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4 WAYS TO

REDUCE NOX

EMISSIONS

MAKING

WAVES IN

A GLOBAL

MARKET

RECYCLING

PROCESS

CONTROL

EQUIPMENT

JUNE 2014PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

NEW CONTROLVALVES

PROTECT VITAL

WATER SUPPLY

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CONTENTS JUNE 2014

4 Industry News

10 Trade Show Prof ile

Case Studies 12 New Control Valve Is an Overnight

Success EOV control valves protect vital water supply

14 Making a Big Splash Sphero® S underwater pelletizing machinery system makes waves in China

Water & WastewaterSolutions 18 Uniform Distribution in Headers

and Distribution Systems Part 2 of 2

Maintenance Solutions 24 Know Your Pump Base Plate

Installation Options Part 2 of a 3-Part Series

Pump Solutions 26 A Revolution in Pumping Eff icieny

All-Flo's A200 pump reduces energy costs, improves performance

Part 3 in a 4-Part Series

Dewatering Solutions 30 Controlling All the Variables VLT® AQUA Drive produces huge water savings from food processor's deep well

Motor Solutions 36 The Next Generation of Premium

Eff icient GearboxTwo stage helical-bevel design adds bite to food and beverage indus try

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Power GenerationSolutions

40 Utilities Are Frightened of a "Death Spiral."They Shouldn't Be.

Industry and regulators need a more accurate and adaptive view of tomorrow's energy market

Processing Solutions 42 Short Design Means Big Innovation

Splitted gear box and improved maintenance possibilities for plunger pump

Valves & Controls

Solutions 46 4 Ways to Achieve NOx Reductions

without Turbine DamageReduction in emissions isn't just desired—it's required

Sealing Solutions 50 Safe and Eff icient Bolting Superbolt makes easy work for boiler feed pump workers

52 Modern PumpingProducts Featured Product Release: MILTON ROY Primeroyal X Metering Pump

Pumping Trends 56 Going Green (And Earning Some Too) Automation Service's Steve Ploudre explains how recycling process control equipment improves

the environment and the bottom line

www.modernpumpingtoday.com

P.O. Box 660197 | Birmingham, Alabama 35266

No part of this publication may be reproduced or transmitted in any form or by anymeans, electronic or mechanical, including photocopy, recording, or any informationstorage-and-retrieval system without permission in writing from the publisher. Theviews expressed by those not on the staff of Modern Pumping Today , or who arenot specifically employed by Highlands Publications, Inc., are purely their own. AllIndustry News material has either been submitted by the subject company or pulleddirectly from their corporate website, which is assumed to be cleared forrelease. Comments and submissions are welcome, and can be submitted [email protected].

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

TIM GARMONPresident

LARRY DAUGHETY Vice President

DENNIS DAUGHETY Vice President

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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]

JOEL DORNING Assistant Art [email protected]

CHRIS GARMON General [email protected]

LINDEY SCOTT Circulation [email protected]

JAMIE WILLETT Circulation [email protected]

INGRID BERKY Administrative Assistant

NANCY MALONE National Sales Manager

TONYA BROWNING Account Executive

CURTIS FROST Account Executive

RANDY MOON Account Executive

KRISTI NEIL 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 RoeBusiness Development Manager,

Wastewater Pumps Xylem Inc.: Flygt

Greg TowsleyDirector of Regulatory andTechnical Affairs, Grundfos

Trey Walters, P.E.President, Applie d Flow Technolo gy

EDITORIAL ADVISORY BOARD

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4 | JUNE 2014 www.modernpumpingtoday.com

INDUSTRY news

NETZSCH ANNOUNCES

R.F. MACDONALD PARTNERSHIP

Netzsch, theworld’s larg-est manu-facturer ofprogress-

ing cav-ity pumps,rotary lobepumps andnow mul-tiple screwpumps forthe indus-trial market,announces the signing of R.F. MacDonald Company as theirdistributor in Southern California to service the Industrialmarketplace in this region.

R.F. MacDonald Co. will represent Netzsch in all industrialmarkets as well as oil and gas downstream. Our new

distributor has been in business since 1956 with a strongpresence selling industrial boilers as well as a broad range ofindustrial products that complement the Netzsch offerings.

GIW INDUSTRIES EXPANDS OPERATIONS

WITH KSB BRAND

GIW Industries announces a new look and logo as thecompany unites under the KSB corporate brand. All slurry

products have been rebranded under the umbrella of GIW® Minerals. The primary GIW® Minerals world class productsare specially designed centrifugal pumps used to transporta mixture of liquids and solids—commonly referred to asslurry. What this means to customers i s well over a century'sworth of experience in pumps and hydrotransport. TheKSB global mining team st rives to be an innovative partner

that provides customers with the best slurry and processsolutions. GIW is a global business with the majority of itscustomers located outside of the USA.

The previous few years have seen a variety of expansionprojects designed to improve production efficiencies atKSB's GIW Industries manufacturing facility. As the resultof a recent growth in production, sales, and productendorsement in the mining market, KSB is moving forwardwith a three-year multimillion dollar expansion projectencompassing its Grovetown and Thomson, Georgia,production facilities. Started in January of this year, theexpansion project includes additional foundry and heattreat capacity, along with a new distribution center at theGrovetown production facility. The Thomson production

facility will receive upgrades in process flow and theinstallation of larger equipment. When completed, thisexpansion will more than triple the company's capabilitiesand provide customers with one of the most advanced slurrypump manufacturing facilities.

The markets served will continue to expand as the needfor raw materials increases due to population growth andurbanization. Part of this growth i s the need for larger

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INDUSTRY news

equipment sizes. The current expansion will ensure thatKSB's GIW® Minerals products will be ready for growingmarket demands. This investment in large casting capacitywill provide for the most efficient plant to handle sizeablecastings. The expansion will meet the requirementsneeded for the handling of larger components to allowthe company to increase efficiencies while continuing to

uphold its world class quality and safety standards.Why expand? Richard Sterzen, industrial engineeringmanager at KSB's GIW Industries facility, explains, "Inthe entire world, only 10 percent of iron foundries makewhite irons, and nobody can make the materials wedo. In addition, there are only a few foundries that canmanufacture the large casting sizes our customers need."

The economic impact of KSB on the Grovetowncommunity in Georgia is far reaching. GIW Industrieshas been in business for well over a century and itsfacilities have been located in Grovetown and Thomsonfor forty-nine years and forty years respectively. Thecurrent expansion will provide new permanent employeepositions, along with a large number of temporary

construction jobs, over the next three to four years.This project is a large investment for the KSB

subsidiary, GIW Industries. Long term, this expansion willgive GIW® Minerals products a significant advantage inthe global mineral processing industry. It will allow theKSB global mining team to continue to provide marketleading quality products, services, and solutions for itscustomers.

DEMATIC SPONSORSFIFTH THIRD RIVER BANK RUNDematic, a global supplier of logistics systems for thefactory, warehouse and distribution center, is supporting thecompany’s hometown through it s sponsorship of the 5K raceat the Fifth Third River Bank Run. The event was held May 10in downtown Grand Rapids, Michigan. This is the first year

Dematic has sponsored the race, which includes walk andrun distances of 5K, 10K and 25K."We are proud to support our community with event

sponsorships like the Fifth Third River Bank Run," sayspresident and CEO of Dematic North America, John Baysore."With more than 1300 Dematic employees and many localbusiness customers based in the West Michigan area, itis vital that we be involved in making Grand Rapids aneconomically strong, healthy and desirable place to live andwork."

Dematic provided more than 100 event volunteers,participants and spectators, including approximately80 runners. In its 37th year, the River Bank Run drewapproximately 38,000 onlookers, 2000 volunteers, and over

21,000 contestants.

TÜV RHEINLAND INDUSTRIAL SOLUTIONS GOESWIRELESS WITH PORTABLE X-RAY DETECTORTÜV Rheinland Industrial Solutions (TRIS), a full-serviceinspection, testing and certification company, expands itsdigital radiography capability with a portable X-Ray detectorusing wireless and battery-operating technology. The wireless

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INDUSTRY news

capability will allow TRIS to provide faster results at reducedcosts to the company’s oil and gas, power generation,construction and other industrial clients.

Designed to operate in the harshest industrialenvironments, the portable X-Ray detector can be wirelesslyconnected or tethered to a laptop computer. TRIS technicianscan quickly set it up in some of the most challenging field

conditions and survey hard-to-reach areas such as piperacks.Digital radiography improves field safety and productivity

through the advantages of reduced exposure and shootingtimes. It eliminates the need for film and chemicalcomponents necessary for traditional radiography, reducingcosts. Instant radiographic inspections and review help TRISclients receive results faster while digital storage makes foreasy documentation and retention of inspection records.

TRIS provides both field and laboratory inspectionservices, including all NDT methods, QC/QA functions,proof loading, calibrations, tensile testing (includingultimate strength, yield, elongation and reduction of area),compression, shear testing and slow bend testing.

FLUID TRANSFER, INC. LAUNCHES NEW WEBSITEFluid Transfer, Inc., an aftermarket parts supplier of plunger,piston, and reciprocating pumps for the hydro blasting, oil,gas, and fluid transfer industries and also a supplier of OEMparts, has launched a new website at www.fttipumpparts.com. Based in Norton, Ohio, the new site provides bothregional and national customers an easy-to-use resource

for consulting on service to a variety of manufacturers,including American Aero, Aqua Dyne, Armco, Butterworth,FMC, Gardner-Denver, GASO/Wheatley, General, Geoquip,Haliburton, Hammelmann, Jet Tech, Jetstream, Kamat, Kerr,Myers/Aplex, National, NLB, Oilwell, Partek, Tritan, Union,Uraca, Weatherford, and WOMA.

HI, FSA COLLABORATE ON WEB SEMINARThe Hydraulic Institute, in collaboration with Henri Azibert,technical director of the Fluid Sealing Association andassociated HI committee members, has developed a newwebinar session focused on how dual gas seals improvepump system reliability and performance.

Henri Azibert, FSA technical director and pump industryconsultant, remarks, “HI’s new webinar session on Dual GasSeals is the most complete course available in the pumpingindustry. Engineers from a diverse array of industries willlearn about the in-depth influences. The Fluid SealingAssociation has collaborated extensively with HI to developthis new session and will jointly promote its benefits to thepump user community.”

The June 24 webinar will begin at 1:00pm EDT and willbe led by Jason Ferris, manager of product development,Flowserve Corporation. Cost is just $99.00, with HI membersreceiving an additional 25 percent discount, along withattending earning one (1) Professional Development Hour(PDH) credit after the session. HI also offers corporate groupwebinar site licensing for the lowest prices in training largergroups. ■

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TRADE SHOW prof ile

For over one hundred years, the American Society ofHeating, Refrigeration, and Air-Conditioning Engineers—better known as ASHRAE—has set the standard as the

foremost source of technical and educational information andthe primary provider of opportunity for professional growthin the related fields o f heating, ventilating, air conditioning,and refrigerating. Each year, the ASHRAE Annual Conference

provides a launch pad for innovative ideas, skilled instruction,and industry camaraderie.

TECHNICAL PROGRAM

A mainstay of the ASHRAE Annual Conference, the technicalprogram addresses broad topics in the application of technologyto practice, specific applications in ground source heat pumps,O&M and indoor environmental quality, as well as new reportson research taking place worldwide. The conference’s technicalprogram features various tracks, each speaking to current needsthat professional engineers face in the field.

The complex relationship between indoor and outdoorenvironmental conditions, coupled with the impacts ofclimate change, requires buildings that are comfortable andhealthy for the occupants yet also energy efficient. “TheIndoor Environment—Health, Comfort and ProductivityTrack” highlights the state of knowledge of the balance o fenvironmental health and energy efficiency in buildings andresearch directions.

“The Ground Source Heat Pumps State of the Art: Design,Performance and Research Track” addresses all aspects ofdesign that lead to optimally performing systems in additionto avoiding common pitfalls that lead to poorly performingsystems.

With low energy and zero energy buildings becoming moreprevalent, there are many issues that arise with installation,startup, commissioning and operations and maintenance

(O&M). “The Installation, Commissioning, Operation,Maintenance of Existing Buildings Track” focuses on lessonslearned, improvement of process and team communicationsand efforts to improve the installation, startup, operations andmaintenance, and commissioning o f HVAC systems.

“The Refrigeration Track” emphasizes global perspectiveson new refrigerants, variable refrigerant flow applications,magnetic bearing compressors, and refrigerant management.Non-comfort cooling applications in food preservation andmedical cryogenics also are highlighted

ASHRAE is known for its standards—their development andtheir adoption worldwide. “The Standards, Guidelines andCodes Track” highlights the applications of ASHRAE’s standardsto practice as well as European (CEN) and ISO standards thatsupport building performance.

ASHRAE 2014

Annual ConferenceSetting the Standard, Raising the Bar

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JUNE 2014 | 11www.modernpumpingtoday.com

RESEARCH SUMMIT

AND BOOKSTORE

The second annual ASHRAE ResearchSummit presents innovations in HVAC&Rresearch with particular emphasis onhigh performance building design andits role in a clean energy economy,

and brings together researchers topresent and discuss the latest research.Researchers will present papers,seminars and forums or participate inpanel discussions. Also, highlights onongoing ASHRAE funded research arepresented. Join us in this comprehensivecompilation of research-related papersand programs that peer into what thefuture holds.

Authors of some 200 conferencepaper abstracts have been invitedto submit papers for the ResearchSummit and conference. More than

300 books, meeting papers, and otherrecent publications will be available forpurchase in the ASHRAE bookstore. Thebookstore provides HVAC&R technicalliterature from ASHRAE and otherpopular industry publishers.

EDUCATIONAL SEMINARS

The two full-day seminars include“Introduction to Buildings EnclosureCommissioning,” which introducesthe Building Enclosure Commissioning(BECx) process by outlining key qualitybased activities that achieve a successfulbuilding enclosure. The seminar willinclude overviews on such designphase BECx activities as developingthe Owner’s Project Requirements, theBECx plan, and critical building scienceand architectural issues to address in

the design review and specifications,and construction phase BECx activitiessuch as construction observation andperformance testing. The seminarwill aid in understanding how BECxcontributes towards commissioninggoals and requirements and LEED.

The other full-day seminar,“Introduction to Buildings EnclosureCommissioning,” provides guidance onhow to perform commercial buildingenergy audits. Best practices andother information relevant for buildingowners, managers and governmententitles are covered. The seminarincludes a summary of materialsessential for performing ASHRAE Level1, 2 and 3 audits, time-saving tips for

every auditor, how to hire an auditor,what to ask for in a comprehensive auditreport, and how to build a successfulenergy efficiency retrofit team.

Numerous half-day short coursesinclude “Designing High-PerformanceHealthcare HVAC Systems,”“Designing Toward Net Zero EnergyEfficiency Commercial Buildings,”“Troubleshooting Humidity ControlProblems,” “Building DemandResponse and the Coming Smart Grid,”“Commissioning for High-PerformanceBuildings,” “Application of Standard62.1-2013: Multiple Spaces Equationsand Spreadsheets,” and “ExceedingStandard 90.1-2013 to Meet LEEDRequirements.” Each course earnsthree professional development hours(AIA LUs) or .3 CEUs. Attendeesare encouraged to check with theirstate for their continuing educationcredits requirements and to bring allidentification numbers to the course toensure they receive proper credit.

THE PATH TO

PROFESSIONAL GROWTH

With access to varied offerings andunmatched expertise, attendees of theASHRAE Annual Conference continueto distinguish themselves among theirpeers and develop new approaches tothe growing challenges of efficiency,power, and sustainability that are thedriving forces of the HVAC&R industry.This year’s conference promises to buildon the wealth of ASHRAE’s resourcesand encourage current professionals topromote new ideas. ■

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CASE Studies

Further to investigations of “PinHoles” by non-destructive testingof a strategic flow control valve

at Dŵr Cymru Welsh Water’s Pontsticill

WTW near Merthyr Tydfil, it was foundthat in fewer than five years, cavitationhad caused extensive detrimentaland potentially fatal wear to theplug valve, which was in danger ofimminent failure. Should this have failedcompletely, the Water Treatment Works

would have flooded and reinstatementwould probably have taken several days,placing 70,000 customers at risk oflosing supply.

Although there was a replacementplug valve on hand, Dŵr Cymru WelshWater sought advice from IndustrialValves’ technical specialists (IVL FlowControl) as to the suitability of thistype of valve in this environment. Onstudying the available data it was proved

that the pressure differentials presentcould not be handled by this type ofplug valve, and it would inevitably leadto a repeat of the cavitation problems

and another potential loss-of-supplysituation. IVL recommended a series300, 23.62 inch (600 millimeter) EOVcontrol valve as an alternative, alongwith a technical assessment which DwrCymru Welsh Water were happy toaccept.

Craig Stanners is the director at IVL Flow Control and can be reached 07772.699313 or [email protected] Redman is the technical director at IVL Flow Control. Contact him by calling 07972.194965 or via email [email protected]. IVL Flow Control provides solutions for a range of water utilities and industrial markets.

For more information, visit www.ivlflowcontrol.co.uk or meet the team this year at WEFTEC.

About The Author

The 23.62 inch (600 millimeter) EOVcontrol valve installed and running.

New Control Valve Is

an Overnight SuccessEOV CONTROL VALVES PROTECT VITAL WATER SUPPLY

By Craig Stanners and Martyn Redman, IVL Flow Control

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WORKING THROUGH

THE NIGHT

The difficult replacementwas carried out overnight,and the removal of theexisting valve and re-installation of the new

valve was achievedwithin an eight hourovernight shutdownperiod between 8pm and4am, with IVL’s engineerson hand to assist.

Thankfully this type ofwork goes unnoticed bythe general public, butwhen dealing with suchlarge volumes of waterfrom a health and safetyand water quality pointof view, the planning

and effort that goesinto ensuring a smoothtransition has to beabsolutely meticulous.

This was anotherexample of teams workingtogether to protectessential services and anexcellent example of apositive intervention that will benefitboth customers and the company.

The new 23.62 inch (600 millimeter)control valve is already showing thatit is resistant to cavitation at PontsticillWTW, performing within an accuracy of±0.5 percent and controlling flows from0 gallons per day (when closed) up toaround 25.1 million gallons (95 millionliters) per day.

FIRST CLASS ALL THE WAY

Furthermore, in this situation the newcontrol valve will have a lifetime oftwenty to thirty years, when servicedand maintained regularly.

“The detailed planning, competentrisk assessment and above all,leadership and teamwork to get thejob done in such a short space of timeovernight is highly commendable,”adds Dŵr Cymru Welsh Water’s chiefoperat ing officer, Peter Perry. “Thecommitment, proactive approach andlong-term solution for this essentialwork have been first class.”

IMPROVED OPERATION

“We had noticed a problem with theold valve when we were carrying outregular checks of the raw water valve,”add Chris Holloway, production asset

engineer at Dŵr CymruWelsh Water. “Therewas water spraying outof very small holes inthe valve body. Whenit came to changing thevalve (and the capital

team told us they weregoing to change the typeof valve), I was a bitconcerned that that theoperation of it wouldchange and we wouldnot be able to restartthe works in the way wenormally would.”

He continues, “Onthe night after the newvalve was installedand everything wasready to go we decided

to try to bring on theworks using the normalmethod, where we haveto bring the flow onvery quickly for the first10.6 million gallons(40 million liters) perday to make sure theDAFs get a decent flow

to start with. I was surprised that theflow came on so smoothly and didexactly what I was hoping it would do.All changes following this were muchsmoother than we were getting with theold valve.

“Since the install of the new valvewe have noticed that the changes tothe flow required by network and thehigh lift pumps (which can be as muchas 5.3 million gallons [20 million liters]per day at any one time) have been alot smoother than before. The controlof the chemicals, which are flow-pacedfrom the front-end has also improvedenormously.” ■

Above: The new 23.62 inch(600 millimeter) EOV control

valve is already showing thatit is resistant to cavitation.

Right: The PontsticillReservoir, an important watersource to local residents.

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CASE Studies

Chris Laurent is the marketing communications manager for Maag, the worldwide leading manufacturer of gear pumps,pelletizing systems, and filtration systems for demanding applications in the plastics, chemical, petrochemical, and foodindustries. Its subsidiary Automatik Plastics Machinery has been manufacturing innovative pelletizing systems of thehighest quality for several decades. It is the world leader in underwater strand pelletizing systems. He can be reached at

[email protected] or 41.44.278.8349. For more information about the Sphero®

S, visit www.sphero-s.com.

About The Author

By Chris Laurent, Maag

Sphero® S underwater

pelletizing machinery

system makes waves

in China

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Building on oversixty years oftechnological and

industry experience,Automatik PlasticsMachinery—a subsidiary of Maag, amember of Dover Corporation's PumpSolutions Group (PSG®)—launchedits innovative design, the Sphero®

S underwater pelletizing system,before the scrutiny of attendeesat the Chinaplas 2014 technicalconference this past April. As oneof the largest and fastest growingindustrial sectors on the globe, theChinese market provides a provingground for new designs and ideas andthe Chinaplas conference annually

brings together a wide variety ofleaders from the plastics and rubberindustries. Specifically designed andengineered for the mid-tier polymerproduction market, the Sphero® S is

ideally suited to meet the demandsin compounding, masterbatch, andrecycling applications.

ITS PUBLIC AWAITS

“Chinaplas was the perfect venue forus to introduce our new Sphero® SSystem,” says Andreas Weidner, Chinasales director for Automatik Plastics

Machinery. “Launchingthe Sphero® S in front ofthe over 40,000 visitorsto Chinaplas was a greatexperience, and we received

an overwhelmingly positive responsefrom everyone at the event. We lookforward to showcasing the Sphero® Sat other upcoming shows.”

PERFECT PELLETS FOR THE

PERFECT PRODUCTS

Automatik’s new Sphero® S underwaterpelletizing system is designed forthe medium-throughput polymerproduction market and engineered toperform in compounding, masterbatchand recycling applications. The system

APPLICATIONS

Compounding/masterbatch/recycling based on:

• Polyolefins, e.g. LDPE, HDPE, PP

• Styrene polymers, e.g. PS, SAN, ABS

• Acrylic resins, e.g. PMMA, APN

• Polyesters, e.g. PET

• Polyamides, e.g. PA 6, PA6.6

• Polyurethanes, e.g. TPU

• Hot-melt adhesives

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CASE Studies

Urs Gull,director ofsales for Maag,with the newSphero® Sunderwater

pelleti zingsystem atChinaplas

2014

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delivers exceptional value through industry leadingtechnology, production proof components, reputation anddesign innovation.

Specifically designed to be a cost-effective alternativeto larger and more customizable systems, the Sphero® S incorporates avariety of innovative

features suited formedium throughputs,typically between1500 to 6600 pounds(roughly 700 to 3000kilograms) per hour.The major technologicaladvancements includenew pneumatic divertervalves that optimizethe flow channel andease the cleaning of thecutting chamber, and auser-friendly, ergonomic

design for easy cleaningand quick changes of theknives and die plates.

Other improvements to the Sphero® S include a newframe that allows it to be mounted on a single mobilestructure, which guarantees a perfect alignment and areduced footprint. Starting the system is almost instant,accomplished with a simple press of a button. The water

bypass design has also been fine-tuned resulting in aspeedier start-up. In addition, special attention has beengiven to the design of the cutter head to guarantee processintegrity and ensure the production of evenly shaped, high-quality pellets. System options include a flow meter with

shut-off valve, sightglass, stroboscope,

water blow out device,visual indicator forheating cartridgesperformance

READY FOR

TODAY’S

PRODUCTION

PROCESS

“Pelletizing is one ofthe most importantsteps in the productionprocess of a widevariety of plastic and

rubber products,”Andreas Weidneradds, “and Automatik

pelletizing systems have been designed to integrateperfectly into the production line to simplify operationsand maximize output in the most efficient manner possible.The new Sphero® S will continue this tradition, only nowwith a simpler and more cost-effective design.” ■

FEATURES & BENEFITS

• Upgraded water by-pass design for utmost processintegrity and fast start-up

• Enhanced cutter-head produces quality, evenly cutpellets

• Ergonomic design for minimized cleaning and dieplate changing times

• Single mobile-frame structure for superioralignment and reduced footprint

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WATER & WASTEWATER solutions

In part one of this article, we examined two commonsystems, one using compressible gasses, and the otherusing non-compressible liquids, that provide uniform

distribution of cooling fluid in both cooling applicationsand many spray applications. In this month’s concludinginstallment, we’ll take a closer look at the benefits of thecalculations for compressible flow as well as for expansion

factor as it relates to the change in the density of an idealgas. As you will see, accurate measurement and thoughtfulcalculation can save operators many hours of regret—not tomention a boon to the bottom line.

OLD NEWS IS GOOD NEWSAn old article in a text book from the 1960s provides agood answer—in that, they suggested that with a pipe ofconstant diameter, the head losses through the nozzle wereapproximately equal to the friction losses equal to aboutone-third the frictional flow in the pipe.

Put in scientific terms, the friction head or h f is equal tothe value shown in equation 2:

Remember that you will need to have the head greaterthan the hydraulic head on the outside of the pipe.

Another way to look at the solution to the problem is toperform an analysis across the orifice. In a simple case wehave

If the value of C is 0.60, and the value of the large pipeflow is Q and the individual orifice value is q, and thehydraulic head differential between the inside of the pipeand immediately outside the pipe is hd which accounts forthe submergence of the pipe. If you set the nozzle lossesgreater than the pressure head against the pipe plus the pipefriction, the design works.

An example will help. I have a 3-inch (76.2 millimeter)pipe 300 feet (91.44 meters) long. I want to distribute 100gallons (378.54 liters) per minute through it uniformly. Headlosses through the length of the pipe are 4.47 feet of headloss per 100 feet. The pipe is submerged by 3 feet of water.The total head loss is then 4.47 * 3+3 = 16.41 feet of heador just about 5 PSIG.

I want to use 30 nozzles or orifices, and each one shouldtake about 3.33 gallons per minute.

The nozzle size should be

In the proper units q = 7.42*10-3 cubic feet per second,g is 32.18 square feet per second and h is 16.41 feet.Running the numbers that gives A2 is 5.381*10-4 square feetor 0.0775 square inches.

That translates to a hole of approximately 0.0987 inches

in diameter or a 3/32 inch hole. The water will flow outuniformly. The water will also flow in uniformly, undervacuum conditions. If the system is going to be a freedraining system with no vacuum in the pipe, then theavailable head with be that on the outside of the pipe lessthe friction losses in the pipe, meaning that a larger openingwill be required.

David L. Russell, P.E., is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., aspecialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projectsranging from environmental process designs and hazardous wastes to water systems and wastewater treatment. He can be

reached at 770.923.4408 or by visiting www.globalenvironmental.biz.

About The Author

By David L. Russell, Global Environmental Operations, Inc.

Equation 2

Where:

K is the hydraulic coefficient equivalent to the headlosses in the total length of the pipe at full flowconditions;

L is the length of the pipe,

l is the fractional length of the pipe where the lossesare occurring, and

Qo is the total flow in the pipe at maximumconditions.

Hf = (KQo2 /L2)(I-I2 /L + I3 /L2)

qn = CAo2(2gh)0.5

q = 0.60 A2(2gh)0.5

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Warning: If you are trying to use this design for developinga uniform draining system, remember that the maximumvacuum you can reliably have on the system, is aboutnegative 13 psig or about 30 feet of suction. Beyond that youwill start to get cavitation in your pump.

COMPRESSIBLE FLOW

Compressible flow occurs in air and other gases. The formulamust account for a few more variables such as the initial andfinal states and temperatures. As the air crosses the orifice itchanges temperature, decreasing sharply as it expands fromthe nozzle. In order to prevent the moisture in the gas fromfreezing and possibly plugging the nozzle, one needs toaccount for the change in temperature across the orif ice.

The equations for compressible gas flow across a nozzleare a bit different.

For this we need to introduce an entire new set of terms:Equation 2 above needs to be modified by introducing the

expansion factor to account for the compressibility of gases.

CALCULATION OF EXPANSION FACTORThe expansion factor Y, which allows for the change in thedensity of an ideal gas as it expands isentropically (no netchange of energy through the nozzle or orifice), is given by:

For values of β (ratio of orifice diameters) less than 0.25

β4 approaches 0 and the last bracketed term in the aboveequation approaches 1. Thus, for the large majority of orificeplate installations:

Equation 3

Where:

Y is 1.0 for incompressible fluids and it can becalculated for compressible gases.

m = ρ1 Q = C Y A2 2 ρ1 (P1-P2)•

Equation 4

Where:

Y is the expansion factor, dimensionless

r is P2 /P1 (Absolute pressures)

k is specific heat ratio (cp/cv), dimensionless*

Y = r2 / k k 1-

r

(k-1)/k

1-

β

4

k-1 1-r 1-β4 r2/k

Y = r2 / kk 1-r(k-1)/k

k-

1 1-r

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WATER & WASTEWATER solutions

NOTE: For air, it is 1.4, which is good enough for mostcases, unless one really has a heavy vapor concentration inthe gas. Or get Cv and Cp from online tools and referencessuch as those found on EngineeringToolbox.com.

Substituting equation 4 into the mass flow rate equation(equation 3), and making a few substitutions using the GasLaw, we get:

And make sure all the units are consistent, if using Englishunits, then the temperature is in Rankine degrees. And thus,the final equation for the non-choked (i.e., sub-sonic) flow ofideal gases through an orifice for values of β less than 0.25.

Where:

k is specific heat ratio ( ), dimensionless

m is mass flow rate at any section, kg/s

Q1 is upstream real gas flow rate, m³/s

C is orifice flow coefficient, dimensionless

A2 is cross-sectional area of the orifice hole, m²

P1 is upstream gas pressure, Pa with dimensions ofkg/(m•s²)

P2 is downstream pressure, Pa with dimensions ofkg/(m•s²)

M is the gas molecular mass, kg/mol (also known as themolecular weight)

R is the Universal Gas Law Constant is 8.3145 J/(mol•K)

T1 is absolute upstream gas temperature, K

Z is the gas compressibility factor at P1 and T1 anddimensionless—but most of the time it is 1 for air atenvironmental temperatures generally encountered.

A final check of the velocity of the gas through theorifice should be made to insure that it is not supersonic(exceeding the speed of sound) and it should be checkedfor temperature to insure that the gas vapor which containswater will remain above freezing. This is important for both

vacuum extraction and vapor venting.The entire program can be easily arranged on an Excel

spreadsheet, and the total orifice size and pressure dropand gas flow can be easily calculated. Then using thesame essential data, select a drill size and a spacing whichis suitable to the length of the horizontal well. A briefcalculation of the total orifice size and appropriate area isvery straight forward and easily performed. ■

Equation 5

Where:

T1 is the initial temperature

Q1 = C A2 2ZRT1 k P2 P2

M k-1 P1 P1

2k

k+1k

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EXPERIENCETODAY

1 9 90

YA S K A WA A M E R I C A , I N C .

D R I V E S & M O T I O N D I V I S I O N

1 - 8 0 0 - Y A S K A W A Y A S K A W A . C O M

Follow us:

For more info:

http://Ez.com/yai632

©2014 Yaskawa America Inc.

We recently came across a two decades old photo of some young

up and coming engineers that were part of our drive engineering team at the time.

Guess what?

All those people are still with us. In fact, they are among our company leaders today.

Imagine. Twenty years of experience from each of them going to work for you every day.

Incredible knowledge. Penetrating insights. Real results.

Yaskawa puts all of that to work for you every day. Think of what you can do with a partner like that.

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MAINTENANCE solutions

In part 1 of this series, we looked at many of the ways inwhich pumps can be mounted—introducing some of thepractical and financial considerations for best practices

in base plate installation options. In this installment, we’llexamine more closely some of the “Best-in-Class” users’decisions and an important exception to the general guidelinesfor secure-in-place installation.

EPOXY-FILLED OR FULLY-

MOLDED EPOXY BASE PLATES

Best-in-Class users oftenspecify and generally insiston full epoxy or epoxy pre-filled steel base plates. Bothfull epoxy and epoxy pre-filledbase plates dispense with thelabor-intensive conventionalgrouting procedures that will beneeded with old-style hollowbase plates. Much labor andcorrective maintenance canbe eliminated by buying eithersolid epoxy or steel base platespre-filled with epoxy. The lattercan also be fabricated in-plant. The conventional hollowbase plate in figure 4 is beingprepared for filling with epoxy.Once filled, this base platebecomes a monolithic block thatwill never twist and never get out of alignment (see reference4). The overall cost of this superior mounting is usually belowthat of conventional leveling and grouting methods. In otherwords, the life cycle costs of full epoxy or epoxy pre-filled

steel base plates can be overwhelmingly attractive (seereference 3).

Since about 2000, Best Practices Companies (BPCs) haveincreasingly used “monolithic” (all-in-one, and/or epoxypre-filled steel) base plates in sizes approaching about 5 feetby 8 feet (1.5 meters by 2.5 meters). Larger sizes becomecumbersome due to heavy weight.

In the size range up to about 5 feet by 8 feet (1.5 metersby 2.5 meters), conventional grouting procedures are beingphased out in favor of base plates pre-filled with an epoxyresin or grout (see reference 3). The epoxy filling processincludes five successive stages, all done under controlledconditions. The entire process is most often done beforeshipment to the site; at other times a competent work team is

entrusted with items 3 through5 at the destination or owner’splant site:

1. Base plate fabrication.(No pour holes are neededfor pre-filled base plates,although figure 4 showsthese large openings)

2. Stress relieving3. Pre-grouting (grit blasting

followed by primerapplication) in preparationfor pre-filling. (If thereare large pour holes, theinverted base plate mustbe placed on a sheet ofplywood, figure 4)

4. Fill with epoxy grout andallow it to bond and cure

5. Invert and machine themounting pads to be flat;then verify flatness before

shipment. Protect and ship—possibly even with pump,coupling and driver mounted and final-aligned.

The advantage of pre-filling is notable. Jobs with pumps in

the 750 kilowatts category and total assemblies weighing over24,600 pounds (~11,000 kilograms) have been done withoutdifficulty on many occasions. In contrast, a conventionallygrouted base plate requires at least two pours, plus locatingand repair-filling of voids after the grout has cured. Epoxypre-filled base plates travel better and arr ive at the site flat andaligned, just as they left the factory. Their structural integrity is

Heinz P. Bloch, P.E., is one of the world’s most recognized experts in machine reliability and has served as a foundingmember 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 [email protected].

About The Author

By Heinz P. Bloch,

Process Machinery Consulting

Know Your Pump Base PlateInstallation Options

Part 2 of a 3-Part Series

Underside of a base plate after a prime coat has been applied. It isready to be filled with epoxy. The large pour holes identify it as anold-style “conventional” base plate being converted to pre-filled style(Source: reference 4)

Figure 4

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better because theydo not require groutholes. Their installedcost is less and theirlong-term reliabilityis greatly improved.

SECURING PUMPS

IN PLACE—WITH

ONE EXCEPTION Again, and forgeneral emphasis:Proper fieldinstallation of pumpshas a measurablepositive impact onpump life. Even asuperb design willgive poor resultsif poorly installed.A moderately

good pumpdesign, properlyinstalled, will givegood results (seereference 2). Properinstallation refers toa good foundationdesign, no pipestrain and goodshaft alignment, toname just a few. Nopump manufacturerdesigns its pumpsstrong enough to actas a solid anchoringpoint for incorrectlysupported piping, orpiping that causescasings and pumpnozzles to yieldand deflect. Also,pumps have to beproperly secured totheir respective baseplates and thesebase plates haveto be well-bonded

to the underlyingfoundation. Epoxygrout is used todo this bonding inmodern installations.

There is oneexception, however:Vertical in-line pumps (figure 5) are not to be bolted to thefoundation. They are intended to respond to thermal and othergrowths of the connected piping and must be allowed to floator slide a fraction of an inch in the x and y-directions. Thefoundation mass under vertical in-line pumps can be much lessthan that under the more typical horizontal pump. For verticalin-line pumps it is acceptable to make the concrete foundationabout one-and-a-half to twice the mass of the pump-and-driver

combination (seereference 3). Adecade-long rule ofthumb for horizontalpumps aims for afoundation massof 3 to 5 times the

combined mass ofpump, driver andbase plate.

A LOOK AHEAD

In the conclusion ofthis series, we willlook at what pumpusers need to knowabout with regardto the best-practicespecifications foralignment jackingprovisions and

create an adaptablechecklist for baseplate installationoptions andguidelines. Noinstallation checklistcan cover theentirety of pumpusers’ experiencesand specifications,but some concernsremain worthyof attention inthe majority ofapplications. ■

REFERENCES

1. Bloch, H. P., andA. R Budris. PumpUser’s Handbook:Life Extension, 4thEdition (2013).Fairmont Press (ISBN0-88173-720-8).

2. Bloch, H. P., and F.K. Geitner. MajorProcess EquipmentMaintenance andRepair ,” 2nd Edition.

Gulf PublishingCompany (ISBN0-88415-663-X).

3. Bloch, H. P. PumpWisdom: ProblemSolving for Operatorsand Specialists

(2011). John Wiley & Sons (ISBN 978-1-118-04123-9).

4. Monroe, Todd R. and Kermit L. Palmer. “Methods for the Design andInstallation of Epoxy Pre-filled Base Plates” (1997 Marketing Bulletin).Stay-Tru® Services, Inc., Houston, Texas.

5. Barringer, Paul, and Todd Monroe. “How to Justify MachineryImprovements Using Reliability Engineering Principles,” Proceedingsof the Sixteenth International Pump Users Symposium (1999).Turbomachinery Laboratory, Texas A&M University, College Station,

Texas.

Vertical in-line pumps are not to be bolted to the foundation. They should be allowed to move with theconnected pipes

Figure 5

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PUMP solutions

Paul McGarry is the All-Flo sales and marketing manager for North America. To learn more, visit www.all-flo.com, and

www.aoddpumpefficiency.com .

About The Author

By Paul McGarry, All-Flo Pump Co.

All-Flo’s A200 pump reduces energy costs, improves performance

A Revolution in Pumping Efficiency

PART 3 IN A 4-PART SERIES

All air-operated double diaphragm pumps (AODDPs)are not created equal. In fact, significant differencesin performance, efficiency, and total cost of ownership

exist from one manufacturer’s pump to another. Sometimes

these differences are so pronounced that they can add up tolosses of hundreds of thousands of dollars every year.

If AODDPs were truly the interchangeable commodityproducts as some believe, would this be the case? Theanswer is an emphatic no. There is still room for innovationand improvement in the field of AODDPs. One example ofwhere these ideas have found a home—as we’ve seen in thefirst two installments of this series—is All-Flo’s A200 pump.The A200 stands apart from other AODDPs on the market.As you read this month’s article, the importance of choosing

the right pump for your application will become abundantlyclear.

A QUICK RECAP

Before we move on, let’s take a moment to look back athow we got here. The first two artic les in this series coveredhow AODDPs work, how to read performance curves, andhow to calculate pump operating costs. We also delved intohow All-Flo’s new A200 model drastica lly improved uponits predecessor and has raised the bar for performance andefficiency across the entire industry.

Please reference the prior installments if you need arefresher, but for your convenience, here’s a reminder o fthe primary takeaway: All-Flo seriously advanced pump

Figure 7

Discharge Flow - Liters/Min.

P r e s s u r e I n l e t / O u t l e t P S I G (

B a r s )

T o t a l H e a d i n F e e t ( M e t e

r s )

Discharge Flow - U.S. Gals./Min.

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performance and efficiency withthe A200. This was achieved byreducing and optimizing deadspace on the liquid and airsides of the diaphragms and byimproving the timing of the mainair valve.

SETTING THECOMPARISON CRITERIATo get a fair apples-to-applescomparison underway, wewill start with some specificassumptions. First, theapplication scenario. For ourpurposes, we are going tosuppose that the AODDP being evaluated needs to transfer8000 gallons (30,283.29 liters) of liquid every hour, for eighthours a day, over the course of a year. It will do this with aliquid discharge pressure of 20 PSI. Second, 8000 gallons(30,283.29 liters) per hour is equivalent to a flow rate of 133

gallons (503.46 liters) per minute. This means that the pumpin our example operates at 133 gallons (503.46 liters) perminute against a discharge pressure of 20 PSI.

Using the performance curve shown in figure 7, we canfind out how much air is required to run the pump. Simplyfind 133 gallons (503.46 liters) per minute on the horizontalaxis and then look to see where that value intersects with20 PSI on the vertical axis. You can see that they meetbetween the two blue lines that represent 80 and 100 PSI.This means that the required operating pressure is around 90PSI. The intersection point also lies between the red lines thatrepresent 60 and 80 SCFM. This tells us that we can estimatethe air consumed by the pump to be 70 SCFM.

WHAT DOES THIS MEAN?To put it all together to calculate operating costs, we use thefollowing equations:

As you can see, in our example, this particular pump cantransfer 8000 gallons (30,283.29 liters) per hour at a costof $0.91 per hour. This makes the extended annual costsomewhere in the neighborhood of $1900.

ONE OF THESE PUMPS IS NOT LIKE THE OTHERSThe impressive pump performance used in the previousexample belongs to All-Flo’s A200. In Table 1, we’ve putthose numbers (found under A200 Redesigned Pumps)up against the operating costs of the A200’s own All-Flopredecessor (Legacy Pump Model ) as well as AODDPscurrently sold by other manufacturers. As you can see, theA200 beats the competition in every single category.

Sure, the differences in operating costs demonstrated hereare stark, but remember—this is just for one pump. Some

All-Flo customers run four hundred pumps or more at anygiven time, so imagine extending these savings across anentire operation! You don’t have to be a mathematician tounderstand that those kinds of numbers can dramaticallyimpact a company’s bottom line. That’s why it’s so important

to know exactly what you’re getting into—exactly whatyou’re getting for your AODDP investment—before you makea purchasing decision. The numbers don’t lie.

COMING UPIn our next, and final, article in this series, we will discusshow to make sure you get the ideal AODDP for your needs.We’ll clue you in on what to look for when evaluatingAODDP performance and give you the right questions to askpump manufacturers. ■

RedesignedPumps

OriginalPump Model

Brand A Brand B Brand C Brand D

Required air pressure (psi) 90 82 81 100 120 97

Required SCFM 70 122 108 135 125 175

$ Per hour $0.91 $1.59 $1.41 $1.76 $1.63 $2.28

$ Per 8-hour day $7.31 $12.71 $11.28 $14.10 $13.06 $18.28$ Per five-day week(8 hours per day)

$36.55 $63.71 $56.40 $70.50 $65.28 $91.39

$ Per year (52 weeks) $1,901 $3,313 $2,933 $3,666 $3,394 $4,752

70 SCFM x 1 hp/4 SCFM = 17.5 hp

17.5 hp x 0.746 kW/hp = 13.06 kW

13.06 kW x $0.07/kWh = $0.91 per hour

Table 1: The operating requirements of the redesigned A200 AODDP and other pumps.

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DEWATERING solutions

Food processing plantsrequire a dependablesource of water in large

quantities for the washing

and rinsing, steaming,cooking and cooling of food,and during plant sanitationoperations. That’s why alarge Midwest food processorwanted full control over itswater supply by constructinga private water well on itsown property. However, whatlooked like a simple solutionwas quite complex belowthe surface—as the welldriller discovered when heembarked on the project.

"The food processor's waterproduction requirements andthe utilization of local wellsmeant our first and seconddrilling choices wouldn’twork," says Roger Renner,owner of E.H. Renner andSons, a leading well-drillingfirm located in Elk River,Minnesota, near the TwinCities metro area. "In fact,I'm the fourth generation inour family firm, and I can

truly say this was the mostchallenging job I've everhad."

DIFFICULTIES WITH ADEEP AQUIFERFrom the start, Rennerrealized the project wouldbe difficult when there

were objections to using adesirable shallow aquifer.An aquifer is a water-bearinglayer of permeable sand,

gravel or rock that channelswater to a well. In this case,the first choice aquifer—ashallow sand and gravelformation located from 112to 442 feet (34.14 to 134.72meters) deep—could not beused, because local residentswere concerned that theirwells would dry up.

"That meant we had to lookat deeper aquifers in twogeological formations knownas the Jordan formationand the Franconia-Ironton-Galesville (FIG) formation,"says Renner. "A nearby citywas drawing water out ofthe Jordan formation. Thatforced the processing plantto go deeper—down 705 feet(214.88 meters), over a tenthof a mile. At that depth, thebedrock is the FIG formation,which dates to the CambrianEra. This water was depositedmillions of years ago before

the dinosaur age. Yet, thewater quality is generallyacceptable for all types ofuse today."

Although drilling a deepwell is difficult, Renner'smain challenge was that theFIG formation has extremelylow well productivity, which

James Klauer is regional sales manager for Danfoss, a world leader within energy-effic ient and climate-friendly solutions for

selected industries. For more information, visit www.danfoss.com.

About The Author

By James Klauer, Danfoss

Controlling All the

VLT® AQUA Drive produces huge water savings from food processor’s deep well

The Danfoss VLT® AQUA Drive

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was measured at a specific capacity of 1 to 2 gallons (3.79to 7.57 liters) per foot of drawdown – compared to a specificcapacity of 20 gallons (75.71 liters) per foot drawdownin the sand and gravel formation. Also, the FIG formationwould max out at a relatively low 350 gallons (1324.89

liters) per minute. The food processing plant ’s operation,however, needs a dependable 350 GPM flow rate running24 hours a day, 7 days a week. That adds up to 10 to 12million gallons (37.9 to 45.4 million liters) per month, 150million gallons (567.8 million liters) per year—a larger

Deeper aquifers proved to be necessary.

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volume of water than used by smallcities.

"The plant depends on that rate offlow to process food around the clockall year long," Renner emphasizes."At the same time, we had to respectthe low specific capacity to avoid

over pumping the well and preventexcessive drawdown. Plus, the state

Department of Natural Resourcesrequires the pumping water level tobe monitored and controlled to keepthe pumping water level above theexisting horizon of the formation. Thatmeant we needed an intelligent pumpcontrol system that could monitor

and adjust a lot of different factors toensure reliable water production."

VFD INTELLIGENCE AT WORK

Considering the challenges, Rennercontacted Brian Peterson of Schwab,Vollhaber and Lubratt, Inc., (SVL)of Shoreview, Minnesota, near St.Paul. As a provider of technicaland engineering services for HVAC

and pump applications, Petersonrecommended a Danfoss VLT® AQUADrive to operate the pump motor.

"This facility is extremely dependenton maintaining a variable water flowbetween 150 to 350 gallons (567.81to 1324.89 liters) per minute at aconstant pressure of 65 pounds persquare inch (psi)," says Peterson."The Danfoss VLT® AQUA Drive isa variable frequency drive (VFD)that is built in Loves Park, Illnois,and is specifically dedicated towater and wastewater applications.

They come off the shelf with theonboard intelligence to handle all themonitoring and control parameters this job required."

The VFD was employed in aclosed control loop. The control andmonitoring programming included

• A wake-sleep sequence that, uponwaking, ramps up the GPM of the

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pump to provide a minimum flowof water to cool the motor. As theplant needs more water flow, theVFD increases motor speed to therequired pre-set pressure of 65psi. The typical production flowrate is 185 to 285 gallons (567.81

to 1078.84 liters) per minute,with process cleaning peaking atthe 350 gallons (1324.89 liters)per minute limit.

• To control the flow rate, the VFDmonitors a pressure transducerthat sends a 4-20mA signalback to the drive. The driveintelligence ensures a constant65 psi, but also limits the flowto 350 gallons (1324.89 liters)per minute by monitoringthe flow meter. Even with

fluctuating pumping levels overthe 12-month per iod the VFDadjusts the speed of the motorto compensate for the changingpumping levels. During the initialVFD programming, adjustmentswere made that limited the 100horsepower motor to only 56 Hzto avoid possible over pumping inthe event of a water main break.

• A pressure transducer was alsoinstalled in the well to controlthe maximum amount of waterdrawdown. If the pumping waterlevel in the well falls below the

preset 520-foot (158.5 meter)depth, the VFD would limit orhold the speed of the pumpto avoid severe pump damagecreated by cavitation. This

"This was the most challenging job I've ever had," says Roger Renner, owner of E.H. Renner and Sons.

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over pumping mode protectionfeature is particularly needed inthe autumn when well pumpinglevels are lowest and when theprocessing plant's production is atits peak.

•

Finally when plant water demandfalls below the minimum GPM

needed to cool the submersiblemotor, the VFD stops the pumpand enters the sleep cycle. Whenthe plant calls for water whilethe VFD is in the sleep state, thewater pressure falls below a presetminimum pressure of 50 psi, then

restarts the pump and ramps upto the preset 65 psi. Thus, the

wake/sleep sequence protectsthe motor against overheating ifthe minimum flow rate cannot bemaintained and shuts off the flowwhen the plant does not call forwater.

Peterson notes that "the VFD'sextended closed loop function canhandle three distinct control sensors:the flow meter, drawdown gauge andthe pressure. The VLT® AQUA Drivesbuilt-in intelligence can process allthose inputs simultaneously. Plus,the system incorporates phase failureprotection, under-voltage and over-voltage protection that protects thedrive and the submersible motor,pump and bearing. This protection canprovide some water production evenwith a loss of a three-phase power

down to two-phase current."The plant is so dependent on

maintaining water flow that thecustomer also added an identicalVFD housed in a NEMA 1 enclosure.It hangs on a wall inside the plant,beside the original Danfoss VLT®

AQUA Drive."The spare is a redundant backup,"

says Peterson. “If there were acatastrophic failure due to a utilityissue, lightning, physical damage orother unforeseen event, the spare drivecan be put into service by just a flipof the switch. For the same reason,the plant also wanted a replacementsubmersible motor and pump on theshelf. But the system has been soreliable since it went into service in2010 that the redundant measureshave not been needed."

GIGANTIC PAYBACK, PLUSGREAT SUPPORTAlong with reliable water production,the processing plant benefited fromtremendous water savings by operating

its own well."Maintaining variable flow at a

constant pressure of 65 psi is jobnumber one," says Renner. "Thereliability of the VLT® AQUA Driveis critical to keep this plant running.Plus, by enabling the use of their ownwater source, the VLT® AQUA Drivemakes it possible to run the plant veryprofitably."

Renner calculates that the plantconsumes about 12 million gallons(45.4 million liters) a month. If theydid not have their own well andwere paying a local price of about

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two dollars per 1000 gallons(3785.41 liters), the water costalone would have been $24,000a month, nearly $250,000dollars a year.

For a processing plant whosebusiness depends on high,

reliable quantities of water,"Saving a quarter of a milliondollars a year certainly justifiesa complex well project like this,because the payback is so fast,"Renner concludes. "The well hasbeen operating since 2010. Theentire project, including welldrilling and lining, was paidback in less than two years."

"And SVL and Danfosshave been a pleasure to workwith. The level of supportwas unbelievable. All of the

parameters required a lot ofprogramming. If we had anissue, the Danfoss applicationengineer was available, evenon a Sunday. It's hard to findthat level of support in a VFDmanufacturer. The Danfoss teamwas instrumental in making thisproject a huge success." ■Savings in water costs will quickly pay back this complex well job.

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MOTOR solutions

The Next Generation of

Premium EfcientGearbox

John Shanesy is the product marketing specialist for NORD Gear Corporation, a part of NORD Drivesystems. NORD providesa wide range of products with gearboxes ranging in torque ratings from 90 to 2,200,000 pound inches, and electric motorsrating in power from 1/6 to 250 horsepower. In addition, the product line consists of high-performance AC Vector Drives and

AC Drives for panel mount or distributed mount. For more information, visit www.nord.com.

About The Author

By John Shanesy, NORD Gear Corporation

Two stage helical-bevel designadds bite to food and beverage

industry

NORD 92.1 Series Gearbox

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Since 1965, NORD Drivesystemshas been providing application-specific concepts and solutions,

which include energy-saving drives,and now the next generation ofpremium efficient gearbox has arrivedfor the North American market.The two stage helical-bevel design,referred to as the 92.1 and 93.1series, offers high-performance, upto 97 percent efficiency and a 60percent increase in torque to weightratio over the previous series. Bothseries are available in five gearcase sizes and are characterizedby an open, smooth, self-drainingouter surface, and are the result ofthorough research assessing the needsof today’s users. Across a range ofindustries, but particularly in food

and beverage processing, usersare searching for increased powerwithout sacrificing efficiency. NORDDrivesystems believes the two stagehelical-bevel design is the answer.

MEETING THE NEEDS THE FIELD

Designed using FEM (Finite ElementModeling Technology), this high-strength aluminum alloy housingis manufactured using NORD'sUNICASE™ Design. The UNICASE™design consists of a one-piecehousing where bores and mountingfaces are machined in one step,

producing precise tolerances thatensure accurate positioning of gearteeth, bearings and seals. Internalreinforcements inside the gear caseincrease the strength and rigidityof the gearbox, resulting in a high-strength housing. This, in turn,provides for larger, high-capacityoutput bearings, increased overhungload capacity and increased hollowbore capacity. By NORD offeringa leak-free design, longer gear andbearing life, quiet operation andhigh output torque capabilities,the customer benefits from highefficiency, low maintenance and along service life.

Providing exceptional modularityand adaptability for all mountingpositions, numerous possibilities exist

for input, output and motor options.Input and output options are stockedat the factory to guarantee quick-shipment upon order. Available witheither a NEMA or IEC input, a NORDmotor or brake motor, the 92.1 and93.1 are well suited for applicationsin the conveyor indust ry, materialhandling, car wash, and the food &beverage industry, including washdown environments.

THE 92.1 SERIES

The 92.1 series, easily identified byits high-strength lightweight design, is

a universal housing offering foot, face(B14) and shaft mount as standard.An optional B5 mount is available.The 92.1 series is cost effective whencompared to the 93.1 and is ideal forcooling, due to its large surface area.

• Universal foot and flange-mounthousings

• Easy wash-down solution• Cost effective design• Foot, face (B14) and shaft mount• External surfaces connected

with large radius and generousmold release slopes provide for acleanable, drainable housing

THE 93.1 SERIES

The 93.1 series is characterizedby the closed design and comes

as shaft and flange mount (B14)as standard. Optional drilled andtapped holes can be provided for footmount requirements. In addition,an optional through-bolt, B5-flangeis readily available. Because thereare no cavities to this design, NSDtupH surface conversion system isavailable.

• Closed gearbox design• No hidden chambers (cavities) for

material build-up• Optimal for NSD tupH Surface

Conversion System

NORD 93.1 Series Gearbox

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MOTOR solutions

OPTIMIZED FOR THE FOOD

INDUSTRY

The 93.1 Series is optimized forthe food industry because of thelightweight, aluminum housingincorporating the newest technology.Designed and manufactured with

inclined surfaces guarantee thedraining of cleaning liquid in allmounting positions. By adding NORD'sNSD TupH surface conversion system,washdown liquids always run off.The benefits of NSD TupH include nopeeling, flaking or blistering of paint byproviding a higher level of corrosionresistance.

The 93.1 series is much lighter andoffers better thermal conductivitythan stainless steel. The design isoptimized for use in the food andbeverage industry and complies with

international guidelines and standardssuch as EHEDG, ANSI, and ANSI /NSF. For sealing lubricants insideand keeping contaminants outsidethe reducer, NORD's four componentQUADRILIP™ sealing system, isstandard for both hollow and solid shaftunit types.

FOCUSED ON EFFICIENCY AND

THE CUSTOMER

As the world continues to strive forincreased efficiency, the new 92.1and 93.1 units are the answer. Whilea typical worm gear type drive maybe only 70 percent efficient, the 97percent efficiency of the 92.1/93.1series are truly the premium efficientgearbox. Dramatic energy savingsand a much lower cost of ownershipare accomplished which, in turn,improves the bottom line. Whilesome manufacturers in the powertransmission industry claim animproved bevel design but attacha lesser efficient hypoid gear stage,others sell the customer a high efficient

motor but attach an inefficient wormgear drive.

This gear cutting technology allowsfor the production of gear sets witha higher maximum ratio per stagethan many other speed reducermanufacturers. This allows for atrue helical-bevel, double reductiongear unit with a maximum ratio of70:1. With a company-wide focuson design, innovation and a superiorproduct, customers and end usersaround the world rely on NORD forperformance, efficiency, and superiordependability. ■

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POWER GENERATION solutions

The electric and gas utility industries are facing substantialchanges. For decades, rising sales have contributed toincreasing revenues and profits, but the combination

of improved energy efficiency with the growing use of solarelectric systems and otherforms of “distributed energy”has reduced growth rates,which could lead to smalldeclines in future sales. Butthese potential small declineswill not lead to the kind of“death spirals” claimed bysome industry alarmists, as ournew report, The Utility of theFuture and the Role of EnergyEfficiency , shows. Still, theindustry and their regulatorswill need to make substantialchanges in the next few yearsin order to continue providingquality service at a reasonableprice, while providing utilitiesreasonable returns on theirinvestments.

THE FORECAST FOR

UTILITY SALES

According to the alarmists,utility sales could plummet,requiring utilities to raise rates so they can recoup their fixedcosts (such as the cost of the current distribution system), andthese rising rates would drive additional customers to leavethe system, a phenomenon they call a death spiral. Our studyexamines three potential sales scenarios, employing increasing

levels of energy ef ficiency, solar electric power and electricvehicles.

The most extreme scenario includes levels of energyefficiency now being achieved in only a few states plus the

use of solar electric powerthat eventually uses nearlyall available roof space.Under this extreme scenario,national electricity salesdecline about 10 percent by2040, an average reductionof 0.39 percent per year.Under a more likely mid-rangecase, sales grow 0.04 percentper year, while under thereference scenario, developedby the Energy InformationAdministration, sales grow 0.7percent per year.

ENERGY EFFICIENT

OPTIONS FOR A NEW

WORLD

In our view, a 10 percent salesdecline over twenty-five yearsis far lower than what wouldbe required to initiate a death

spiral. Under the more likelyscenario, sales are essentially

flat. In such a scenario, utilit ies that have relied on rising salesto fuel profits will need to pursue new business models if theywant to see profit growth. To address this finding, our reportrecommends that utilities offer optional energy-related servicesto their customers, including energy efficiency and technical

Steven Nadel is the executive director of the American Council for an Energy-Efficient Economy (ACEEE), a nonprofit,501(c)(3) organization, that acts as a catalyst to advance energy efficiency policies, programs, technologies, investments,and behaviors. Read the ACEEE’s newest report, The Utility of the Future and the Role of Energy Efficiency , in full at

www.aceee.org/research-report/u1404.

About The Author

By Steven Nadel, American Council for an Energy-Eff icient Economy

Utilities Are Frightened

of a Death Spiral.ÓThey ShouldnÕt Be.Industry and regulators need a more accurate andadaptive view of tomorrow s energy market

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help and financing for larger customersinstalling and operating high-efficiencycombined heat and power systems. Suchefforts can contribute to utility profits,reduce customer bills (since consumptionis lower) and also provide services thatcustomers value, positioning the utilities

to offer additional services.

To support this effort, we alsorecommend that regulators

• adjust rates so that fixed costsare fully recovered as sales levelschange,

• provide utilities financial incentivesfor meeting energy efficiency goals,

• reform ratemaking so that costs arefairly allocated and price signalsencourage efficient use of energy,and

• develop rules to improve the abilityof utilities to offer optional servicesin ways that provide a level playingfield relative to non-utility providers.

Quite a few states have taken some ofthese steps, but only a few states havetaken most of them. In addition, werecommend upgrading management of theelectric grid to better handle increasedamounts of variable and distributedgeneration.

STOP DIGGING, START CLIMBINGOur research also identifies several thingsnot to do. In our view, the ‘first rule ofholes’ applies: When you’re in a hole, thefirst thing to do is stop digging. If salesare level or declining, then utilities andregulators need to be careful of investingtoo much in new generation, transmissionand distribution. Our report notes howAustralian utilities invested so much intransmission and distribution that ratesdoubled, and how German utilities over-invested in generation, contributing to asteep drop in stock prices. While some

investments in fast ramp-up generation,transmission to link control areas, gridhardening, and grid control will beneeded, these should be prioritized socosts and rates are kept to reasonablelevels.

Our call for increased utility investmentin energy efficiency fits in well withproposed regulations (see the EPA’s “CleanPower Plan Proposed Rule” on theirsite: www2.epa.gov/carbon-pollution-standards/clean-power-plan-proposed-rule) on existing power plants publishedlast week by the Environmental ProtectionAgency. The proposal calls for substantial

cuts in carbon dioxide emissions from thepower sector, but provides utilities andstates with the flexibility to use energyefficiency programs and policies to helpachieve those reductions. An earlierACEEE report from April 2014 found thatenergy efficiency could achieve all of the

needed reductions while also increasingGDP and employment.

In summary, if we can get the rulesright and continue to develop thetechnologies and systems we will need,utilities can maintain profitability,customers can receive the services theyneed, bills can be kept to reasonablelevels, and we will al l enjoy a cleaner

environment.■

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PROCESSING solutions

Lewa plunger pumps according to API 674 are usedwherever high hydraulic power is needed, especially inthe oil and gas sector and the process industry. These

pumps are characterized by their compact construction andlow weight, which is particularly significant for offshoreinstallations. To meet the special requirements of customerseven better, Lewa now offers a newgeneration of pumps with splittedgear housings. This special featuresignificantly facilitates maintenance,permitting the use of a fully balancedcrankshaft which generates less noiseand vibration, thus reducing wear. The

power range was also extended withtwo quintuplex plunger pumps.

A CLOSER LOOK

The very short design of Lewa plunger pumps is made possibleby the special alignment of the plunger and crosshead.These pumps also have outstanding efficiency, low energy

consumption, and a long service life. The new structure with thesplitted gear housing and the fully balanced crankshaft doesn'tjust reduce wear, but also particularly facilitates maintenance.The design of the pump also permits the maintenance ofcomponents without disassembling the process pipeline. Thecrankshafts are drop-forged and shot-blasted, leading to a

homogeneous grain structure and lowstress level. The integrated gear unit isself-adjusting and both the crankshaftand the pinion shaft are practically f reeof axial load.

G5K 500 AND G5K 800

Lewa plunger pumps are very powerfuland work with volumetric accuracy.Their large valve cross-sectionsmake the suction pressures required

comparatively small. This mostly eliminates the need of abooster pump. Starting at a power of 15 kilowatts, flexibleuse is possible at different drive speeds up to 800 ki lowatts, at

Thomas Bökenbrink is a product manager for Lewa GmbH, the world's leading manufacturer of metering and processdiaphragm pumps as well as complete metering systems for process technology. The company, headquartered in Leonberg,Germany, has developed over just a few decades into an international group, and its position in the world market was further

strengthened by its integration into the Japanese Nikkiso Co. Ltd. in 2009. For more information, visit www.lewa.com.

About The Author

By Thomas Bökenbrink,

Lewa GmbHShort Design

Means

New quintuplex pumps

with drive powers of up

to 800 kilowatts.

Lewa skid with plunger pumpand ATEX-compliant diesel engine.

Splitted gear box and improvedmaintenance possibilities for

plunger pump

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pressures of up to 3500 bar and a maximum f lowrate of 76,600 gallons (290 cubic meters). Theyare especially used for uncritical fluidslike glycol, methanol, or inhibitors thatare similar to water in terms of theirviscosity.

Now both quintuplex variants,

the G5K 500 and G5K 800, areavailable with maximum power ofup to 800 kilowatts. By increasingthe number of plungers, the sizeof the individual components canbe reduced for the same hydraulicpower. That leads to a reductionin weight, in turn facilitatingmaintenance. They also achieve alow residual pulsation of about sevenpercent, thanks to the five plungers.

SIMPLE MAINTENANCE

AND GREAT FLEXIBILITY

To protect the gear unit from low oil levels andexcessive temperatures, the pump is monitored by defaultby a temperature and pressure switch. In the oil and gasindustry, this is often implemented using t ransmitters. Withinthe gear housing, the crosshead pins and plain bearings aresupplied by an integrated pressure oil lubrication system, so noadditional systems are required. Because all the oil seals areaccessible from outside, no gear oil needs to be drained duringmaintenance tasks, which has a beneficial effect on downtime.

The pump head is equipped with an innovativeplunger seal. Pressure and/or spring support of

the seal packing allows a long service lifeand high availability. The gland packing

is entirely maintenance-free; it neverrequires adjustment of pretensioningor repacking. Any packing leaks are

returned internally, so no externalpump is needed for returning theleakage back into the suction lineand no monitoring is necessary.

Due to the modularconstruction, a pump canbe configured that meets the

requirements resulting from theapplication. Different pump head

designs and valves are availablefor this purpose. The pump head

design makes it possible to exchangethe conversion kit, that is, the plunger

and stuffing box, thus adjusting the volume

conveyed and the discharge pressure over a certainrange. All pumps are optimized for operation with speed

controlled electric motors and/or diesel engines, but of coursethey can also be operated without a frequency converter. Themaximum regulation range is between ten and one hundredpercent of the rated speed. Depending on the applicationand/or the fluid, a wide variety of materials is available forselection. A number of different connection geometries andseveral options for monitoring and flushing are also offered. ■

The divided gear housing of the new quintuplex pump permits the use of a ful ly balanced

crankshaft and facilitatesmaintenance.

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VALVES & CONTROLS solutions

Government regulations requireall industries who rely ongas-powered turbines—which,

in the industrialized world, meansnearly all industries—to reduce theirNOx emissions. Companies who failto reduce theiremissions tothe prescribedrate must beprepared to incurharsh financialpenalties.Furthermore,since emissionsstandards changeover time, thequest for newstrategies andtechnologiesto reduce NOxemissions isunending.

In the followingarticle, we’llbriefly discuss

the causes andconsequences ofNOx emissions,plus explore fourtechniques forreducing NOx

emissions without damaging theturbines necessary to keep industrymoving. Before we begin, though, itmay prove helpful to ask yourself afew questions about your company’semission reduction strategy:

• Can you identify your NOxemissions and how they relate tocombustion instability?

• What can your operators do tocontrol combustion dynamics?

• What ways are available to

Eric Yax is the director of sales and marketing for IMI Sensors—Energy and can be reached at [email protected]. IMI Sensors, adivision of PCB Piezotronics, is the pioneer of ICP® technology and a global supplier of accelerometers, vibration transmittersand switches. PCB Piezotronics was founded in 1967 as a manufacturer of piezoelectric quartz sensors, accelerometers,and associated electronics for the measurement of dynamic pressure, force, and vibration. For more information, visit

www.imi-sensors.com/reducenox or call 800.959.4464.

About The Author

By Eric Yax, IMI Sensors

to Achieve NOx Reductions without Turbine DamageReduction in emissions isn’t just desired—it’s required.

4 WA YS

On-TurbineInstability Sensor

CloseCoupledSensor

Gas TurbineCombustor

Remote Sensor(located outside of turbine room)

"Infinite" Coil

Suggested Sensor Placement

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monitor combustion instability?• What measures have you

implemented to reduce NOxemissions?

• Are you protected againstpotential catastrophic failuresthat result from NOx reduction

strategies?• What does your conditionmonitoring look like?

You may not have the answers to allof those questions right now, but theyshould place you in the proper mind-set to improve your NOx reductionstrategies and address your need forbetter condition monitoring.

THE PROBLEM OF COMBUSTION

INSTABILITY

What is NOx, and how does it

relate to combustion instability? Theproduction of NOx—the commonterm for mono-nitrogen oxides NO(nitric oxide) and NO2 (nitrogendioxide)—emissions occurs in thecombustion process of any gas-fueledturbine. In common practice, NOxemissions are kept low by using lowercombustion temperatures and burningleaner fuel mixtures. However, thiscombination can lead to combustioninstability.

This instability can damagecomponents in the combustionchamber such as nozzles, baskets,and transition pieces, as well asdownstream components, such asblades. The damage invariably resultsin downtime, loss of production, andcostly repairs. Further, a breakdownof one turbine component, such as ablade, has a domino effect on manyother parts, resulting in serious repaircosts.

Turbine operators who utilize NOxreduction strategies use sensors tomeasure dynamic pressure to obtain

early warning of conditions that canlead to excessive pulsations and causeinstability.

HOW TO CONTROL

COMBUSTION DYNAMICS

In order for your industry to continuebe profitable, you must developa strategy to control combustiondynamics while reducing NOxemissions. Strict emission laws andregulations make it difficult for manygas turbines to continue operationwith old combustion technologyproducing high NOx emissions.

For decades, gas turbine operatorshave used pressure sensors andspecialty accelerometers to monitorpressure and vibration levels withinvery demanding, high temperatureenvironments. This technology isdesigned to detect and measure

dynamic pressure spikes

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