pumping solution

BELL & GOSSETT TURN UP THE HEAT

TOMORROW'S DEWATERING PUMP TODAY

PACKAGED PUMP SYSTEMS TO THE RESCUE

MARCH 2015PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY

NATURAL GAS-POWEREDFACILITY A MODELOF EFFICIENCY

CONTENTS MARCH 2015

12

18

38

4 Industry news 10 trade show ProfIle Case studIes 12 Warming Up a Newport Mansion Bell & Gossett pumps power a state-of-the-art heating system

14 Mine to Double Productivity with Waterjet Cutting System DRC Copper Mine installs Jet Edge 5-Axis waterjet

water & wastewater solutIons 18 STEP: Another Alternative to Alternative Sewers 22 The Pursuit of a Green Carbon Steel Corrosion Inhibitor Part 3 in a 4-part series

MaIntenanCe solutIons 26 Electronic Water-Conditioner Keeps Boilers Scale Free Scalewatcher saves San Antonio housing agency the cost of replacing boilers every six months

PuMP solutIons 28 Packaged Pump System Improves Quality of Life City of Southside, Alabama, selects EBARA for emergency lift station upgrade

34 Digester Mixing on Track Biogas Energy brings Landias GasMix system and chopper pumps to North State Rendering

dewaterIng solutIons 38 A Pump System for the Future Boskalis invests in a new, environmentally friendly high flow pump unit

Motor solutIons 40 The Need for Speed One-minute V-belt changes with energysaving Tenso-set motor base

http://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.comhttp://www.mcs.com

Power generatIon solutIons 42 Fast, Efficient, and Environmentally Friendly Rubart Station, Caterpillars largest natural gas-powered facility, is a model of efficiency ProCessIng solutIons 46 Offshore Opportunities Continue for Pumping Professionals

ValVes & Controls solutIons 48 Say Good-Bye to Inaccurate Chlorine Readings New analyzer measures near zero levels of chlorine for repeatable accuracy

sealIng solutIons 50 Strategic Mechanical Seal Partnerships Building owner-manufacturer relationships that benefit all parties Part 2 in a 2-part series

54 Modern PuMPIng ProduCts Featured Product Release: BALDOR ELECTRIC COMPANY NXR High Voltage Rib-Cooled Motor

PuMPIng trends 56 Going the Distance DIGI International's Aaron McNally on the new reach for industrial wireless communication

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J. CAMPBELL Editor [email protected]

DONNA CAMPBELL Editorial Director [email protected]

SCOTT GORDON Art Director [email protected]

LISA AVERY Assistant Art Director [email protected]

JAMIE WILLETT Circulation Consultant

INGRID BERKY Administrative Assistant

TONYA BROWNING Account Executive

JERRY DICHIARA Account Executive

DAVID MARLOW Account Executive

SANDY HAYS Account Executive

Terry BellDrives and Motion Solution Engineer

Baldor Electric Company

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

Process Machinery Consulting

Robert G. Havrin Director of Technology, Centrisys Corporation

Michael ManciniConsultant and Trainer,

Mancini Consulting Services

John M. Roach Engineering Manager

for New Product Development,Trebor International, Inc.:

A Unit of IDEX

Lisa RilesBusiness Development Manager,

Wastewater PumpsXylem Inc.: Flygt

Greg TowsleyDirector of Regulatory and Technical Affairs, Grundfos

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

EDITORIAL ADVISORY BOARD

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

The ACEEE Intelligent Efficiency Conference is designed specifically for:

Energy efficiency program developers and administrators State and local government policymakers, staff, and

associations Chief technology officers and chief information officers Service providers Investors Entrepreneurs Hardware and software developers ICT solution providers Building automation providers Smart manufacturing, smart transportation, smart

buildings, and smart cities leaders

Speaking roles at the conference are by invitation only. Interested parties who would like to share topic ideas, speaker

suggestions, or learn about sponsorship opportunities, can e-mail the Intelligent Efficiency program team or visit the IE web page: www.aceee.org/conferences/2015/ie.

VINYL SAVES LIVES PROJECT AT THE INTERNATIONAL PLASTICS SHOWCASEThe vinyl (PVC) industry and its leaders have selected American Red Cross International Services to benefit from a week-long special Vinyl Saves Lives project and demonstration during NPE2015: The International Plastics Showcase, one of the worlds largest trade shows, being held March 23-37, 2015, at the Orange County Convention Center in Orlando, Florida.

The project will ask the showcases 60,000 attendees to support American Red Cross in the fight against Ebola (i.e., all proceeds will be designated to American Red Cross International Services), and demonstrate to an international audience that vinyl is a critical component in the manufacture of hundreds of medical products and therefore plays a key role in Africa and elsewhere helping to save lives.

The Vinyl Saves Lives project will utilize a 40-foot-wide booth to maximize exposure to showcase attendees and offer special demonstrations of dozens of medical products used in the treatment and isolation of Ebola. Included in the booth display will be an actual patient isolation bed field unit and several medical personnel protective garments as broadcast internationally during the Ebola crisis in Africa, plus a chance for attendees to learn how vinyl/PVC, the second most-used plastic materials, have been used to help save lives for decades.


INDUSTRY newsThe American Red Cross has raised nearly $5.6 million

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

MANUFACTURING DAY LAUNCHES NEW WEBSITEThe partners responsible for producing Manufacturing Day at the national level announced today the refresh of its website, MFGDAY.com. The upgraded site boasts more resources for sponsors, companies, supporters and volunteers, making it easier than ever to participate in this years annual celebration of manufacturing, which is scheduled for Friday, October 2, 2015.

Users can now sign up to host events, find MFG DAY events in their areas, and learn more about sponsorship opportunities through the newly updated interactive site. With user-friendly links to social media channels, scholarships, and success stories, potential participants, manufacturers, educators and students can better collaborate and access important industry resources.

For three years, Manufacturing Day has celebrated the world of modern manufacturing. The annual event is meant to inspire the next generation of manufacturers across the North American

continent. In 2014, more than 1650 companies, educational institutions and associations in all 50 states, Canada and Puerto Rico participated by holding Manufacturing Day events attended by 360,000 people. With the launch of this new site is hoping to increase participation and further educate the public about the benefits of manufacturing. For more information, visit www.mfgday.com.

B&W SUBSIDIARY AWARDED $220 MILLION CONTRACT FOR U.K. POWER PLANTThe Babcock & Wilcox Company (B&W) announced today that its Denmark-based subsidiary, Babcock & Wilcox Vlund A/S, has been awarded contracts totaling more than $220 million to design, manufacture and operate a biomass power plant in Rotherham, South Yorkshire, England.

B&W Vlunds consortium partner, Interserve Strategic Projects, will construct the plant for the developer, Copenhagen Infrastructure Partners.

The Rotherham Biomass Plant will feature a B&W Vlund-designed multi-fuel boiler with a DynaGrate fuel combustion system, a dry flue gas desulfurization system (dry FGD) and will burn waste wood to generate approximately 40 megawatts of electricity.

The contracts also call for B&W Vlund to provide operations and maintenance services for an initial term of fifteen years once the plant is commissioned.

We greatly appreciate the confidence Copenhagen Infrastructure Partners has shown in B&W and this consortium and look forward to executing this project, said Paul Scavuzzo,


INDUSTRY news

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B&W senior vice president and general manager, global power division. The market for biomass power and waste-to-energy technologies in Europe continues to be strong, and B&W is well-positioned to meet the demand for reliable, clean energy solutions. This is B&Ws fourth major renewable energy project announced in the European market in the last seven months.

The project was booked in the first quarter of 2015 and B&W Vlund has received a full notice to proceed with its work. Plant completion is scheduled for third quarter of 2017.

FLOWROX TO PARTICIPATE AT THE PHOSPHATES 2015 INTERNATIONAL CONFERENCE AND EXHIBITIONFlowrox, a global leader in heavy-duty industrial valve manufacturing and services, will exhibit at the Phosphates 2015 International Conference & Exhibition to be held at the Marriott Tampa Waterside Hotel in Tampa, Florida, on March 23-25.

Currently in its eighth edition, the Phosphates International Conference presents a global point of convergence for networking and trading in the fertilizer, industrial and feed phosphate industries; all of great interest to Flowrox, given their use of slurry pipelines to process phosphate salts.

Understanding slurry dynamics was instrumental in Flowroxs development of its Scaling Watch and SKW Heavy Duty Slurry Knife, a pair of products designed to help phosphate processing operators monitor and control the flow of phosphate slurries.

The Flowrox Scaling Watch is actively used in industries such as oil and gas, pulp and paper, metallurgy and minerals mining to proactively detect buildup that can lead to scaling that reduces the flow of materials.

Complementing the Scaling Watch is the SKW Heavy Duty Slurry Knife, designed to control the flow of fluidsan industrial need in high demand by the mining industry given the coarse nature of its slurry and the potential for clogging or jamming.

Anthony Clark, Flowrox vice president of sales, will be delivering a presentation during the event focused on the Flowrox Scaling Watch and the use of a tomographic instrumentation to monitor scaling in phosphate production and processing.

The aforementioned sensor allows producers to utilize a non-intrusive instrument to accurate display real-time scale growth; thus providing the user with useful data to help them minimize anti-scaling chemicals, validate the effectiveness of anti-scaling chemicals and minimize lost production, equipment failures, and costly maintenance caused by scaling.

Any decrease in fluid movement is often tied to a loss of revenue in an industry that depends on optimal pipeline performance, said Todd Loudin, president of Flowrox. Our products have been engineered to keep our customers pipelines operational and profitable.

Flowrox will be showcasing the Scaling Watch and SKW Heavy Duty Slurry Knife as viable solutions to help those in the phosphate industry achieve operational excellence using devices that reduce the effects of transporting minerals.

The 2015 Phosphates International Conference will bring together over 400 delegates from more than 40 countries who represent producers, service providers, technology companies, traders, and executives who seek to network, learn and engage in new business relationships.

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

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

New: less than two years old Innovative: original,

groundbreaking, and capable of revolutionizing the offshore E&P industry

Proven: through full-scale application or successful prototype testing

Broad Interest: broad appeal for the industry

Significant Impact: provides significant benefits beyond existing technologies

In support and recognition of innovative technologies being developed by small businesses, OTC has created a new Spotlight on New Technology Small Business Award in 2015.

The small business applications were evaluated using the same five criteria above, but also were required to have fewer than 300 employees.

Our Spotlight Award winners embrace OTCs mission to advance technical knowledge of offshore developments and environmental matters, said Spotlight Award Committee Chair Steve Balint. And with the creation of the Small Business Awards, we are recognizing the fact that companies both big and small are developing innovative technologies and creative solutions to meet the worlds energy demands.

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

PROGRAM FOR YOUNG PROFESSIONALSThe changing environment of exploration, production, refining, and operations demands leadership from the next generation to reach these new frontiers, both domestic and worldwide. With the oil and gas industry entering these new environments the career opportunities for young professionals are endless.

The Next Wave 2015 program will offer insight from industry

leaders into the challenges ahead and how to face these as a young professional while recognizing the increased interconnectivity of the global industry. Speakers with technological, operational, academic, and political backgrounds will be the guides for the discussion and share their valuable experience and advice on what lies ahead. The discussion will address how technological advancements in operations are expanding opportunities, while taking into consideration the political aspects surrounding these new frontiers and the knowledge young professionals will need to tackle their careers.

This program will investigate how the industrys global contribution, in this highly connected world, will have an impact far beyond the office. The panel will discuss many aspects of working in some of the most challenging and new environments and explain the benefits of having a diverse outlook. Ultimately, attendees will hear what is needed to obtain a job in these new markets and how to become a driving force for the future of the industry.

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


TRADE SHOW prof ile


CASE Studies

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

UPDATING THE PASTThe old cast-iron steam boiler was obsolete and expensive to run, costing the homeowners $20,000 a year in oil alone. Property caretaker Jeff Ward started investigating options to convert the system from steam to hot water, downloading manufacturers manuals to compare and contrast pumps for the system. He set up a beta test in the house to find the most effective and energy-efficient model by measuring output through an amp meter.

B&Gs ecocirc vario circulator pump met Wards criteria, most notably because of its electronically commutated permanent magnet motor designed specifically for hydronic systems. In Wards test, the ecocirc heated the room while operating at just of an amp and maintained consistent pressure.

ECOCIRC: A CLOSER LOOKCompared to its competitors in the field, the ecocirc has numerous advantages. First, it uses less wattage at maximum speed 60 watts versus 85 watts resulting in roughly a 30 percent savings in energy. In addition, its variable speed capabilities allow it to adjust to demand instead of running at maximum speed at all times, resulting in less energy use.

While proper pressure within the system was a primary consideration, the ecocirc also proved it could handle the long heat runs in the 20-room house for just pennies a day in electricity costs, another priority for Ward.

MIXING OLD AND NEWSteve Graham of local B&G representative Fluid Industrial Associates Inc. (FIA), helped marry the new circulator technology with the homes existing radiators sixty-seven in all. It was a challenge to reuse the radiators and run new piping without it becoming a major construction project, said FIA Vice President George Carey. But aesthetically the radiators fit the look of the house and the homeowners wanted to keep them.

The process of disassembling and cleaning all of the radiators took two years. Crews had to work around some of the complicated plumbing features of the house, such as two of the radiators being located behind built-in bookcases. Specialized tubing connects the radiators and the 25

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

About The Author

By Mark Handzel, Bell & Gossett

Warming Up a Newport Mansion

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

This Newport, Rhode Island, 1920s villa contains a state-of-the-art heating system powered by a Bell & Gossett pump system.

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

Bell & Gossett pumps powera state-of-the-art heating system

MARCH 2015 | 13 www.modernpumpingtoday.com

ecocirc pumps, now in a centralized location in the house, to the new modulating gas boiler.

A THOROUGH JOBThe ancient boiler was only part of the homes heating problem. Previously, there were only two zones to control the temperature in the house. Installed by Steve Antoch of A&L Plumbing and Heating, the new system features thirty-four zones, and has Wi-Fi capability. Now, while the homeowners are out, they can send a text to Ward, who can program the system remotely so they arrive to comfortable temperatures inside the house.

Another key feature of the system is its outdoor reset, which takes into account the outdoor temperature when heating the water. For example, water is heated to 180 degrees Fahrenheit (82.2 degrees

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

RESULTS YOU CAN SEEThe new system is already paying

dividends, with fuel costs plunging about 80 percent in just a few months. This is the fastest payoff ever, Ward said. We dont need oil anymore.

Contrast that with the carriage house on the property, which is still fueled by an outdated system, costing about four times as much to heat than the main house now does.

With the radiator adapted to new system, the historic homes heating will be more effective and efficient.

The ecocirc vario circulators were designed with highly efficient electronically commutated permanent magnet motor (ECM/PM technology) specifically for hydronic systems.


CASE Studies

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

(DRC) are planning to double the mines productivity with the use of a new Jet Edge Edge X-5 5-axis waterjet.

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

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

About The Author

By Nancy Lauseng, Jet Edge

Mine to Double Productivity with Waterjet Cutting System

DRC Copper Mine installs Jet Edge 5-Axis waterjet

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


RELIABILITY IN ACTIONThey run their first machine 24/7, says Jetstream Cutting Solutions director Malcolm Cruickshank. The Jet Edge X-Stream pump was key to the success of the first machine because they could utilize the higher pressure to increase productivity.

For their second waterjet system, the mine operators selected Jet Edges premiere 90,000 psi (6200 bar) Edge X-5 system with dual independently programmable 5-axis cutting heads and laser plate mapping system, Aquavision Di industrial PC controller, and 5-axis waterjet cutting software.

Cruickshank notes that the mine officials chose a Jet Edge system for their second machine based on the reliability of their first Jet Edge pump, and Jet Edges ability to quickly supply spare parts when needed.

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


CASE Studies

Reliability is very important to them due to the remoteness of the mine, he says. They appreciate the speed with which Jet Edge can supply spares.

INTUITIVE AND EASYJake Hall, a Jetstream subcontractor and director of Mobile Digital Solutions of Sylvania, Australia, oversaw the installation of the Jet Edge system and trained the mines waterjet operators how to use the new 5-axis machine.

The Edge X-5 is a good system, Hall notes. Its intuitive and easy to operate. Ive seen lots of systems in my eleven years working with waterjets and it seems to do the job very well and is easy to teach. The Aquavision Di controller is extremely

reliable. The software is great. It solves a lot of the problems of other CAD/CAM software. Its been specifically designed with waterjetting in mind. Lead ins and outs are easy and its easy to nest multiple parts. Most importantly, youre not stuck to a certain order. With some software, if you miss one step, you have to start all over again. Jet Edges software is flexible and its not labor intensive. The library of materials is good and the speed control is good.

Hall added that he has been very impressed with Jet Edges X-Stream intensifier pumps, service and training.

The X-Stream pump is bullet-proof, he says. We feel comfortable that we have a good support network and that we can call Jet Edge any time, day or night.

Mine officials plan to double productivity with help of their latest Jet Edge waterjet. The Jet Edge Edge X-5 work envelope can accommodate very large plates.

w?


WATER & WASTEWATER solutions

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

About The Author

By Jennifer Cisneros, Bio-Microbics, Inc.

STEP:

Another

Alternative

to

Alternative

Sewers

hat kind of options does a neighborhood developer have to easily manage and monitor

the wastewater generated from the homes of cluster developments or a small community

The easy-pull-cleaning swab handle is used to maintain the exterior and flush out the angled slots.


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

THE NEW FACE OF WATER UTILITIESAs part of a progressive replacement program, municipalities will continue to develop and install innovative technology, prescreening / pretreatment systems and better maintenance procedures. The challenge many strong industries within the economy face are to understand what technologies are available and will they work on their site to improve their wastewater treatment facilities. The investment seems high upfront, but the payoff is significant overtime with reduced maintenance and operation costs.

The water utility business model is changing. Historically, water and wastewater utilities have functioned as monopolies without competition. As the price of water services rises, the cost of new technology drops, and concern for securing a water supply increases, we are likely to see a rise in use of these "disruptive" technologies, which can undermine the monopolistic nature of the water utility.

Now technological advances are allowing more options for water efficiency, water re-use, and water harvest.

WHAT TO DO?Small municipalities can explore the option of updating their wastewater facilities. And those public/private that do not have the resources for a large infusion of cash to update these facilities might consider outsourcing to treatment facilities that already have this technology in place.

A STEP system prescreens wastewater from large solids and inorganic clogging debris; and is a form of pressure sewer that has several advantages over traditional gravity collection systems. As an ideal conveyance method where gravity collection systems are not possible, the STEP system includes

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

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

THIS SECTION SPONSORED BY WWW.ADEDGETECHNOLOGIES.COM



of effluent from STEP Units allows the collection system to be designed the same way as a water system. Small diameter PVC pipe is laid in shallow trenches. Infiltration problems are eliminated, and hence, treatment plants can be smaller; lift stations and manholes are not required. Maintenance and operating costs are the same as, or less than, conventional sewers. Per -unit costs can be much lower, especially in areas with dispersed dwellings, hilly terrain, high water table or rock. The on-site costs can be deferred until occupancy.

Available from Bio-Microbics, Inc., the BioSTEP (Septic Tank Effluent Pumping) Systems are ideally suited for all onsite wastewater pumping applications, from single family residential to small diameter collection systems. These effluent pumping systems filter out solids so that only liquid from the "clear zone" between the tank's scum and sludge layers is pumped. This reduces biological loading and clogging of downstream components, extending drainfield life. All systems are pre-assembled with corrosion resistant, durable components, ensuring reliability. All BioSTEP Systems are available as individual components or preassembled in ready-to-install System Packages. Our Filtered Pump Vaults provide your pump with critical protection from solids larger than 1/16 inches (1.59 millimeters) Each vault incorporates slotted filter screens into easily removable panels, allowing for an easy and quick servicing.

COSTS, INSTALLATION, OPERATION AND MAINTENANCE The cost of a STEP/STEG system can be divided into two major components: The on-lot cost and the collection network cost. On-lot installation costs include the pump, tank, controls, building sewer, and electrical service. A STEG system would not have the pump, controls and electric service costs. The initial on-lot costs are usually paid by the lot owner. The installer must follow the guidelines established by the utility for the selection and placement of components. Depending on the style of pump and tank

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

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

Once installed, BioSTEP STEP/STEG devices are designed to be cleaned in placeno removal of any components.

Installation of adjustable footing to handle weight of the submersible pump.

selected by the utility, and the STEP pressure requirements needed to inject sewage into the network, the on-lot costs are estimated to be $3500 to $5000 for a single-family home. The electrical cost would be about thirty dollars per year.

Licensing requirements for personnel who install STEP/STEG systems varies, but they must typically be licensed by the state or region in which they work. Like all other alternative collection systems STEP collection network require minimum excavation. The required depth of the pipeline is minimal and can generally follow the terrain. The collection network is installed either through trenching or horizontal directional drilling (HDD). HDD reduces or eliminates the need for large, deep trenches that disrupt existing utilities, landscaping, roads and driveways. STEG systems must maintain an overall slope toward a lift station or treatment facility. However, since there are no heavy sewage solids to be transported, slope can be significantly reduced or eliminated. In all cases, slope and sewage velocity requirements are less than a conventional gravity sewer. Many small communities have both STEP and STEG within the same cluster of sources.

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

If pumps in STEP configurations are installed with quick-disconnect fittings, maintenance is facilitated and

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

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



By Matthew LaBrosse and Donovan Erickson, U.S. Water Services, Inc.

The Pursuit

Part 3 of 4

of a Green Carbon SteelCorrosion Inhibitor



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

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

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

About The Authors


It is known that oxidation of inhibitors can affect their performance. For instance, reversion of some phosphonates to orthophosphate is quite common under the right oxidation conditions.2 Some manufacturers have suggested that their phosphorous based organic inhibitors be protected with amine to prevent this phenomenon (see reference 2). It is thought that combined chlorine (e.g. chloramines) is less destructive of inhibitor structures than free chlorine. Another example of a performance issue for inhibitors is the oxidation of azoles and the resultant increase in yellow metal corrosion if too much azole is lost in the affected system. This can lead to a serious secondary problem of increased mild steel corrosion caused by plating of the copper onto the mild steel (see reference 3). Some water technology providers have recognized this serious problem and used various methods to combat the loss of azole due to oxidizing biocides (see reference 4).

Oxidizing biocides like sodium hypochlorite are used to reduce biological problems in cooling systems. They also minimize loss of heat transfer and minimize health related issues like Legionella pneumophila. Biological slimes can lead to under-deposit corrosion and efficiency loss due to a combination of organic and inorganic scale deposits (see reference 5). Legionella is a serious health concern and has even lead to the death of affected individuals (see reference 6). Aside from possible negative health consequences, poor biological control can also be a great liability to facilities and management for unprotected systems. Although oxidizing biocides perform the very necessary function of minimization of biological problems, they are also known to reduce the efficiency of some scale and corrosion inhibitors as previously mentioned. One of the main purposes of this current research is to identify green inhibitors that are least affected by oxidation. The relationship between inhibitor choice, mild steel corrosion rates, and copper corrosion rates was also investigated in this work.

METHODOLOGYAs was the case in previous work, the goal is to be as green as possible while performing adequately for the purpose intended. In the first paper, green criteria were identified as high biodegradability,

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

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




chloride has been omitted from the testing because it is inorganic.

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

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

Table 6. Later tests runs were done using a water that would be considered low hardness to simulate a soft water system, shown in Table 7.

TEST APPARATUSFigure 5 shows the test apparatus, consisting of a circulation loop with the return water line aerated before returning to the sump. This provided the necessary oxygen to simulate cooling tower water. The flow rate was 7.0 gallon (26.5 liters) per minute in 1 inch (25.4 millimeters) clear PVC piping for ease of visual inspection. This corresponds to a linear velocity of 3.2 feet (0.98 meters) per second, which is in the range of accepted flow rates for corrosion coupon racks (see reference 7). The temperature for each run was maintained at 95 degrees Fahrenheit (35 degrees Celsius); the heat was provided by the circulation pump. Oxidizing biocide was also added to the sump using an ORP monitor and relay set-point. This feature allowed for automatic oxidant addition for the five day test runs.

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

Figure 5: Corrosion testing circulation loop

CONTROLLER

HOCI

OR

P R

ELA

Y

SUMP

ORP pH COND

CORROSION RACK


Item Concentration Unit (ppm)

Ca 543 CaCO3

Mg 140 CaCO3

HCO3 328 CaCO3

Cl 114 Cl

SO4 505 SO4

Polymaleic Acid 8.5 Active

Copolymer 8 Active

Tolyltriazole 3 Active

Table 6: High hardness synthetic water conditions

Item Concentration Unit (ppm)

Ca 80 CaCO3

Mg 50 CaCO3

HCO3 110 CaCO3

Cl 180 Cl

SO4 60 SO4

PBTC 1.9 Active

Copolymer 8.1 Active

Tolyltriazole 3.1 Active

Table 7: Low hardness synthetic water conditions

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

2. Association of Water Technologies Technical Reference and Training Manual, 2nd ed., chapter 4, section 5.10.6 (2009).

3. H. Van Droffelear and J.T.N. Atkinson, Corrosion and Its Control: An Introduction to the Subject, 2nd ed., chapter 2, page 25-26 (1995).

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


6. B.J. Marston, H.B. Lipman, and R.F. Breiman, Surveillance for

Legionnaires Disease: Risk Factors for Morbidity and Mortality, Archives of Internal Medicine, 154, 2417-2422 (1994).

7. B.P. Boffardi, Corrosion and Fouling Monitoring of Water Systems, The Analyst Technology Supplement, Spring (2010).

8. Association of Water Technologies Technical Reference and Training Manual, 2nd ed., chapter 4, section 5.10.1 (2009).


10. D.L. Hjeresen, Green Chemistry and the Global Water Crisis, Pure and Applied Chemistry, 73, 1237-1241 (2001).

11. Rohrback Cosasco Systems, Inc., Model 9020 &9020-OEM Corrater Transmitter User Manual, November (2004).

REFERENCES



MAINTENANCE solutions

San Antonio Housing Agency (SAHA) is saving thousands of dollars a year at its Woodhill Apartments on expensive maintenance and replacement boilers every six to nine months following the installation of the patented, award-winning Scalewatcher computerized, electronic water-conditioner from Scalewatcher North America. Purchased following a successful four month trial at the apartments, the Scalewatcher has successfully kept all four boilers scale free since it was installed.

MEETING AN IMPORTANT NEEDSAHA provides housing assistance to over 70,000 children, adults and seniors through its Public Housing, Section 8 Housing Choice Voucher and Mixed-Income housing programs. The Agency owns and manages 6254 public housing units at seventy-one properties, employs more than five hundred individuals, has an annual operating budget of $172 million and real estate assets valued at over $500 million.

The Agency chose the Woodhill apartments as the BETA site because in spite of attempts at water treatment, it had a consistent history of domestic hot water boiler failure due to scaling. At the site a 100 gallon boiler typically had a life span of six to nine months. With four boilers in the boiler room the cost of replacing each boiler was $3,590.

KEEPING WATCH ON THE BOILERSA Scalewatcher unit was installed on to the pipes in the boiler room to treat all four boilers. However, SAHAs

Project Manager, Neville Blair decided that the newest boiler would be the control boiler for the purpose of the test. After 64 days a section of copper pipe was removed for inspection and it was observed that there was no scale at the bottom of the boiler.

After 180 days the heater tank was valved off and drained. It was noted that there was soft sand- like deposit on the bottom of the tank and the copper coils were clean. Previously, scale would have formed a hard crust on the copper coils and at the bottom of the tank. The new boiler at this stage would be halfway through its useful life.

THE IMPORTANCE OF PREVENTATIVE MAINTENANCE We had no hestiation in buying the Scalewatcher, said Neville Blair. Previously we had used a liquid water treatment that had cost $200 per month and had been ineffective. Since Scalewatcher has been installed we have had to replace just one boiler, which we believe was due to age and not scale.

Twelve months following the Scalewatcher installation, the bottom of the heater was once again inspected and the copper coils were found to be clean. The sand-like

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

About The Author

By Jan de Baat Doelman, Scalewatcher North America Inc.

Electronic Water-ConditionerKeeps Boilers Scale Free

SCALEWATCHER SAVES SAN ANTONIO HOUSING AGENCY THE COST OF REPLACING BOILERS EVERY SIX MONTHS

A closer look at the patented Scalewatcher computerized electronic water conditioner.


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

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

electronically applied force field, induced by a coil wrapped around the outside of the pipe work, which keeps the minerals in suspension and thus prevents limescale forming. The unit can be attached to all types of pipework material, regardless of size.

Scalewatcher models are based on continuous research and over twenty-five years experience and expertise

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

Agents / Reps Wanted

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

Please fax your resume to 1-201-792-4803 or email to

[email protected]

Custom-engineering pumps to meet your specific requirements Since 1919

THIS SECTION SPONSORED BY WWW.SCHENCK-USA.COM


PUMP solutions

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

SCOPE OF CHALLENGEThe traditional suction lift station located on Highway 77 is one of Southsides main lift stations and has been in service since 1991. The station had experienced several problems over the last few years including multiple failures due to the age and strain on the system. As a result of these failures, the high costs for repairs and the encroaching seasonal inclement weather, the situation was quickly considered an emergency installation. A quick turnaround was very critical in order to meet the needs

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

About The Author

By Regina T. Marsden Crupe, EBARA Fluid Handling

Packaged Pump System Improves Quality of LifeCity of Southside, Alabama, selects EBARA for emergency lift station upgrade


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

THE SOLUTIONCDG Engineers & Associates worked with The Eshelman Company to select and install an EBARA EP1 duplex packaged pump system to replace the

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

to reduce clogging from fibrous waste (non-dispersibles) and thereby reduce maintenance and increase efficiency of operation.

The old station was removed and the 20 feet (6.1 meters) deep wet well cleaned and epoxy coated prior to installation. The EBARA packaged system is pre-assembled at the factory

PROJECT AT A GLANCEClient: Southside Water Works and Sewer Board, Southside, Alabama

Industry: Municipal wastewater, sewage

Problem: Emergency lift station rehabilitation

Result: Cost effective, expedited and simplified installation

Products Installed: EBARA Model EP1 Duplex Packaged Pump System

Highlights:

Factory pre-assembled and sole source responsibility for complete station provided

Two, 30 horsepower model DLFU submersible cast iron wastewater, sewage pumps

Pumps rated to deliver 150 gallons (567.81 liters) per minute at 145 feet (44.2 meters) TDH with K-series impeller design to reduce clogging

R7 insulated fiberglass enclosure with large doors

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

Six-inch liquid filled pressure gauge protected from wastewater by pressure isolator ring

Standard check valves

Emergency by-pass connection

Thern portable hoist

THIS SECTION SPONSORED BY WWW.WORLDCHEMICALUSA.COM


PUMP solutionsand shipped directly to the site ready to be installed.

EBARAs standard package design includes a corrosion resistant, steel reinforced, polymer concrete base. Wet-well access covers are pre-cast into the base frame providing durability and sturdiness. All discharge piping, valves and controls are protected inside an R7 insulated, weatherproof fiberglass enclosure. Large doors on both sides of the enclosure provide easy access to system components.

Safety grates protect personnel from falling into the wet well when the access doors are open. Penetrations for the piping and cables are sealed from the wet well to prevent


harmful gases from entering the enclosure. Dedicated pressure gauges and sensing piping for each pump are standard on the EBARA system. Pressure sensor rings isolate the gauges from the pumped wastewater to eliminate clogging of pressure gauge lines and ensure accurate, repeatable pressure readings.

Everything is at head and hand level, explained Jeff Harrison, PE, CDG Engineers & Associates. This eases maintenance and removes the need to send personnel into dangerous confined spaces present in traditional below ground valve vaults.



PUMP solutions

The station runs on 460/3/60, and is designed with a float switch level control system with reduced voltage soft starters to limit inrush current to the station.

This station was loaded with optional features, including individual board mounted discharge gauges, an emergency bypass connection and a (Thern) portable hoist; these options making regular maintenance more manageable and efficient.

THE RESULTThe installation concluded with a clean-water (accommodated by the

City of Southsides Fire and Rescue Department) start-up and testing with minimal onsite adjustments made to the controls and floats to ensure optimal performance.

Once the EBARA EP1 packaged station arrived on site, it was installed and on line at the end of the second day. It was a very quick retrofit, which kept downtime and bypass pumping to a minimum and was delivered and installed well within the city of Southsides capital budget.

What would have taken two months to install a new system, the city of

Southside was able to complete in two days due to the refurbishment of the existing wet well and the selection of the single-source and complete EBARA packaged pump system.

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


PUMP solutions

The rendering business is not known for its glamour or its cutting edge technology, but in North Americas first project of its kind, thats all about to change for an industry that is positioned for growth.

SMART DECISIONS, GREEN TECHNOLOGYBiogas Energy have built an anaerobic digestion (AD) facility at North State Rendering in Oroville, California that is already paying dividends, with uninterrupted biogas generating electricity, fuelling trucks, and running boilers. The economics seriously stack upnot to mention the massive reduction in carbon footprint.

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

WASTE RECEPTION AND PRE-PROCESSINGGrease trap waste and food waste from kitchens, restaurants, and food manufacturers is expensive to render, so by diverting this material to the digester, North State Rendering reduces costs and frees up rendering capacity for higher-value materials.

The waste reception equipment prepares high-solids feedstocks for the digester, whilst a grease trap reception system separates out contaminants such as plastic and metals.

With this flexible reception facility configuration, the digester can process a wide variety of materials, from food and yard waste to high-liquid grease trap material. Wastewater from the rendering process is

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

About The Author

By Soren Rasmussen, Landia, Inc.

DIGESTER

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

Landia's externally mounted GasMix at North State Rendering.

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

MIXINGONTRACK



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

ANAEROBIC DIGESTER TANKSFrom the reception area, the material is pumped into two tanks (40 feet [12.2 meters] diameter by 24 feet [7.3 meters] high), where the first acid-forming phase of the biogas production process takes place.

These heated tanks contain bacteria that break down the material and prepare it for the main digester tank, which stands 64 feet (19.5 meters) tall. When the material is ready, it is pumped into the main digester where biogas-producing bacteria get to work.

Brian Gannon continues: We had been using submersible propeller mixers inside our main digester, but with our re-design of the tank, we switched to a new system that meets all of our

needs. One of the main issues with submersible digester mixing systems is that the equipment is inside the tank, which from a maintenance point of view is a nightmare. The downtime caused by having to open the digester to lift the mixers out for repairs and maintenance caused serious process interruptions and safety issues.

We now have a Landia digester mixing system, which is mounted externally, so maintenance is much easier. Even during commissioning

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

POWER IN THE PUMPIn addition to its ease of maintenance, Brian also points to the Landia (patent-pending) GasMix System being able to agitate the entire digester tank

(especially one 64-feet high!), whereas other units often cannot prevent a crust from forming on the top level of the tanks contents.

The anaerobic digestion facility is designed to process a very wide range of feedstock, he says, so its pumps and mixers have to cope. The Landia chopper pumps, which form part of the GasMix system, are absolute troopers. They just keep on working. We wouldnt be achieving what we are now without them.

Biogas digester at North State Rendering.


PUMP solutionsComprising two 30-horsepower

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

maximum of 30 percent of the installed capacity.

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

wastewater treatment plant, improving the quality of wastewater and enabling reductions in discharge fees.

We generate enough electricity to power the entire North State Rendering plant, adds Brian. Heat from the generator is also used to heat the digesters, so were able to optimize energy efficiency.

ENERGY AND FUEL PRODUCTIONBiogas Energy estimates that North State Rendering will reduce diesel costs by 75 percent by introducing a gas-cleaning skid to create a pipeline-quality biomethane that is then compressed in a CNG fueling station.

As the biogas-to-CNG upgrade system produces pipeline-quality natural gas, producers can inject the gas into the pipeline to sell to other customers. Finally, any surplus biogas is fed to a boiler at the rendering plant to reduce the need to purchase natural gas. With a diverse use for the biogas, North State Rendering will maximize revenue and hedge against price increases in electricity, diesel, and natural gas.

SOURCES OF FACILITY FUNDINGFor its new anaerobic digester, North State Rendering was able to take advantage of grants from the California Energy Commissions Alternative and Renewable Fuel Vehicle Technology Program.

State and federal inducements can also include tax incentives, sales tax exemption, grants for renewable energy project and truck conversion costs, and incentivized electricity production pricing.

Brian Gannon concludes: Renderers have a big head-start over other companies trying to develop new waste-to-energy facilities. Unlike newcomers, renderers already have the necessary permits in place to process waste material. They also have the trucks to collect waste, and the energy consumption that biogas facilities can help fuel.

As energy and fuel prices climb and wastewater discharge fees escalate, waste processors can turn waste into an asset. For Biogas Energy, our experience at North State Rendering

and the introduction of Landias GasMix digester mixing system means that we can help our clients generate renewable energy with a system that maximizes production while facilitating operations and maintenance.


DEWATERING solutions

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

THE CHALLENGE Boskalis Technical Service Nederland in Capelle aan den IJssel manages several mobile pump units with high and ultra high flows and clearly prefers environmentally friendly equipment and has very specific requirements from their pumps which include

The pump must have a minimum capacity of over 20,000 gallons (75,708 liters) per minute and a pressure in excess of 3 bar;

Competitive excellent suction capacity capabilities (NPSHr) and suitable for use as a dewatering pump;

High fuel efficiency combined with the lowest exhaust emissions;

Henno Schothorst is product manager at BBA Pumps and can be reached at [email protected]. For more information, visit www.bbapumps.us.

About The Author

By Henno Schothorst, BBA Pumps

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


The pump unit should fit into a 20 foot (6.1 meter) container for easy transport;

The maximum weight should be no more than 26455 pounds (12,000 kilograms).

Boskalis has a number of widely divergent projects around

the globe. This makes multi-functionality and ease of logistic handling important factors in the purchase of new equipment. In addition, durability and corporate social responsibility are central to the companys values.

As an example Bas van den Brand, a technical inspector with Boskalis Nederland, mentions the topic of weight: For a pump system of this size, 26,000 pounds (11,793.4 kilograms) is usually the maximum permissible due to limitations in handling on site. Also, the soil layers can be substantially compacted and cannot always carry the weight.

THE SOLUTIONEarly in October 2014, Boskalis Nederland officially commissioned the delivery of a BBA high flow pump unit of the type BA-C500S11 D711 with a very attractive efficiency of 86 percent. The auto prime pump provides a capacity of over 24,200 gallons (91,607 liters) per minute (max. head 122 feet (37.19 meters)) and is driven by a modern Stage IV Volvo Penta diesel engine; the TAD1374VE.This provides a power of 510 horsepower and delivers the lowest specific fuel consumption in its class.

Exhaust gas is treated using AdBlue.It is fully equipped with the newly developed, extremely silent

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

THE RESULTThe new BA-C500S11 has now been deployed in a first project in Muiden. The A1 highway is being widened and partially rerouted. The Boskalis Nederland employees on location are

very impressed with the pumping performance, especially with regards to the low noise emissions.

Upon commissioning positive feedback abounded:

This pump unit only has to work half throttle to do the jobat 1250 revolutions per minute it provides as much capacity as the old one at 2000 revolutions per minute.

Incredible, theres not even any smoke from the exhaust at start-up.

Its amazingly quiet.The former pump unit regularly clogged up due to solid

materials as a result of the vertical drainage hose we use herefortunately the BA-C500S11 can just pump it.

BBA Pumps has decided to include this pump unit in its standard product range. This technology cant be ignored any longer.

1129 Cainhoy Road, Unit CWando, SC 29492

[email protected]


MOTOR solutions

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

IMPROVING SPEED AND SAFETY Enhancements on the Tenso-set base include features that improve the speed and safety of belt

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

About The Author

By Don Sullivan, Regal Power Transmission Solutions

TheNeed

for

SPEED

One-minute V-belt changes with energy-saving Tenso-set motor base


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

DROP-IN REPLACEMENT The Tenso-set base is a drop-in replacement for most standard motor bases, and utilizes the same jackscrew design to adjust and hold tension on the belt. However, the Tenso-set base includes a coil spring inside the screw housing that pushes against the carriage to maintain tension as the belt naturally breaks-in and seats itself further into the sheave groove due to loss of mass.

The Tenso-set design helps eliminate the need for frequent belt re-tensioning, including during the first 24 hours of run time, which saves the maintenance staff at least one service call. More important for the building owner, it better maintains the drive's energy efficiency by preventing the normal tension loss that occurs over time. Some of the largest commercial buildings in the United States are already testing this base to determine return on investment.

QR: QUICK RELEASEThe QR option for the base allows release of all belt tension

after just a few turns of the tensioning screw. The QR base has a patent-pending sliding gate that covers a cutout in the motor frame. This allows the head of the tensioning screw to pass through the base, so the carriage easily slides forward to slacken the belts. After belt installation, the carriage can be moved back and the sliding gate closed to retain the head of the jackscrew for tensioning.

Browning also offers free mobile apps for efficiency calculation, belt selection, troubleshooting and GPS locating of stocking distributors. These can be accessed through iTunes and Android websites.

BENEFITS AT A GLANCE Significantly reduces time required to change

v-belts

Promotes greater efficiency by constantly maintaining v-belt tension

Tube rail and one-piece carriage design promotes and maintains superior drive alignment

Improved safety. No need to cut off belts or roll them onto sheaves


POWER GENERATION solutions

In 1957, six western Kansas rural electric distribution cooperatives created Sunflower Electric Power Corporation to purchase and develop a reliable, long-term power supply. In 2007, members of Sunflower formed Mid-Kansas Electric Company, an affiliated generation and transmission company, to support a business acquisition. Today, Mid-Kansas, which is governed by a democratically elected board of directors, provides wholesale services to its six members serving electric consumers across thirty-three counties in central and western Kansas.

POWER NEEDMid-Kansas has a power generation portfolio made up of coal, natural gas, wind resources and transmission line assets that include more than 1000 miles (1609 kilometers) of high-voltage lines ranging from 115 to 230 kilovolts. This diversified portfolio allows Mid-Kansas to provide reliable energy and transmission service at the lowest possible cost to its members.

In 2012, the Mid-Kansas team began formal planning for ways to meet the growing demand for electricity and provide

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

SOLUTIONThe Mid-Kansas team spent months visiting reciprocating engine-based generating facilities to learn about the technology and configurations of different facilities. A technology selection study completed by Burns and McDonnell, a full-service engineering, architecture and construction firm, identified that reciprocating internal combustion engines (RICE) could provide flexible and cost-effective generation.

This benefits Mid-Kansas members in the Integrated Market, which includes a day-ahead look at potential load generation to determine the most reliable and economical combination of generation resources, by serving the load and dispatch generation to meet real-time load across a nine-state footprint.

By Cinthia Hertel, Mid-Kansas Electric Company

Fast, Efficient, and Environmentally Friendly

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

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


After Caterpillars new 20-cylinder RICE units became the technology of choice, Mid-Kansas partnered with Caterpillar and Burns and McDonnell to construct a new generation facility, Rubart Stationnamed after Perry Rubart, long-time Pioneer Electric Cooperative trustee. Construction began in February 2013, and the facility was completed nineteen months later.

Located just 13 miles (20.9 kilometers) east of Ulysses, Kansas, Rubart Station is powered by twelve Cat G20CM34 natural gas RICE units and has a nominal 110 megawatt output capability. The efficiency and fast-start feature of the G20CM34 allow a quick response to the Integrated Markets conditions, often affected by the massive wind penetration in southwest Kansas.

Its easy to see the benefits of Caterpillars RICE technology when we analyze the fast start time, quick response to changing load demands and high-efficiency performance, said Steve Ricard, executive manager of generation at Mid-Kansas. If needed, we could run at full loadthats 110

megawatts of power in less than nine minutes. Thats pretty impressive.

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

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

Were blessed with an abundance of

wind. However, just because a wind

turbine is spinning doesnt necessarily

mean full power is being generated. The

reality is that varied production, which

naturally occurs with wind resources,

requires other controllable generating resources to balance

the input with the output for a stable power supply

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


POWER GENERATION solutions

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

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

drought was another consideration. Rubart Station utilizes a closed-loop cooling system, which reduces water use by recycling cooling water rather than using an open-loop, evaporative cooling process.

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

from large sources of air pollution. Rubart Stations major source PSD permit allows for unlimited hours of operation, which provides tremendous operational capability to this highly flexible generating asset.


Reciprocating engine facilities have a unique capability for maintaining a very flat efficiency curve across a wide load range, Nelson said. Rubart Station adds high efficiency, low emissions and virtually no water consumption to our portfolio, which cannot be achieved with any other Mid-Kansas asset. The facility can produce 10 megawatts, 110 megawatts, or anything in between without losing efficiency, and thats an enormous advantage for us.

In addition to cutting-edge Caterpillar technology, Rubart Station includes forward-looking building design. No detail was too small, as stairwell placement, cable tray layout, module spacing, convenience of access points, forklift mobility and overhead hoist width were all thoroughly considered. Even the smallest details helped build a strong foundation for Rubart Station, which supports the Mid-Kansas generation portfolio in multiple ways.

We had a very robust due diligence process when planning and designing Rubart Station, said Paul Reynolds, senior manager of generation engineering and environment at Mid-Kansas. While we applied some features that worked for others, we also tried to learn from their experience. Rubart Station was built from the ground up, so we had the opportunity to control many facets of the design, and we listened to and learned from the experiences of others.

We like to think of Rubart Station as the Swiss Army knife of our power generation portfolio because its capabilities are so diverse and the project execution was excellent, said Nelson.

RESULTSRubart Station is also permitted for an additional 110 megawatts of Caterpillar engines. Burns & McDonnell developed a site plan incorporating enough space to install twelve more engines, if the need arises. Caterpillar technicians and engineers continue to serve Rubart Station with parts and maintenance support.

Caterpillar was very dedicated to the success of this project, and any challenges we had along the way were met head on, said Tom Dinkel, project supervisor at Rubart Station. The Cat products are very reliable, and the

team works very, very hard to provide everything we need.

While Rubart Station has become the most efficient installation in the Mid-Kansas portfolio, it is also Caterpillars largest natural gas-powered facility in the world to date.

Caterpillars mission and goals line up with what were trying to

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


PROCESSING solutions

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

WHAT IS OFFSHORE PUMPING AND WELDING?Every facet of an offshore oilrig revolves around a synchronous movement to pull oil from beneath the ocean floor. This task comes with a caveat: salt water is corrosive to metal. As a result, the pipes, including those above

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

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

By Monica Gomez

Offshore Opportunities Continue for Pumping Professionals

Trained welders find work on offshore oilrigs across U.S. waters and around the globe.



Monica Gomez writes on professional issues facing the upstream pumping and oil processing markets. She can be reached at [email protected].

About The Author


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

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

WHAT CAN YOU DO IN YOUR SPARE TIME AT SEA?When you think about working on an oilrig, far from the entertainment and variety you would find on land, you probably associate solitude and boredom with the job. Yet, in reality, you will have many different recreational opportunities. Modern oilrigs often have advanced living quarters, outdoor sporting courts, movie rooms, and Internet access, keeping you active and entertained during your off-hours. Moreover, with Internet access you will be able to stay in contact with your family and friends while at sea.

As the demand for energy continues to grow, more trained pumping professionals will be needed to maintain and operate offshore drilling sites throughout 2015 and beyond. Because of its lucrative pay, flexible schedule, short training required, and recreational opportunities, a career on an offshore drilling rig is one of the most promising career opportunities for skilled professional pumping specialists in 2015.

TULSA WELDING SCHOOL

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