simplebooklet thumbnail

Modern Pumping Today June 2020

JUNE 2020
M
PT
Providing Solutions for the Worldwide Pump Industry
Modern Pumping Today
®
Go Beyond
Efciency Standards
Electric Diaphragm Pump
Changes the Game
SWPA's Checklist for
Submersible Pump Buyers
Providing Solutions for the Worldwide Pump Industry
www.mptmag.com

JUNE 2020
www.mptmag.com
P.O. Box 660197
|
Birmingham, Alabama 35266
Modern Pumping Today®
SUBSCRIPTION
inquiries or changes:
205.380.2048
CHRIS GARMON
CFO
DONNA CAMPBELL
Vice President, Editorial
TIM GARMON
CEO
RUSSELL HADDOCK
President
www.highlandspublications.com
312 Lorna Square
|
Birmingham, Alabama 35216
866.251.1777
@modpumpmag
J. CAMPBELL Editor
jay@mptmag.com
TONYA BROWNING Vice President
tonya@mptmag.com
JEFF FLETCHER National Sales Manager
jeff@mptmag.com
LISA AVERY Art Director
CRISTELA TSCHUMY Graphic Designer
SETH SAUNDERS Digital Media Specialist
INGRID BERKY Office Manager
MPT
No part of this publication may be reproduced or transmitted in any form
or by any means, electronic or mechanical, including photocopy, recording,
or any information storage-and-retrieval system without permission in
writing from the publisher. The views expressed by those not on the
staff of Modern Pumping Today, or who are not specifically employed
by Highlands Publications, Inc., are purely their own. All Industry News
material has either been submitted by the subject company or pulled
directly from their corporate website, which is assumed to be cleared for
release. Comments and submissions are welcome, and can be submitted to
jay@mptmag.com.
TONYA BROWNING
Vice President
A NOTE ON THIS ISSUE:
Thank you for joining us for the June issue of MPT. As
businesses head into the nal scal quarter of 2020,
they are setting their purchasing budgets for the year
ahead. In this month’s SWPA Insight (pg. 12), Executive
Director Adam Stolberg and John Wilson, president
of Industrial Flow Solutions, lay out some important
keys to consider if you plan on entering the market
for a new submersible wastewater pump. Be sure to
check out our “Submersible Wastewater Pump Buyers
Guide” and keep it handy.
Pumps, fans, and compressors account for about
60 to 70 percent of total electrical energy usage by
U.S. manufacturers. However, goals to improve pump efciency and reduce
energy costs may not carry a high priority to owners and operators when their
primary focus is to keep operation running smoothly. In our Maintenance &
Reliability section (pg. 26), Ben Keiser of Applied Flow Technology argues that
the time has come for “Going Beyond Efciency Standards.
Lastly, we love to share outside-the-box technology with our readers, and in
this month’s Pump Solutions section, you can get a closer look at how the all
electric diaphragm pump is changing the game in double diaphragm pumping
(pg. 34). It is a positive displacement pump for municipal sludge, slurries,
pastes, or anything that an air operated diaphragm pump can pump.
J. Campbell, Editor
Modern Pumping Today
EDITORIAL ADVISORY BOARD:
Terry Bell Product Manager, ABB
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting
Robert G. Havrin Director of Technology, Centrisys Corporation
Michael Mancini Consultant and Trainer, Mancini Consulting Services
John M. Roach Engineering Manager for New Product Development, Trebor International,
Inc.: A Unit of IDEX
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
14 18
34
INDUSTRY NEWS
What's happening in the industry .................................. 6
SWPA INSIGHT
Submersible Wastewater Pump Buyers Guide ................12
CASE STUDIES
When It Comes to Clean Water Compliance,
Linko Cleans Up .....................................................14
Integrated regulation updates ensure compliance, and streamlined reporting
save times while maintaining consistency across all industries
WATER & WASTEWATER FOCUS
A World in Crisis Needs Safe Water .............................18
International Code Council calls attention to the need for water
conservation and efciency
MAINTENANCE & RELIABILITY
I/O for the IIOT Part 1 of 2 ..........................................22
Edge I/O creates a simpler way to meet the needs of today’s IIoT applications
Going Beyond Efciency Standards Part 1 of 2 ................26
PUMP SOLUTIONS
Analysis of Peristaltic Pumping Technology in
the Mining Industry Part 2 of 2 ....................................30
Adding value, minimizing costs
All Electric Double Diaphragm Pump
Changes the Game ..................................................34
How EODD pumps outperform and outlast air operated double diaphragms
MOTOR SOLUTIONS
Optimizing Asset Performance ..................................36
Sulzer offers long-term maintenance support for Colombian industries
SEALING SOLUTIONS
Quick Payback on Wear Ring .....................................40
Electricity cost saving on pumps tted with Vesconite Hilube wear rings
MODERN PUMPING PRODUCTS
Liberty Pumps: Model 404 and 405 ..............................42
EFFICIENCY POINT
Pushing the Limits of a Microdrive ............................... 48
Yaskawa’s Edward Tom says there’s no reason to fear new drive tech
CONTENTS
30
36
42
22
6
|
June 2020
|
Modern Pumping Today www.mptmag.com
INDUSTRY NEWS
CUI GLOBAL CHANGES
NAME TO ORBITAL
ENERGY GROUP
CUI Global, Inc. announces
it will change its name
to Orbital Energy Group,
Inc., effective immediately.
The new name reflects
the company’s strategic
repositioning to become a diversified energy
infrastructure services company. Orbital Energy’s
common shares will continue to be listed for trading
on the Nasdaq under the new ticker symbol OEG.
In conjunction with the name change, the company
will be launching a new corporate website at
www.orbitalenergygroup.com.
The name change follows the company’s platform
acquisition of Reach Construction Group, completed on
April 1, 2020. Headquartered in Apex, North Carolina,
Reach is an engineering, procurement and construction
company with expertise in the renewable energy
industry. The company believes the name Orbital Energy
Group more accurately depicts its extensive capabilities
and innovative products, evolving business and new
brand—a brand that provides a wide range of energy
infrastructure solutions.
“We are excited to change our name to Orbital Energy
Group as part of our company-wide transformation,” says
Jim O'Neil, vice chairman and CEO of Orbital Energy.
“This rebranding marks a key milestone as we leverage
our engineering and construction capabilities.
SWETYE ADDED TO BOARD OF HYDRAULIC
INSTITUTE
Jim Swetye, Grundfos technical training manager, has
been named to serve on the board of the Hydraulic
Institute for 2020-2021 as vice president of education.
“It is really an honor to be entrusted with this role
as an educator,” says Swetye. “For me, the great thing
about this organization is that we at the Hydraulic
Institute can continue to develop training based on the
knowledge and skill sets needed to assure that sound
technical decisions are made concerning the world’s
pumping systems. And these systems are a critical part
of global infrastructure.
As vice president of education, Swetye is responsible
for leading educational initiatives within HI. The
position ensures educational content is in alignment
with HI’s technical standards and guidelines, while also
remaining accessible and addressing user needs.
In addition to serving on the board of HI, Swetye
serves on the board of HI’s educational subsidiary
8
|
June 2020
|
Modern Pumping Today www.mptmag.com
INDUSTRY NEWS
Pump Systems Matter (PSM) as vice chairman. PSM, the
primary focal point for HI’s pump systems education
and outreach, helps the pump industry and users gain a
more competitive business advantage through strategic,
broad-based energy management, and pump system
performance optimization.
WATSON-MARLOW FLUID TECHNOLOGY GROUP
ACQUIRES FIRST NSF/ANSI/CAN 61 ACCREDITATION
Watson-Marlow Fluid Technology Group announces that
it received the first NSF/ANSI/CAN 61 accreditation in the
world for its chemical metering hose pumps for drinking
water supply. Companies manufacturing, selling, or
distributing water treatment or distribution products in
North America must ensure their products comply with
NSF/ANSI/CAN 61: Drinking Water System Components—
Health Effects.
This global performance-based standard evaluates
the quantity of contaminants that leach from equipment
and the components and materials that come into contact
with drinking water. These indirect additives can occur
at any point in the journey from source to tap, including
production, treatment, and distribution.
“In a critical sector like drinking water supply, utilities,
and municipalities need to know that the equipment they
are using is safe and fit-for-purpose, says Rick Balek, sales
manager, Watson-Marlow Inc. “The NSF mark provides
assurance that our products have been tested by one of
the most respected independent certification organizations
in existence. Our commitment to quality, compliance, and
safety is company-wide and we share our customers’
priority in ensuring that safe supply goes beyond treatment
and disinfection and right up to the tap.
FRANKLIN ELECTRIC
ACQUIRES CPS PUMPS
Franklin Electric Co., Inc.
has finalized a strategic
acquisition of CPS Pumps
to expand its product
offerings focused in the
large submersible and
industrial pump business
segments. Franklin
Electric has acquired the product lines and assets of CPS
Pumps, along with its current manufacturing process in
Rossville, Tennessee.
The acquisition brings Franklin Electric a deep and
diverse set of key products and expertise, including a full
portfolio of line shaft turbines, split case, end suction, fire
protection, and ANSI-style pumps, allowing the company
to better serve global customers in the agriculture
Click to request your free, no obligation
sample, or visit our website.
Try before you buy! Request your free sample!
Or visit our website.
10
|
June 2020
|
Modern Pumping Today www.mptmag.com
INDUSTRY NEWS
irrigation, municipal, industrial, and mining markets.
This includes an expanded selection of unparalleled
water system solutions with flows up to 40,000 gallons
per minute and 2,500 feet that help cover almost any
pumping application.
DSC DREDGE LAUNCHES DREDGE PRODUCTION
SMARTPHONE APP
DSC Dredge launches its new app for iOS mobile
devices–the DredgeMaster Suite. This addition to DSC’s
technology suite illustrates the company’s initiative in
building the most comprehensive experience for dredge
owners and operators.
“We get dozens of requests to do dredge evaluations on
a weekly basis,” says William “Bill” J. Wetta, senior vice
president and chief technology officer of DSC Dredge,
“For years we have tried to figure out a way to allow
customers to have access to this information themselves
without giving away all of our trade secrets. From this
desire to better serve our customers, the concept of the
DSC DredgeMaster Suite app was born.
The first comprehensive solution of its kind, the
DSC DredgeMaster Suite app has been developed
entirely in-house as a collaborative father-son effort,
as Wetta’s youngest son, Nick Wetta, has spent
the past two years working tirelessly to bring this
concept to life.
ARMSTRONG SPONSORS POST-COVID VIRTUAL
SUMMIT EVENT
Armstrong Fluid Technology is sponsoring a virtual
summit June 10, designed to help building owners and
operators create and maintain healthy indoor spaces
in today’s challenging environment. Entitled “Healthier
Buildings for a Greener Future: Improving Air Quality
in Buildings Post-COVID, the discussions will focus on
indoor air quality, sustainability, energy savings, and
occupant comfort.
The first session of the virtual summit, “Risk Reduction in
the MUSH Sector,” will feature a panel of industry experts
from the municipal, university, school, and hospital (MUSH)
sectors and will address health challenges in indoor
spaces. Part of the session will focus on government’s
role in providing further incentives to upgrade and
retrofit buildings.
The second session, “Going Green: How Technology
Can Improve Employee Health and Reduce Emissions,
will focus on what solutions exist to help building owners
and operators improve the health and sustainability of
buildings. Healthy building advocates and technology
providers will discuss building technologies hurdles,
obstacles to building upgrade projects. and how building
owners can overcome them.
The virtual summit is free and registration is available at
www.armstrongfluidtechnology.com.
u
12
|
June 2020
|
Modern Pumping Today www.mptmag.com
SWPA INSIGHT
Submersible
Wastewater Pump
Buyers Guide
A
s businesses head into the final fiscal quarter of
2020, they are setting their purchasing budgets for
the year ahead. Below, SWPA Executive Director
Adam Stolberg and John Wilson, president of Industrial
Flow Solutions, lay out some important keys to consider
if you plan on entering the market for a new submersible
wastewater pump.
When choosing a submersible wastewater pump,
what is the basic checklist a potential end-user
should start with?
It is important to understand the type of lift station involved,
the source of the wastewater, any solids the pump will be
exposed to, along with a number of other criteria. A high-
level check list includes understanding the:
Make-up of the wastewater, potential solids size and
materials. Critical to pump selection, confirm if the
pump will be used for sewage water including size of
solids or a combination of stormwater and sewage with
potentially larger solids.
Origin of the wastewater (i.e., residential, industrial,
hospitality, hospitals, or prisons). This helps determine
the type of effluent and potential for additional
entrained foreign material.
Need for pumps suited for explosive environment or
chemical exposure.
Application—whether the pump is for a new installation
or a replacement.
Space allowed for pump. Ensure there are no space
restrictions that could affect the selection.
Control scheme and if a back-up pump is available.
Monitoring requirements for pump performance.
Understanding the desired control approach and
location of the lift station, i.e. a remote location with
minimal regular inspections, will dictate the type of
control and monitoring approaches needed.
Technical requirements such as flow, total dynamic
head, voltage, basin sizing, and other special needs.
A complete understanding of the above will allow you to
select the correct type of pump used in a given application.
In most cases, a shredder or chopper pump will hold
an advantage to traditional “non-clog” pump designs.
Shredder or chopper pumps reduce solid matter to a size,
allowing these to pass through the pump to the bar screen
at a municipal treatment plant; whereas a traditional non-
clogging pump builds up solids in the eye of the pump
impeller causing the pump to fail.
What characteristics should a purchaser look
for in a manufacturer or distributor’s reliability?
Where could one find resources to best assess a
product’s reputation?
The goal of any application is to maximize uptime while
minimizing total life-cycle costs. To help ensure your system
operates to full performance, consider these key factors:
Quality: Manufacturer’s proven track record of pump
performance in a given application. Understand the
installed base of a current manufacturer, including
years of successful performance.
Technical Expertise: Both manufacturers and
distributors should have in-depth product and
application knowledge in industries that they serve. A
solid understanding of proper pump selection, pump
operation, and application needs is essential for long
term performance. These skill sets also help diagnose
and address possible issues after installation.
By SWPA Executive Director Adam Stolberg and John Wilson, Industrial Flow Solutions
Modern Pumping Today
|
June 2020
|
13www.mptmag.com
SWPA INSIGHT
Responsiveness: Manufacturers and distributors
should not only have components on hand to support
the need for new pumps or spare parts to minimize
disruption to facility operation, they should also
offer proper service capabilities. Since periodic
maintenance is required for submersible pumps,
be sure to find a partner with local support and
adequate inventory.
Also, be sure to validate past performance and
capabilities of both the manufacturer and distribution. This
can be done by requesting reference lists, contacts, and
case studies while also reviewing technical capabilities
online via company websites, social media posts, and
online reviews.
Who should be involved in the decision-making
process? Does it vary depending on if this is a
private or municipal purchase?
Engage all key stakeholders. This could include the
building owner, facility manager, engineer, operator, and
service technicians. These individuals influence the final
purchase to ensure long term performance and minimal
cost of ownership. Be it a private or municipal purchase, all
influencers should be consulted in the process. While the
weighting of each input may vary, the immediate need and
long-term performance will be taken into consideration.
At a minimum, the engineer, whether contracted or in-
house, along with the service technician(s) should work
together in the analysis and selection process. While an
engineer determines lift station design and compliant
pumps for a respective application, the service technician
provides the knowledge required for future maintenance
and repairs. Combining these subject matter expert’s
opinions during the decision-making process will greatly
improve the longevity of a system.
When is the best time in the life-cycle of an old pump
to start shopping for its replacement?
A spare pump should always be on hand for emergency
repairs. Typically, the search for a replacement should
start once the spare has been installed. In cases where
it is not feasible to have an inventory of spare pumps,
it is important to implement preventative or predictive
maintenance strategies to minimize unexpected down time
and prevent unexpected costs due to emergency repairs or
replacements. It is recommended to monitor performance
such as:
Preventative maintenance—implement a program
to regularly inspect and service pump systems.
Document the findings to provide better insight to parts
or replacement purchasing strategies.
Monitoring the system for frequent high-water alarm
occurrences. This could signal a pump is unable to
keep up with demand due to the possibility of an
undersized pump or damage to an impeller.
Also monitor a pattern of frequent clogging. In these
cases, an upgrade to a shredder or chopper pump
is in order.
Pump performance monitoring—this could include
monitoring seal chambers to determine if water has
entered an oil filled mechanical seal chamber.
After the submersible is installed and running, when
is the best time to assess the purchase and what
performance factors should the pump user consider?
This process should start immediately after choosing a
partner to work with, be it the manufacturer, distributor, or
system installer. It is important to confirm the following:
Proper equipment specified.
On-time delivery of equipment and documentation.
Necessary documentation such as instruction manuals,
drawings and recommend spare parts listings
were provided.
Installer’s technical expertise regarding proper
installation and performance validation.
Availability of on-site support.
After installation, the assessment approach is an
ongoing process. Key considerations include:
A comprehensive start-up procedure, along with a
follow-up report.
Product meets the technical characteristics
represented by electrical and hydraulic performance
checks.
Performance matches engineering specifications and
manufacturer’s supplied documentation.
Service contract options.
Availability of customer and technical support from the
manufacturer/distribution.
Given the impact submersible pumps have on a facility, be
sure to continually assess the performance of the product,
the manufacturer, and the distributor.
u
The Submersible Wastewater Pump Association (SWPA)
is a national trade association representing and serving
the manufacturers of submersible pumps for municipal
and industrial wastewater applications. Founded in
1976, the association’s primary focus is on industry
guidelines, education, and promotion. SWPA’s Summer
Meeting and Plant Tour is scheduled for August 2020. For
more information, visit www.swpa.org.
14
|
June 2020
|
Modern Pumping Today www.mptmag.com
CASE STUDIES
When It Comes
to Clean Water
Compliance, Linko
Cleans Up
Integrated regulation updates ensure compliance, and
streamlined reporting save times while maintaining
consistency across all industries
By Rich Prinster, Aquatic Informatics
Modern Pumping Today
|
June 2020
|
15www.mptmag.com
CASE STUDIES
S
anitation District No. 1 (SD1) has managed Northern
Kentucky’s wastewater and stormwater for more than
seventy years and is committed to keeping its rivers
clean. Every day, SD1 cleans thirty-seven million gallons of
water, serving a population of 115,000 customer accounts
with a network of over 2,000 miles of pipe below ground.
Sarah Griffith, laboratory and industrial pretreatment
manager, oversees the laboratory and manages the industrial
pretreatment and FOG (or fat, oils, and grease) programs
at SD1. In the lab, the team performs 40,000 analyses per
year, seven days a week. On the pretreatment side, the team
oversees, inspects, and samples fifty-five industrial users
in the service area, and also permits and inspects 200 food
service establishments (FSEs) under the FOG program. SD1
has the second largest pretreatment program in Kentucky.
THE CHALLENGE
After using Linko, a compliance management software by
Aquatic Informatics for several years, a newly developed
environmental compliance module was released by the
computerized maintenance management system (CMMS)
that many departments within SD1 used for the scheduling
and tracking of work. As an exercise in due diligence, the
industrial pretreatment and FOG program teams attempted
to move to this new module, as it seemed like a practical
decision for the organization.
Although the CMMS was a very robust and
comprehensive program for other teams within the
organization, it quickly became apparent that the CMMS’
compliance capabilities were not advanced enough to
manage SD1’s pretreatment and FOG programs.
“The CMMS worked to the extent that you can handle
industries as assets and track utilization of time, explains
Griffith. “However, it was just not able to handle compliance
and compliance is a big part of what we do.
ORGANIZING THE DATA
In order to not lose Linko’s purpose-built compliance
capabilities, SD1 decided not to fully move away from it
for their pretreatment and FOG program management so
it was not hard to switch back to full functionality.
“To be honest, it was easy to stay with Linko, and it
wasn’t hard to justify to our executives, says Griffith. “Staff
members were still naturally wanting to use the programs
and it was already much easier to perform the functions
we needed in Linko versus in our CMMS.
Pretreatment programs involve a lot of data, compliance
is complex, and regulations do change. In many ways,
temporarily moving to a CMMS helped SD1 realize the value
of purpose-built software. “We spent a lot of energy trying
to make the CMMS work for something it wasn’t made for,
especially when we already had a solution that worked,
says Griffith. “In some sense, it was good for us to become
familiar with the limitations of our CMMS, but at the end of
the day, Linko’s compliance capabilities aren’t to be found
anywhere else.
Now that SD1 had confirmed that their old software
solution had the best capabilities, they moved over to
cloud hosted environment.
“From my experience with different types of software,
I’ve found that hosted environments generally work better
for specialty software, says Griffith. The transition from
on premise to hosted is simple with no training required
and allows for better access to the program and an added
level
of security.
16
|
June 2020
|
Modern Pumping Today www.mptmag.com
CASE STUDIES
REGULATIONS AND COMPLIANCE
SD1 also uses the LabSync function that allows for the
automated transfer of results from the lab. They run LabSync
nightly, so each morning new data is ready to review from
LIMS. The program alerts SD1 to possible compliance
issues, giving them a preliminary check on compliance.
“It’s comparable to having a second set of eyes check
for compliance, but on the front end. We then can review
those possible issues and move forward with enforcement
as needed, resulting in amazing time savings,” says Griffith.
“I’d say that it saves us thirty minutes per event, per
industry. This is the module that we use the most, and with
everything so automated, it eliminates redundancy and a lot
of manual work.
Regulations, and how regulations are interpreted, change
over time. By automatically integrating change of regulations
in the cloud environment, SD1 is able to keep on top of
regulations without involving IT for software updates.
Compliance Assistant and LabSync are preloaded with
nearly all weekly definitions, making compliance easier
to determine. The Compliance Assistant can determine
compliance against rolling quarters and can identify
significant non-compliance issues. “Other programs we’ve
tried cannot do this well or at all, says Griffith.
SAVING TIME IN A CHANGING WORLD
SD1 does all reporting through Linko. Having the ability to
extract all of the events, site visits, sampling events, etc. from
one location saves a lot of time. In addition, state reports
often change slightly every year, so a key time saving
feature is the ability to query data to answer the questions
required for the reports as opposed to having to spend
hours combing through results manually.
Permitting is another function that falls on Griffith’s
team. Standardized permit templates with Permit Writer
allows SD1 to establish standard permits and easily
tweak when needed. Violations can be issued and
tracked along with an enforcement response plan that
automates compliance.
“This is a great tool for keeping permits standard,
especially when changes occur and we have to reissue all
fifty-five industry permits at the same time. It’s really nice to
be able to pull all the pieces together and create all of the
permits at once, says Griffith.
“At the end of the day, if you aren’t familiar with
pretreatment, you would think that it’s just comparing a
number against the limit. If that were the case, Excel would
work. But, regulations change, interpretations change, and
having a software platform that keeps up with that saves
time and improves compliance.
u
Rich Prinster is Linko strategic business development
manager for Aquatic Informatics. Prinster has been with Aquatic
Informatics for more than eight years where he has helped
hundreds of municipal pretreatment programs address their
data management issues with Linko software. He focuses on
bridging data silos within water utilities to enable better, more
timely decisions. Aquatic Informatics provides software solutions
that address critical water data management, analytics, and
compliance challenges for the rapidly growing water industry.
Water monitoring agencies worldwide trust Aquatic Informatics
to acquire, process, model, and publish water information in real
time. For more information, visit www.aquaticinformatics.com
.
18
|
June 2020
|
Modern Pumping Today www.mptmag.com
WATER & WASTEWATER FOCUS
A World in Crisis
Needs Safe Water
By Dominic Sims, International Code Council
International Code Council calls attention to the need
for water conservation and efciency
A
lthough 70 percent of our
planet is covered with water,
less than one percent is
drinkable. Clean water is the world’s
most precious commodity and
accessing it is still a challenge for
many populations around the globe.
To ensure populations have access
to clean water as they grow, the
International Code Council, in addition
to many jurisdictions, manufacturers,
and organizations, are working to
improve water conservation, label new
homes and structures as more water
efficient, and spread the word about
the need for smart water use.
According to the World Economic
Forum, 2.2 billion people currently
do not have access to clean drinking
water. And the World Health
Organization (WHO) estimates that
by 2025, half of the world’s population
will be living in water-stressed areas.
The Flint, Michigan, water emergency
and drought in South Africa are just
two examples that shine a spotlight
on a growing global issue. Not only
is water vital to our communities
and economy, it is also important for
public health.
Modern Pumping Today
|
June 2020
|
19www.mptmag.com
WATER & WASTEWATER FOCUS
ABOUT WATERSENSE
WaterSense, a voluntary partnership
program sponsored by the U.S.
Environmental Protection Agency (EPA),
is both a label for water-efficient products
and a resource for helping you save water.
The WaterSense label makes it simple
to find water-efficient products, new
homes, and programs that meet EPA’s
criteria for efficiency and performance.
WaterSense-labeled products and services
are certified to use at least 20 percent less
water, save energy, and perform as well as
or better than regular models.
Now is the time to band together
to create solutions to
provide greater
accessibility to safe and clean water.
Here are a few ways to help promote
water conservation and
efficiency:
HARVEST RAINWATER
One significant way to conserve
water and use it more efficiently is
through rainwater harvesting. This
method captures, diverts, and stores
rainwater from a structure or surface
in order to store it for later use.
However, while modern rainwater
harvesting systems have not yet
become commonplace in North
America, in many locations with
constrained or contaminated sources,
interest in the use of rainwater
harvesting systems for both potable
and non-potable use has grown in
recent years.
With the recent publication and
release of the 2021 International
Plumbing Code
®
(IPC
®
), the CSA
B805/ICC 805 standard was included
as an alternative for collection and
distribution systems using rainwater.
Furthermore, this same standard
will be part of the 2021 International
Residential Code
®
(IRC
®
), which is
slated to be published later this year.
This CSA B805/ICC 805 standard
addresses roof surface rainwater and
stormwater being used as source water
for single-family, multi-residential, and
non-residential environments. It also
addresses non-potable applications
like irrigation, fire protection, toilet and
urinal flushing, and vehicle washing.
In addition, potable applications such
as food preparation, dishwashing,
and bathing are also included where
permitted by the applicable jurisdiction.
APPLY THE MOST MODERN
BUILDING CODES
Another way to ensure water is being
used efficiently is to implement the
most modern, up-to-date plumbing
codes. Modern building codes
lead to resilient communities, safe
plumbing and efficient technologies.
Plumbing professionals and well-
trained code officials maintain these
systems and ensure our communities
have safe, accessible water.
Plumbing codes help ensure the
proper performance of plumbing
systems in residential and
commercial buildings. For example,
the International Plumbing Code
incorporates innovative technologies
and detailed engineered designs
that permit the installation of
smaller, more precise water usage
and water drainage systems,
resulting in the savings of millions of
gallons of water. Most recently, the
Code Council and the Residential
Energy Service Network (RESNET)
partnered to develop a joint standard
accredited by the American National
Standards Institute—ANSI/RESNET/
ICC 850-2020 Standard Calculation
and Labeling of the Water Use
A World in Crisis
Needs Safe Water
20
|
June 2020
|
Modern Pumping Today www.mptmag.com
WATER & WASTEWATER FOCUS
Performance of One-and Two-
Family Dwellings Using the Water
Rating Index. This standard helps
communities with water conservation
efforts by setting technical
specifications for inspections, testing
and ratings of home water efficiency.
Plumbing codes are also critical
for emergency situations like the
current pandemic. For example,
code officials ensure that healthcare
infrastructure, including temporary
structures and occupancies, are
built and maintained to ensure
safety. From adequate facilities
to ensure handwashing to safe
and sanitary plumbing systems
that mitigate the spread of
contagions and much more, the
role of code officials and inspectors
remains vital.
LOOK FOR THE
WATERSENSE LABEL
In partnership with the U.S.
Environmental Protection Agency’s
(EPA’s) WaterSense Program, the ICC
Evaluation Service, LLC
®
(ICC-ES
®
)
PMG Listing Program aims to help
identify water efficient products that
meet EPA’s criteria for efficiency and
performance. To receive WaterSense
certification, products undergo rigorous
testing for efficiency
and performance.
Since its inception in 2006 through
2018, WaterSense has helped
Americans save a cumulative 3.4
trillion gallons of water and more
than $84.2 billion in water and
energy bills, according to the EPA.
Additionally, the use of WaterSense
labeled products saved 462.5 bil
lion
kilowatt-hours of electricity.
PROMOTE WATER SAFETY
In an effort to increase awareness,
this past Building Safety Month—
an educational, interactive
campaign that takes place each
May presented by the Code
Council to help promote the
importance of building safety—
devoted an entire week to bringing
awareness to the importance of
water safety and urging action to
ensure clean water through proper
construction, conservation and
safe disposal.
No matter the time of year, it’s
important for us to implement
water conservation and efficiency
methods to ensure the health and
well-being of all.
u
Dominic Sims is chief executive
officer of the International Code
Council. The International Code
Council is a nonprofit association that
provides a wide range of building
safety solutions including product
evaluation, accreditation, certification,
codification, and training. It develops
model codes and standards used
worldwide to construct safe,
sustainable, affordable and resilient
structures. For more information,
visit www.iccsafe.org.
“Now is the
time to band
together to
create
solutions
to provide greater
accessibility to safe
and clean water.
22
|
June 2020
|
Modern Pumping Today www.mptmag.com
MAINTENANCE & RELIABILITY
I/O for the IIOT
Edge I/O creates a simpler way to meet the needs
of today’s IIoT applications Part 1 of 2
Logging temperature data to a database is too complex.
By Benson Hougland, Opto 22
Wire sensor
to temperature
input
Install and
configure input
module
Write code
to log data
Log data
Write code
to get data
Sensor
I
n an era of increasing connectivity
and technical capabilities, it seems
like simple ideas should be, well,
simple to achieve. Suppose you need to
do something like:
Log temperature data from a
refrigeration unit into a database.
Receive a text message if a
warehouse door is opened after
hours.
Publish process flow and pressure
data into a SCADA system.
Send an air compressor’s total
running time to a cloud analytics
system Control a security light
with your smartphone.
Simple ideas, right? But, in fact,
while we can do all of this with current
technology, it’s expensive, demands
special skills, and involves many
steps—all of which make any IIoT
project far from simple.
IIOT PROJECTS ARE
TOO COMPLEX
The majority of signals in the real
world are basic wired switches,
sensors, and transmitters, despite
advances in smart wireless
devices. Getting signal data
where you want it to go is
complicated. Take temperature
data, for example. First, you—
or someone you hire—needs
to have the skills required
to specify and procure all the
numerous components of an I/O
or PLC system that will work with a
temperature sensor.
Then you must install an appropriate
enclosure for the PLC and I/O,
assemble them, and supply them with
power. Next, you install a temperature
sensor in the refrigeration unit, and
connect it to a suitable input channel
on a temperature input module
mounted on the PLC rack. Then you
program that PLC, using the
vendor’s proprietary software, to
configure the input channel for the
correct signal type and to acquire and
log the I/O data.
Controller
Modern Pumping Today
|
June 2020
|
23www.mptmag.com
MAINTENANCE & RELIABILITY
Next, you’ll likely need a PC with a
software application that can read the
PLC’s memory for the logged data,
and translate the data into a format
the database can understand. Finally,
some software will need to log into
the database and post, or insert, the
logged, translated data. And if the
database isn’t on premises, or in the
cloud somewhere that’s accessible,
good luck!
CONTROL SECURITY LIGHT
Turning on a security light from your
phone sounds easy, but it still involves
many steps. Once you have the light
contact wired to an output on a PLC
or PAC and the output configured,
you’ll program the PLC to turn the
light on or off based on an input from
an HMI, which is usually running on a
separate PC.
But if your HMI software program
isn’t mobile-ready, you’ll need to find a
different HMI package, buy it, and build
new interface screens.
SEND COMPRESSOR ON-TIME
What about sending the compressor
on-time to a cloud analytics platform?
Again, first you must specify, buy,
and install the right equipment. Then
you wire a status contact on the
compressor to a digital input module
on the PLC, PAC, or controller to sense
its on/off status.
After that, you program the PLC
to configure the input and write
ladder diagram or a function block
to totalize how long the input is on,
which will keep track of how long the
compressor has been running. Next,
you’ll need a gateway or other suitable
computer that can read the PLC’s
memory for the totalized data and
provide that data to the cloud analytics
package of your choice in a format it
can understand.
Not simple.
A COMPLICATED, COSTLY
PROCESS
As we can see in just these few
examples, meeting seemingly simple
needs today is a complicated process.
In many cases, you already have
sensors, contacts, and transmitters
in place with the data you need, but
that data is locked in proprietary PLC
systems behind someone’s control
program. To access that data, typically
you have to:
Change the program in the PLC,
PAC, or other controller to acquire
the data you need.
Purchase and activate necessary
middleware (hardware and
software, including licenses)
with the protocols, languages,
and translators required for
your application.
Write code
sending to
database
Configure
firewall
Store data in
the cloud or on
premises
PC workstation
or server
24
|
June 2020
|
Modern Pumping Today www.mptmag.com
MAINTENANCE & RELIABILITY
Configure and program
middleware as necessary to move
data where it’s needed.
Understand and configure internet
gateways and network connections,
including server firewalls, security
certificates, and user accounts.
Establish communications between
the PLC, PAC, or controller and the
data’s destination.
MOVING TOWARD SIMPLICITY
The goal we’re trying to reach with the
IIoT is a simpler process of gathering
real-world signal data, communicating
it, and making it available where it
needs to be used. Whether you’re
monitoring remote assets, acquiring
data for analysis or regulatory
purposes, controlling equipment and
processes, or bringing visualization
to operators and supervisors, you
want to avoid complexity and the
time and money costs that go
with it. Fortunately, automation
manufacturers are introducing newer
kinds of I/O—called edge I/O—with
features designed to help streamline
IIoT projects.
KEY SIMPLIFIERS
These new edge I/O products do
not require a PLC or industrial
PC. Instead, they are designed as
intelligent, distributed I/O devices to
meet the needs of IIoT applications,
especially those that require data
acquisition or communications.
What are some of the key features
of new edge I/O products that help
simplify IIoT projects?
Easy to spec and buy. A single
part number includes everything
you need: I/O, networking,
processor, power, and
embedded software. Edge I/O
units don’t necessarily require
a power supply, instead using
power over Ethernet (PoE) for
the unit’s processor as well
as excitation for outputs and
self-wetting discrete inputs.
Typically, the cost is within many
maintenance budgets.
Compact and sturdy. Edge I/O
products are small industrial
units that can be placed almost
anywhere. They operate within
a wide range of ambient
temperatures and comply with
environmental requirements,
including UL Hazardous Locations
and ATEX approvals. Edge
I/O is available in small form
factors and may be DIN-rail or
panel mounted.
Web-based configuration.
For
maximum flexibility in
diverse applications, edge I/O
JUNE 2020  MPT Modern Pumping Today Providing Solutions for the Worldwide Pump Industry  www.mptmag.com      Go Beyond Eff...
26
|
June 2020
|
Modern Pumping Today www.mptmag.com
MAINTENANCE & RELIABILITY
Going Beyond
Efciency Standards
P
umps, fans, and compressors account for about 60
to 70 percent of total electrical energy usage by US
manufacturers. Inefficient operation leads to higher
energy costs. However, goals to improve pump efficiency
and reduce energy costs may not carry a high priority
to owners and operators when their primary focus is to
keep operation running smoothly. Owner/operators are
more interested in improving reliability, minimizing repair
costs and downtime, and increasing profits. A systemwide
approach to an efficient and reliable design and operation
of a piping systems is much more effective than a
component by component approach (i.e., only addressing
the pump itself).
A quality flow analysis software tool provides engineers
and operators a better understanding of their system. This
empowers them to make more well-informed decisions
on how they could concurrently improve efficiency and
reliability while reducing energy, repair, and maintenance
costs, minimize downtime, and increase profits. Before we
get into the benefits of flow analysis software, let’s discuss
efficiency. In this article, we are going to focus on liquid
piping systems and pumps.
In 2016 the US Department of Energy (DOE) launched
the first Energy Conservation Standard for Clean Water
Pumps. 10 CFR Part 431 is the new standard that increases
the importance of energy efficiency for pump systems.
WHAT IMPACT IS THIS STANDARD
GOING TO HAVE?
In short, pump manufacturers will need to ensure their
pumps meet a Pump Energy Index (PEI) which complies
with a minimum allowable efficiency based on the DOE
pump energy conservation standards. When plant end
users are looking to purchase a pump, they will need
to consider the PEI for the pump as well as standard
operating values such as flow rate, required total dynamic
head (TDH) at the operating point, best efficiency point
(BEP), etc.
The details regarding the energy conservation standard
or how the PEI is calculated is outside the scope of this
article. Rather, it is important to bring awareness to the
existence of the standard and that it is a big step forward
in the efforts of using more energy efficient pumps.
Unfortunately, purchasing a pump with a compliant PEI
does not guarantee it will operate efficiently. There are
many ways pumps become inefficient.
In other cases, systems may be designed to meet future
requirements with increased capacity but must operate
to meet current market needs. Pumps may often be
oversized, but not just for meeting future requirements.
Sometimes, pumps get significantly oversized when design
factor upon design factor is applied from the engineer, to
the supervisor, the client, and finally the manufacturer. In
either case, control valves may be installed to meet current
demands. Energy is added from the pump, and then
excess energy is removed as pressure loss across a control
valve. This is one of the most common ways that energy is
wasted, leading to high energy costs.
DRIVES TO MAINTAIN HIGHER EFFICIENCY
It is like driving your car with your foot on the gas pedal
and the brake at the same time. If possible, it is better
to incorporate a variable speed drive (VSD) or variable
frequency drive (VFD), which can adjust the pump curve
via the affinity laws to operate at different flow demands.
This will maintain higher efficiency as well as help the
pump continue to operate closer to the BEP more so than
a control valve would. Flow analysis software can be used
to help determine what speed the pump should operate at
to achieve these goals.
Part 1 of 2
By Ben Keiser, Applied Flow Technology
Outside of the new Energy Conservation Standard,
there are not many standards for designing pump
systems. Often, system components are designed
independently, and time may not be spent to evaluate
how components will interact with each other. This
can lead to inefficient pump operation if the system
causes the pump to operate away from its BEP.
Modern Pumping Today
|
June 2020
|
27www.mptmag.com
MAINTENANCE & RELIABILITY
There are a few other factors leading to inefficient pump
operation. System aging and equipment wear take their
toll on reducing system efficiency. As corrosion, fouling,
and internal pipe scaling become prevalent, the system
pressure loss increases. Also, as pumps wear out, the
performance can deviate to a degraded pump curve.
Overall, the pump and system would not be operating
where they were originally designed to operate which
leads to decreased efficiency and higher energy costs.
Calculating the efficiency for a pump is a simple task
and is even easier with flow analysis software. When
modeling a piping system with flow analysis software, a
pump curve can easily be specified for a pump component.
If an efficiency or power curve is entered as well, then
the resulting efficiency based upon how the system is
operating is simply an output parameter that requires no
additional calculation. The resulting pump efficiency has
a direct impact on energy costs. Improved efficiency can
have a dramatic effect in
lowering energy costs.
OPERATING AT THE BEST EFFICIENCY POINT
Although pump efficiency is important, the proximity of
operation of the pump to its BEP is more critical. The BEP
is the operating flow rate at which the pump’s efficiency is
at its maximum. Operating closer to the BEP can increase
the efficiency of the pump itself. But it will have a much
bigger impact on the overall reliability of the pump and
that may be more important to focus on rather than the
efficiency value itself.
Figure 1 is known as the Barringer Curve and it
provides a graphical relationship between pump
efficiency and reliability. Plotted is a typical pump curve
and its associated efficiency curve. The BEP flow rate is
represented by the vertical dotted line which identifies
the maximum value of the efficiency curve. The bell-
shaped curve is a reliability curve which represents the
mean time between failure (MTBF). If a pump is operating
at the BEP, this would represent an MTBF value of 1.0.
This means that when operating consistently at the BEP,
the pump will operate most reliability and will last the
longest period from failure to failure. For some pumps, an
acceptable range of flow rates to operate at could be from
80 to 110 percent of BEP. When operating in that zone,
the reliability curve shows a significant decrease to 0.5
“Flow analysis software
can be used to help
determine what speed the
pump should operate at to
achieve these goals.
28
|
June 2020
|
Modern Pumping Today www.mptmag.com
MAINTENANCE & RELIABILITY
MTBF. This means more failures, more repairs, more often.
As the pump operates at flow rates further to the left and
right of the BEP, there are some common problems that can
occur in different areas where the pump is operating on its
curve. Obviously, the pump is less efficient and will result
in higher energy costs. But the real problem is the constant
reliability issues that will be present such as cavitation,
recirculation within the pump, seals and bearings wearing
out faster, etc. Higher energy costs are easy to deal with
in comparison to the significant repair and maintenance
costs, downtime, and lost production and profits.
A LOOK AHEAD
Although it is good that there are more efforts now for
vendors to provide more efficient and energy compliant
pumps, it is easy to see from Figure 1 that it is not just
about efficiency. With more focus on improving reliability,
not only will this minimize repair costs, increase profits,
etc., it will naturally improve pump efficiencies as well. In
next month’s conclusion to this article, we’ll look into how
to improve reliability as well as efficiency.
u
Ben Keiser is technical sales consultant at Applied Flow
Technology. Keiser holds a bachelor's of science in chemical
engineering (2009) from the Colorado School of Mines. He
can be found teaching many of AFT's technical seminars and
stopping over for lunch and learns with AFT customers. Founded
in 1993, Applied Flow Technology has grown to be a leader in
the pipe flow modeling software market. With a primary focus
on developing high quality fluid flow analysis software, AFT has
a comprehensive line of products for the analysis and design
of piping and ducting systems. For more information, visit
www.aft.com.
% FLOW
Figure 1: Barringer Curve that demonstrates the relationship between efficiency and reliability for a pump.
% HEAD
High
Temperature
Rise
Low Bearing
and Seal Life
Suction
Recirculation
Low Flow
Cavitation
Reduced
Impeller Life
Discharge
Recirculation
Low Bearing
and Seal Life
Cavitation
Pump Curve
Efficiency
Curve
Reliability
Curve
BEP
0.5 MTBF
+10%
BEP
-20%
BEP
Mean Time
Between Failure
(MTBF)
JUNE 2020  MPT Modern Pumping Today Providing Solutions for the Worldwide Pump Industry  www.mptmag.com      Go Beyond Eff...
Modern Pumping Today
|
June 2020
|
31www.mptmag.com
PUMP SOLUTIONS
EVIDENCE OF GROWING UPTAKE
More and more mining industry
customers are turning to peristaltic
technology to provide solutions to
specific problems. This is because
peristaltic pumps can help mine
operators face up to key challenges,
which include:
Reducing downtime
Reducing operating costs
Meeting environmental regulations
Managing and reducing
water inventories
Reducing chemical usage
Lowering maintenance costs
One beneficiary of peristaltic
technology is a large copper and
gold mining company in Arizona
that had to frequently replace
components on hard chrome iron
centrifugal pumps used in a difficult
tailings slurry application. The
pump impellers were wearing out
every two weeks, causing significant
downtime and costly repairs. The
mine considered several different
pump technologies, finally selecting
Bredel 100 hose pumps. In this
application, the hose pumps transfer
tailings slurry almost 2,200 feet to
a separate plant. With no seals to
flush and the ability to pump tailings
with a high solids concentration
(80 percent) the mine uses much
less water with Bredel hose pumps,
achieving considerable savings in
both maintenance costs and water
usage. Another example can be
seen at Jaguar Mining Inc., which
operates four gold mines in Brazil.
The company first adopted Bredel
hose pumps at its Turmalina mine
when it was faced with pumping
paste backfill comprising 4 percent
cement and 69 percent solids. No
centrifugal pump could handle
the task.
To overcome the challenge
presented by paste backfill, the
mine operator installed a Bredel 100
on a trial basis and the results were
so impressive that it subsequently
purchased the pump, which is now
transferring the mix with an S.G.
of 2.8 at a rate of 1,765 cubic feet
per hour over a distance of 1,378
feet. Today, the Turmalina site has
installed multiple Bredel hose pumps
for applications including backfill
operations, flotation processes,
leaching processes, and working
with reagents.
A similar success story at a large
mine in New Brunswick, Canada, saw
centrifugal slurry pumps replaced
with Bredel hose pumps. The 65
percent solids of the zinc and lead
thickener underflow slurries was too
high to allow the centrifugal pumps
to deliver the desired flow rate,
32
|
June 2020
|
Modern Pumping Today www.mptmag.com
PUMP SOLUTIONS
while abrasive wear was causing an
unacceptable frequency of costly
repair. Because the abrasives in the
slurry do not affect Bredel pump life,
the mine is now able to minimize
downtime and achieve reliability at
the desired flow rate.
ACCURATE CHEMICAL
METERING
Another potential area of saving
is through accurate chemical
metering. The range of chemicals
used in mining processes is vast
and includes copper sulphate,
xanthate, SIBX/ MIBX, GUAR, cyanide,
sulphuric acid, lime, flocculants, zinc
sulphate, aerophine, sodium silicate,
BIOX, surfactants, and sulphides
to name but a few. However, by
using microprocessor-controlled
brushless DC drive technology,
Bredel hose pumps will properly
maintain the flotation rates of ore
extracts to ensure economical use
of expensive chemicals and create
significant process efficiencies.
Bredel hose pumps have become
first choice in mines throughout the
world for applications that include
dosing process reagents and
pumping shear-sensitive polymers
for flocculation and coagulation,
abrasive lime slurries for pH control,
or corrosive chemicals like cyanide
for gold recovery.
Ores, of course, have different
mineral contents and pumps must
consistently vary their dosing
rates to optimize chemical usage
and maintain plant throughput.
Additionally, process reagents
such as cyanides and acids are
often highly corrosive but as the
chemically resistive hose of a Bredel
peristaltic pump is the only part in
contact with the pumped product
then there are no working parts
exposed to the chemical.
The world’s largest trona soda ash
mine in Wyoming was experiencing
problems with its diaphragm
metering pumps used for dosing
flocculant into the trona processing
lines. The diaphragm pumps would
last only five to six months due
to the highly corrosive nature of
the flocculant. Even after trying to
add large amounts of water to the
flocculants, which subsequently had
to be removed from the process, the
diaphragm pumps would still fail.
The mine purchased several
Bredel hose pumps to address pump
maintenance and flocculant wastage
problems. The hose pumps’ inherent
corrosion resistance allows the mine
to pump pure flocculant into the
discharge lines and holding tanks.
With no need to add water, the mine is
saving money in water usage, process
downtime, and maintenance costs.
CONCLUSION
Moving ores, concentrates, and
residues in slurry form are essential
parts of industrial mining processes.
In an effort to reduce water, energy
and chemical consumption, and
improve slurry transportation
reliability, more and more mining
operators are discovering the
simplicity and benefits of peristaltic
hose pumps. With thousands of
Bredel hose pumps already at work
around the world, there is little doubt
that hose pumps are the solution.
u
1.) Bredel 2100 hose pump handles paste backfill at 69 percent solids and 4 percent cement at Turmalina Mine, Brazil. 2.) Unlike other pumps, the performance of Bredel hose
pumps is not affected by abrasive slurries and chemicals.
Watson-Marlow Fluid Technology
Group (WMFTG) is the world leader
in niche peristaltic pump manufacture
and associated fluid path technologies.
Founded on nearly sixty years of
supplying engineering and process
expertise and with over one million
pumps installed worldwide, WMFTG
pumps are tried, tested, and proven
to deliver. For more information, visit
www.watson-marlow.com.
1 2
34
|
June 2020
|
Modern Pumping Today www.mptmag.com
PUMP SOLUTIONS
All Electric Double
Diaphragm Pump
Changes the Game
T
he all electric diaphragm pump is changing the
game in double diaphragm pumping. It is a positive
displacement pump for municipal sludge, slurries,
pastes, or anything that an air operated diaphragm pump
can pump, but without the hassle of the usual drawbacks
of having air. As air is being obsoleted by more and more
customers these days for many reasons, such as cost,
efficiency, functionality, safety, and lower energy usage, the
EODD (electrically operated double diaphragm) pump
can offer the lowest in class operating costs—and superior
durability, if it is constructed of nodular
ductile iron and has an efficient motor
and pump design. In most cases,
this can mean up to 95 percent
volumetric efficiency on
average compared
to any
other pump. You no longer need to use electricity to
run air to run a pump. A whole other cost center is now
removed with only mechanical fluid dynamics to deal with
instead of fluid and air.
SIMPLE SOLUTION, MYRIAD BENEFITS
High efficiency electro-mechanical drive and slow stroke
rates keep energy bills low and wear parts cost to a
minimum. Mechanical simplicity makes seldom needed
maintenance a breeze, unlike progressive cavity pumps,
gear, rotary lobe, or peristaltic type pumps. A design
that offers a robust construction with integral
metal core ball check valves and fabric-reinforced
diaphragms that offer a smooth mechanically
controlled linear drive would prove the most
desirable. Large ports and a diaphragm that
is to one side of the fluid column offer passive
pumping as well as for better fluid velocity and
more room for the fluid, and, therefore, is less
prone to plugging. Other pumps require tight
How EODD pumps outperform and outlast air
operated double diaphragms
By Chuck Martin, ABEL Pumps
EM Model running in tandem duplex configuration.
Modern Pumping Today
|
June 2020
|
35www.mptmag.com
PUMP SOLUTIONS
tolerances simply to operate, and
that immediately makes them
susceptible to plugging by nature. If
it will flow, it usually can be pumped
with an EODD pump, even to a range
of about 40 percent solids, if it is
compressible and will freely flow.
Large valve clearances also
contribute to this winning equation.
True process control is achieved
via optional variable frequency
drive, technology unavailable in air
operated diaphragm pumps. There
is no air valve to stick or malfunction
in cold and hot weather. Optional
discharge dampeners and suction
stabilizers are available to minimize
flow pulsations under variable or
demanding system conditions. A
form of flow control would also make
this kind of pump a game changer in
double diaphragm pumping!
ELECTRICALLY OPERATED
DOUBLE DIAPHRAGM PUMPS
The EODD pump also offers the
extreme versatility of opertaing
in duplex mode with two pumps
working at the same time—
something that an air operated
double diaphragm pump cannot
do. Since an EODD pump operates
by working in a 90 degree out-
of-phase design, you can use two
pumps in tandem at the same time
and not only the traditional lead/
lag traditional fashion. This means
that you only use one motor, one
gearbox, one baseplate, and one
manifold piping system system—
further saving on material, time,
money, and even weight as
compared to two independent
pump systems.
CONCLUSION
A truly all electric double
diaphragm pump with a superior
design will provide the very
best return on investment that
checks all of the boxes when it
comes to pump selection and
lasts two to three times longer
with better parts wear and less
maintenance than air operated
double diaphragms.
u
ABEL develops and manufactures reciprocating positive displacement pumps for varying
flow rates and pump pressures and specializes in diaphragm pumps. Depending on the
design, they are suitable for abrasive, aggressive, and even shear-sensitive media. We are
recognized around the world as the technological leaders in mechanical diaphragm pumps.
Solids handling pumps (for paste-like and non-Newtonian media) and high pressure plunger
pumps complete our range of products. For more information, visit www.abelpumps.com.
36
|
June 2020
|
Modern Pumping Today www.mptmag.com
MOTOR SOLUTIONS
Optimizing
Asset Performance
Sulzer offers long-term maintenance support for
Colombian industries
By Jennifer Cardillo, Sulzer
Sulzer offers pump expertise to the major industries including oil and gas which uses the BB5 pump extensively.
Modern Pumping Today
|
June 2020
|
37www.mptmag.com
MOTOR SOLUTIONS
F
or over eighty years, Sulzer
has provided maintenance and
repair solutions to the South
American industry. Today, specialist
teams offer a wide range of services
for rotating equipment to support
customers in power generation, oil
and gas, mining, and water as well
as general industry. In Colombia, the
Bogota Service Center provides a
comprehensive range of services that
includes long-term parts and service
contracts, which simplify maintenance
projects and reduce lead times
for components.
Many industrial operations use
rotating equipment for a range
of applications. Having in-depth
knowledge about pumps, compressors,
and steam turbines, no matter who
built them, is very valuable. Sulzer's
Colombian service center has
extensive in-house expertise and can
also call on a worldwide network of
engineering facilities. This enables
repairs and upgrades to be completed
efficiently and cost-effectively.
Precision machine tools can optimize pump components from any manufacturer.
SEEPEX’s BRAVO Chemical Metering
Systems provide maximum reliability and
whole process control. These modular
and scalable systems incorporate
progressive cavity Intelligent Metering
Pumps (IMP) and are the most flexible
solution for disinfection, pH control and
flocculation in your industry.
BENEFITS
Simplified design reduces installation
and operating costs
Less chemical use due to minimal
pulsation
NSF/ANSI 61 certified progressive
cavity pumps
Single source for pumps and controls
MAXIMUM RELIABILITY AND
SUPERIOR PROCESS CONTROL
BRAVO
CHEMICAL METERING SYSTEMS
SEEPEX Inc.
sales.us@seepex.com
T +1 937 864-7150
www.seepex.com
For more information visit:
www.seepexsales.com/go/bravo
BRAVO_7.125x4.625_06.2020.indd 1 6/9/2020 3:21:48 PM
38
|
June 2020
|
Modern Pumping Today www.mptmag.com
MOTOR SOLUTIONS
EXPERT MAINTENANCE SUPPORT
Major industries in Colombia can
minimize downtime and improve
reliability by taking advantage of
Sulzer's expert maintenance support.
Extensive industry knowledge and
expertise in rotating equipment
ensures that customers receive
a fast response for spare parts
and servicing.
As a pump original equipment
manufacturer (OEM) and
independent maintenance provider
for all rotating equipment, Sulzer has
decades of experience in maximizing
reliability and optimizing costs.
In-house designers, manufacturing
facilities and testing capabilities
ensure a comprehensive service.
David Lora, general manager of
Sulzer Colombia, adds, “We offer
customers the opportunity to take
advantage of Sulzer's expertise in
repair technology and to benefit
from this knowledge. We are able to
organize long-term parts and service
contracts for assets, which ensure that
maintenance is completed on time
and continued reliability is assured.
IN-HOUSE SPECIALISTS
To determine the most opportune
time for repairs to be completed,
Sulzer can design and install vibration
monitoring equipment and analysis
tools to implement a preventative
maintenance schedule. Using pre-
planned outages for repairs is the
most cost-effective way to deliver
improved reliability.
For pump equipment, Sulzer can
also design, build and install the
electrical control equipment, including
drives and accessories. Matching
equipment to the application is just
the first step, it is important for the
controls to be properly integrated with
the wider infrastructure.
In addition to these services, Sulzer
also provides experienced field
service engineers for on-site support
of existing machinery as well as the
installation and commissioning of new
equipment. These skilled engineers
receive regular training, for example
API 686, 4th edition, to ensure they are
up to date with the latest guidelines
on the on the recommended practices
for machinery installation and design
in the petroleum sector.
CUSTOMER TRAINING
To help customers with their in-house
maintenance, experts from Bogota can
deliver training courses on operational
best practice and routine maintenance
for a wide range of equipment. This
helps to
extend reliability and the
efficiency of important assets, which
in turn, optimizes productivity for the
customer. David Lora concludes, “We
appreciate the challenges of working
in heavy industry and the importance
of asset reliability. Our goal is to
deliver the most effective and
efficient maintenance service for our
customers and help them to
achieve
their objectives.
u
Sulzer is a global leader in fluid
engineering. We specialize in pumping,
agitation, mixing, separation, and
application technologies for fluids of all
types. Our customers benefit from our
commitment to innovation, performance,
and quality and from our responsive
network of 180 world-class production
facilities and service centers across the
globe. Sulzer has been headquartered
in Winterthur, Switzerland, since
1834. In 2019, our 16,500 employees
delivered revenues of CHF 3.7 billion.
Our shares are traded on the SIX Swiss
Exchange. Throughout the Americas,
Sulzer provides cutting-edge parts as
well as maintenance and repair solutions
for pumps, turbines, compressors,
motors, and generators. We service
our own original equipment as well as
third-party rotating equipment operated
by our customers. Our technology-
based solutions maximize reliability and
lifecycle cost effectiveness. For more
information, visit www.sulzer.com.
Modern Pumping Today
|
June 2020
|
39www.mptmag.com
40
|
June 2020
|
Modern Pumping Today www.mptmag.com
SEALING SOLUTIONS
Quick Payback on
Wear Ring
M
etal-on-metal contact can result in galling and
unwanted pump vibration, as well as severe damage
to the pump; therefore, wear rings have become
a critical component in many pump systems to prolong the
life-cycle of a pump. Vesconite Bearings’ Hilube polymer
wear rings are proving so popular that they are currently the
company’s most important wear component for the pump
industry—furthermore, they additionally save systems on
electricity costs to such a great degree that the components
offer a fast return on investment.
HOW HILUBE WORKS
The wear rings are used to restrict the pressure
leakage of the fluid between the inlet of the
impeller and the pump casing in centrifugal
pumps. The wear rings are made from the
thermoplastic Vesconite Hilube, which is
a low-friction, wear-resistant polymer
that replaces traditional metals such as
bronze and stainless steel as well as
other thermopolymers.
Here are the benefits:
They replace metal
components that require large
running clearances to avoid
metal-on-metal contact.
They improve efficiency since tighter
running clearances can be applied.
They do not require pump redesigns,
since they can fit into the same housings
used by metal wear rings and, because
they are press fit, do not require mechanical
fitment or glue.
They can be easily machined from a variety of
tube stock or they can be machined for use us-ing
Vesconite Bearings’ machining capability.
They are impervious to salt-water corrosion and thus are
ideal for sea water and reverse osmo-sis pumps where
galvanic corrosion may destroy stainless steel wear rings.
Electricity cost saving on pumps tted
with Vesconite Hilube wear rings
By Phillip de Villiers, Vesconite Bearings
Modern Pumping Today
|
June 2020
|
41www.mptmag.com
SEALING SOLUTIONS
Quick Payback on
Wear Ring
They resist cavitation, a problem
often encountered with metal
wear rings.
Vesconite Hilube is approved,
including by NSF61 and WRAS, for
drinking water applications.
ELECTRICITY COST SAVINGS
The installation of Vesconite Hilube
polymer wear rings can result in
electricity savings that more than pay
for the wear ring. This was the result
of a study by a large pump original
equipment manufacturer (OEM)
that compared energy usage on a
typical submersible pump when a
Vesconite Hilube wear ring was in
place and when a bronze wear ring
had been installed.
Vesconite Hilube is a low-friction
wear-resistant polymer. Wear
rings made from the material are
designed to seal the pressure
leakage of the liquid between
the inlet and the impeller and the
pump casing, and should result in
a higher pumping efficiency due to
lower bypass.
VERIFIED PERFORMANCE
The pump OEM’s results
independently proved Vesconite
Hilube’s ability to improve pumping
efficiency and decrease electricity
usage. The study showed a 0.11
kilowatts per hour energy reduction
when operation of the pump with a
large diameter bronze wear ring was
compared with operation of the same
pump type with a dimensionally-
identical Vesconite Hilube wear ring.
Assuming the Vesconite Hilube
wear ring’s use on an industrial
pump, operating twenty-four hours a
day, 365 days a year, the electricity
savings from installing a Vesconite
Hilube wear ring add up, particularly
when the pump is operated in a
jurisdiction in which electricity
charges are high.
In the specific pump that was
studied by the OEM, the wear ring
would have a three-month payback
even where a low electricity cost was
assumed. Electricity savings for a five-
to-ten stage submersible pump can be
significant if the electricity savings of
each stage are added together.
HOPE FOR THE FUTURE
With concerns about global
CO
2
emissions from electricity
generation—which reached
12Gt in 2010—as well as an
awareness that pumps account
for 10 percent of global electrical
energy consumption, technological
interventions are valued by pump
manufacturers and pump users.
They are also of interest to state
and national governments that
are interested in reducing carbon
emissions to keep global warming
under 1.5 degrees Celsius.
u
Vesconite Bearings is a world-leading
manufacturer of low-friction, low-wear
polymer bearing materials for a wide
range of industries. Selling to over 100
countries, these include the pump,
agriculture, railways, mining, heavy
transport, hydro, renewable-energy,
earthmoving, marine, and construction
industries. For more information, visit
www.vesconite.com.
42
|
June 2020
|
Modern Pumping Today www.mptmag.com
MODERN PUMPING PRODUCTS
LIBERTY PUMPS
Model 404 and 405
As regions in the United States and Canada
begin to re-open for business, they are
doing so with some new requirements
and restrictions on how they operate. To
provide better sanitization, many are being
required to add additional wash station
areas for their employees and customers.
The Liberty 404 and commercial model
405 are the perfect solution for these
additions and remodels!
The opportunities exist in manufacturing
facilities, restaurants, schools, health
care facilities, and almost all public
and commercial buildings!
Liberty’s model 405 is one of
the few models made here in
the U.S. that features high-
temperature capability along
with higher-head pumping
(max head 34 feet). The
2-inch inlet, discharge, and
vent allow it to be installed
commercially on multi-
compartment sinks, and
it arrives fully assembled
saving valuable labor time.
Keep in mind we offer new
versions with pre-installed
alarms and NightEye
®
(Wi-Fi)
enabled options for both the 404
and 405!
Our QuickTree
®
Technology
provides a separate access cover
for easy switch inspection. For
gray wastewater applications, the
405 is perfect for laundry trays,
multi-compartment sinks, bar
sinks, utility sinks, dishwashers,
and allows you the freedom to
install fixtures where gravity drain
lines are not available. The system
arrives fully assembled and ready
to install.
Featured Product
For more information, visit www.libertypumps.com.
Modern Pumping Today
|
June 2020
|
43www.mptmag.com
MODERN PUMPING PRODUCTS
PULSAFEEDER
PulsaPro Hypo Valve
The Hypo Valve is the latest innovation for the PulsaPro Pump Series and
is designed to manage off-gassing in dosing applications. The Hypo Valve
technology allows pressurized process fluid to cyclically flush liquid and vapors
through the pump’s discharge check system, while maintaining high performance
and chemical dosing accuracy. This avoids common issues, such as vapor-
lock, which lead to reduced capacity and inaccurate chemical dosing, while
also preventing unnecessary maintenance work. For more information, email
prosales@idexcorp.com or visit
www.pulsa.com
.
AUTOMATIONDIRECT
Enclosure Thermoelectric Coolers
Seifert SoliTherm
®
Thermoelectric Coolers use the Peltier
Effect for closed-loop cooling. The only moving parts are
axial fans so there is virtually no maintenance. The Seifert
Peltier thermoelectric cooling units can be mounted in
nearly every position (except roof mounting) because
they don't have a compressor or any moving parts aside
from the fans. These thermoelectric cooling units are
resistant to extreme ambient conditions and can operate
effectively in dusty and oily environments and both indoor
and outdoor applications. For more information, visit
www.automationdirect.com/thermoelectric-coolers
.
MITSUBISHI ELECTRIC AUTOMATION, INC.
FR-E800 Series Variable Frequency Drive
The FR-E800 is built upon Mitsubishi Electric´s proven variable speed control technology
through years of reliable operation across various applications. It incorporates advanced
capabilities in a compact footprint allowing for bookshelf style mounting. Additional features
include extended programming functions, advanced fault detection features, and auto-tuning
of PM motors for applications where energy efficiency is extremely important. The auto-
tuning function includes configurable parameters to reach optimum performance, higher
torque, faster acceleration, and lower noise level for quiet operation. For more information, visit
https://us.mitsubishielectric.com/fa/en/products/drive-products/inverters-freqrol/fre/fre800/fre800overview
.
LYCO WAUSAU
Stainless Steel Vacuum Pump
Lyco Wausau introduces a new stainless steel liquid ring
vacuum pump with a close-coupled stainless steel wash down
motor (Model 101-40-3SSM or Model 102-40-3SSM). It’s ideal
for food processing, pharmaceutical, medical, and chemical
plants where frequent washdowns are required. The compact
pump can provide vacuum up to 28 inches of mercury or move
up to 52 cubic feet of volume per minute. Lyco Wausau offers
a wide selection of reliable pumps, replacement parts, and
accessories. For more information, call 715.845.7867 or visit
www.lycowausau.com
.
44
|
June 2020
|
Modern Pumping Today www.mptmag.com
MODERN PUMPING PRODUCTS
ASSURED AUTOMATION
MAG Series Magnetic Inductive Flow Meters
The Assured Automation MAG series are volumetric magnetic induction flow meters
that measure flow rate and totals at rates up to 160 gallons per minute, and also
measure temperature. The rugged meter body includes electronics, display, user
interface, and output signal generation in one compact unit. In addition to being more
compact it is also less expensive than comparable meters and sensors. Analog, binary,
pulse, and frequency outputs offer various options to process the measured data. For
more information, visit
www.assuredautomation.com/MAG-meter
.
ENDRESS+HAUSER
Micropilot FWR30 Radar Level Sensor
Endress+Hauser launches the Micropilot FWR30, its first cloud-connected radar,
to provide full transparency in the storage and transport of liquids. As the world's
first 80 GHz wireless IIoT sensor, it combines high-end technology and user-
friendly digital services in one cost-effective device. The instrument’s continuously
recorded measurement data can be accessed at any time, from anywhere due
to the device's cloud connection, with communication made possible by an
integrated SIM card. Installation is easy and can be done in less than three
minutes. For more information, visit
eh.digital/fwr30_micropilot_us
.
SENSOR TECHNOLOGY LTD.
TorqSense Torque Sensors
Equipment rentals are increasingly helping companies overcome the hurdle of
finding investment capital to fund development and verification projects. Having
survived more than one downturn and recovery, Sensor Technology has a rental
option in place for its TorqSense range of torque sensors. Potential users can choose
to rent the equipment, rather than purchase it, thus circumventing the bottleneck of
raising capital purchase approval. And to help companies along, if they decide that
they want to hold onto their TorqSense for longer than they had anticipated, Sensor
Technology is happy to convert the rental to a sale. For more information, visit
www.sensors.co.uk
.
FLOMATIC
Sylax 3 Butterfly Valves
The Sylax 3 has a strong ductile iron valve body, 316SS disc standard, EPDM seat, and
stainless steel stem. The valve is rated for 250 PSI bi‐directional and dead end rating
and has a 230 degrees Fahrenheit (110 degrees Celsius) maximum temperature
rating. The valve is NSF/ANSI 61 and 372 certified for use with ANSI 125/150# flanges
with standard curved and ergonomic handle for easy operation and standard ISO
5211 top flange for easy actuation. For more information, visit
www.flomatic.com
.
Modern Pumping Today
|
June 2020
|
45www.mptmag.com
MODERN PUMPING PRODUCTS
CIRCOR
RTK Discharge and Pump Protection Control Valve
The RTK Discharge and Pump Protection Control Valve works as two valves in one: it brings
together a pump protection recirculation valve and a control valve. In this capacity, the valve not
only cut costs but also increases the life span of pumps by both regulating the main flow and
the recirculation flow with a single valve. In industrial processes that use boiler feedwater and
condensate pumps, the water is circulated in a closed loop by a pump. These pumps require a
minimum amount of water flow to avoid problems that can stem from overheating and cavitation.
For more information, visit
www.circor.com
.
MSA SAFETY
TG5000 Gas Monitor
Facilities and plant engineers will find the next-generation TG5000 Gas Monitor
from MSA Safety offers them a safe, reliable, and effective solution to the detection of
oxygen, combustible, and toxic gases in a wide range of light industrial applications,
including wastewater treatment, industrial plants, and commercial buildings. The
feature-rich yet affordable TG5000 Gas Monitor helps personnel work safely with
confidence in an extensive number of environments, offering a variety of gas sensor
options and installation configurations. For more information, visit
www.msasafety.com
.
ASSMANN CORPORATION
Small Conical Bottom Storage Tanks
These new small conical tanks are available with an all-plastic stand
virtually eliminating points for corrosion due to steel components. These
new conical tanks include polyethylene stands that raise the base off
the floor, allowing room for drainage. The tanks feature a 45-degree
molded-in slope bottom for complete drainage and are designed for
stationary use indoors or out. If special stand elevations are required,
Assmann Corporation has the ability to construct steel tank stands to
accommodate your needs. The conical tanks are seamless molded one-
piece units. Both the tank and the stand are corrosion resistant. For more
information, visit
www.assmann-usa.com
.
AVT RELIABILITY
Machine Sentry Gateway
Easy to install and simple to use, Machine Sentry Gateway removes the need
for manual data collection from MSF-1 sensors. This improves workforce
safety and frees up valuable time for operatives on the plant floor. It can
connect up to 100 vibration sensors to the internet via the ethernet, Wi-Fi, or
3G/4G cellular network, and extends Bluetooth connectivity up to 160 feet.
An IP65 rating makes it suitable for both indoor and outdoor use. For more
information, visit
www.avtreliability.com
.
46
|
June 2020
|
Modern Pumping Today www.mptmag.com
AN
FOR THE
PUMP INDUSTRY
“Guiding, teaching, informing. For pump users, Modern Pumping Todays content strikes the
right balance. MPT has positioned itself above the mixed bag of journals that seem primarily
driven by marketing interests.
Heinz P, Bloch, P.E.
Reliability expert and founding member of the board
of the International Pump Users’ Symposium
Visit mptmag.com
48
|
June 2020
|
Modern Pumping Today www.mptmag.com
EFFICIENCY POINT
To listen to an extended version of this
interview, be sure to subscribe to MPT’s
podcast, The Efficiency Point.
D
rive technology is
always changing to
meet the industry’s
greater need for efficiency
and control. Edward Tom, the
drives product manager for
Yaskawa America’s drives
and motion division, stopped
by a recent episode of MPT's
podcast, The Efficiency Point,
to discuss his company’s
recently released GA500
Industrial Microdrive and why users need not be
intimidated by high-tech drives.
MPT: What’s the history of the GA500 design and where
does it branch off from earlier Yaskawa products?
Edward Tom: The GA500 actually has a pretty long
lineage going back. But just starting more with the recent
one, it does replace our current product, and what it does
is take its main core items, the ones that we feel are great
benefits, great design points for it. But where it really
branches off is by adding to it, making it easier to use for
customers and more user friendly. Also when it comes to
just the operation of a habit so that if a person needs to
interface with it later on and do any troubleshooting, it
makes that easy for them as well. So the biggest thing with
it is that, when compared to its predecessor, it's something
we like to say is easier to use, it has more capabilities built
into it in terms of its control portion, and also an expanded
horsepower range. So the GA500 is pushing the limits of
what would be considered a microdrive.
MPT:
Who would be the target audiences for the GA500?
Edward Tom: The target audience for the GA500 is any
industrial application, so industrial pumping applications
of that sort as well. And what it’s really intended to do is to
help make it easier for people to interface with it. The first
thing we want to do is make sure the drive relieves some
of the tension that some people might have—even if it's
their first time interfacing with the device. A lot of times,
some people may look at that black box and kind of freeze
up a little bit. And we want to make sure that when they do
take a look at it, they have the information and they feel
comfortable with it. So that's one of the main things we
wanted to try to address with it.
What we’ve learned is that, a lot of times, users kind
of look at it and if it’s completely new, they really are
just scared. I think that’s not uncommon, and you don't
know how to start or you're afraid of breaking it, we'll
say. So eliminating that fear was one of the big things we
wanted to do.
MPT: Which industries present the problems this
product will solve?
Edward Tom: I mean, in VFDs and just drives in general,
one of the two of the things that we offer is the energy
savings aspect of it, being able to run at whatever
speed that an application needs to as well as also lower
the maintenance portion. When you are able to vary
the speed much more on electrical standpoint versus
mechanical, what you now do is also eliminate some of the
maintenance that's associated with having the mechanical
components in there.
So a lot of it really is intended to make daily use
easier—simplify a lot of the systems that are out there
so that there's not that higher complexity and there's
less to worry about, whether it be from the beginning
of the design phase with someone creating the machine
all the way to the end user having it installed at their at
their facility.
u
Pushing the Limits
of a Microdrive
Yaskawa’s Edward Tom says there’s no reason to
fear new drive tech
Edward Tom, Yaskawa
Covid-19 Responses: Our facility is open and working • 24/7 Emergency Service On-Site
Babbi Bearing Repair,
Refurbishment & Manufacturing
BABBITT BEARING REPAIR
































ISO9001:2015

