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CONTENTS AUGUST 2014

4 Industry News

10 Trade Show Prof ile Case Studies 12 To Be or Not To Be Prepared for Floods

16 Sustainable Savings for Wastewater Treatment First North American installation of environmentally friendly deammonication system saves $200,000 per year

Water & WastewaterSolutions

20 Recycling Earth's Rapidly Shrinking Resource A basic primer on how food and beverage plants can reuse water effectively and efciently Part 1 in a 3-Part Series

24 A Holistic Approach to Process Control Providing process improvement and energy savings Part 1 in a 2-Part Series

Maintenance Solutions 30 Making More "Elbow" Room

Vortab's Elbow Flow Conditioner removes swirl in tight spaces

Pump Solutions 34 How to Select Diaphragms for AODD Pumps

Asking the right questions and utilizing the best available tools will help AODD pump operators maximize diaphragm lifePart 1 in a 2-Part Series

36 The Right Tool for Many JobsLandia chopper pumps nd a variety of uses across the country

Dewatering Solutions 38 Pressure Sewer System Success InvisiQTM offers an alternative to gravity sewage problems

Motor Solutions 40 Intelligent Pumping Means Eff icient Motor Use

Energy-optimized pumps feature integrated MLE motor to simplify commissioning, startup

42 AMPing It UpIntroducing the industry's rst online asset management tool for critical drivetrain couplings

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www.modernpumpingtoday.comP.O. Box 660197 | Birmingham, Alaba

No part of this publication may be reproduced or transmittedmeans, electronic or mechanical, including photocopy, recorstorage-and-retrieval system without permission in writing views expressed by those not on the staff ofModern Pumping Today , or who arnot specically employed by Highlands Publications, Inc., aIndustry News material has either been submitted by the subdirectly from their corporate website, which is assumedrelease. Comments and submissions are welcome, and [email protected].

For address changes, please contact Lindey Scott:[email protected]

TIM GARMONPresident

LARRY DAUGHETY Vice President

DENNIS DAUGHETY Vice President

www.highlandspublications.com312 Lorna Square | Birmingham, Alab

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@ModPumpMag

RUSSELL HADDOCK COO/Publisher [email protected]

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DONNA CAMPBELL Editorial [email protected]

SCOTT GORDON Art [email protected]

CHRIS GARMON General [email protected]

LINDEY SCOTT Circulation [email protected]

JAMIE WILLETT Circulation Consultant

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

TONYA BROWNING Account Executive

RANDY MOON Account Executive

Terry BellDrives and Motion Solution Engineer

Baldor Electric Company

Heinz P. Bloch, P.E.Consulting Engineer,

Process Machinery Consulting

Robert G. HavrinDirector of Technology,Centrisys Corporation

Michael ManciniConsultant and Trainer,

Mancini Consulting Services

John M. RoachEngineering Manager

for New Product Development,Trebor International, Inc.:

A Uni t of IDEX

Lisa RilesBusiness Development Manager,

Wastewater Pumps Xylem Inc.: Flygt

Greg TowsleyDirector of Regulatory andTechnical Affairs,Grundfos

Trey Walters, P.E.President, Applied Flow Technology

EDITORIAL ADVISORY BOARD

Power GenerationSolutions

46 The Power Is Out There EIA projections show hydro growth limited by economics not resources

Processing Solutions 48 Vital Components in High Demand

AUMA actuators adopted by the Caspian Pipeline Consortium

Valves & ControlsSolutions

50 One Moving Part, One AnswerCeramPump's valveless design improves denitrication

Sealing Solutions 52 Change Is in the Air New pressure/temperature sensor ends testing leaks, brings data to users

54 Modern PumpingProducts

Featured Product Release: McCROMETER's FPI-XTM Dual Sensor Electromagnetic Flow Meter

Pumping Trends 56 Ontario Is On Tap WaterTAP's Dr. Brian Mergelas highlights Ontario's lead position in the water industry's revolution

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4 | AUGUST 2014 www.modernpumpingtoday.com

INDUSTRY news

DEMATIC CMMS SOFTWARE SUPPORTS RESIDENTMAINTENANCE PROGRAM

Dematic, a supplier of logistics systems for the factory,warehouse and distribution center, has enhanced its ResidentMaintenance Program by including Dematic ComputerizedMaintenance Management Software (CMMS) with every on-sitemaintenance contract. The CMMS allows on-site maintenance

teams to more effectively manage maintenance activities whileincreasing uptime and operating performance of automatedmaterial handling systems and other infrastructure systems at theuser’s si te.

Dematic CMMS is a robust and flexible software tool capableof increasing the productivity and reliability of your mechanicaland electrical equipment. The software provides the toolsneeded to assess and track equipment repairs, forecast futurerepairs, and maximize uptime. Dematic CMMS incorporatesall the planning and scheduling of required maintenance andensures the technicians have the right parts available whenand where needed. In addition, the CMMS offers instantaccess to data for generating high level reports and graphicrepresentations that provide the insight required to identify,diagnose and take corrective action on potential issues beforethey become a problem. Dematic CMMS also offers automatedand customized notifications, predictive analytics, spare partmanagement, along with resource scheduling and forecasting.

The Dematic Resident Maintenance program providesproduction, warehousing and distribution operations withtechnicians who perform preventive, correct ive and emergencymaintenance, as well as operational assistance to ensure thematerial handling system functions at optimum efficiency.

Dematic can also provide service support for other facilityinfrastructure such as HVAC, manual fork trucks, etc. ResidentMaintenance offers a range of options from a specific sub-system support team to a complex facility support staff. DematicResident Maintenance programs increase performance, reduceoperating costs and prolong the life cycle of systems. The netbenefit to the customer is: dependable operation and high

system uptime.FLOWROX LAUNCHES NEW INDUSTRIALIMAGING INSTRUMENT

Flowrox, a global leader in heavy-duty industrial valve, pumpsand instrumentation manufacturing and service, is releasing tothe oil and gas market the Flowrox Deposition Watch—a newinstrument designed to enhance the monitoring of pipelinesand related flow-process equipment affected by paraffin waxand asphaltene depositions. The Flowrox Deposition Watch isa predictive device, as opposed to reactive solutions offered bycompetitors, allowing its operators to address deposition issueswell before these reach critical levels that can cause downtimeor costly damage.

Crude oil contains a variety of molecular substances thatchallenge the oil and gas companies with the buildup of paraffinwax when it crystallizes into a solid deposition on the pipewall—along with the accumulation of asphaletene—which canaltogether reduce the fluid flow or plug pipes and valves. Thedeposition of paraffin wax and asphaltenes is a common reasonfor a major decrease in production and revenue in oil wells asit affects valves, pumps and pipelines, along with other pipelinecomponents critical to the fluid control process.

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INDUSTRY news

The Flowrox Deposition Watch was developed specificallyfor use in the oil and gas industry since this instrumentwill allow customers to generate real-time images of anydepositions affecting a piping system—without ever having toopen up the pipeline and slow down production.

“This is completely new technology which has very littlecompetition,” says Todd Loudin, president and CEO of North

American Operations for Flowrox. “The Flowrox DepositionWatch can model mathematically deposition profiles andprovide calculations on the free available pipe remaining.”

Using the Flowrox Deposition Watch will allow theindustry to make better decisions regarding when to addchemicals and the frequency of addition of these expensivechemicals for treatment of depositions, as well as allowingthem to make better decisions regarding when to disassemblea pipeline for manual cleaning. The cost of an unplannedshutdown due to deposits has the potential for becoming acatastrophic event in the operation, and thus engineers andoperators tend to overfeed chemicals to cleanse depositionsor schedule more physical cleanings of the pipeline thannecessary.

The Flowrox Deposition Watch utilizes electricalcapacitance tomography (ECT) to create real time imagesof the inside of the piping and uses electrical capacitancetomography to detect the differences in permittivity of thevarious substances found in the p iping system. In addition,the Flowrox Deposition Watch utilizes a patented algorithmthat creates a 3D image of the process fluid in the piping andgenerates trend data as well as show free volume inside thepipe and the growth rate of the deposition growth over time.

Ultimately, the Flowrox Deposition Watch can show itsoperators the deposition thickness, deposition profile, growthrates over time, composition, and free flow volume—all ofwhich allow engineers to understand areas where pipes areprone to these damaging deposits.

YASKAWA ACQUIRES SOLECTRIA RENEWABLES, LLC

Yaskawa Electric Corporation and Solectria Renewables,LLC announced recently that the companies have reached adefinitive agreement whereby Yaskawa Electric will acquireSolectria Renewables through its US subsidiary, YaskawaAmerica Inc. Solectria Renewables will continue to operate as a

Headquartered in Lawrence, Massachusetts, Solectriamanufactures high performance photovoltaic (PV) inverters forthe residential, commercial, and utility-scale power systems.Since being founded in 2005, Solectria has grown to becomea leader in the North American solar market. The companyemploys over 160 people throughout the United States. whollyowned subsidiary.

Founded in 1915, Yaskawa Electric is a $3.6 billion globalleader in factory automation solutions, and has also establisheda leadership position in the low power PV inverter market in

Japan.This acquisition will benefit Yaskawa and Solectria customers

alike. Yaskawa will bring scale, global sales, and manufacturingfacilities, as well as diversification to Solectria. Likewise,Solectria will bring over twenty years of power electronicsexperience, ten dedicated to the PV industry, and an indepth knowledge of medium and high voltage PV products toYaskawa.

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INDUSTRY news

Yaskawa America president and COO, Mike Knapek, explains:“This is an effort to broaden Yaskawa’s exposure in the renewableenergy market and expand the use of our technology expertise.Solectria has built a strong and successful organization in thesolar inverter market over the past ten years. The philosophiesand strategies of both organizations are highly aligned onenabling sales growth and market expansion through superior

customer experiences. We are very excited to bring Solectria intothe Yaskawa family to provide world leading inverter solutions.”Solectria CEO, James Worden, says, “While this is a significant

step for Solectria, I am even more thrilled about what it meansfor our customers. They will have the same management teamand personal interaction they are accustomed to, with theadvantage of a powerful, diversified, global partner. Our entireteam should feel incredibly proud about what we have built overthe past 10 years, but the best is yet to come.“

FIRELANDS ELECTRIC COOPERATIVE TO EMPLOYACLARA’S ETWACS SYSTEM

Firelands Electric Cooperative (FEC) today announced plansto use the new eTWACS® power line communications systemfrom Aclara Technologies LLC, a leading provider of smartinfrastructure technologies to water, gas and electric utilities, forits advanced metering infrastructure (AMI) requirements.

Based in New London, Ohio, FEC will begin AMI deploymentto replace residential, commercial and substation technologywith eTWACS communications modules, receivers, metertransponders, receivers and processors by summer 2017, layingthe foundation for incremental deployment of future, advancedtechnologies.

“It has been a very positive experience working with Aclara’spersonnel,” says April Bordas, general manager at FEC. “Ihave talked to many other general managers and cooperativeemployees about their eTWACS system and have receivednothing but positive comments. We are excited about the benefitsof our new AMI system.”

Aclara’s advanced technology will allow utilities to collect and

analyze valuable data to better serve their customers. Utilitiescan also implement other uses over time, like outage assessmentand restoration, voltage monitoring and energy monitoring fordistributed generation through net metering.

eTWACS technology dramatically increases the capacity toperform daily, interval and on-request meter reads to meet thedata requirements of FEC. Data provided by Aclara’s AMI systemwill allow the utility to better understand patterns of usage andidentify programs to reduce system peaks and cos ts. Moreover,meters on the eTWACS system can be connected automatically,eliminating service calls.

“Our eTWACS system offers utilities the flexibility to performoutage management, load control and distribution management,”says Roxy Podlogar, director of product management at Aclara.“The time it takes to retrieve a full complement of 'shifted'meter data from a 5000-meter bus, including intervals, voltages,kilowatt hours, tamper indicators, error flags and demand, isabout twenty minutes.”

Utilities employing eTWACS product can send and receivemore data via power lines. The eTWACS protocol providesconcurrent, bi-directional transmission of data simultaneously.All substation buses are read in parallel, and the protocol allowsa single outbound command to retrieve data from all feeders.■

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The Texas A&MTurbomachineryLaboratory sponsorsthe two annual symposia,held in the fall of each year,to promote professionaldevelopment, technologytransfer, peer networking,and information exchangeamong industry professionals.These two events are led byengineers with vast experiencein the petrochemical,process, chemical, utility,contractor, and consulting fields, along withmanufacturers of rotating equipment andfluid-handling equipment from around theworld.

Both symposia feature lectures, tutorials,case studies, discussion groups, and shortcourses, as well as exhibits of the latestservices and full-sized equipment. Theseinternational meetings emphasize thetechnology and troubleshooting that usersneed in today's challenging workplace.

CONNECT WITH YOUR INDUSTRY

The Pump and Turbomachinery Symposiacontinue to be the only meeting organized byusers for users. The members of the AdvisoryCommittee, who provide overall guidance, arerecognized leaders in the rotating equipment

and power generation community. TheSymposia provide an outstanding opportunityfor users concerned with maintenance,performance, troubleshooting, operation, andpurchase of rotating equipment. The technicalsessions provide an opportunity for attendeesto select lectures, tutorials, discussion groups,and case studies that best meet their personaland professional needs and interests.

Discussion groups highlight this “user-focused” approach that truly elevatesthe Pump and Turbomachinery Symposiaexperience. Peer-to-peer interaction andnetworking opportunities abound throughoutthe Symposia events.

PUMP AND

TURBOMACHINERYSYMPOSIA 2014


TRADE SHOW prof ile

Topics for this year’s discussion groups include• Vertical Pump Problems and Solutions• Couplings and Alignment• Monitoring Vibration and Other Critical Machine

Conditions• Subsea Pumps and Drivers• Centrifugal Pump Operation, Maintenance, and

Reliability• Improving Mean Time Between Pump Failures• Monitoring Vibration and Other Critical Machine

Conditions

LEADERS IN THE FIELD

The exhibits feature products from many key companiesin the industry. Exhibiting companies normally sendtheir "first-team" players to these symposia; hence,you can get knowledgeable help at the exhibit hall, inaddition to seeing major exhibits of equipment, designs,

and accessories. Prospective exhibitors at this year’sSymposia include companies such as St. Marys Carbon,Cincinnati Gearing Systems, Graphite MetallizingCorp., and many others.

CONTINUING EDUCATION

The Turbomachinery Laboratory provides continuingeducation opportunities to users of industrialturbomachinery and pumping systems at theannual International Pump Users Symposium andTurbomachinery Symposium. The five short coursesprovide attendees the best of both worlds in terms ofintroducing important developments in the context oftoday’s industry, yet also offering detailed attention andclarity to technical concerns. ■

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AUGUST 2014 | 11www.modernpumpingtoday.com

Don’t Miss The Top Exhibitors This Yea

Make Your Plans Now and Schedulean Appointment TODAY!

AMERICAN SPINCAST254.613.5150www.amspincast.comBooth # 1549

BASETEK, LLC877.712.2273www.basetek.comBooth # 451

BOERGER, LLC612.435.7341www.boerger.comBooth # 318

CINCINNATI GEARING SYSTEMS513.527.8634www.cincinnatigearingsystems.comBooth # 841

CMI ROTATING SERVICE CENTER, INC.281.487.2354www.rscturbo.comBooth # 1200

EX ONE724.765.1328www.exone.comBooth # 216

FLUID ENERGY CONTROLS323.721.0588www.fecintl.comBooth # 850

FUSION BABBITTING CO., INC.414.645.5800www.fusionbabbitting.comBooth # 551

GARTNER COATINGS281.997.3500www.gartnercoatings.comBooth # 1042

HILLIARD CORPORATION607.733.7121www.hilliardcorp.comBooth # 713

KSB, INC.804.222.1818www.ksbusa.comBooth # 538

PUMPWORKS 610888.405.0209www.pumpworks610.comBooth # 416

R + W AMERICA630.521.9911www.rw-america.comBooth # 406

REM SURFACE ENGINEERING860.621.6755www.remchem.comBooth # 852

SIMERICS256.489.1480www.simerics.comBooth # 410

ST. MARYS CARBON814.781.7333www.stmaryscarbon.comBooth # 432

TURBO FILTRATION, LLC251.457.8807www.tfcglobal.comBooth # 1935

UNIVERSAL PLANT SERVICES281.479.6000www.universalplant.comBooth # 1733

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CASE Studies

It’s safe to say that most of thecountry has experienced extremelyvolatile weather within the last fewyears. Research shows that weatherpatterns are, and will continue to be,increasingly volatile due to changingclimate trends. Whether it’s dauntinglycold temperatures or unexpected heavysnowfall—it’s no longer a question ofif severe weather will occur, but ratherwhen , and when it will affect yourassets.

The risk of floods are increasing asthe climate becomes more volatile, andnow more than ever, it is important tounderstand what led us to this point

and how to stay ahead of floodingwaters. Information is power, andpreparation is key to protecting assetsin an emergency situation.

IMPACTS OF CLIMATE CHANGE

The earth’s climate is influenced byboth natural and human factors, fromseasonal ocean cycles like El Niño andLa Niña to deforestation, agriculture

and urbanization. Communities,infrastructure and governments areall at risk of negative impacts due toa changing climate. One of the mostdevastating results is the increasein the frequency of volatile weather

events, such as flooding. Scientistshave taken note of a greater number ofthe more extreme weather occurrencesin recent years. New research suggeststhat warming in the arctic region isresulting in a weaker temperaturecontrast that is slowing down the jetstream. This has led to slower movingweather systems or ones that havebeen persisting for longer periods of

time over the same areas. Extremeweather tends to occur more often withthese stalled weather systems.

In 2007, the Intergovernmental Panelon Climate Change (IPCC) concludedthat intense rain events have become

Jeremy Duensing i s the transportation product manager at Schneider Electric based in Minneapolis. In addit ion to severalyears on the forecast desk, he has also started a forecast verification program and is a member of the American MeteorologicalSociety ITS/Surface Transportation Weather Committee. Jeff Johnson currently serves as the Schneider Electric’s chief scienceofficer and is a certified consulting meteorologist, whose certification illustrates the highest level of professionalism and overall

knowledge of the science of meteorology. For more information, visit www.schneider-electric.com .

About The Authors

By Jeremy Duensing and Jeff Johnson, Schneider Electric

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more frequent in the last fifty years.This, combined with increased run-offfrom land use changes, means moresignificant flash flood events can andwill occur. In addition, as the oceanswarm, scientists predict that thenumber of hurricanes, and potentially

their intensity, could increase. Highersea levels from warmer waters also canlead to greater storm surges.

According to the U.S. GeologicalSurvey, flooding already costs theU.S. more than seven billion dollarsin damages, killing more than ninetypeople annually. Increased floodinghas potential to wreak even morehavoc on dense populations, with3800 towns and cities in the floodplain.

From that, it’s not surprising thatfloods claimed more in terms ofnumber of lives and property damagethan any other type of natural disasterduring the last century. By the end ofthe century, assuming no change inbuilt infrastructure or values, a 2013article in the Journal of Flood RiskManagement projected an increase ofapproximately 30 percent in damagesfrom flooding alone. These trendsare likely to continue; an article inNature found the recent emergence ofa statistically significant positive trendin the risk of great floods is consistentwith results from a climate model, andthat model suggests that the trend willpersist.

Accurate, real-time data givea complete picture of conditionsdecision-makers face, essential in orderto properly prepare for an increasein frequency and severity of floods.Improved visibility allows faster,more informed decisions based onaggregated data rather than estimatingwhen a disaster will affect certainassets. Traditionally, several disparatesources were needed to gather

information on the two key factors thatdetermined flood conditions: floodingparameters and weather conditions.Today, software can integrate allpertinent information into a singlesource that provides a clear, real-timesnapshot of the environment.

FLOODING PARAMETERS:WHAT TO WATCH FOR

A clear understanding of the mostcritical parameters to monitor for apotential flood is essential: water level,tide prediction and wave height. Newtechnology gives asset managers the

ability to set alert parameters and tobe notified whenever one of thesefactors crosses a threshold that triggersa response.

Tide Prediction

Tide predictions are based on the

gravitational force of the moon andsun acting on large bodies of water

at a given time. These are especiallyhelpful when severe weather andrainfall are approaching, as the tidecan significantly impact the severityof conditions. For example, a stormthat hits at low tide may not requirethe same level of preparation and

resources as a storm that arrives at hightide.

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CASE Studies

Water Level The measurement of a body of water’s level is an obviousfactor when determining the likelihood of a flood, but quickaccess to accurate readings may be difficult. Plott ing waterlevel observations from thousands of ocean buoys and rivergauges alongside other high-impact weather informationsuch as radar and local storm reports, a system manager

increases his or her situational awareness with a real-time,geographic representation of high-impact ocean tides andriver depths.

In addition, hourly forecasts of ocean water levels givecritical guidance on where large-scale weather patterns will

have an impact on tide levels in the future. This pinpointsspecific times of day where a normal tide may be higherthan expected due to strong storms and winds.

Wave Height High tide timing and levels are key as well as waveconditions during that time frame, to help best estimate how

infrastructure may be impacted. High waves may have littleimpact if they are predicted to occur during low tide. Thesesame high waves occurring during a higher than normal tidemay have a much higher impact and will direct the size andtype of response necessary.

Above: Water level and wave height hourly forecast

Left: River stage observations

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WEATHER FORECASTING ISESSENTIAL

Current technologies can combinereal-time data with accurate weatherforecasting to give public safetyofficials an even more powerful toolfor storm preparedness. Operators

now have the ability to use a real-timemap of water conditions that can alsodisplay hourly forecasts to achieveoptimal awareness of when waterlevels, tides and wave heights willcoincide with high-impact weather.

The climate is changing, and with itthe frequency and increasing severityof extreme weather events, includingfloods. Pumping system operatorsmust have a clear view of currentcircumstances in their territory, aswell as an accurate understanding ofhow forecasted weather events willstrengthen or mitigate the impact ofsevere weather. With an aggregatedview of flooding parameters andintegrated weather forecasts, resourcescan be mobilized more quickly,communities can receive moreadvanced warning, and managers canbe better informed to protect peopleand infrastructure. ■

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CASE Studies

Sustainable solutions can offer more than justenvironmental benefits. Green technologies can offersignificant cost savings as wel l. Virginia utility HamptonRoads Sanitation District (HRSD) was looking for thesewhen Chief of Special Projects, Charles Bott, approached

World Water Works, a leading designer and manufacturer ofwastewater treatment solutions, about the innovative and veryenvironmentally friendly Demon® deammonification system.

This unique system replaces the complicated methods ofconventional nitrogen removal with a two-step single-stageprocess that provides many benefits. In addition to reducing afacility’s energy requirements and carbon footprint, this processcompletely eliminates the need for chemicals. A few months

after installation, HRSD has not only been presented with theAmerican Association of Environmental Engineers and Scientists(AAEES) Honor Award for Environmental Sustainability, but isalso on track to save $200,000 this year.

When companies talk about sustainable solutions, they often

focus strictly on the environmental benefits and the upfrontcost of the installation. However, with systems like the Demon® treatment process, innovations that help save the environmentcan also help to save your facility money.

UPGRADING CAPACITY WITH INNOVATION

HRSD operates thirteen different wastewater treatment plantsacross southeast Virginia, serving over 1.6 million people and

Chandler Johnson is the chief technology officer at World Water Works, manufacturer of specialized advancedwater treatment solutions focused on performance, flexibility, and longevity. For more information, visitwww.worldwaterworks.com

.

About The Author

By Chandler Johnson, World Water Works

S USTAINABLE S AVINGSFOR W ASTEWATER

T REATMENT

First North American installationof environmentally friendly

deammonification system saves$200,000 per year

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handling a total of249 million gallons(942 million liters) perday. Since its foundingin 1940, the grouphas been dedicatedto innovation in

wastewater treatment,pioneering newtechnologies andeven patenting uniqueprocesses.

HRSD initiallyapproached the projectfrom the perspectiveof cost management.Responding tonew regulations onwastewater quality,HRSD had addeddenitrification filters to its York River plant. This upgrade wasundertaken with the expectation that the plant would beexpanded from 15 million gallons (56.8 million liters) per dayper day to 30 million gallons (113.5 mil lion liters) per day, butwhen that expansion was delayed, they were left with a partial15 million gallons (56.8 million l iters) per day and partial 30million gallons (113.5 million liters) per day plant that was veryexpensive to operate from a chemical standpoint.

Manager Charles Bott had seen operational Demon® systemswhile over in Europe, and when he returned stateside, he

was sure this was theperfect solution forHRSD. “With a lot ofthese processes that areemerging in Europe,they almost seem toogood to be true,” he

explains. “But once yousee them in action, andyou see that they areaccomplishing exactlywhat they promise.When I got back fromGermany, I was dyingfor a Demon®.”

A CHEMICAL-FREEAND CARBON-FIXING PROCESS

The process wasdeveloped by researchers at the University of Innsbruck, led byDr. Bernhard Wett, as an alternative to traditional methods forremoving ammonia from wastewater.

Conventional nitrogen removal has required a large amountof energy, a carbon source—usually methanol, and often otherchemicals as well. These systems use a multi-step nitrification/ denitrification process: The waste ammonia (NH3) is oxidizedto nitrite by ammonia oxidizing bacteria (AOB); this nitrite isoxidized again to nitrate by nitrite oxidizing bacteria (NOB);and then this nitrate is converted into nitrogen gas in two

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CASE Studies

additional biological steps. The first twosteps require relatively high levels ofdissolved oxygen, supplied by blowers.The last two require an additional carbonsource (usually methanol) and producea large amount of sludge, which isexpensive to handle and dispose.

Demon®

changes all of this. Itemploys a two-step, single-stage process

to provide equally effective nit rogenremoval. First, the same ammoniaoxidizing bacteria convert about half ofthe ammonia into nitrite. Next, a secondclass of bacteria (Anammox) converts theremaining ammonia with this nitrite toproduce nitrogen gas. Anammox bacteria

work in an anaerobic environment, sothis second step requires no dissolved

oxygen and therefore no extra energy.It also requires no methanol or otherchemicals.

Overall, the system completelyeliminates the need for chemicals, greatlyreduces sludge handling volumes byup to 90 percent and reduces nitrogen

removal energy requirements by up to 60percent. In addition, since the Anammoxconsumes carbon dioxide, the process iscarbon fixing and can reduce the carbonfootprint of a wastewater treatmentfacility.

“When you look at the process andconventional nitrogen removal side-by-side, there’s really no comparison,” saysBott, “For a facility like the York Rivertreatment plant, where the chemicalcosts were so expensive, a chemical-freeprocess was exactly what we needed.”

THE FIRST NORTH AMERICANINSTALLATION

Bott approached World Water Works,about installing a Demon® system atthe York treatment plant because WorldWater Works first introduced the systemto the North American market, andhas the exclusive right to distribute thesystem in the United States.

For HRSD, World Water Works couldsee that it was just a perfect fit. First off,HRSD already had much of the rightequipment. The plant’s existing batchreactors and equalization tanks couldeasily and quickly be retrofitted for theprocess. More importantly, though, theyhad people who understood the processand were invested in bringing the latesttechnologies to their facilities.

But a full scale Demon® system wasyet to be installed outside of Europe. Oneof the main reasons for this was the needfor seed Anammox bacteria in order tostart up the system. It took two and a halfyears for Dr. Wett to cult ivate enoughbacteria for the first operating Demon® installation in Austria. Other European

plants could obtain start-up Anammoxfrom this plant, and purchase moreif necessary to keep their installationrunning.

This would not be so easy for HRSD,since shipping the seed bacteria overseaswould be both expensive and logisticallydifficult. But fortunately, World WaterWorks had the right relationships withEuropean facilities and had alreadydeveloped the infrastructure to supplyAnammox to installations in the UnitedStates.

With this harvesting ability, WorldWater Works and HRSD were able to

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go through with the installation. Giventhe set-up at the York River plant, therelatively simple and inexpensiveimplementation took fewer than fourmonths. Successful operation hascontinued since January.

“The start-up went very smoothly.

World Water Works provided greattechnical support and great supportoverall,” says Bott.

LOW MAINTENANCE,HIGH REWARDThe York River Treatment Plant’s Demon® system has fulfilled the hopes HRSDhad for it. Although the energy savingsare harder to quantify, the chemicalsavings have been extremely significant.By reducing the volume of methanoland other chemicals used at the site,the utility will be able to save about$200,000 per year.

“Demon® would have reduced costs forany plant, but in this particular instanceit significantly reduced costs from achemical standpoint,” explains Bott.

The system is also low maintenanceand, after a little getting used to, requiresa low amount of operational oversight.A specially designed biomass separationdevice keeps bacteria levels stable andautomated controls make system nearlyworry-free.

The benefits of the system have alsoattracted a lot of outside interest. Forbringing the system to North America,World Water Works and HRSDreceived the American Association ofEnvironmental Engineers and ScientistsHonor Award for EnvironmentalSustainability, and in the eight shortmonths of operation, more than a dozengroups have stopped by to check it out.

“As I knew from my own experience,when you read about this sort of system,it can seem too good to be true,” saysBott, “But once you see it, once you’vebeen in the plant and seen how it’s

incorporated, you can really understandhow it works. We’re always excited tointroduce other groups to this system,since it’s been so successful for us.”

BEYOND YORK RIVERAnd HRSD is only experiencing theminimum the process has to offer. Forfacilities looking to reduce energyrequirements of a main treatment plant,Demon® can be integrated into the mainstream solution and provide even morenoticeable benefits with big energycost savings in addition to the reducedchemical costs.

World Water Works has also developedWaterEnergy™, a process that integratesDemon, along with other systems, into awastewater solution that can actually makefacilities have 5 to 30 percent net positive rateof energy production. It may sound a littlebold, but the technology is there and only

requires an opportunity to make it happen—asseen with with Demon® and HRSD.

Breakthroughs in wastewatertreatment hold a lot of promise fora greener future. But the key takeaway from the installation of thesystem at the York River TreatmentPlant is that a green wastewatersolution, like the Demon® process,

can be very cost effective as well assustainable. ■

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WATER & WASTEWATER solutions

W ater is required throughout a food and beveragefacility for various uses, including makeupwater for cooling towers and boilers, washingof equipment and input for the production of goods. Thatwater can be delivered through a supply connection froma municipal system, extracted from the local environment’snatural water supply, such as a ground well, or byreclaiming existing wastewater f rom the facility’s processeswith advanced reuse treatment, lowering the plant’s freshwater requirements.

Since water is an essential element in food or beverageoperations, reusing it can reduce a business’s water usageratios, help meet sustainability goals, lower supply risk, andcontribute to cost savings, making it a top priority for manycompanies today.

THE BENEFITS OF REUSING WASTEWATERWater is a resource that has been taken for grantedfor decades but is now a critical focal point for manycompanies, communities and governments as the earthfaces a water crisis.

Only 2.5 percent of the world’s water is fresh water, andof that, only 1 percent is accessible as much is trapped inglaciers and snowfields (see reference 1). As a result, only

a tiny fraction of the planet’s water is available for everydayuse. By one estimate, global fresh water demand willexceed supply by a staggering 40 percent in 2030 if currenttrends continue (see reference 2).

As corporate citizens, businesses must look at theirimpact on the environment and assess how their operationsaffect the communities they operate in and serve. Byreducing their source water requirements, food andbeverage companies of any size can do their part to reduceenvironmental impact, while reinforcing their corporatesocial responsibility. Many companies also realizesubstantial cost savings from water-related investments.

Other benefits of water reuse include

• Enhancing sustainability practices• Ensuring the appropriate water quality standards for

food and beverage processes• Mitigating business risk by lessening dependency on

external water sources

These reasons help explain why water reuse is growingaround the world. From this white paper, business leaderswill gain an understanding of the deployment of water

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

About The Authors

By Nate Maguire, Greg Claffey, and Keel Robinson, Xylem

A basic primer on how food and beverage plants

can reuse water effectively and ef cientlyPART 1 IN A 3-PART SERIES

Recycling Earth’sRapidly Shrinking

Resource

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reuse technologies, including whichelements should be considered wheninvesting in a system.

WASTEWATER EFFLUENT

Wastewater that is discharged intoa collection network is generally

handled by a Publically OwnedTreatment Works (POTW) or treatedunder the National Pollutant DischargeElimination System (NPDES).

Publically Owned Treatment Works(POTW)In the U.S., POTW facilities aretypically owned by local governmentsor municipalities, and are designed totreat domestic sewage, not industrialwastewater. Some industrial faciliti escan be permitted to discharge waterto these treatment plants if they followcertain pretreatment processes, suchas removal of solids, reduction ofbiochemical oxygen demand (BOD)and adjustment of pH.

POTWs are sensitive to industrialdischarge because of the potentialimpact it can have on their facility’soperations. As a result, many requirecorporations to pull permits for

NATIONAL RAISINCOMPANY

The National Raisin Company,in Fowler, California, is one ofthe largest independent raisin

processors in the global industry.Processing approximately 200tons (181.44 tonnes) of raisinsdaily, the company generatesbetween 60,000to 80,000 gallons(227,125 to 302,833liters) of wastewaterper day, primarilyresulting from washingraisins.

During washing,dust, sugar and othercontaminates soakinto the water. Thecompany needed asolution that wouldenable them to cleanand reuse this largevolume of watereffectively.

The company called uponXylem to provide a customizedtreatment system designedspecifically for their unique waterrequirements. National Raisinrecouped installation costs in less

than two years, and continues tosave hundreds of thousands ofdollars a year on its wastewaterdisposal bill.

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discharge and charge significant fees.In addition, fines and other penaltiescan be imposed for discharge permitviolations.

National Pollutant DischargeElimination System (NPDES)

Discharging water into a river, lake,creek or other body of water fallsunder the NPDES, a division of theEnvironmental Protection Agency(EPA). Companies wishing to dischargewastewater through the NPDES need totreat the water more heavily than if theywere to discharge to a POTW facility.

As a government-regulated system,there are strict permit requirements forthis type of discharge. In fact, many ofthese standards are more stringent thanthose imposed for reuse. Violationsof these discharge requirements canresult in the EPA issuing punitive finesand consent decrees, which subjectplants to routine inspections to ensurecompliance to standards. By notfollowing the mandated provisions,companies can also find themselvesresponsible for environmental damageremediation.

Companies that are dischargingwastewater either through POTW orNPDES should consider their full costof wastewater disposal when evaluatingtreatment and reuse of wastewater.

IDENTIFYING THE RIGHTTREATMENT OPTION

There are a wide variety of technologiescommercially available for wastewatertreatment in reuse applications. Thosetechnologies can be classified asconventional treatment processes, whichcan remove solids, and adjust pH and chlorine levels, oradvanced processes, which filter and oxidize water resultingin a higher quality product. Advanced methods give theplant more flexibility wi th how and where the recycledwater is used.

CONVENTIONAL TREATMENT PROCESSA conventional treatment process removes solid waste foundin water. The technologies in this category provide minimaldisinfection and include the use of screens, dissolved airflotation and primary clarifiers, filters, biological treatmentvia conventionally-activated sludge, chlorination and pHadjustment, reducing solids and Biochemical OxygenDemand (BOD). For some reuse applications, such as turfirrigation, conventional treatment may be all that i s needed.

ADVANCED TREATMENT PROCESS

When a conventional treatment process isn’t adequatefor meeting the required treatment standards, advancedtreatment technologies can be implemented. Thesetechnologies go further to remove contaminants that

conventional treatment processes can’t. They are arrangedfor specific needs, including:

• Removal of solids and bacteria via microfilt ration orultrafiltration membranes.

• Biological nutrient removal with sequencing batch

reactors (SBR) or membrane bio reactors (MBR).• Removal of dissolved organics or salts with reverse

osmosis.• Removal of trace contaminants and pathogens via

oxidation and disinfection.• Removal of dissolved organics and contaminants via an

adsorption process or ozone-enhanced biological activefiltration. ■

REFERENCES

1. Shiklomanov, Igor. “World Fresh Water Resources.”Water in Crisis: A Guide tothe World’s Fresh Water Resources. Ed. Peter H. Gleick. 1993. Print.

2. The Water Resources Group. Background, Impact and the Way Forward . Rep.26 Jan. 2012. 16. Web.

Reusing water can reduce food and beverage operations’ water usage ratios, help meet sustainability goals, lowersupply risk, and contribute to cost savings.

Table 1: Example treatment process

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Secondary wastewater treatment,specifically activated sludgetreatment, can be broken downinto a series of unit processes, eachof which are linked to the processimmediately before and after by thehydraulics and the biology of thesystem. For example, in a typicalModified-Ludzak-Ettinger process(MLE process, figure 1), the basic unitprocesses would be

• Anoxic treatment formicrobiological removal of n itrates(“denitrification”)

• Aerobic treatment formicrobiological removal of BOD(Biological Oxygen Demand) andconversion of ammonia to nitrate(“nitrification”)

• Internal mixed liquor recycle toreturn nitrates to the anoxic zonefor denitrification

• Secondary clarification to separatethe sludge from the treatedwastewater

• Sludge wasting (WAS) for removalof sludge from the system

• Sludge return (RAS) forreplenishment of active microbes tothe treatment tank.

Additional unit processes might bealkalinity control and carbon addition.

Tilo Stahl, PhD is a systems engineer at BioChem Technology, Inc., and Frank DiScuillo Jr. is the superintendent of theLebanon (Pennsylvania) Authority Wastewater Treatment Facility. BioChem Technology specializes in the monitoring,

optimization, and control of wastewater treatment processes. For more information, visitwww.biochemtech.com

.

About The Authors

By Tilo Stahl, BioChem Technology, Inc., and Frank DiScuillo Jr.,Lebanon Authority Wastewater Treatment Facility

A Holistic Approach

to Process ControlProviding Process Improvementand Energy SavingsPart 1 of 2

Influent Effluent

Secondary Clarifier

Nitrate Recycle

Return Activated Sludge

WasteActivatedSludge

Anoxic Aerobic

Figure 1: MLE Process Schematic

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Process control in a WWTP like thisis typically treated as control of theunit processes to meet subordinateobjectives. There are a number ofreasons for this approach:

• Unit processes are well understood,

whereas the linkage between theprocesses is less understood.• Nutrient removal plants have

become more complex, with lots ofmoving parts.

• If the control of one unit processfails, that part can be operatedmanually whereas linked controlsystems can be more difficult tounderstand and back up manually.

• The overriding plant objective isto meet permit, and anything thatis perceived to jeopardize this isrejected.

• Control systems rely on good,reliable instrumentation, and untilrecently, this has not been availableor economically feasible.

As a result of these conditions,controls are broken down intosubsystems:

• Aeration blowers are controlled to amaintain a constant pressure in theair header – as the air demand ofthe system increases, the pressuredrops and the blowers ramp up tomaintain the pressure, or vice versa.

• Flow control valves in eachaeration zone are controlled by aproportional-integral (PI) controlloop that reads and responds toan error signal from the dissolvedoxygen (DO) probe – opening orclosing the valve to increase ordecrease air through the diffusers tomaintain the DO set point.

• Blower header pressure and DO setpoints are static and are manuallyselected by the operator.

• The internal mixed liquor recyclerate is either constant or a fixedmultiple of the influent flow rate.

• Swing zones (zones that canbe either aerobic or anoxic byswitching diffusers on and off)are switched manually, mostlyseasonally.

Manual set points are selected toensure that the plant meets permit underall expected conditions. However, thelevel of contamination of the influentwastewater (“loading”) typically variesby a factor of 3 to 8 between daily high

and low loading levels. That means thatthe plant will over-treat during a largepart of the day, when the loading iswell below the maximum. It also meansthat the plant consumes more energythan necessary, possibly stresses thebiology under low loading conditions,

and does not optimally utilize the plantcapabilities.

HOLISTIC PLANT CONTROL:PROJECT DESCRIPTIONThis paper presents a control systemfor the city of Lebanon (Pennsylvania)Authority Wastewater TreatmentFacility. The plant was upgraded in2012 to reduce the amount of nitrogen

discharged into the Chesapeake BayWatershed. The nitrogen discharge is

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measured as a TMDL (Total Maximum

Daily Load) of 146,000 pounds(66,224.5 kilograms) per annum, whichat the current average daily flow rate ofsix million gallons (22.7million liters)per day equates to a permissible nitrogenconcentration of 8 mg/l.

Due to the physical constraints of theplant location (see figure 2), treatmentintensity had to be increased withoutincreasing the size of the treatmentreactors. For this reason, the plantchose to introduce Integrated FixedFilm Activated Sludge (IFAS) for BODremoval and nitrification, with anoxic/ aerobic swing zones. The IFAS elements

are shown in figure 3. The IFAS zones

have course bubble diffusers to providethe necessary air scouring for the IFASelements, and the swing zones areoutfitted with fine bubble diffusers toprovide energy efficient supplementalaeration when needed. The planthas internal mixed liquor recycle fordenitrification, and a trickling filterbypass for supplemental carbon whenneeded for denitrif ication. The layout ofthe bioreactors is in figure 4.

The overall control objective is tooptimally utilize the plant capacity tomeet the effluent permit requirementswith the lowest possible energy and

chemical consumption and withoutsystem disruptions.

The control system for the plant has thefollowing functions:

• Determine optimal DO set points ineach zone in real time to achieverequired treatment levels.

• Maintain DO levels in the IFASzones.

• Switch on/off swing zones whenneeded, and maintain DO levels inthe swing zones when on.

• Control air flow to each controlzone to meet the localized oxygendemand.

• Control blowers to meet the totaloxygen demand.

• Minimize system pressure in the airheaders (most-open-valve control),particularly when adding/removingfine bubble (swing zone) aeration tocoarse bubble (IFAS) aeration.

• Control internal recycle flow tomaximize denitrification (totalnitrogen removal).

• Control a trickling fil ter bypassto increase available carbon fordenitrification in the anoxic zones.

• Control carbon addition in thetertiary denitrification filter.

The control system could also controlthe waste rate of the sludge and the solids

retention time, if desired by the operatoror plant engineer. The basic controlsystem architecture is in figure 5.

EXECUTIONThe integration of all of these control

objectives was achieved through thecombination and integration of two basiccontrol systems: BIOS and BACS.

1. The BioChem BIOS: The BioprocessIntelligent Optimization System(BIOS) uses real time process datato calculate optimal DO set pointsfor each control zone and the ideal

Figure 2: Satellite view of the plant during construction showing major process components

Figure 3: View of the Infilco-METEOR® IFAS elements

Influent Effluent

Swing Zones

Anoxic AnoxicIFAS

Figure 4: Layout of secondary treatment trains

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internal mixed liquor recycle rateand trickling filter bypass flow ratefor minimal energy consumption andmaximum total nitrogen removal. Ituses a feed-forward control model,the influent ammonium loadingdata and actual plant operatingconditions to calculate optimalnitrification rates and minimumDO set points to achieve therequired treatment level. It controlsthe mixed liquor recycle rate toachieve best possible denitrificationfor total nitrogen removal. Inthis particular application it alsodetermines the overall aerobiccapacity that is required to meetthe demand and switches the swingzones on and off accordingly. Thedenitrification reaction in the anoxiczone requires BOD in the form ofcarbon compounds to support themicrobial respiration, and in thecase of carbon deficiency in theinfluent flow the BIOS can alsocontrol a bypass from the parallel-operating trickling filter treatment

train to increase available BOD andmaximize total nitrogen removal.

2. The BioChem BACS: The BioprocessAeration Control System (BACS) usesairflow and residual DO readingsto calculate the required airflow toeach control zone to meet the DOset point, controls the blowers todeliver the precise amount of airrequired to meet the demand, andcontrols the air flow valves to eachcontrol zone to distribute the air persystem requirements, while alwaysmaintaining one valve in a “wide-

open” position (typically about 85percent open) to minimize systempressure and reduce the load (andthus the energy requirements) of theblowers.

The use of swing zones with finebubble diffusers and IFAS zones withcoarse bubble diffusers on the sameair header is a peculiarity of Lebanonplant, because the fine bubble diffusershave a significantly higher restriction(and thus higher dynamic pressure) thanthe coarse bubble diffusers. As a result,the most-open-valve is on one of theswing zones when they are aerated,and on the IFAS zones when the swingzones are not aerated. The swing zonesutilize a mechanical mixer to maintainsolids suspension when they are un-

aerated. This scheme allows the blowersto operate at a pressure of about 7.8psi when the swing zones are aerated,and a pressure of 6.9 ps i when theynot. This saves a significant amount of

blower energy compared with a constantpressure blower control scheme, wherethe pressure would always have tobe above the level of the fine bubblediffusers, to ensure aerobic operation ofthe swing zones when they are switchedon.

The two control concepts areintegrated into one control panel (figure6) with a single user interface in the formof a touch screen HMI and an Ethernetconnection to the plant SCADA. Thecontrol panel also houses the entireinput/output switching for the fielddevices and instrumentation. ■

Figure 5: Control system architecture

Figure 6: View of the control panel

Carbon DosageSystem

ValveSystem

Biological ReactorField Instrumentation

Process ControlSystem

Plant ProcessData

BlowerSystem

DiffuserSystem

Trickling FilterBypass System

Nitrate RecycleSystem

CarbonFlowrate SP Valve Position SP

Total AirFlowrate SP

DO SP andSwing Zone

Control

BypassFlowrate SP

Nitrate RecycleFlowrate SP

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MAINTENANCE solutions

In industrial installations,process plants are designedto minimize floor space.

Abbreviated floor space canresult in inadequate short runs ofstraight pipe required upstreamfrom pumps, flowmeters, andother critical componentsused in the process industries.Inadequate lengths of upstreampiping, valves, compressors,spiral welded pipe, expansions,reductions, and elbows alter themedia’s tangential, radial, andaxial velocity vectors. Thesealterations generate swirl, jetting,and velocity profile distortions.

Wastewater treatmentengineers who can’t findroom for the recommendedstraight pipe run needed byelectromagnetic flow meters insewage lift stations will find theVortab Elbow Flow Conditionerfrom the Vortab Companyeliminates the problem by removing swirl and asymmetricvelocity profiles caused by pumps placed too close to the meter.

To provide accurate and repeatable flow measurement,electromagnetic and other types of flow metering technologies

require a specific amount of straight pipe run upstream anddownstream from the installed location of the meter. Thestraight pipe runs create a swirl-free and symmetric velocityprofile in the pipe that can be measured accurately over andover again.

When electromagnetic flow meters are placed too closeto pumps in sewage lift stations, there can be measurementproblems. Sewage lift stations are required to pump wastewater

from one elevation to a higher level when gravity flowisn’t feasible for any number of reasons. Often there isn’tenough available plant real estate to support the straight piperun required by electromagnetic and other flow metering

technologies.The Vortab Company’s elbow flow conditioner eliminates the

flow meter upstream piping requirements by conditioning theflow stream into a flow regime, mimicking adequate straightrun. In addition to conditioning the flow stream, the 90-degreeangle tab-type Vortab Elbow Flow Conditioner eliminates thepipe cost and technician labor for the 5 to 10 upstream and 3 to5 downstream pipe diameters required by mag meters.

The Vortab Company is a global supplier committed to meeting the needs of its customers through innovative solutions to themost challenging requirements for optimizing flow meter accuracy and repeatability in gases or liquids. For more information,call 800.854.9959 or visit www.vortab.com .

For More Information

By Randy Brown

Making More“Elbow” RoomVortab’s Elbow Flow Conditioner removes swirl in tight spaces

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The Vortab Elbow was developedusing the same tab-type flowconditioning technology as the straightrun Vortab Flow Conditioners, whichhave been laboratory proven andsuccessfully installed in hundreds ofplants worldwide.

To validate the Vortab Elbow’s uniquedesign--ball valves, gate valves, out-of-plane and in-plane elbows andswirl generators were installed at theimmediate inlet of the Vortab elbow andtested in state-of-the-art gas and liquidcalibration facilities.

The Vortab Elbow Flow Conditionerisolates the flow irregularities andconditions the flow stream into a swirl-free and symmetrical velocity profile.Swirl reduction and velocity profilecorrection occur naturally in longlengths of straight pipe due to diffusionand turbulent mixing. Vortab’s anti-swirland inclined vortex generating profilecorrection tabs, projecting from theinside pipe surface, generate vorticesthat accelerate these natural pipe effectsto create a uniform, non-swirling,symmetrical flow profile in a muchshorter section of pipe.

The simple, flexible designs of theVortab Elbow, the Vortab InsertionPanel (VIP) and the Vortab Insert Sleeve,Short Run, Meter Run and Field Kitconfigurations provide a cost effectivesolution to crowded installations forflow meters and other critical processequipment. Vortab provides the mosteffective flow disturbance isolation,lowest pressure drop and leastaffected by fouling of any of the flowconditioners available.

Vortab flow conditioners can bemade from carbon steel, 316L stainlesssteel or Hastelloy C-276. A variety ofprocess connections are also available—ANSI flanges, male NPT threads, buttwelded preps or retaining wafers.Delivery time for the Vortab flow

conditioner is available in less thanfive weeks, depending on size. Customconfigurations are also available fromthe factory.

Flow disturbances adversely affectdifferential pressure, turbine, vortexshedding, ultrasonic, and magneticflowmeter technologies. Poor pipingpractices increase flowmeter error, oftenoutside of the specified performancelimits of the flowmeter manufacturer.Flow disturbances can induce cavitationand noise in pumps, control valvesand other critical process componentsresulting in excessive wear and damage.

In today’s flow meteringenvironment, accuracy, andrepeatability are critical. The VortabElbow ensures accurate and repeatablemeasurement by eliminating flowdistortions that degrade flowmeterperformance. The simple, flexible

designs of the Vortab Elbow and theVIP provide a cost effective solution

to poor installations for flow meters,control valves, pumps, and otherprocess equipment—as well as the mosteffective flow disturbance isolation,lowest pressure drop, and least affectby fouling of any of the conventionalperforated plate, tube, or rotational

vane type flow conditioners offered inthe market today. ■

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PUMP solutions

Selection of the right diaphragm for an air-operateddouble-diaphragm (AODD) pump is a criticalconsideration for safety, efficiency and trouble-free

operations. A number of factors must be taken into accountwhen choosing the proper diaphragm that will be suitablefor a specific application. Previous experience is always avery helpful guide, but new applications will often requireresearch and outside advice to determine the appropriatediaphragm that will meet specific application requirementsand parameters.

In selecting a diaphragm, there are seven primary factors toconsider:

1. Chemical resistance: Material compatibility with thefluid being pumped. The spectrum of fluids pumpedcan range from water to aggressive acids and caustics.Each diaphragm material has been tested to measureits compatibility agains t many chemicals. The operatorshould evaluate the pumped fluid against publishedchemical compatibility guides.

2. Temperature ranges: Capability to remain flexible in lowtemperatures and not deteriorate in high temperatures.Temperature is a very critical factor, and the workingrange available in diaphragm materials varies greatly.The type of fluid can also affect the working temperaturerange of the material.

3. Abrasion resistance: Ability to withstand wear andfriction from contact with solids and particles in the fluid

being pumped. Diaphragms are available to handle fluidsranging from clear to heavy slurries to dry bulk pumping.

4. Sanitary standards: Requirements that the diaphragmcomply with hygienic or sanitary standards. Applicationsin the food and beverage industry must utilize

diaphragms that comply with U.S. Food and DrugAdministration (FDA) 21 CFR 177 standards. Diaphragmsused in the pharmaceutical industry must comply withUnited States Pharmacopeia Convention (USP) Class VIstandards.

5. Inlet condition (flooded suction and suction lift): Capacity to pump fluid from one location to another. Fordifferent pumping configurations and conditions, certaindiaphragm materials are more efficient and longer lastingthan others. Outside advice from an expert such as aWilden distributor can assist in determining the optimummaterial for specific applications.

6. Flex life: Expected longevity of the diaphragm beforerequiring replacement. Achieving maximum mean timebetween repairs (MTBR) is a key goal in selecting adiaphragm. However, some materials have inherentlyshorter flex lives than others even under ideal conditions.

7. Cost: Total cost of ownership determined by multiplefactors such as initial price, rated flex life for theapplication and costs of downtime and diaphragmreplacement labor. Because of the many variablesinvolved, advice from an outside expert such as aWilden distributor can greatly assist in selecting the bestperforming, most cost-effective option for individualapplications.

Over the years, a number of materials have been tested

extensively for use in diaphragms in AODD pumps.These materials can be grouped into three primaryfamilies: rubber, TPE (thermoplastic elas tomer) and PTFE(Polytetrafluoroethylene or Teflon ®). We'll begin with a closerlook at rubber diaphragms and examine TPE and PTFE inmore detail in next month's installment. Each family and the

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

About The Author

By Rob Jack, Wilden ® and Pump Solutions Group (PSG ® )

HOW TO SELECT DIAPHRAGMSFOR AODD PUMPS

Asking the right questions and utilizing the best available tools will help AODD pump

PART 1 OF 2

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materials within each family offer properties and attributesthat make them suitable for different applications.

RUBBER DIAPHRAGMS

Rubber diaphragms are compression molded of syntheticrubber with a nylon fabric mesh positioned within the rubberto improve the diaphragm’s flexing characteristics. The

following are the rubber diaphragm materials available:• Neoprene is an exceptional

general-purpose, low-costdiaphragm. Perfect fornonaggressive chemicalapplications such as water-based slurries, well wateror seawater, it providesgood flex life and abrasionresistance.

• Buna-N provides excellentperformance in applicationsinvolving petroleum/oil-based fluids such as leadedgasoline, fuel oils, kerosene,turpentine and motor oils. Inwide use throughout the fuel processing industry, Buna-Nis also referred to as nitrile and provides moderate flex lifeand moderate abrasion resistance. For food and beverageapplications, versions are available that comply with FDA21 CFR 177 standards.

• EPDM is an excellent material for extremely coldtemperatures and is an economical alternative whenpumping dilute acids or caustics. EPDM diaphragms arein use in the manufacturing, food, pharmaceutical andpaint/ coating industries. The material exhibits good flexlife and moderate abrasion resistance, and it is availablein versions that comply with FDA 21 CFR 177 standards.

EPDM is also a good choice where statically dissipativematerials are required.

• Viton ® is excellent for extremelyhot temperatures and providesexceptional performancewith aggressive fluids suchas aromatic/chlorinatedhydrocarbons and strong,aggressive acids. Viton is oftenthe only diaphragm materialsuitable for applications whereharsh chemicals are used becauseof its high temperature limit andchemical resiliency. It providesmoderate flex life and moderateabrasion resistance. ■

NOTES

Hytrel®, Viton® and Teflon® are registered trademarks of DuPont™Company.Geolast® and Santoprene® are registered trademarks of ExxonMobil.Saniflex™ and Wil-Flex™ are registered trademarks of Wilden®.

THIS SECTION SPONSORED BY WWW.UNITEDRENTALS.COM/PUMPS

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PUMP solutions

An old adage warns that if the only tool available isa hammer, then every problem will look like a nail.However, when it comes to chopper pumps, Landiacustomers have been finding a variety of uses for this tool.From Arkansas to Utah, and a myriad other locations acrossAmerica, operators continue to find innovative solutionsto problems with the help of Landia chopper pumps. Thefollowing two case studies illustrate just a few of thesesolutions currently in use in the field.

CASE STUDY 1:PROTECTIVE CHOPPER PUMP CUTS GREASE

At the BentonUtilitiesWastewaterTreatment Plantnear LittleRock, Arkansas,a toughnew LandiaEradiGatorchopper pumpis ensuringthat greaseand scum arecontinuouslychurned up toprevent othersmaller pumpsin the processfrom blocking.

Therecirculatingchopper pumpwas suppliedwith a custom-built bracketto fit into thebottom of a

squaretaperedscum pitat Benton,where the scumpit receives skimmed-offwastewater from the plant’s clarifiers.

“We’re really using the Landia chopperpump more as a mixer so that a layer of scum can’t build upand block the existing smaller pumps we have on our railsystem,” notes Jonathan Buff, manager of Benton Utiliti esWastewater Treatment Plant, comments. “Either way, i t’s veryeffective.”

Art Savage is regional sales manager for Landia, Inc. For more information Landia’s range of applications, call 919.466.0603,email [email protected], or visit www.landiainc.com .

About The Author

By Art Savage, Landia, Inc.

The Right Toolfor Many JobsLandia chopper pumps find a varietyof uses across the country

We’re really using the Landia chopper

pump more as a mixer. . . . it’s veryeffective. –Jonathan Buff,manager of Benton

Utilities Wastewater Treatment PlantBenton, Arkansas, where a recirculating Landia chopper

pump churns up grease and scum.

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Landia’s EradiGator chopper pumps are widely used in liftstations and scum pits for mixing and macerating debris andgrease, in order to prevent clogging of pumps and piping.

“Previously, we did experience problems with blockedpumps, especially because we are working with just a3-inch line,” adds Buff. “But the Landia chopper pumpkeeps everything churned up and on the move, with no

problems for our existing units, which can now sendthe mixed scum to our digesters with no breakdowns ordowntime.”

CASE STUDY 2:MIXER AND PUMP RETROFIT FOR BIOREACTORS

At the newly expanded 30 million gallons (113.5 millionliters) daily wastewater treatment facility in AmericanFork, Utah, Landia has completed a successful pump andmixer retrofit that has transformed eight existing oxidationditches into new high-rate activated sludge bioreactors withbiological nutrient removal, solids dewatering, and UVdisinfection.

A total of forty-eight Landia submersible mixers andsixteen Landia axial flow pumps are achieving completemixing and nitrate recycling in a new activated sludgeprocess at the site run by the Timpanogos Special ServiceDistrict, close to Utah Lake, which serves ten cities in theregion.

Working in close conjunction with leading Utah andIdaho engineering firm Bowen Collins and Associates, Inc.to select long-lasting equipment that would give optimumperformance, mixers from Landia now mix the sludge in theanaerobic and anoxic tanks, while internal Landia recyclepumps send nitrified mixed liquor from the aeration basinonto the anoxic tanks.

Operating at low propeller speed, each Landia mixer isequipped with large surface area propeller blades to ensuregentle treatment of the activated sludge.

The axial flow pumps operate on variable frequencydrives, by which each pump’s flow rate is optimized for therequired Nitrate recycle rate.

“The move to bioreactors has been a learning experiencefor us, with a great deal of hard work put in to achievethe required mixing and recirculation,” says Ed Yates,maintenance coordinator for Timpanogos Special ServiceDistrict. “Landia’s pumps and mixers are performing welland the support we’ve been given by the company to helpget the equipment up and running to our satisfaction hasbeen exemplary.”

The $77 million project, which also features a newheadworks and influent pump station, has increased thecapacity of the treatment plant from 18.3 million gallons(69.3 million liters) daily to 30 million gallons (113.5million liters) daily.

Over the past twenty-five years, Landia has installedthousands of mixers and axial flow pumps in U.S.wastewater treatment plants for mixing and pumping ofactivated sludge. ■The newly expanded wastewater treatment facility in American Fork, Utah, where

Landia has completed a successful pump and mixer retrofit

Serving the water, wastewater,general, electrical and environmentalindustries, Bowen Collins andAssociates’ numerous successfulprojects include the a sewer masterplan and asset management assessmentfor Salt Lake City’s sewer system,which consists of approximately 640miles (1029.98 kilometers) of pipe,8500 manholes, and 33 lift stations.

THIS SECTION SPONSORED BY WWW.UNITEDRENTALS.COM/PUMPS

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DEWATERING solutions

D esigned as an intelligentalternative to conventionalgravity sewering options,InviziQ™ provides controlled transferof sewage, but because it does not rely

on gravity it offers the freedom to installsewers in any area, irrespective of theterrain, slope, environmental sens itivityor topography. It features a networkconstructed from small diameter pipe,and can be installed either in narrowtrenches or via directional drilling. This

gives virtually unlimited freedom in thedesign and layout of the network, whichcan then be sized to meet the specificneeds of each individual project.

LEADING THE WAYIN DUTTON WAY

Moyno has secured a significantsuccess by being nominated as thepreferred supplier for a major newpressure sewer network in Australia.Having evaluated various other

alternatives, urban water corporationWannon Water has chosen Moyno’sinnovative InviziQ™ pressure sewersystem as the most cost-effective andeasy-maintenance option for the Dutton

Way project in Portland, Victoria.The Dutton Way residential project

currently houses 180 properties whichare serviced by septic sewage tanks.This figure will increase to 314 homes,all of whom will have the option toinstall an InviziQ sewage pumping

The 2013 acquisition of Robbins and Myers by National Oilwell Varco (NOV) saw the coming together of NOV Mono andMoyno, creating the world’s largest designer and manufacturer of progressing cavity pumps and associated equipment.The business now offers a broad portfolio of products and services to help global process industries improve production,

reliability, and profitability. For more information, visit www.moyno.com .

For More Information

By Daniel McClusky, Moyno

InviziQ™ offers an alternativeto gravity sewage options

Moyno’s InviziQ™ pressure sewer systemhas been nominated by

Australian urban watercorporation, WannonWater, as the preferredoption for a major newnetwork in Victoria,

Australia.

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system that feeds into the existingPortland sewer network. The InviziQsystem is the perfect answer for adevelopment like Dutton Way. as itwill give each home access to a highlyeffective sewage solution and can bescaled up as new properties are addedover time.

SUPPORT WHEN YOU NEED IT

Moyno was able to present the InviziQsystem to Wannon Water and tookthe opportunity to demonstrate theirability to provide technical support for

a large-scale project. As the InviziQ™system used on the Dutton Way projectis installed by a certified installer, freetraining sessions have been providedfor local contractors to obtain certifiedstatus. Any Dutton Way resident whochooses to install an InviziQ systemon their property will be supportedby Wannon Water, who will beresponsible for main taining the unit’spump and motor assemblies for life.

InviziQ uses advanced PCB-basedcontrol technology and versatilesoftware allowing it to self-monitorand run diagnostic tests to ensure that

the system is operating efficiently. Itcan also support two-way telemetryfor remote monitoring, and multipleInviziQ systems can be linkedto enable centralized networkmanagement.

A SMARTER ALTERNATIVE

InviziQ offers dry well design, the firstand only PSS alternative deliveringclean access to the system motor andother working parts of the unit. Thesystem ensures no confined spaces,improving safety and simplifying

maintenance. Plus the InviziQsafeguards and design greatly reducethe possibility of people and petsfalling into an exposed unit, givingowners added peace-of-mind.

InviziQ’s leading edge solid-statelevel sensor provides more reliabilitythan traditional, mechanical floatalternatives, which are subject tofailure due to exposure to raw sewage.The sensor has no moving parts andis designed to provide trouble-freeperformance for the life of the unit.

Residents can now experience thefreedom to build and operate wherever

they want—choose their location,determine their sightline, and buildon their terms. The InviziQ PressureSewer System is a smarter alternative toconventional gravity sewage options.Rather than relying on gravity and anetwork of costly lift stations to transfersewage, PSS utilizes reliable grindingand pumping technology to efficientlyand responsibly move sewage totreatment facilities—no matter theterrain, slope, environment sensitivityof the area, or complex topography ofthe region. ■


The InviziQ™ system will give each home in Dutton Way access to a highly effective sewage solution and can be scaledup as new properties are added.

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MOTOR solutions

Pump users are asking forgreater efficiency andmore integrated solutions

from both their pumps andmotors, and Grundfos constantlystrives to make its pumps evenmore efficient and energysaving. Using state-of-the-arttechnology and cutting-edgedesign, Grundfos pumpingsolutions meet virtually allcustomer requirements forefficiency, reliability, and costeffectiveness.

SIMPLIFIED SOLUTIONFirst introduced at the 2014AHR Expo, the Grundfos LCSEsplit-coupled end suctionpumps are now available inthe United States. Available intwenty-one different models,the fully integrated, intelligentLCSE pumping system featuresthe MLE variable speed motor inranges from 3 to 30 horsepowerin 3500 revolutions per minuteand 3 to 25 horsepower in 1800revolutions per minute. Speedcontrol pumps like the LCSE

offer energy savings of up to 50percent.

“Our integrated pumpsystems help our customers meet the energy challengenow by improving system performance and reducinglifecycle costs,” says David McLean, vice president ofbusiness development for Grundfos Commercial Buildings.

“The intelligent MLE motorsystem greatly simplifies pumpcommissioning and startupfor each of the models. As apioneer of innovative pumpingsolutions, Grundfos is dedicatedto developing the highestquality pumps and pumpingsystems while at the sametime contributing to a betterquality of life and a healthierenvironment.”

Ideally suited for newcommercial HVAC/Rapplications and retrofits, theLCSE offers one sole supplierfor pump, motor, and drive,resulting in reduced planning,purchasing, installation, wiring,and commissioning costs.

BENEFITS OF A SYSTEMSAPPROACHThe LCSE offers a systemsapproach, which, throughintelligent technology, adaptsprecisely to current demand todeliver performance, energyefficiency and reliability. Theintegrated, energy-optimized

MLE system consists of a systemcontroller, variable frequencydrive (VFD) and standard

asynchronous motor all in one, and can be fi tted with loosesensors. Both are configured and interfaced at purchase,and their plug-and-pump design results in quick and easyinstallation.

Helen Mubarak is the public affairs coordinator for Grundfos North America and can be reached at [email protected] an annual production of more than 16 million pumps, Grundfos is the global leader in advanced pump solutions and atrendsetter in water technology, specializing in circulator pumps for heating and air conditioning as well as centrifugal pumpsfor industrial applications. Product CSI specifications, range charts, brochure, pricing, and selection of the products areavailable at www.grundfosexpresssuite.com .

About The Author

By Helen Mubarak, Grundfos North America

INTELLIG ENT PUMPIMeans Efficient Motor Use

BENEFITS OF AN MLE MOTOR • Special pump-related functionalities,

which are matched to specific pump types• Low acoustic noise from motor due to

high switching frequency (9 to 18 kHz)• Automatic motor efficiency optimization• Nominal output by highest pulse

frequency as a standard option• Motor temperature rise class B (even with

integrated variable frequency drive)• Integrated variable frequency drive

cooling by motor fan

Energy-optimized pumps feature integrated MLE motorto simplify commissioning, startup

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GOOD TO GO

In addition, the LCSE features a footprint35 percent smaller than that of a frame-mounted design. Its design allows forrapid mechanical seal access withoutmotor removal. The unique designrequires no baseplate grouting orcoupling alignment in the field. The LCSEalso features Grundfos GO technology,which allows building managers toremotely control and monitor thepump from a smart phone or tablet.The GO also facilitates installation andcommissioning.

SAVINGS WHERE THEY COUNT

Power consumption accounts for85 percent of all costs incurredduring the life cycle of a pump—nine times more than the initialpurchase price and cost of regularmaintenance. Therefore, even the

smallest improvement in efficiencycan translate to sizeable savings.Grundfos LCSE split-coupled endsuction pumps are the latest speedcontrol pumps to enter the marketand offer pump users a moreefficient way to meet their needs. ■

BENEFITS • Pump with integrated motor, drive and control• One sole supplier• 35 percent smaller foot print than frame mount

design• Lower weight offers installation ease• Eliminates coupling alignment• Rapid mechanical seal replacement without

motor removal

APPLICATIONS • HVAC• Plumbing• Pressure Boosting•

Industrial• Water Utility• Wastewater• Agriculture

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MOTOR solutions

Emerson's Power TransmissionSolutions introducesindustry's first online tool fortracking the location, life historyand latest revision drawings andinstallation instructions for allcritical drivetrain couplings ownedby customers, whether installedor in spares inventory. Ideal forpetrochemical equipment, turbinegenerators, and mill drives, thesystem identifies and graphicallydisplays coupling location in thedrivetrain.

Developed by Emerson's Kop-Flex business unit, the web-based tool, known as the AssetManagement Program (AMP) forcouplings, accurately identifiescouplings, graphically displaysthe location in a specific drive,identifies parts/couplings at thesite that are interchangeable,makes assembly drawings a clickaway and gives a detailed service history and action to betaken during service intervals. Also, the system providesaccess to latest engineering drawings, repair history, sparesinventory, and interchangeability information.

THE COUPLING AMPDeveloped by a worldwide engineering team experienced incoupling design, maintenance, repair, and troubleshooting,

the Coupling AMP provides in-depth information oncomponents critical to the operation of major systemssuch as compressors, turbines or pumps. Plant engineersplan shutdown maintenance with tight timeframes, yetthey struggle to identify couplings by make, model, serialnumber, stock code, manufacturer's part number, and so on.

Adding to this disorganization are emergencies. Engineersmay take parts from new or old couplings and use them

Documents

Modern Pumping - 082014