time was required and the weightmethod precision tolerances increased.
As can be seen, the precision of the Coriolis meter is
much tighter than the positive displacement meter, and
was as precise as the weight method at 9 gallons (34 liters)
per minute and more precise at the higher flow rates. The
Coriolis flow meter and the weight method have a high
degree of correlation and statistically are indistinguishable
over the entire time and range of flow measured. On the
other hand, the positive displacement meter, with a much
wider precision range, does not conform as well to the
weight method of flow measurement.
An unanticipated error of the weight method did occur
during the precision tests. It was observed that the weight
measurements fluctuated much more than the precision
of the load cells would indicate. The tank of water, sitting
on four load cells, inadvertently became a spring-mass
system. The weight on the load cells fluctuated with system
vibrations, such as mechanical vibration and pressure
pulses from the pump. To correct for this, the weight
uncertainty was estimated by comparing the theoretical
mass flow (overall weight change compared to overall time
passed) to the actual observed weight loss for each recorded
time interval. The average fluctuation for all of the time
intervals was added to the overall precision of the weight
method, increasing the tolerance of the flow rate. The
interesting thing about this is that the positive displacement
meter consistently produced more weight variation than the
Coriolis flow meter.
As can be seen on the precision graphs, the tolerance
of the weight-method flow rate is larger for the PD meter
than the Coriolis flow meter, even though the flow rates are
nearly identical. The widest discrepancy was observed at
the mid-range flow rate. Earlier discussion of how pressure
pulses may affect the Coriolis flow meter showed that this
was not observed in the tests conducted. The system did not
seem to affect the meter. The opposite of that was proven
during the weight-method precision test; the meter has an
effect on the system. While the effects of the Coriolis flow
meter could not be separated from pump variations, the
positive displacement meter effects are quantifiable.
80
The decision to invest in Coriolis mass flow meter

measurement technology in Blackmers Research and
Development Laboratory and production facilities was
based on observations from Blackmers customer base.
Many Blackmer customers have evaluated Coriolis flow
meters and found them to be the best flow-measurement
solution in systems where Blackmer pumps are applied.
Increased flow-measurement precision and higher reliability
were the most common improvements cited by end-users.
For example, EMCO Chemical Distributors, Inc. of Pleasant
Prairie, Wisconsin, reports excellent results using Blackmer
sliding vane pumps in systems that use Coriolis flow meters
for flow measurement. A recent multiple pump installation
at EMCO for railcar unloading has yielded highly reliable
system performance and excellent measurement accuracy
with no reported problems after eighteen months in
operation.
80
78
76
Flow Rate (GPM)
Flow meters from two highly respected equipment

manufacturers were purchased in an effort to eliminate
possible bias between brands of the same technology.
One unexpected observation that was discovered
during testing was in noise generation. In both LPG
and solvent tests, Coriolis mass flow meters (from both
manufacturers) operated with less airborne noise than
the positive displacement (PD) meters that Blackmer had
been using. The PD meter devices generated their own
pressure pulses in the discharge line. We had become
accustomed to the noise and had accepted it. We were
very favorably impressed with how quiet the new meters
were in operation.
We attempted to operate the sliding vane pumps at
speeds where the pressure-pulse frequencies would be
at the same resonant frequencies as the Coriolis flow
meters themselves. We then varied the speeds to levels
(pressure-pulse frequencies) above and below the meters
published natural frequency. We could not induce any
constructive or destructive interference into the vibrating
Coriolis tubes by intentionally operating them in the
natural frequency range of the tube spring/mass system.
Nothing we could do within the normal operation of the
pumps caused any degradation of meter accuracy.
Proper mounting of the meter was found to be critical
for accurate and reliable meter performance at low flow
rates. Mounting the meter horizontally was the only
application parameter that we determined to have an
effect on the meters.
Measurement precision and repeatability were
markedly better with the Coriolis flow meters than
Blackmers PD flow-measurement technology. This was
determined by measuring the weight (mass) of the liquid
pumped with highly accurate NIST-traceable load cells
to verify the actual performance of both the PD meter(s)
and the Coriolis mass flow meters.
Blackmers customer base has a great deal of
experience using Blackmer pumps with Coriolis mass
flow-measurement technology. We have had no reports
from the field of any incompatibilities or other issues to
date after many years of service.
The meter test results from Blackmers Research
and Development Laboratory have been compelling
enough to convince us to install the Coriolis flow
meters on our production test stands. We have installed
an Endress+Hauser mass flow meter on one of our
production pump test rigs. This rig tests three different
sizes of Blackmer sliding vane LPG pumps daily. We
have experienced greatly improved measurement
accuracy and very good reliability in a production
environment.
82
74
72
70
Meter Lower Limit
68
Meter Upper Limit

66
0
20
10
30
40
60
50
70
80
Time (Seconds)
Coriolis Meter
Figure 10:
Positive Displacement Meter
124
122
120
118
Flow Rate (GPM)
DISCUSSION AND CONCLUSIONS
Figure 9:
116
114
112
110
108
Meter Lower Limit
Meter Upper Limit
106
104
0
10
15
20
25
30
35
40
45
Time (Seconds)
Figure 11:
Coriolis Meter
124
122
120
118
Flow Rate (GPM)
Blackmer sliding vane pumps are often applied in fueltransfer applications. Blackmer provides pumps to major
petroleum distributors that have switched from positive
displacement meters to Coriolis mass flow meters in
systems where Blackmer pumps were installed. Again,
information from the field is positive in the installed
base where Blackmer sliding vanes pumps are used in
conjunction with the Coriolis flow meters. This further
supported Blackmers decision to investigateand,
ultimately, invest inthe technology.
116
114
112
110
108
Meter Lower Limit
Meter Upper Limit
106
104
0
10
15
20
25
30
35
40
45
Time (Seconds)
FEBRUARY 2015 | 43
VALVES & CONTROLS solutions
Take the Knife to High Costs

in Wastewater Treatment
Specialty AWWA C520-10 knife gate valve
saves construction and operating costs
By Dick Smith
ey knife gate valves have been

used in the municipal sewage
treatment market for nearly
fifty years. The valve incorporates unique
design features that overcome typical
problems found in other knife gate valve
designs. Today, the Wey knife gate valve
has spread throughout the industry in
all of Central Europe and other parts
of the world where the original valve
installations continue to perform
successfully.
Increased valve flow capacity (Cv)

will result in improved overall plant
efficiency due to reduced pumping
motor power consumption.
ENERGY SAVINGS AS A RESULT

OF GREATER VALVE FLOW
CAPACITY (CV)
This following case study is based on an

actual sewage treatment plant expansion
where the valves were supplied by Wey
Valve, Inc. (see Table 1) and presents
these four premises:
Valve Size
Quantity
3 inch (76.2 millimeter)
16
58
30
15
10 inch (254 millimeter)
16 inch (406.4millimeter)
Reduced valve envelope sizes

results in smaller building sizes.
Reduced valve size and weight
results in reduced foundation and
pipe support sizes.
Reduced valve face-to-face
dimensions results in less piping.
The basis for the cost comparison was
a listing of flow capacities (Cv) for a
popular eccentric plug valve (70 to 80
percent area) vs the Wey model VM knife
gate valve.
The headloss (H) in feet through
a valve is determined by: H = (Q/
Cv)2 X 2.31 where Q is in gallons per
minute and the power consumed (P) in
horsepower, is determined by
P = QH / [3960(e)]
Table 1: Size and quantity of valves used in sewage

treatment plant expansion.
where (e) is the overall pump/motor efficiency.
Cv Ratings Eccentric Plug Value versus Wey Model VM Knife Gate Valve
80000
70000
Cv Ratings
60000
50000
40000
30000
Wey VM Model KGV
20000
Eccentric Plug Valve
10000
0
6"
8"
10"
Valve Size
12"
14"
16"
The estimated
annual power
cost will be
based on 75
percent use, 8
fps, 70 percent
overall pump/
motor system
efficiency and
$0.09/KWH
power cost.
The estimated
annual power
cost for each
valve under
the assumed
conditions is as
follows:
For More Information

Wey Valve Inc. was founded in Nettleton, Mississippi as the North American sales and manufacturing headquarters for the
Wey brand valve line. Since then, Wey Valve Inc. has developed various specialized models of knife gate and shear gate
valves to solve specific process problems.
44 | FEBRUARY 2015
Operating cost per year Eccentric Plug Value versus Wey Model VM Knife Gate Valve in US dollar*
10000
US Dollars
1000
Wey VM Model KGV
100
*Based on .09/KWH & 8 FPS Flow Rate
Eccentric Plug Valve

10
1
3"
4"
6"
8"
10"
12"
Valve Size
14"
16"
18"
20"
24"
Positive Seat
Seal
The seat in
Wey knife
gate valves is
a combination
of metal and
elastomer. The
elastomer is
mechanically
retained to
prevent "pullout". The gate
is guided and
supported for
the full length
of the stroke
which when
combined
with the seat
seal provides bidirectional bubbletight shut-off from
-28" Hg vacuum to
full pressure rating.
By taking the
Annual Usage Costs
annual cost savings
Annual
per valve size times
Valve Size
Quantity
Eccentric
Savings
Wey
VM
the number of valves
Plug Valve
used on the project
16
$336.00
$24.00
$312.00
the total annual
cost savings when
58
$2378.00
$116.00
$2262.00
using Wey knife
Self-Cleaning
30
$2880.00
$30.00
$2850.00
gate valves on this
Design
15
$3330.00
$36.00
$3294.00
project will yield
Wey knife gate
a $17,372 year
valves have a unique
10 inch (254 millimeter)
7
$2240.00
$21.00
$2219.00
one cost savings or
gate geometry and
5
$2505.00
$20.00
$2485.00
a cost savings of
body bore contours
$434,300 over a
to prevent solids
4
$3068.00
$24.00
$3044.00
twenty-five year life
from clogging in
16 inch (406.4millimeter)
1
$916.00
$10.00
$906.00
of the project.
the valve. There is
It is noteworthy
little space for solids
139
Total annual savings $17,372.00
that despite the
to build up and
Table 2: Projected annual cost savings.
fact that the Wey
in the event some
model VM valve
small amount of
has a substantially larger flow capacity
a bad reputation in the municipal
solids is present, it is flushed out during
than the commonly used eccentric plug
wastewater treatment market. Major
actuation.
valve, the average selling price of the
problems that users have found include
Wey valve is less than the eccentric
leakage to the exterior of the valve
Reduced Operating Force
plug valve. Eccentric plug valves are
past the top gland as well as leakage
The unique gate geometry again plays a
also available with 100% bore areas
past the seat of the valve. Knife gate
role in reducing operating force along
(higher Cv's) but with a substantial price
valves have also been known for
with a molecular graphed polymer
premium that more than offsets any
solids jamming in the seat and chest
infusion on the stem reduces operating
savings in energy costs.
areas of the valve and requiring high
friction. Manually actuated valves utilize
Further cost advantages associated
input torque to actuate the valve, with
a non-rising "jack screw" mechanism to
unreliable actuation after prolonged
with the use of the model VM valve
open and close the valves resulting in
periods of non-use. However, Wey
include reductions in building
saved envelope space.
Valve offers time-tested proven
space, size and cost of footings and
solutions to these common problems.
foundations, piping, and size and
Long Life Reliability
numbers of pipe hangers. Also, use
An important measure of reliability in
Top Transverse Seal
of the model VM valve could make it
the wastewater treatment industry is
Wey knife gate valves do not make
possible to use potentially smaller valve
how long a valve can remain "dormant"
use of stuffing box and packing gland
sizes and reduced pump and motor
and then operate dependably after
top seal designs. Instead, a unique top
sizes. Furthermore, the Wey model VM
many years of inactivity. Wey Valves
"transverse" seal prevents leakage to
knife gate valve fully complies with the
have a proven reputation for reliable
the exterior. If leakage does eventually
AWWA C520-10.
operation after many years without
occur, the valve can be repacked while
operation. Experienced engineers often
in service and under full pressure. (See
RETHINKING KNIFE GATE VALVES
specify Wey knife gate valves for this
link to packing demonstration.)
Knife gate valves in general have had
reason alone.
FEBRUARY 2015 | 45
SEALING solutions
Strategic Mechanical
Seal Partnerships
Building owner-manufacturer
relationships that benefit all parties
Part 1 of 2
By Heinz P. Bloch, Process Machinery Consulting
t would be
inappropriate to
criticize equitable
owner-manufacturer
partnerships;
however, there is still
a need to become
more aware of the
hidden, long-term
adverse effects of onesided partnerships or
alliances. That said,
the purpose of this
article is twofold: One
is to steer readers
away from onesided partnerships or
vendor alliances. The
second is to explain
why global singlesource procurement
strategies for
reliability-critical
components rarely (if
ever) meet a buyers overall objectives
and expectations.
The decision to single-source
reliability-critical components often
has unforeseen consequences and is
decidedly not made with employee
training in mind. Global purchasing
of mechanical seals can stifle the
incentive for the global partners
competitors to call on you in the
future. You then no longer have access
to and are no longer acquiring an
understanding of innovative products.
Figure 1: A highly effective tapered, bi-directional, pumping ring (Innovative Vendor).
It is those innovative products which

can greatly benefit modern user
plants. Once a plant shuts out all
but one component supplier, other
contenders will usually abandon their
valuable teaching and mentoring
roles. When that happens, the
purchaser ends up on the losing end
of an inevitable chain of events.
SINGLE-SOURCING AND ITS

UNINTENDED CONSEQUENCES
There can be significant drawbacks
to the highly publicized global
supplier agreements which supply

chain experts now often advocate.
Years ago, such drawbacks were
recognized by an organization starting
up a large grass roots olefins plant.
The owners had initially asked the
EPC (engineering and procurement
contractor) to purchase mechanical
seals exclusively from winning
bidder Aa well-known worldwide
supplier. Although starting up with
100 percent of these parts being
supplied by Vendor A, compelling
reasons to add B and C became
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.
46 | FEBRUARY 2015
evident very soon after plant startup. As

matters stand today, decades later and
after certain disappointments with A,
that vendors products are still installed
in 75 to 80 percent of the process
pumps at this plant.
Yet, the other 20 to 25 percent
of the facilitys mechanical seals
have long since been divided up by
manufacturers B and C. All three
vendors compete well and are eager
to conduct periodic technology update
briefings for the olefin plants engineers
and operating technicians. Due to
moves toward global procurement it is
not unusual to find owner-user facilities
with only onesolidly entrenched
seal vendor. Because they are the
designated supplier, single-source
vendors often see no incentive to alert
their customers to superior solutions
offered by others.
To illustrate: Only Vendor C
makes the tapered pumping ring in
figure 1. This proprietary component
opens up interesting solutions for
moving fluid from the smaller of the
tapered rings two diameters to the
larger one. Efficient flow movement
is accomplished by its impeller-like
Figure 2: Cog-style pumping rings associated with relatively inefficient flowrate and heat removal capability
(Vendor B).
geometry with large clearance between

this rotating part and the surrounding
stationary seal parts. Careful
examination of the more traditional
pumping rings offered by A and B
(figure 2) may disclose much narrower
clearances and H/Q (head vs. flow)

characteristics less desirable than
those of figure 1. Chances are that
preferred vendor A never shares this
information with any of its locked-in
clients.
FEBRUARY 2015 | 47
SEALING solutions
MAKING ALLIANCES
MUTUALLY BENEFICIAL
As mentioned earlier, not all

mechanical seal supplier agreements
benefit both parties equally and
some rather one-sided alliances
exist. At a pump users conference
the suggestion was made that the
supposed seal alliance partner
should disclose pumping services

where another manufacturers seal
would outperform the partners
products. One seal manufacturer
participating at the conference
disparaged the suggestion; another
vendor simply said they had no
comment.
Fortunately, there is at least one
well-known major manufacturer with

experience in what we really need:
sealing products that represent best
life-cycle cost value. And, of course,
the application of sealing products
which represent best long-term value
is the only approach that makes sense,
regardless of whether these products
are
Already in your plant and
originally supplied by one of the
alliance partners competitors,
Supplied by your alliance partner
company and installed in your
plant at the next downtime event,
or
Supplied by one of the alliance
partners competitors and installed
in your plant during the next
downtime event.
Note also that a knowledgeable
partner supplier will often point
out substantial and valuable pump
improvement opportunities. The
implementation credits for these
measures will not only outlive seal
life, but will drive up equipment
MTBR/MTBF (mean-time-betweenrepairs/mean-time-between-failures)
as well. Valuable maintenance
cost savings will result from such
cooperative communications.
For an agreement to meet the test
of mutual benefit, achieving at least
90 percent of the seal life obtained
elsewhere for a given service should
be one of the stipulated goals.
Since energy efficiency, regulatory
compliance and effective supply
chain management are part of the
life-cycle cost objectives, the use of
(dry) gas seals, and perhaps even seals
manufactured by the competition,
cannot be ruled out. Since the
partners must share data on best
available sealing technology, the
supplier must compile and disclose
this technology to the user. User and
supplier will then have joint access to
all available data and can track their
combined achievements against best
available technology.
The supplier should benefit from a
base fee paid and should, in addition,
earn a success fee that gradually
peaks at achieving the 90 percent
mark mentioned above. Additional
bonuses may be negotiated and predefined as the 90 percent mark is
exceeded.
48 | FEBRUARY 2015
DEFINE THE SCOPE OF SUPPLY AND

STIPULATE BUY-BACK PROVISIONS
The supplier should agree to furnish
products and services including
Mechanical seal hardware (complete

seals and components) and/or the
repair of same for a given population
of rotating equipment as defined in
an appropriate tabulation that will
have to be appended to the narrated
agreement.
Detailed and specific instructions,
assessments, life-cycle cost
impact calculations (including
energy efficiency) and other
recommendations, as needed for
enhancing the reliability of all
sealing systems predefined and
covered by the agreement.
Training of operators and
maintenance workforces on a
predefined time schedule. Unless
otherwise agreed, training is to be
conducted quarterly.
An on-site technician is to be
supplied. This technician should
spend a specified number of manhours per year at the users facility.
Management of the supply chain

of the inventory of complete seals,
the rebuilding of seals (regardless
of origin), without jeopardizing the
availability of equipment within
the population to meet the plant
production requirements.
Conceivably, the supplier should
purchase the current and useable
mechanical seal inventory from
the usersubject to the following
conditions:
The inventory must be utilized on
equipment currently in use and
expected to be in use over the term
of the contract.
The inventory must be of current
design and suitable for providing
reliability commensurate with the
goals set forth in this agreement.
The inventory meeting the above
criteria should be acquired by the
supplier at an agreed discount on its
present book value.
The inventory should be paid for
in the form of a credit memo to
be used to offset the base fees to
be paid to the supplier. The credit

memo should not exceed a defined
share of the base fee in any given
month over the life of the contract.
Any inventory purchased by the
supplier that has not been used in
fulfilling this contract should be
repurchased by the plant owner at
the termination or completion of
this contract. Repurchase should
be at the same price as paid by the
supplier, plus carrying costs of the
unused inventory at 10 percent per
year.
A LOOK AHEAD
Although it is not our intention to

prescribe iron-clad stipulations or the
exact wording one must use, all mature
owner-manufacturer relationships
are anchored in communication,
cooperation, and consideration. In the
second part of this article, 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.
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
FEBRUARY 2015 | 49
MODERN PUMPING products

JWC ENVIRONMENTAL
10K Series Muffin Monster
Sewage Grinder
The new 10K Series Muffin Monster from JWC Environmental

combines superior waste grinding capabilities in a compact,
easy-to-install unit thats perfectly suited to a variety of
wastewater grinding applications. This newest addition to the
hard-working family of Muffin Monster grinders is available in
pipeline, open channel and pump station configurations that
pack big power in
a small package.
The 10K Series
Muffin Monster
incorporates the
same benefits
of the larger
Monster units,
including lowspeed operation
with high torque
and less interrupts. The dual-shaft design actively pulls material
into and through the hardened steel cutters, so the grinder
can handle a wider variety of debris compared to single-shaft
macerators and grinders.
Featured Product Release
For more information, contact Kevin Bates at 714.428.4647

or kevinb@jwce.com or visit www.jwce.com.
FLOWROX
Expulse Pulsation Dampener

We all know that a fluent process without any distractions is the ultimate goal for any modern plant. One of
the distractions can be caused by pulsation, which is a common issue with several positive displacement
pumps and can result to annoying noise and vibrations in the process pipeline. It can
also potentially lead to breakages over time. Flowrox Expulse is a flexible inline
pulsation dampener, which settles restless pipes, pressure peaks and uneven
flows. The design is based on a double hose structure with an expansive inner
hose, reinforced outer hose and compressed air in between the two. Due to its
structure, Flowrox Expulse is able to absorb up to 90 percentages of pulsations
and even more in the right process conditions. The dampener also enables
energy savings in pumping by reducing vibrations and by temporarily storing
pressure to the flexible inner hose. For more information, conctact Josh Baci, sales
order process and engineering manager, at 410.636.2250 or sales@flowrox.com.
GRIFFCO VALVE INC.
Unibody Back Pressure and Pressure Relief Valves

Griffco Valve Inc. introduces its new leak-free Unibody valve for use in chemical-feed, metering,
and dosing pump systems. Available as a back pressure valve and 2-port pressure relief valve,
Unibody features single-piece construction with union connections machined together with the
valve body to form a solid piece of material. It is engineered to be the most reliable and universal
valve on the market, virtually eliminating downtime and extending performance life, according
to the company. Griffco Valve products are sold worldwide through authorized distributors.
The new Unibody allows for fast installation with standard union connections that
can be configured to any piping material. Trouble-free and leak-free operation is
ensured because there are no threads, gaskets, glues or welds to cause problems.
Servicing the system is easy with simple, quick union disconnects, and because the
valves have standard dimensions to ensure drop-in replacement, according to Griffco
Valve. For specific product information and to download a technical bulletin, visit
www.griffcovalve.com/products/back-pressure-valves/unibody.
50 | FEBRUARY 2015
MORGAN MOLTEN METAL SYSTEMS

HotRod Sheaths
Morgans Molten Metal Systems business announces its HotRod pyrometry sheaths and other
pyrometer assembly products, which protect thermocouples in furnace heating control systems.
Industry proven for over 30 years, the pyrometer assemblies are made of a durable,
erosion-resistant clay-graphite mix with special plasticity properties, which is then
extruded into the proper shape. The pryometer assemblies are designed to have
a metal wire inserted into them, and are then put into a metal bath to measure
the temperature. HotRod sheaths are designed for used in furnaces and other
high temperature environments, and are supplied with a inch (12.7 millimeter)
threaded steel tube for quick and easy attachment to the furnace pyrometry system.
For more information, visit www.morganmms.com/hotrod-sheaths.
OMEGA ENGINEERING INC.
SVH-110 High Pressure Solenoid Valve

The SVH-110 Series direct acting solenoid valves are normally closed valves that open when energized
and close when de-energized. When the coil is energized the plunger lifts the piston off the valve seat,
opening the valve. Upon de-energizing the coil, a spring closes the piston to seat it. The normally open
valve operates similarly, closing when energized and opening when de-energized. No minimum pressure is
required. The SVH-110 Series are used to control the flow of high pressure air, water, hydrogen, nitrogen and
other gases or light liquids compatible with materials of construction. They are also suitable for cryogenic
applications. For more information, call 800.TC.OMEGA or 203.359.1660, or visit www.omega.com.
SEEWATER INC.
Simple Simplex
Control Panels
The Simple Simplex (SSP-X) high quality, low

cost control panels are designed to alert of a
high liquid level and control a 120/208/240V
pump under 1HP. The SSP-1 and
SSP-2
feature 2 and 3 float operation.
The SSP-3 Plugger includes
a 120V
receptacle
for quick
and easy
installation
of the
pump/
pump
switch.
Standard
features:
8 inch x
6 inch
x 4 inch
NEMA 4X
indoor/
outdoor
enclosure,
red beacon
alarm light,
85 decibel
buzzer, alarm test and silence buttons. Ideal
for sewage pump chamber, sump pump
basin, and onsite applications (UL Listed/
Made in the USA/Three-Year Warranty). For
more information, call 888.733.9283 or visit
www.seewaterinc.com.
ALL-FLO PUMP
COMPANY
A100 and A150 Stainless

Steel and Aluminum Pumps
All-Flo Pump Company has launched a
line of air operated diaphragm pumps
that has raised the bar on efficiency
standards across the industry. Now available is the 1 inch
(A100) and 1- inch (A150) stainless steel and aluminum pump
models. For use in a wide variety of chemical and fluid transfer
applications, the new air operated diaphragm pump line offers
an extended set of improved feature over legacy products. The 1
inch (A100) and 1- inch (A150) models complement All-Flos
already available inch (A050) and 2 inch (A200) products. The
newly designed All-Flo pump boasts a new, high-efficiency, air
valve, built with fewer parts, making it the most efficient pumps
in the industry. This significant cost-savings comes at a good time
for customers as energy costs continue to increase. For more
information, visit www.all-flo.com.
FEBRUARY 2015 | 51
PUMPING trends
REUSE, REPURPOSE,
AND RETHINK
Dr. Lynn E. Broaddus

on the crisis facing U.S.
freshwater resources
r. Lynn E. Broaddus is the president

of Broadview Collaborative,
Inc., a think tank specializing in
resource sustainability at the intersections
of water, energy, food, soil, buildings,
and transportation. Recently, she led
the Charting New Waters initiative for
the Johnson Foundations at Wingspread,
and was a featured speaker at the 2014
WEFTEC exhibition, where she spoke
with Modern Pumping Today on the crisis facing U.S. freshwater
resources and the increasing demand for water reuse and
repurposing.
Modern Pumping Today: How would you describe the state of
U.S. freshwater resources?
Dr. Lynn E. Broaddus: The crisis facing freshwater resources really
boils down to two things: quality and quantity. In certain areas of
the country, we really are running out of water for a number of
reasons. Its been over-pumped from groundwater resources, and
its been over-transferred around the country. And, although the
Clean Water Act has made a huge difference, in other areas, the
challenge exists around water quality where, over time, pollution
from non-point runoff is building up and we see the proverbial
death by a thousand cuts.
For example, the Toledo water crisis really exemplified this
problem. Toledo sits on Lake Erie and, despite the vast amount
of water available in the surrounding rivers and the Great Lakes
themselves, phosphorus and nitrogen had built upprimarily
from agricultural runoff, to some extent from urban pollution.
That build-up and the slow warming of the water temperature due
to climate change created the perfect soup for cyanobacteria, or
toxic algae, to blossom. Cyanobacteria contain neurotoxins
obviously a dangerous addition to the water supplywhich led the
city to shut down its water system for two days.
But this is not a forty-eight-hour problem, and its not limited to
Lake Erie. The real solution is to address non-point runoff.
MPT: How can we go about better protecting the water supply?
Dr. Lynn E. Broaddus: One is to do a better job of treating water
and recovering nutrients from our urban sewage treatment plants
and also a better job of working with rural residents and our food
producers to manage their properties, and in particular their soil
health, so that those soils can hold nutrients better rather than lose
them to their water.
MPT: What information have you received from your agricultural
partners that has been most helpful?
Dr. Lynn E. Broaddus: They are facing a time of great challenges.
Our agricultural producers care deeply about being able to feed
the planet. They see a growing population and feel an urgent need
52 | FEBRUARY 2015
to increase their production, which means applying more fertilizers

and farming their land more intensely. However, this creates a
challenge for their water supply. So how can we meet growing
demand with a limited land base, with stresses on our water, and
with a limited phosphorous supply? Ag people are squeezed on
one end, water providers are squeezed on the other, and on top of
it all, both are feeling pressure from a changing climate.
MPT: What role do the limits of an ever-ageing infrastructure
play?
Dr. Lynn E. Broaddus: America is in dire need of a more efficient
water distribution system. We are losing a massive amount of
water every day. Estimates are anywhere from 10 to 40 percent
depending on where you live. Plus, we have a significant
amount of clean water being wasted by ending up in our sewage
systembe that by rainwater or groundwaterand were spending
resources treating that water unnecessarily.
Eventually, we might require a full transition to a more efficient
system, but for now we see resource managers beginning to
experiment and tinker with new distributed technologies where
they can treat wastewater onsite, collect stormwater or foundation
water for use onsite, rather than transport it long distances through
urban areas.
Heres where we really see industry leading the waycertainly
through entrepreneurship and new technologies but also with their
existing internal operations, which are at the forefront of water
reuse and water collection. They are meeting their own needs
for internal cooling, landscape irrigation, or even for internal
processes.
MPT: How can the water industry play a part in shaping that
transition?
Dr. Lynn E. Broaddus: Its critical that the water and wastewater
industries shore up their existing approach relative to water
availability and energy availability. When companies collect and
reuse water onsite, theyre not only saving money in the long run
but also insuring themselves against disruptions or overstressed
demand in the supply. You see this already with regard to energy
efficiency: more and more companies capture some of their
energy expenditure onsite to repurpose back into their production
processes, which not only insures them against demand but also
fluctuations in price.
Were seeing a great deal of innovation in parts of the country
where people have already seen some of these limitations placed
on their water supply or where regulations have been put in place
that incentivize reusing and repurposing water rather than pay
stormwater charges. One of the most exciting things happening
in the wastewater industry is the push to become energy neutral,
which will make a major contribution to both enabling Americas
energy independence and reducing greenhouse gas emissions. We
really have phenomenal resources available to uswe just havent
had to be that careful before.

Modern Pumping - 022015

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MODERN

12 Remotely Managing Pumps on the Farm

water & wastewater solutIons

16 The Pursuit of a Green Carbon Steel Corrosion Inhibitor

22 How to Select the Most Effective Blower Technology

for Wastewater Applications

26 Eliminating Pipe Failures from Pneumatic Conveying Line

30 Small and Simple

Watson-Marlow's 120 peristaltic pump answers customers' needs

Hidrostal's pump cleans carrots for consumption

34 Screening System Eliminates Clogging from Membrane Bioreactor

36 New Bearing Designs Meet Demands for Extended Pump

Power generatIon solutIons

38 The Wind Is Blowing East

In South Korea and China, Alstom is providing power generation solutions

P.O. Box 660197 | Birmingham, Alabama 35266

40 Using Coriolis Mass Flow Meters

with Positive Displacement Sliding Vane Pumps

RANDY ARMISTEAD Associate Publisher

ValVes & Controls

44 Take the Knife to High Costs in Wastewater Treatment

DONNA CAMPBELL Editorial Director

JAMIE WILLETT Circulation Consultant

46 Strategic Mechanical Seal Partnerships

INGRID BERKY Administrative Assistant

Building owner-manufacturer relationships that benefit all parties

JEFF FLETCHER Associate Publisher

TONYA BROWNING Account Executive

Modern PuMPIng ProduCts

DAVID MARLOW Account Executive

52 Reuse, Repurpose, and Rethink

Dr. Lynn E. Broaddus on the crisis facing U.S. freshwater resources

312 Lorna Square | Birmingham, Alabama 35216

EDITORIAL ADVISORY BOARD

Drives and Motion Solution Engineer

Heinz P. Bloch, P.E.

Consultant and Trainer,

Business Development Manager,

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

Trey Walters, P.E.

For address changes, please contact Lindey Scott:

President, Applied Flow Technology

The ExOne Company, a global provider of three-dimensional

our customers expectations and product quality standards

HI/FSA LAUNCHES INTRODUCTION TO

Beginning Tuesday, March 10, 2015, the Hydraulic Institute

SMITH & LOVELESS INC. ACQUIRES SCHLOSS

Smith & Loveless Inc., the global leader in advanced grit

WATEREUSE SYMPOSIUM CALL FOR ABSTRACTS

The WateReuse Association is accepting abstracts for

QUANTUMFLO UPGRADES NASCARS DAYTONA

Award-winning pump technology leader, QuantumFlo, is

ASHRAE, IAQA APPROVE CONSOLIDATION

A consolidation between ASHRAE and the Indoor

TRADE SHOW profile

WWETT SHOW 2015

ttended by over 4000 septic, sewer, and

For thirty-five years WWETT exhibitors have been

The WWETT Show places a premium on continuing

IMCA), Southern Section Collection Systems

Given the recent news of a West

ade Qualls has been farming in Lake

During watering season, irrigation happens

One day in late spring of 2014, Qualls was