May 2015

SYSTEMS
The Leading Magazine for Pump Users Worldwide
THE GIFT OF
CLEAN
WATER
PUMP TECHNOLOGY
CHANGES COMMUNITIES
EXCLUSIVE COVERAGE FROM ZAMBIA & MALAWI
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From the Editor

F
or most of us, our access to safe

water has never been a concern. At
every turn of the tap, we know that an
abundant amount of clean water will
flow. Pumps & Systems Managing Editor
Amelia Messamore will never again take
this for granted.
Amelia traveled more than 20,000
miles to remote villages in Zambia and
Malawi, Africa, last month and spoke
with women and children who spent
Managing Editor Amelia Messamore speaks to
hours each day collecting water that was women in Big Concession Village in Zambia.
fi lthy and fi lled with disease. The task
was so daunting and time-intensive that these women could not work. Their children
could not go to school or play.
Thanks to the LifePump, a progressive cavity hand pump designed by nonprofit Design
Outreach and manufactured in part by SEEPEX, these women and children and their
entire communities can now enjoy clean water every day.
The gift of clean water has changed their lives forever.
Its hard to wrap my mind around the impact that water has on peoples lives, Amelia
says. It literally can mean the difference between life and death.
While more than 750 million people worldwide still lack access to clean water, many
pump technology companies and organizations are doing their part to change this.
It was really inspiring to see that the technology we write and read about every day
is being used to transform entire communities, Amelia says. These pumps are doing
so much more than improving healththey are giving people their lives back. They are
restoring family relationships, revitalizing local economies, improving the education of
hundreds of children, providing safer infrastructure, improving food security. Ill never
forget the joy I saw on the childrens faces as
they turned those handles and stuck their little
hands under the water. Its incredible to think
that the pump they play around has completely
changed their lives.
For more articles, images, slideshows, videos
Read our full coverage beginning on page 51
and information on how you can help, visit
and find out how you can help.
pumpsandsystems.com/giftofcleanwater
Editor, Michelle Segrest

msegrest@pump-zone.com
Pumps & Systems
is a member of the following organizations:
EDITORIAL
EDITOR: Michelle Segrest
msegrest@pump-zone.com 205-314-8279
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SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
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CONTRIBUTING EDITORS: Laurel Donoho,
Lev Nelik, Ray Hardee, Jim Elsey
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VP OF SALES: Greg Meineke
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EDITORIAL & PRODUCTION
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
postage paid at Birmingham, AL, and additional mailing ofces. Subscriptions: Free of charge to qualied industrial pump users. Publisher reserves the
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Schaeffler Introduces a Genuine Breakthrough

in Condition Monitoring:
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Real Solutions - Real Savings
When a customer faced the daunting task of performing end-of-warranty
inspections on scores of gearboxes and generators, Schaeffler was
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was deemed cost-prohibitive, and the facility was not staffed with
highly trained data analysis experts.
Armed with a single yellow carrying case containing a WiProM
diagnostic unit, Schaeffler experts set about the task of analyzing
factors such as meshing of gears and generator performance. Within
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data that has, so far, saved the customer over $1 million.
We rest our (yellow) case.
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2015
Superior-quality products.
Comprehensive reliable solutions.
This issue
MAY
Volume 23 Number 5
THE GIFT OF
CLEAN WATER
52 PUMP TECHNOLOGY CHANGES
COMMUNITIES
Article & Photos by Amelia Messamore
Reporting from Zambia &
Malawi
Exclusive coverage of
innovative pump technology
that is transforming rural
areas.
59 PUMP INDUSTRY IMPROVES WORLD

WATER ACCESS
Compiled by Pumps & Systems Editors
Pump companies and nonprofit organizations
are teaming up to give clean water to
communities worldwide.
64
TRADE SHOW COVERAGE

IDA WORLD CONGRESS 2015
AMERICAN WATER WORKS ASSOCIATION ANNUAL

CONFERENCE & EXPOSITION
COLUMNS
SSPECIAL
PECIAL
SECTION
WATER HANDLING
PUMPING PRESCRIPTIONS
18 By Lev Nelik, Ph.D., P.E.
66 SPECIAL REPORT
THE COST OF CLEAN WATER
By Michelle Segrest, Pumps & Systems
Reporting from the International World
Summit, Abu Dhabi, UAE
How pumps play a role in the
WATER-ENERGY NEXUS
Pumping Machinery, LLC

Find the True Best Efficiency Point
PUMP SYSTEM IMPROVEMENT

24 By Ray Hardee
Engineered Software, Inc.
Understand How Valves & Fittings
Affect Head Loss
70 WATER LOSS AUDITS DECREASE COSTS

By Edward R. Osann, National Resource Defense Council
Intelligent tracking and pressure adjustments can protect
aging infrastructure.
74 WISCONSIN NONPROFIT WORKS TO ACHIEVE GLOBAL

FRESHWATER SUSTAINABILITY
By Dean Amhaus, The Water Council
The Water Council uses partnerships and research to address water challenges.
First of Two Parts
2
8
107
108
112
FROM THE EDITOR

NEWS
PRODUCTS
PUMP USERS MARKETPLACE
PUMP MARKET ANALYSIS
Vaughans Rotamix System sets the standard for hydraulic mixing, providing the customer with
lower operating and maintenance costs, more efficient breakdown of solids and Vaughans
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- Over 1000 installations worldwide
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- 10 Year Nozzle warranty
See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP
This issue
SSPECIAL
PECIAL
SECTION
MAY
DEPARTMENTS
REMOTE MONITORING &

INTELLIGENT PUMPING
76 EFFICIENCY MATTERS
How Automated Optimization
Can Push the Limits of
Efficiency
By Mark R. Anderson
Concepts NREC
28 EMBEDDED HUMAN MACHINE INTERFACES EXPAND THE REACH

OF REMOTE MONITORING
By Greg Philbrook, AutomationDirect.com
This pared-down technology can make smaller and simpler applications more practical
and economical.
80 MAINTENANCE MINDERS
Remote Monitoring Solutions
Prevent Valve Failure at
Combined-Cycle Power Plants
By Cynthia Stone
GE Intelligent Platforms
36 CONTROLLERS MANAGE EQUIPMENT UNCERTAINTY

By Brian Phillippi, National Instruments
Combined monitoring and control software options help provide flexibility and
improve uptime.
82 MOTORS & DRIVES
40 3 THINGS END USERS SHOULD CONSIDER WHEN OPERATING INTELLIGENT
How to Prevent the 2 Most

Frequent Causes of Motor
Failure, First of Two Parts
By Rob Amstutz
GE Power Conversion
PUMP SYSTEMS
By Andres Suazo, Phoenix Contact
IoT provides flexibility for plants and other facilities, but system types and security must
remain top priority.
46 MONITORING BRINGS RELIABILITY TO WASTEWATER COLLECTION SYSTEM

By Lauryn Colquitt, Mission Communications
Remote terminal units help an Oregon utility monitor 40 major pump and lift stations.
PRACTICE & OPERATIONS

90 THE VOLUMETRIC EFFICIENCY OF
VAPOR LOCK
By Ross Draper
Fluid Process Equipment
WITHSTAND ABRASIVE FLUIDS
& ENVIRONMENTS
By Rob Judd
U.S. Synthetic
EDITORIAL ADVISORY BOARD
BRYAN S. BARRINGTON, Machinery Engineer,

Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy Americas
WALTER BONNETT, Vice President Global
Marketing, Pump Solutions Group
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
CHRIS CALDWELL, Director of Advanced
Collection Technology, Business Area Wastewater
Solutions, Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment Manager
Pumping Equipment, Square D by Schneider
Electric
SYSTEMS
104 DIAMOND BEARINGS
CANADIAN CITY FROM DANGEROUS

& COSTLY FLOODING
By Bryan Orchard
KSB
ROBERT K. ASDAL, Executive Director,

Hydraulic Institute
Principles of ControlledVolume Metering Pumps &

Advantages of Dual Seals
By Hydraulic Institute
The Leading Magazine for Pump Users Worldwide
94 SUBMERSIBLE PUMPS PROTECT
THOMAS L. ANGLE, P.E., MSC, Vice President

Engineering, Hidrostal AG
How To Avoid Compression

Packing Failure
By Carl H. Jones
FSA Member
87 HI PUMP FAQS
100 IMPELLER DESIGN PREVENTS
ROTARY POSITIVE DISPLACEMENT

PUMPS
By Bill Blodgett
LobePro Rotary Pumps
85 SEALING SENSE
THE GIFT OF
Cover image by
Amelia Messamore,
Pumps & Systems
CLEAN
WATER
PUMP TECHNOLOGY
CHANGES COMMUNITIES
EXCLUSIVE COVERAGE FROM ZAMBIA & MALAWI
WILLIAM E. NEIS, P.E., President, Northeast

Industrial Sales
BOB DOMKOWSKI, Business Development
Manager Transport Pumping and Amusement
Markets/Engineering Consultant, Xylem, Inc.,
Water Solutions USA Flygt
LEV NELIK, Ph.D., P.E., APICS, President,

PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump &
Equipment Company
DAVID A. DOTY, North American Sales Manager,

Moyno Industrial Pumps
MIKE PEMBERTON, Manager, ITT Performance

Services
WALT ERNDT, VP/GM, CRANE Pumps & Systems
SCOTT SORENSEN, Oil & Gas Automation

Consultant & Market Developer, Siemens Industry
Sector
JOE EVANS, Ph.D., Customer & Employee

Education, PumpTech, Inc.
RALPH P. GABRIEL, Chief Engineer Global, John
Crane
ADAM STOLBERG, Executive Director,

Submersible Wastewater Pump Association
(SWPA)
LARRY LEWIS, President, Vanton Pump and

Equipment Corp.
JERRY TURNER, Founder/Senior Advisor,

Pioneer Pump
TODD LOUDIN, President/CEO North American

Operations, Flowrox Inc.
KIRK WILSON, President, Services & Solutions,

Flowserve Corporation
JOHN MALINOWSKI, Sr. Product Manager, AC

Motors, Baldor Electric Company, A Member of
the ABB Group
JAMES WONG, Associate Product Manager

Bearing Isolator, Garlock Sealing Technologies
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Colfax Fluid Handling delivers what no other pump supplier can
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Discover the many ways were redefining whats possible.
colfaxfluidhandling.com/redefining

ICU"EQORTGUUKQP"U[UVGOU
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
STEVEN LEUNG, XYLEM INC.
MUNISH NANDA, WATTS WATER TECHNOLOGIES, INC.
RYE BROOK, N.Y. (March 26, 2015) Xylem Inc. announced that
Steven Leung will join the company as senior vice president and
president, emerging markets. In this newly created position, Leung
will lead the companys commercial operations across the emerging
markets, including China, Greater Asia, India, the Middle East,
Africa and Latin America, as well as Australia and New Zealand.
He will report directly to Xylem President and CEO Patrick
Decker. Leung will also serve as a member of the companys senior
leadership team and will be based in Shanghai, China. Leung, 58,
joins Xylem from Pentair, where he most recently served as vice
president, global sales for Pentairs valves and controls business.
Leung has undergraduate degrees in management and electronic
engineering from Hong Kong Polytechnic, as well as an MBA from
Oklahoma City University. xyleminc.com
NORTH ANDOVER, Mass. (March 18, 2015) Watts Water

Technologies, Inc., announced that Munish Nanda joined the
company as president, Americas. Nanda comes to Watts Water from
ITT Corporation where he most recently served as president of control
technologies and previously as vice president of integrated supply
chain for ITTs Fluid and Motion Control Group. Prior to joining ITT,
Nanda held several operating leadership and general management
positions with Thermo Fisher Scientific Corporation and Honeywell,
Inc. Nanda is replacing Suellen Torregrosa. wattswater.com
TONY MAJKA, VALVTECHNOLOGIES, INC.

HOUSTON (March 23, 2015) ValvTechnologies,
Inc., named Tony Majka director of
engineering. Based in Houston, Majka will
have global management responsibility for
all ValvTechnologies engineering groups and
activities worldwide. He will lead research
and development, manufacturing, product
Tony Majka
development and design, and production and
application engineering. He will also spearhead engineering process
continuous improvement and product standardization programs.
With more than 15 years in product engineering and a solid machine
tool background, Majka brings strong technical and leadership skills
and experience to the company. Prior to joining ValvTechnologies,
Majka served as manager of valve product engineering and research
and development for Flowserve Corporation. Majka has a bachelors
degree in mechanical engineering and is studying to complete his
MBA from Tennessee Technological University. valv.com
AMY LAKIN, BALDOR ELECTRIC COMPANY
ANDREAS SOBOTTA, HAMMOND

MANUFACTURING COMPANY LIMITED
GUELPH, Ontario (March 16, 2015) Hammond
Manufacturing Company Limited announced the
addition of Andreas Sobotta as vice president
of North American sales and marketing.
Sobottas experience and talent will be valuable
as Hammond focuses on significant long-term
Andreas
growth in Canada and particularly the U.S.
Sobotta
Most recently, Sobotta held the role of national
sales manager with Davis Controls. He has also held Canadianbased roles as vice president of marketing with Festo, business unit
manager with Siemens and co-general manager/director of sales and
marketing at Phoenix Contact. hammondmfg.com
DALE MORK, BOERGER, LLC

MINNEAPOLIS (March 3, 2015) Boerger, LLC
announced the recent hire of Dale Mork as the
Southwest regional manager. Mork comes to
Boerger with more than 14 years of experience
in the industry. Within his role, Mork will focus
on controlled sustainable growth in both new
and existing channels. Mork brings diverse
Dale Mork
experience to Boerger, as his background
includes both end user and original equipment manufacturer
employers. He has a background in equipment distribution across
numerous markets. He brings a wealth of knowledge related to fluid
conditioning and pumping applications. boerger.com
FORT SMITH, Ark. (March 20, 2015) The

Manufacturing Institute announced it will award
Amy Lakin, executive vice president of supply
chain for Baldor Electric Company, with the
Women in Manufacturing Science, Technology,
TIMOTHY H. POWERS, ITT CORPORATION
Engineering and Production (STEP) Ahead Award.
WHITE PLAINS, N.Y. (Feb. 26, 2015) ITT Corporation announced
The STEP Ahead Award honors women who have
that it has elected Timothy H. Powers to its board of directors.
Amy Lakin
demonstrated excellence and leadership in their
Powers, 66, is the former chairman, president and CEO of Hubbell Inc.
careers and represent all levels of the manufacturing industry.
Powers formerly served as senior vice president and chief financial
During Lakins career, she has worked for companies such
as Rockwell Automation, Ingersoll Rand and
Xerox. She has held a number of positions,
including industrial engineering manager,
operations general manager and supply chain
Becht Engineering Co. acquired
Materialise NV acquired CENAT
manager. Amy has a bachelors degree in
The CECON Group
March 12, 2015
mechanical engineering and a masters degree
Feb. 26, 2015
in information systems. baldor.com
MERGERS & ACQUISITIONS
Quality You Can Believe In!
WE THINK
DIFFERENTLYabout water.
Timothy H.
Powers
RONALD BREWER,
J.L. WINGERT COMPANY
GARDEN GROVE, Calif. (Feb.
25, 2015) The J.L. Wingert
Company welcomes Ronald
Brewer as the firms national
sales manager. In this role, he
will oversee the companys
Ronald Brewer
sales and marketing
team seeking new markets for the companys
manufactured and distributed products. Brewer
previously served as national sales manager for
SPX Corporation/Pearpoint, western regional
manager for ITT Residential & Commercial Water
(currently Xylem) and director of international
sales and vice president of sales at the Wilden
Pump & Engineering Company. jlwingert.com
CHUCK MARTIN, M & C

PUMP AMERICAS, LLC
HOUSTON (Feb. 24, 2015)
Chuck Martin joined the team
at M & C Pump Americas, LLC,
as executive vice president
and principal minority owner.
Martin will head up the U.S.
Chuck Martin
business unit of this global
pump manufacturer and ensure the growth and
expansion into U.S. and Northern hemisphere.
Based in Houston, Texas, M & C Pump Americas
will be a stocking location and sales hub that
provides aftermarket pumps and parts for
several popular brands of centrifugal and positive
displacement pumps. M & C Pumps is currently
in the process of expanding and appointing
distributors in the U.S. and Canada.
mcpumpamericas.com
To have a news item considered, please

send the information to Amelia Messamore,
amessamore@cahabamedia.com.
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pu mpsa ndsyst ems.c om | Ma y 2015
officer for Hubbell; executive

vice president, finance and
business development,
Americas Region, at ABB
Inc.; and vice president and
corporate controller at BBC
Brown Boveri Inc. Powers is
also a member of the board
of directors of MeadWestvaco
Corp. itt.com
10
NEWS
AROUND THE INDUSTRY

California Governor Announces
Mandatory Water Reductions
SACRAMENTO, Calif. (April 1, 2015) In
response to the ongoing drought and
record low snow in California, Governor
Jerry Brown announced a statewide
directive including mandatory
water reductions, investment in new
technologies, implementation of
conservation pricing in water rates,
increased reporting of water use data
in the agricultural sector, and more.
California is in its fourth consecutive
year of drought, with 2012 to 2014 being
the driest three-year period in the past
1,200 years.
Highlights of the governors plan
include:
Water Resources Control Board to
reduce water usage by 25 percent in
cities and towns across California
Local water agencies to adjust
rate structures to implement
conservation pricing
Action against water agencies
in depleted groundwater basins
that have not shared data on their
groundwater supplies with the state
Making permanent monthly
reporting of water usage,
conservation and enforcement
actions by local water suppliers
Agricultural water users reporting
more water use information to
state regulators, increasing the
states ability to enforce against
illegal diversions and waste and
unreasonable use of water under the
order sector
The Natural Resources Defense
Council (NRDC) is an international
nonproit environmental organization
with more than 1.4 million members
and online activists. nrdc.org
SPX Named Manufacturer of

the Year at Pump Industry
Awards 2015
GLASGOW, Scotland (March 30,
2015) SPXs Glasgow facility, which
manufactures ClydeUnion Pumps,
was awarded Manufacturer of the Year
at the 2015 Annual Pump Industry
Awards (PIA). In addition, one of
its bright young engineers, Emma
Lambert, has been recognized as the
Engineer of the Year.
This years PIA drew a record number

of submissions. After being judged
by a panel last December to review
the entries, inalists were selected for
the awards evening. A public voting
throughout January and February
determined the winners, who were
revealed at the awards ceremony,
March 19. spx.com
Wrtsil Inaugurates
Manufacturing Plant in Brazil
HELSINKI (March 25, 2015) Wrtsils
irst unit at Porto do Au in So Joo da
Barra (RJ), Brazil, is being inaugurated.
This will be the irst assembly plant and
production unit for generator sets and
azimuth thrusters in Brazil for Wrtsil.
Covering 4,000 square meters of loor
space, the unit will be able to receive
up to 200 tons of equipment. This
is Wrtsils irst ever multi-product
factory that has been built from scratch.
The new unit represents an investment
of 20 million euros of equity capital from
Wrtsil Brazil.
In its initial phase, the activities of
the multi-product factory will focus
on midsize generators and azimuth
thrusters, with the possibility of
expanding the product portfolio
according to market needs. The unit
has already received six engines from
Finland to set up motor generators,
six propellers from Wrtsil in Spain
and hundreds of parts fabricated and
machined in Brazil for the production
of the irst thrusters produced by the
company in the country. The factory
will have approximately 50 employees.
wartsila.com
DOE Announces Two Notices of

Proposed Rulemaking
PARSIPPANY, N.J. (March 20, 2015) - The
Hydraulic Institute (HI) announced
the release of two Notices of Proposed
Rulemaking (NOPR) by the U.S.
Department of Energy (DOE), copies of
which are now available through the HI
website. New details and background
on HIs role in representing HI members
and the pump industry on evolving
regulations are available at Pumps.org/
DOERulemaking.
The long-anticipated NOPR for Energy
Conservation Standards for Pumps was
issued by the DOE on March 17. This
257-page document is now available

for public review and comment. Also,
the NOPR for the Test Procedures for
Commercial and Industrial Pumps was
issued by the DOE on March 13. This
270-page document is also available
for public review and comment. HI
responded on behalf of its members,
both in writing and at the April 29
Public Hearing in Washington, D.C. The
NOPR was published in the Federal
Register on April 2, beginning the 60and 75-day comment periods for the
two proposed rules. pumps.org
Engineered Software, Inc.,

Announces Launch of Website
LACEY, Wash. (March 18, 2015)
Engineered Software, Inc., (ESI)
announced the launch of an all-new
website, eng-software.com, which
combines all three Engineered Software
product families in one location. The
website incorporates several new
features including pages dedicated
to each market segment Engineered
Software supports, PUMP-FLO products
and services locator, case studies and
customer success stories.
eng-software.com
DNV GL Updates Two

Recommended Practices for
the Pipeline Sector
NACE, Texas (March 17, 2015) To relect
the changing needs of the oil and gas
industry, DNV GL has worked together
with its industry partners to update
two recommended practices (RP). The
irst is for corroded pipelines (DNV-RP
F101) and the second is for integrity
management of submarine pipeline
systems (DNV-RP-F116).
The updates have been developed
through the completion of joint
industry projects (JIPs). The revisions
aim to further support the decisionmaking processes related to
maintaining the integrity of pipeline
systems in the following areas:
extension of in-service operation
costly repairs and replacements
long-term planning of activities
based on balanced evaluations of
both technical and non-technical
issues
continuous improvement of integrity
management systems.
Keeping Industry
Up and Rolling
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c"dgctkpi"hcknwtg0"DcnfqtFqfig"dgctkpiu"tgrtgugpv"
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ycujfqyp"gpxktqpogpvu."cpf"gxgt{vjkpi"kp"dgvyggp."
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11
12
NEWS
Updates have also been made to

achieve better compliance with
the newest edition of the offshore
standard DNV-OS-F101 rev. 2013-10
with regard to pressure definitions and
terminology, characteristic material
properties, partial safety factors and
fractile values, and supplementary
material requirements.
Revisions to DNV-RP F101 aim to
improve corrosion defect assessments
through probabilistic evaluation,
corrosion development evaluations
and pressure resistance calculations
accounting for system effects.
dnvgl.com
HI & Ambeone DMCC-Dubai

Sign Training Partnership
Agreement
PARSIPPANY, N.J. (March 16, 2015)
The Hydraulic Institute (HI) and Pump
Systems Matter (PSM), HIs educational
affiliate, recently signed a joint training
partnership agreement with Ambeone
DMCC/Marketways Arabia, in Dubai,
UAE. The training partnership will bring
the first Pump Systems Optimization

Course (PSO) course in the Middle East.
The HI/PSM pump systems education
program will target the oil and refinery
sector as well as building services and
the hospitality industry. Participants
will learn to identify energy savings
opportunities with pumping systems
and reduce the annual costs related to
water and energy consumption through
optimal management of pumping
systems. pumps.org
GE & Kemira Create

Global Alliance for the
Pulp & Paper Industry
TREVOSE, Pa. (March 11, 2015) GE
and Kemira announced a formal
distribution agreement, which
combines GEs water technology with
Kemiras on-site services to serve the
global pulp and paper industry.
GEs newest and most advanced
boiler and utility area cooling
product technologies as well as
membrane cleaning chemistry and
the entire chemistry water portfolio
is now available to the pulp and paper

industry. Also included are the
remote monitoring and diagnostics
products and Novus polymers for
wastewater treatment.
Pulp and paper manufacturers
also will have access to GEs Service
Reliability Center for 24-hour
monitoring and support. ge.com
HI Announces 2015-2016 Board

of Directors & Officers
PARSIPPANY, N.J. (March 9, 2015) The
Hydraulic Institute (HI) announced
the 2015-2016 board of directors and
officers during its annual meeting
recently held in St. Petersburg,
Florida. The board is primarily
responsible for guiding the strategic
direction of HI and providing
organization oversight.
George Harris, president and CEO of
Hydro, Inc., has been elected to serve
as chairman of the board. John White,
Jr., CEO of TACO, Inc., has been elected
to serve as HI president and remains
HIs vice president, government and
regulatory affairs.

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mpsa
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14
NEWS
The other oficers are Michael

S. Cropper, director of product
development for Sulzer Pumps (U.S.)
Inc., who remains vice president of
technical affairs; Bob Hendricks,
president of industrial pump operations
for Flowserve, who remains HI vice
president of member services; and Jeff
Bredeson, senior VP of region Americas
for WILO USA, who is HI vice president
of knowledge and education. Robert K.
Asdal, HI executive director, continues
to serve as secretary/treasurer.
Additional board members, serving
terms of varying lengths, include:
Peter Barry, president, WEG Electric
Corp.
Aris Chicles, president, industrial
process, ITT Industrial Process
Jeremy Frank, president & CEO, KCF
Technologies, Inc.
Allen Hobratschk, president, National
Pump Company
Mark Kreinbihl, group president,
Gorman-Rupp, Mansield Division
Phil Pejovich, president, low
technologies, Pentair Water
Frank Rebori, president, Smith &

Loveless, Inc.
Jeff Wiemelt, president, Sundyne,
LLC
pumps.org
100 Resilient Cities & MWH

Global Partner to Improve
Water/Wastewater Systems
BROOMFIELD, Colo. (March 2, 2015)

100 Resilient Cities (100RC), pioneered
by the Rockefeller Foundation,
WateReuse Merges Leadership
announced a new partnership with
ALEXANDRIA, Va. (March 9, 2015) The
MWH Global, which will provide
WateReuse Association and Research
advisory and technical support services
Foundation announced a plan to merge
to improve water and wastewater
the leadership of their organizations
systems and address other waterto more aggressively address the
related risks in 100RC member cities.
challenges that local communities face
MWH is joining 100RCs Platform
in meeting growing demands for water
Partners, a group of organizations from
supplies in the context of drought,
the public, private and nonproit sectors
climate change, aging infrastructure,
that provide critical tools to help cities
environmental degradation and an
around the world become more resilient
increasingly complex web of federal,
to the shocks and stresses that are a
state and local regulations.
growing part of the 21st century.
At their February 2015 meeting, the
With experience in the assessment,
leadership of the two organizations
planning and execution of lood
adopted a board merger plan that will
prevention strategies, the partnership
serve as the catalyst for a stronger
with MWH Global will be dedicated to
alliance. The plan calls for a core group
helping cities reduce their vulnerability
of directors to simultaneously serve
to water-related risks, strengthen
on each board, facilitating maximum
institutional capacity and promote
strategic collaboration. watereuse.org
integrated planning. mwhglobal.com
To have a news item considered, please send the information to Amelia Messamore, amessamore@cahabamedia.com.
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16
NEWS
EVENTS
Offshore Technology Conference (OTC)
May 4-7, 2015
NRG Park
Houston, Texas
972-952-9494 / 2015.otcnet.org
American Wind Energy Association (AWEA)
Windpower Conference & Exhibition
May 18-21, 2015
Orange County Convention Center
Orlando, Fla.
508-743-8502 / windpowerexpo.org
ALL-TEST Pro, LLC Electrical Reliability
Training Workshop
May 1822, 2015
Crowne Plaza Memphis
Memphis, Tenn.
860-399-4222 / alltestpro.com
Pump School Training: Centrifugal & Positive
Displacement Pumps
June 2-3, 2015
One Midtown Plaza
Atlanta, Ga.
770-310-0866
pumpingmachinery.com/pump_school/pump_school.htm
American Water Works Association Annual
Conference & Exposition (AWWA-ACE)
June 7-10, 2015
Anaheim Convention Center
Anaheim, Calif.
800-926-7337 / awwa.org
EASAs 2015 Convention & Exhibition

June 14-16, 2015
Grand Hyatt San Antonio & Henry B. Gonzalez
Convention Center
San Antonio, Texas
easa.com/convention
ACHEMA
June 1519, 2015
Messe Frankfurt
Frankfurt am Main, Germany
achema.de/en.html
National Fire Protection Association (NFPA)
Conference & Expo
June 2225, 2015
McCormick Place
Chicago, Ill.
800-344-3555 / nfpa.org/training/conference
17
on card
or visit
puCircle
mpsa106
ndsyst
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om psfreeinfo.com.
| Ma y 2015
18
Troubleshooting & repair challenges
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Find the True Best Efficiency Point
received many comments

from Pumps & Systems readers
on How to Calculate Pump
Specific Speed (Pumps & Systems,
January 2015) and How Efficient
Is Your Pump? (Pumps & Systems,
February 2015).
The Pump Video Academy videos
(PVA-6 and 7) that accompanied
these columns showed how the
test was conducted and posed a
challenge to readers to explain why
the actual tested efficiency was so
dramatically different from the
theoretically expected as predicted
by the Hydraulic Institute (HI)
charts or efficiency estimator
computer program.
Some readers suggested that
since only the head-capacity curve
was tested and constructed, it
was impossible to know where
the best efficiency point (BEP) is
without also measuring power
and calculating efficiency. In other
words, the selected conditions
on the curve (3.2 gallons per
minute [gpm], 8.1 feet) might
have been far from the BEP. So
the calculations might not have
presented the efficiency of
the pump.
Letter from a Reader

I read your interesting article, How
Efficient Is Your Pump? which
appeared in the February 2015 issue
of Pumps & Systems magazine.
Toward the end of the article, it
was suggested that the results of a
test, shown in video PVA-7, were an
example of an exception to the rule for
achievable efficiency obtained from a
chart or output from your program. A

small end-suction centrifugal pump
was tested. There was almost a 50
percentage point difference between
the efficiency calculator prediction
and the tested efficiency.
HI charts of achievable efficiency,
as a function of specific speed and
flow rate, are based on a pump
performance at its BEP. As mentioned
in the article, other factors such
as surface finish may also affect
efficiency values obtained from a chart
or program. However, these factors
might only improve or reduce expected
efficiency values by a few percentage
points at most.
The pump test shown in the PVA-7
video was conducted at a single
operating point (3.2 gpm, 8.1 feet).
This may be close to or far from the
BEP. So, the actual efficiency at the
pumps BEP may be quite different
from the tested 4.5 percent value. An
inspection of this pumps performance
curve, as shown in the PVA-6

video that accompanied Pumping
Prescriptions in the January 2015
issue of Pumps & Systems, reveals
that this single test point is at the
right end of the pumps performance
curve. The tested
point in the PVA-7
video is probably not
at the BEP.
Lee Ruiz
Oceanside, California
Neliks Response
To answer Mr. Ruiz question,
we extended the original test to
add power readings to the mix.
By calculating efficiency at each
tested point, we found the peak
and compared it to the value
predicted by HI (or by the efficiency
estimator computer program), as
Mr. Ruiz and others suggested.
Figure 1. The pump data acquisition system established pump performance

curves. Dots are actual test measurements. Solid lines are the expected
manufacturer curves. (Graphics courtesy of the author)
19
Factors such as surface finish may also affect efficiency

values obtained from a chart or program. However, these factors
might only improve or reduce expected efficiency values by a
few percentage points at most.
A new video (PVA-11) presents

this expanded test where a pump
data acquisition system was
used to measure flow, suction
and discharge pressures, and
power. Pump head and efficiency
were then calculated from these
measurements.
Reliability data such as
vibrations and temperatures were
also measured (see Figure 1). The
pump data acquisition system
consists of the input device with

instrumentation, a live data
transmission gateway via
Internet or cell service, and
software to process and display
the data remotely.
As a discharge valve is being
throttled, live data is taken at
each flow point, and the actual
performance curves showing
head, power and efficiency
are constructed.
The density of several data

readings at a given flow shows
system fluctuations caused by the
small size of the pump used for
this example test.
The testing shows that the
BEP is at about 2.5 gpm, where
head is 11.6 feet, power is 0.135
horsepower and efficiency is 5
percent. The article originally
used 3.2 gpm, before the BEP
was established. Next, using an

20
efficiency estimator program, we

determined that the expected
efficiency would be 46.6 percent
(see Table 1). This is a nearly 40
percent discrepancy.
Note that the pump data
acquisition system recorded actual
operation over time and compared
it to the original equipment
manufacturer (OEM) expected
curve. It shows that the actual
power significantly exceeded the
expected, the actual head was
lower than expected and total
efficiency significantly degraded
compared with the OEM curve. We
also see that during the course of
time, the pump operated at four
flows: near BEP (around 2.5 gpm),
between 1.8 and 2.2 gpm, around
0.8 gpm and near shutoff. Based on
density of test points, it appears
that the pump operated for roughly

the same amount of time at each
of these flow rates.
This means that operating
off-BEP is typical. Such operation

would have two consequences:
wasted energy (actual cost is
noted by the program as shown in
Table 1. Results from the efficiency estimator program
Total pump head, feet

Specific gravity, SG
Number of stages
Speed, RPM
Head per stage,feet
Impeller diameter (inches)
Specific speed (U.S.), NS
Specific Speed (metric), nS
Specific Speed (universal), OS
11.6
1.00
1
3,000
12
1.98
755
14.6
0.28
Efficiency, %
46.6%
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22
Figure 1) and reduced reliability

(high radial loads off-BEP cause
shaft deflection, leaky seals and
failing bearings).
For a small pump used for

demonstration, this may not
be a significant issue. But for
any mid-size or large pump, the
YG"DWKNF"OQTG"VJCP"LWUV"OQVQTU0
consequences can be problematic.

We determined that a significant
discrepancy between the
theoretically expected and actually
tested performance is not caused
by evaluation at the point off of the
BEP. Some other explanation must
exist for the difference. Granted,
the pump used for this test is small
(a 2-inch impeller) and has low
power, but the measured efficiency
is still unreasonably low, even for
such a small pump.
As I asked in the February 2015
issue of Pumps & Systems, why?
Refer to the hints from that article,
How Efficient Is Your Pump? The
answer will be presented at the
next Pump School and in the June
2015 issue of Pumps & Systems.
References
1. Karassik, I.J., Messina J.P., Copper, P.,
and Heald, C.H., Estimated Performance
Characteristics section, p. 2.68, Pump
Handbook, 14th Edition, 2008
2. PREMS-2A (Pumps Reliability and
Efficiency Monitoring System), Operating
Manual, notes, rev. 2A, December, 2014,
www.doctorpump.com
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vtcfgoctmu"hqnnqygf"d{"vjg""u{odqn"ctg"tgikuvgtgf"ykvj"vjg"W0U0"Rcvgpv"cpf"Vtcfgoctm"Qhhkeg0

To read more Pumping

Prescriptions articles, visit
pumpsandsystems.com/
pumpingprescriptions.
Dr. Nelik (aka Dr. Pump)

is president of Pumping
Machinery, LLC, an Atlantabased firm specializing in pump
consulting, training, equipment
troubleshooting and pump
repairs. Dr. Nelik has 30 years
of experience in pumps and
pumping equipment. He may
be reached at pump-magazine.
com. For more information, visit
pumpingmachinery.com/pump_
school/pump_school.htm.
23
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A better understanding of complete system operation
By Ray Hardee
Engineered Software, Inc.
Understand How Valves & Fittings

Affect Head Loss
First of Two Parts
his column discusses valves

and fittings and evaluates
how these devices affect the
operation of piping systems. Valves
and fittings connect pipelines,
direct flow, and isolate equipment
and parts of a piping system.
Hydraulic energy is used to move
fluid through the piping system.
Hydraulic energy can be lost in a
valve or fitting in four ways:
friction between the moving
fluid and the internal surface
change in direction of flow
obstruction in the flow path
change in fluid velocity caused
by different shape or crosssectional area of the flow path
Valves and fittings have a
compounded effect on plant
system performance that is
often overlooked when making
calculations and optimizing
piping systems.
Calculating Head Loss

The three common methods for
calculating the head loss in valves
and fittings are:
the K method
the L/D coefficient (pronounced
L over D)
the CV (pronounced C sub V)
Each method can accurately
determine the head loss associated
with valves and fittings under
most industrial applications. The
calculations in this column are
presented as a general way

of calculating the head loss for
valve types, not for valves from
a specific manufacturer.
Last months column (Pumps &
Systems, April 2015) demonstrated
the method for calculating the
head loss in pipes based on pipe
and fluid properties. The same
method can be used to determine
the losses associated with valves
and fittings. Specifically, the head
loss across a valve or fitting can
be calculated as a function of
the velocity of the fluid flowing
through the valve or fitting.
K Value
As the Bernoulli Equation shows,
the fluids velocity in a pipe
contributes to the total energy
of the fluid. The velocity head is
based on the relationship shown in
Equation 1.
2
Velocity head = v
2g
Equation 1
Where
v = Fluid velocity (feet per second)
g = Local gradational constant
(feet per second)
When fluid flows through valves
and fittings, a pressure drop and
resulting head loss occur. The
pressure drop across the device
also varies with the square of the
velocity through it. As a result,
the head loss may be expressed
in terms of velocity head using
the dimensionless resistance
coefficient K as listed in Equation 2.
2
hL = K v
2g
Equation 2
The resistance coefficient K can

be thought of as the number of
velocity head loss caused by a valve
or fitting. The value of K is constant
when the flow is in the zone of
complete turbulence.
The value of K can be calculated
from the geometry of the valve or
Figure 1. Contracting reducer in which the angle of the reducer is greater than 40
degrees but less than or equal to 180 degrees (Graphics courtesy of the author)
25
fitting based on empirical results obtained from

a variety of test data. For example, the K value
for a reducer shown in Figure 1 with a 45-degree
to 180-degree approach can be calculated using
Equation 3.2
0.5 sin (1 - )
2
K2 =
4
Figure 2. The K value is the greatest when making a transition

from a pipeline into a tank.
Equation 3
Where
K2 = K value in relation to the major diameter
(unitless)
= Angle of approach of the reducer in (degrees)
= d1 / d2
d1 = Reducer minor diameter (inches)
d2 = Reducer major diameter (inches)
In Figure 1, Equation 3 is an example of a
method for calculating the K value for fittings
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26
typically found in fluid piping

systems. Equation 3 shows that
the greater the change in pipe
diameter, the greater the K value
for the reducer. It also shows that
the greater the angle of approach,
the greater the value of K.
Figure 1 shows that as the
angle () increases, the fluid must
accelerate from a lower velocity
(v2) to a higher velocity (v1) in a
shorter distance. A greater change
in velocity per distance traveled
results in greater head loss.
Looking at the beta () ratio, the
greater the difference, the faster
the fluid must accelerate within
the reducer, resulting in a greater
head loss.
Parts of the process, such as the
transition from a tank into a pipe
or from a pipe into a tank, are also
described by a K value. Figure 2
shows several types of transitions
and their associated K values (see
page 25). A change in momentum
causes the loss. For example, the
velocity of a fluid is close to 0 feet
per second. But in a pipeline the
fluid must be accelerated, resulting
in a change of momentum. That
change is lost to friction.
L/D Coefficient
The L/D coefficient is often used to
determine the head loss in a valve
or fitting. The head loss formula
using velocity heads in Equation 2
is similar to the head loss formula
for pipelines shown in the April
2015 column (Equation 4).
2
hL = f L v
D 2g
Equation 4
Where
f = Darcy friction factor (unitless)
L = Pipe length (feet)
D = Pipe diameter (feet)
v = Fluid velocity (feet per second)
g = Gravitational acceleration (feet
per second)
Comparing Equation 3 and

Equation 4 allows the creation of
Equation 5.
K=f L
D
Figure 3. A globe valve
Equation 5
With this equation, the value of

K can be determined by comparing
the head loss for a valve or fitting
to an equivalent length of pipe
producing the same head loss as
the valve or fitting.
Studies conducted by the
Crane Company provided close
correlation when the turbulent
friction factor (f T) is used in
Equation 5 instead of the pipe
friction factor that occurs in
the pipeline.
Figure 3 illustrates how the L/D
coefficient is used in a globe valve.
The L/D coefficient for a globe valve
is 340. That value is multiplied
by the Darcy friction factor for
turbulent flow in the pipe diameter
connected to the valve. For
example, for a fully seated valve in
a 4-inch pipeline, the value of f T is
0.016. For a 6-inch valve, the f T of
0.015 is used.
So the K value for a 4-inch globe
valve is
K = f T L = 0.016 340 = 5.44
D
Part 2 of this article will cover
the C V coefficient, calculating head
loss using K value and the cost of
pipeline operations.
References
1. Flow of fluids through valves, fittings, and
pipe. (1957). Chicago: Crane
2. Flow of Fluids through Valves, Fittings
and Pipe Technical Paper 410. 2013
Crane Co. Stamford CT 06902.
To read more Pump System

Improvement articles, visit
pumpsystemimprovement.
Ray Hardee is a principal founder

of Engineered Software, creators of
PIPE-FLO and PUMP-FLO software.
At Engineered Software, he helped
develop two training courses
and teaches these courses in the
U.S. and internationally. He is a
member of the ASME ES-2 Energy
Assessment for Pumping Systems
standards committee and the ISO
Technical Committee 115/Working
Group 07 Pumping System
Energy Assessment. Hardee was
a contributing member of the HI/
Europump Pump Life Cycle Cost
and HI/PSM Optimizing Piping
System publications.
He may be reached at
ray.hardee@eng-software.com.
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28
SPECIAL SECTION
REMOTE MONITORING & INTELLIGENT PUMPING
Embedded Human
Machine Interfaces
Expand the Reach of
Remote Monitoring
This pared-down technology can make smaller and
simpler applications more practical and economical.
BY GREG PHILBROOK
AUTOMATIONDIRECT.COM
any pumping stations and other remote

locations need a local operator interface
and remote monitoring but cannot aord
a personal computer (PC)-based human
machine interface (HMI). To address this issue, new
embedded HMI platforms are becoming available (see
Image 1). These options oer much of the functionality
of a PC-based HMI but at a lower cost and with a smaller
footprint. They are prepackaged for industrial use in the
harsh environments often found at pumping stations.
Thanks to lower costs and simpler implementation
associated with embedded HMIs and the latest wireless
technologies, remote monitoring is no longer the
exception. It has become a normal routine for daily
operations in many industrial applications.
Remote monitoring reduces the costs associated with
maintaining or monitoring assets that would otherwise
require regular site visits. But benets go beyond reducing
travel time and expenses.
past, maintaining the same coverage

would require several employees. Remote
monitoring provides the opportunity for
users who are far from the site to solve
some problems remotely and react proactively to others.
Emails and text messages provide real-time
information, giving operators or maintenance personnel
the ability to take action before a problem results in
downtime or reduced productivity. Personnel do not need
to use a browser to nd remote site status because data
are pushed to them quickly. Once an alert is received, any
Web browser can be used to access the HMI and obtain
more information.
Users can log and store data les of events in the HMI,
then access them remotely or send to a group via email
using le transfer protocol (FTP). This allows managers
to gain insight into trends occurring over time and to be
proactive in addressing issues aecting productivity, cost
or downtime.
Remote Monitoring Benefits

Remote access allows a single user to monitor and
maintain several remote sites in dierent areas, even
if they are in separate regions around the world. In the
Remote Monitoring Options

Any control and monitoring software that runs on a
platform capable of hosting an embedded operating
system (OS) can be described as embedded HMI.
29
Basin installation in Lake Ariel, Pennsylvania

(Images courtesy of CRANE Pumps & Systems)
Image 1. This touch panel embedded HMI can provide

both local operator interface and remote monitoring
for pump stations and related applications. (Images
courtesy of AutomationDirect.com)
ADVANTAGES OF EMBEDDED HMI

OVER PC-BASED HMI
1. Compact with minimum space
requirements
Compared with a PC-based OS, an embedded OS requires

much less processing power and memory because it is
dedicated to a single function, in this case hosting the
HMI software. This results in a lower-cost solution than
a PC-based HMI and provides other benets, such as OS
and application longevity.
A PC and its OS have a shorter life cycle than an
embedded HMI. Replacing the obsolete PC can be
complex and time-consuming, as can porting the HMI
application to the new platform. A simpler and more costeective solution is to use an embedded HMI platform to
provide a local operator interface and remote monitoring.
These prepackaged solutions are well-suited for the harsh
environments often found at pumping stations and oer
a myriad of remote connectivity options.
Connection to Mobile Devices

Many new embedded HMIs can send notications
through emails or text messages when important events,
irregular activities or alarms occur. These embedded
HMIs can also be accessed from any Web browser.
2. More affordable
3. Easier to maintain
4. Simpler installation
5. Simpler configuration software
6. Robust industrial design for use in
harsh environments
7. Longer software life cycle
Most engineers and technicians use a mobile device

such as a smartphone or a tablet every day, providing
them with a wireless link to embedded HMIs at remote
sites. These mobile devices can connect to the Internet
with either Wi-Fi or cellular connection and are becoming
more inexpensive and common.
Embedded HMIs are less expensive and easier to
integrate than PC-based HMIs. Their physical design
and mounting conguration make installation simple,
providing a rugged solution in a harsh environment.
30
SPECIAL SECTION
These units enable quick integration with

automation components using standard interfaces
and protocols such as Ethernet and Modbus.
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If an embedded HMI fails, it can

be quickly replaced with a new
unit loaded with the same
application software.
While implementing an
embedded HMI platform is simpler
than using a PC-based HMI,
certain steps must be followed
for a successful installation. As
with a PC-based HMI, PC-based
software is used to congure the
desired embedded HMI screens,
objects and buttons. The software
conguration is then downloaded
to the target embedded HMI. These
units enable quick integration with
automation components using
standard interfaces and protocols
such as Ethernet and Modbus.
When the application requires
remote monitoring, as with a
pump station, additional steps
must be taken for conguration
and setup. With many embedded
HMIs, setting up the unit for
remote browser-based access and
31
CHECKLIST FOR IMPLEMENTING REMOTE MONITORING USING EMBEDDED HMI
Connect to network accessible from the Internet
Configure access levels for each user
Configure IP address
Operate and monitor a local embedded HMI from

anywhere on the Internet using any web browser
Setup remote access log-on security including

passwords
sending emails or text messages is

relatively simple.
The remote site must provide the
capability to connect to a network
accessible from the Internet.
The user simply connects the
embedded HMI to the network and
congures the Internet Protocol
(IP) address. Then security must
be set up by conguring built-in
embedded HMI tools. The user
then congures remote access
usernames and passwords along
with user access levels. Once
connected, users can remotely
operate and monitor the local
embedded HMI using any web
browser connected to the Internet.
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SPECIAL SECTION
Image 3. This pump station can use an embedded HMI for local and remote monitoring to save both
energy and labor.
More Is Better
Some complex installations
might require a PC-based
HMI (see Image 2, page 30).
For example, a pump station
with scores of pumps, storage
tanks, dynamic pipe routing
options, and extensive process
control and monitoring may
be too much for an embedded
HMI to handle. In these and
other complex installations,
the need for the best-in-class
connectivity and graphical
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34
SPECIAL SECTION
Remote monitoring allows for quick responses to

pump problems and equipment and process faults.
Monitoring Cuts Costs

Most pump stations are monitored
remotely and must operate
automatically without a local
operator. Local monitoring is often
required for troubleshooting and
making some kinds of changes. An
embedded HMI is the best t for
these types of applications.
Pumping systems in irrigation
applications, for example, can
benet from remote monitoring and
control using an embedded HMI. In
these applications, multiple pumps
control water supply based on
demand, with one or more pumps
used to regulate water pressure (see
Image 3, page 32). The demand for
water also changes based on time of
day and environmental conditions.
Remote monitoring allows for
quick responses to pump problems
and equipment and process faults.
Remote access also provides limited
control of the process, resulting
in an energy ecient system with
lower overall operating costs.
When the equipment is manned
locally, the embedded HMI provides
the required local monitoring
functions and allows for process
adjustments. In these and similar
applications, an embedded HMI
connected to mobile devices
through the Internet can provide
a low-cost and relatively simple
remote monitoring solution.
Greg Philbrook is a product

manager at AutomationDirect.com in
Cumming, Georgia. He is responsible
for product strategy, specifications
and development for HMI and
communications
products. He
may be reached
at gphilbrook@
automationdirect.com.
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36
SPECIAL SECTION
REMOTE MONITORING &

INTELLIGENT PUMPING
Controllers
Manage
Equipment
Uncertainty
Combined monitoring and control
software options help provide
exibility and improve uptime.
BY BRIAN PHILLIPPI
NATIONAL INSTRUMENTS
e live in uncertain times when the price of

oil can drop by 50 percent in a matter of
months. To combat this uncertainty, the
pump industry must focus on maximizing
eciency and throughput while maintaining health,
safety and environment (HSE) standards. Because
rotating equipment is so prevalent in the oil and gas
industry, this can be achieved, in part, by increasing the
uptime of the pumps and rotating equipment producing
and rening oil and gas.
Scheduled Maintenance
Most people are conditioned to follow a regularly
scheduled maintenance program as the best way to
keep equipment in pristine working order. Employing a
regularly scheduled maintenance program to save money
on expensive equipment repairs and improve machine
eciency should be easy. The reality, though, is that the
cost of these programs is sometimes higher than running
the machine to failure because, time and eort are wasted
xing something that is in perfect working order.
The costs of safety problems caused by catastrophic
failures is also signicant. Although the likelihood
of the failure is lessened by scheduled maintenance,

an unplanned or even catastrophic machine failure is
still possible if a part of the machine fails before its
manufacturers recommended repair time.
The Cost of Maintenance

To understand the costs associated with maintaining
rotating equipment, the Electric Power Research Institute
(EPRI) calculated the comparative maintenance costs
for dierent techniques per horsepower (HP) per year.
Researchers discovered that a scheduled maintenance
strategy is actually the most expensive to run at $24 per
HP. A reactive maintenance strategy (run to failure) is the
second most costly at $17 per HP, but this method has the
additional cost of potentially compromised personnel and
equipment safety.
Drawing a parallel to pumps used within stimulation
and hydraulic fracturing, a 1,500-HP motor would
cost approximately $36,000 per year while a reactive
maintenance strategy would cost $25,500 per year,
according the EPRI study. That amount does not seem like
much, but when multiplied by the number of stimulation
and fracturing units across the entire eet (in some
37
Image 1. Operators can use a
new, more proactive approach to
equipment maintenance.
(Courtesy of National Instruments)
According to Forbes Magazine, one out

of every three dollars spent on preventive
maintenance is wasted.
Safe Clean Drinking Water
IT MATTERS!
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cases, around 1,500), the cost skyrockets

to $54 million per year for a scheduled
maintenance plan and $38 million for a
reactive strategy.
The equipment must be maintained, but
a better strategy is needed.
Equipment maintenance has become
such an important topic that, according
to Forbes Magazine, one out of every three
dollars spent on preventive maintenance
is wasted. Examining the maintenance
costs and mismanagement of large
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understanding of the maintenance costs,
but it only begins to tell the story of the
true cost of equipment mismanagement.
Mismanagement Example
To identify the true cost of equipment
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38
SPECIAL SECTION
3 WAYS TO GET MORE YEARS FROM A PUMP

1. USE VIBRATION MONITORING.
Vibration monitoring allows end users to gain insight
into the health of their pumps. Through proper analysis,
vibration monitoring can serve as a core element to a
predictive maintenance strategy. In the EPRI study,
researchers found that this new option costs only $9 per
HP and nearly eliminates the risks of secondary damage
from catastrophic failures. A predictive maintenance
strategy should not replace safety systems but should
work alongside them. This strategy also extends pump
life by detecting small anomalies before they become
catastrophic failures.
2. GO BEYOND VIBRATION.
Vibration measurements act as the best indicator for
the health and life expectancy of a pump, but they
are not the only indicator. Monitoring measurements
such as temperature, strain, power quality, pressure
and deflection also gives insight into a pumps health.
or hydraulic fracturing pump can cost approximately

$350,000, the true loss is in production.
Because cash ow is directly tied to production in
the oil and gas industry, a negative economic impact
occurs when drilling stops at a wellsite. This is further
compounded if the failed equipment is a hydraulic
fracturing pump, which may halt the work of the
fracturing crews on site.
Reliability is critical, and companies often bring several
backup trucks that may or may not be needed because
they do not know if their pump will fail, even if it has just
been serviced. Rather than trying to extend pump life by
simply having backups in case machinery failes, pump
users must employ a better strategyincorporating
remote monitoring into their maintenance program.
A Condition Monitoring & Control Solution

One software-designed controller tightly integrates a
real-time processor with a user-programmable, eldprogrammable gate array (FPGA) and modular input/
output and is programmed with system design software.
End users can embed their algorithms into hardware
using software techniques without the diculty of
custom design. With this approach, users can build
control and monitoring systems that are unique to their
applications but exible enough to be deployed on a
broad scale.
When vibration monitoring and operating parameter

monitoring are combined, they can provide a much
clearer picture. Going beyond vibration is typically
the second phase of condition monitoring. If it is not
planned for, however, condition monitoring becomes
difficult and expensive to add later. A platform-based
approach that can adapt to changing requirements
is needed.
3. INTEGRATE WITH CONTROL.

The final step for end users to regain control of
their assets is to completely integrate the condition
monitoring solution with a control platform. By
choosing a flexible platform in step one, all the
elements measured in steps one and two can be used to
adjust the control algorithms in real-time, based on the
operating conditions, to improve efficiency and extend
the life of the pump.
By using a single hardware and software platform, one

companys engineers were able to control and monitor
every aspect of the well servicing and stimulation
equipment commonly found in their industry.
The company had a highly reliable control system
that could measure a multitude of sensors, perform
high-speed analysis and transfer that data back to the
main hub through the Society of Automative Engineers
(SAE) J1939 communication protocol. A platform-based
approach can help end users meet todays needs and
future requirements and deploy a network of predictive
maintenance systems designed to communicate with each
other in real time to keep their machines operating longer
and more eciently.
Brian Phillippi joined National Instruments in 2011 as

an applications engineer, providing technical support and
working on projects for the marketing department. In
2012, he moved to product marketing and was
nominated for the Product Marketing Rookie of
the Year Award. He holds a bachelors degree in
mechanical engineering from Brigham Young
University. Phillippi may be reached at
brian.phillippi@ni.com.
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California Assembly Majority Leader Christopher Holden (Invited)
Michelle Segrest, Editor, Pumps & Systems
Dr. David Rigby, President, Waste Water Management, Inc.
Stephanie Granger, Director, Western Water Solutions Group, NASA JPL
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40
SPECIAL SECTION
3 Things End Users Should

Consider When Operating
Intelligent Pump Systems
IoT provides exibility for plants and other facilities, but system
types and security must remain top priority.
BY ANDRES SUAZO
PHOENIX CONTACT
he Internet of Things (IoT) and Industry 4.0

have had a signicant impact on the commercial
world. People want everything connected so they
can make smart decisions. For example, sensors
around homes can communicate to thermostats to
determine and adjust temperature.
These themes have extended to the industrial world
and can provide similar eciency when implementing
intelligent pumping systems. IoT is slowly becoming the
norm within the industrial world and is changing the
needs of end users. These changes must be addressed and
adopted by original equipment manufacturers (OEMs)
and system integrators.
IoT provides higher system reliability and reduced
maintenance costs to service providers. This can
translate into a more complete oering for the end user.
Remote monitoring and intelligent devices can create a
measurable competitive advantage.
Communication between systems can greatly
improve the control and monitoring of applications
in many ways. As new technologies interact with
dierent media and networks, however, security must
always be a consideration. In a globally connected
world in which many systems rely on public methods
for communication, such as the Internet, protecting
networks from exterior and interior threats is critical.
This article discusses three important factors
regarding IoT connected systems that end users
should consider:
How the systems help pump end users

The advantages and disadvantages of several
communication technologies, wired and wireless
Security considerations to keep in mind when using
these methods
IoT Benefits
Many applications in the pumping industry can
implement IoT ideas. Long gone are the days when all the
control decisions were made directly at the main control
station. When quick decisions are necessary, the ability
to remotely control and communicate information
eciently can make the dierence in managing critical
situations, such as stormwater management. By having
sensors communicate the rapid increase of ow water
into drainage systems, an operator can quickly inform
valves and divert ow to underwater caves to avoid
overow of sewage water into rivers.
Remote maintenance on specialized machinery
can also be implemented via IoT arrangements to
reduce travel and maintenance costs. By remotely
communicating with these systems, an OEM can
improve end users repair contracts by remotely
connecting to machinery to obtain valuable data on
the status of these machines. System availability and
lower shutdown times are a direct eect of using remote
maintenance technologies. Alarms sent to a plant
operator using text messages when a pump fails can
make the dierence in determining and preventing
41
Figure 1. As the IoT moves into the industrial world, remote maintenance will help
reduce travel and maintenance costs. (Graphics courtesy of Phoenix Contact)
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Device,
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external
specialists
connect
External specialist
Customer
firewall
Outgoing VPN
connection
(initiated by the
operator, e.g., via key
switch)
Machine network
Specialist, at home or
anywhere in the world
tank overow. A plant operator

or manager can easily access that
pump and determine the best
course of action to address
the concern.
Communication Systems
Many options are available to
communicate with equipment
within a plant or other facility. This
section details several system types
and their advantages
and disadvantages.
Wired Ethernet Systems

In most of the U.S., having an
Internet connection has become
a commodity. Most homes and
oces enjoy the comfort of highspeed Internet connections. This
network option is slowly becoming
available on the plant oor. More
engineers are demanding that
their IT departments provide a
solution for remote maintenance
or for supervisory control and data
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42
SPECIAL SECTION
REMOTE MONITORING &

INTELLIGENT PUMPING
Figure 2. Security measures, such as encryption and the installation

of firewalls, ensure that data arrives safely in the proper destination.
Certificates provide keys and locks to add a layer of security to data.
acquisition (SCADA) monitoring. A wired Ethernet

connection is the physical connection to a port that
leads to the public Internet.
Some of the advantages of wired systems are:
This method of communication provides system
reliability. When using a physical wired connection,
end users depend on a network infrastructure that
has been in place for many years.
The lack of data restrictions is also a strong asset.
Physical wired connections dont restrict the
amount of data a particular application can use.
This makes wired Ethernet a popular technology
for camera systems or other high-data transfer
applications.
Some disadvantages are:

Bandwidth scalability can be a drawback of this
system. Obtaining a bigger pipeline for faster
data speeds may require building additional
infrastructure. This can be costly, and the Internet
provider may translate these charges to the facility
or end user, depending on the location.
Availability can be troublesome. Many pumping
stations in remote locations do not have a physical
infrastructure built for communicating with the
site. Leased lines have been a popular solution,
but they are costly to maintain and most service
providers are planning to discontinue them.
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Proprietary Radio Systems

Proprietary wireless systems are another strong
method for communicating with multiple sites. A
wireless local area network (WLAN) is a wireless
Ethernet connection between dierent devices in
close proximity. The encryption of over-the-air
transmissions is typically supported by industrial
WLAN radios.
43
Some advantages are:

WLAN can provide the scalability of a wired
Ethernet system by expanding the physical
network connection to a WLAN. Advances in
WLAN technologies allow for high data rates by
using 802.11n for high-speed data applications.
Wireless can also reduce the cost of installation
and the raw materials needed to provide
communication between two points.
Disadvantages of these networks are:

Network interference can become a problem
when transmitting data. Many devices produce
radio frequency signals that may be in the same
frequency range as a WLAN radio. This can lead
to a network slowdown. Adjusting the radio
to dierent frequencies and testing for best
throughput can help.
WLAN radios can only communicate across a
limited distance. When building a network, a site
survey must be performed to determine the signal
strength and availability. This will, in turn, provide
a facility owner/operator with a more concrete idea
of what the data rates will be.
Wireless Cellular Systems

As with wired systems, cellular systems are becoming
a major source of Internet connection. Especially in
the U.S., the build-up of infrastructure to support
cellular systems has been rapid. A physical Ethernet
connection is not always possible to reach the
Internet. Cellular systems are also becoming the
preferred method of a solution for service providers.
Leased lines have been a popular way to gain access
to remote sites. Network providers with supported
leased lines are discontinuing the service or making
it extremely expensive to encourage customers to
migrate to cellular.
The advantages of these systems include:
Cellular networks provide the highest connection
availability. When using cellular systems, telecom
towers provide the connection to the station. By
using a cellular radio, end users can essentially
take advantage of an already built wireless
network so that the data can travel long distances.
Bandwidth is a great advantage of this technology.
Depending on the cost of the radio, it can be
upgraded to Long-Term Evolution (LTE), which
can provide high data rates comparable to a home
Internet connection. These come at a premium.
44
SPECIAL SECTION
However, the availability of this technology gives

end users a choice.
Some disadvantages are:
Data restrictions now become a higher priority. In
wired and proprietary wireless technologies, no price
penalty for data overuse exists. In cellular networks,
data plans must be purchased with the amount of
data needed, with higher charges for higher data
amounts. This is an important consideration because
overage charges can be costly.
Many operators still question the reliability of
cellular technology for critical operations. The
cellular networks are not as stable as a physical,
wired connection. Because of this, a wireless,
cellular system will not be preferred for control of
critical operations.
industries, such as power generation, have already

implemented standards and regulations to protect
networks from threats. Security has been and remains
a big topic that will surely make its way into future
standards implemented across the industrial world.
When working with Ethernet systems, security
must always be considered, especially with any
communication that leaves a facilitys LAN.
Using virtual private network (VPN) technology to
encrypt information must be a priority when deploying
communication systems. An industrial security
device with routing, VPN and rewall capabilities can
provide many features to protect a network. A few
recommendations for increasing an Ethernet systems
security are listed below:
Security
The Internet can be a great tool to network multiple
pumps or machinery for an application. However, its
use allows trac to leave the comfort of a personal or
facilitys network and enter the public domain. Many
Firewalls keep unwanted trac from entering the

network. With rewalls, end users can determine
which Internet Protocol (IP) addresses, ports
and media access control (MAC) addresses can
communicate with a facilitys internal networks.
This restricts the amount and type of trac that can
enter the network. Firewalls also segregate internal

45
networks and keep an industrial network separate

from or restricted from an oce network.
Routing is a powerful tool that can help maintain a
reliable Internet connection. Routers learn external
networks so that they better understand what the
best paths of communication are between dierent
points. This router education ensures quicker and
more stable communication. They can also help
segregate networks and provide enhanced security.
VPN technology can be used to encrypt data. When
accessing the public network, trac ows through
multiple routers before reaching its destination.
This trac is visible to anyone listening on the
line. If trac is not encrypted, a packet can be
easily intercepted and changed, which can cause
high security problems. The use of certicates adds
a higher level of security by implementing a safe
exchange of keys to encrypt and decrypt messages.
Conclusion
IoT is an important tool that is strongly impacting
the industrial world. SCADA and remote maintenance
applications can provide real value and cost savings
that can result in a competitive advantage, and many

dierent technologies can help existing network systems
increase performance.
Wired and wireless Ethernet systems are always
improving to provide end users with better technologies
for the future.
As IoT continues to transform industry, end users
must always consider security when dealing with
the Internet.
Routers and rewalls, which provide additional
security benets, will likely become a requirement by
end users and facility owners.
Andres Suazo is a cellular technology specialist at
Phoenix. Suazo graduated from Purdue University
and Butler University with a degree in electrical
engineering and computer science. During
the past three years, Suazo has aided in
the design of large SCADA and remote
monitoring applications. He may be
reached at 717-944-1300 ext 3522 or
asuazo@phoenixcon.com.

46
SPECIAL SECTION
Monitoring Brings
Reliability to Wastewater
Collection System
Remote terminal units help an Oregon utility monitor
40 major pump and lift stations.
BY LAURYN COLQUITT
MISSION COMMUNICATIONS
lean Water Services (CWS), a water reuse

provider in Oregon that serves more than
500,000 residents, has partnered with local
organizations to educate the public about the
importance of wastewater reuse.
CWS Government and Public Aairs Manager Mark
Jockers says they intend to increase public understanding
and acceptance of water reuse as well as the importance of
recycled wastewater. CWS has formed partnerships with
groups within the community to start a dialogue about
the urban water cycle.
This whole project is really about starting a
conversation about the nature of water. Its about the
fact that all water has been consumed before and will be
consumed in the future, Jockers says. We are trying to
broaden the discussion of water reuse in Oregon and in
the nation in terms of how water is recycled.
Wastewater Treatment
CWS runs four wastewater treatment facilities serving
more than 500,000 residents in Washington County,
Oregon. The company has provided reuse water for
irrigating athletic elds and golf courses and for wetland
recharge for more than 25 years.
CWS uses a High Purity Water system that treats
euent in a three-step process, which includes reverse
osmosis (RO), ultra- ltration and disinfection. Ultra ltration membranes rst remove bacteria, protozoans
and other pathogens. RO membranes then eliminate
salt, organics, trace pollutants and

additional pathogens. The nal step involves
disinfection/advanced oxidation oxidants
and ultraviolet technology to kill remaining
pathogens, destroy N-Nitrosodimethylamine
(NDMA) and other trace pollutants. The
end product of the three-step process meets
federal safe drinking standards.
It is getting people to understand there
isnt any new water. All water is reused,
Jockers says. I think we are shortening the
distance between used and reused.
Remote Monitoring
CWS ocials use remote terminal units
(RTUs) and equipment to monitor their 40 major pump
and lift stations. Personnel oversee wet well levels, pump
runtimes, pump amperage and pump capacity. They also
monitor owmeters and watch for pump, generator and
air failures.
Forest Grove Treatment Plant Manager C.J. Baxter says
all treated wastewater must meet strict pH standards and
be biologically treated to Department of Environmental
Quality (DEQ) requirements.
Baxter says before partnering with a managed
supervisory control and data acquisition (SCADA)
provider, they used an older, unreliable autodialer
system. Personnel were unable to determine if they lost
communications with remote equipment until long after
47
Image 1. An RTU monitors a Clean Water Services pump

station. (Courtesy of Clean Water Services)
an interruption occurred. The dialers at several treatment

plants monitored after-hours alarms. Because lift stations
were on a weekly maintenance schedule, there was a
signicant lag time between communication interruptions
and when personnel discovered them. Scheduling
employees and destinations for after-hours alarms was
also dicult.
You could visit the station one day and have
communication and the next time you visited the station,
you might not have telephone service, Baxter says. You
wouldnt know when you actually lost that service.
Baxter says they looked into radio telemetry but found
it too cumbersome and costly to install. CWS required a
reliable alarm or data logging system that would detect
48
SPECIAL SECTION
communication failures at pump and lift stations. They

also needed to be able to handle at least eight alarms and
call out to dierent alarm groups.
Baxter says that the managed SCADA provider gives
notication if communication with the pump station is
lost. With the new system, schedules and access can be
altered on one website, rather than having to go to each
individual site and reprogram dialer units.
Real-Time Data
Baxter says he especially likes the ability to view pump
station status in real time during a rainstorm or severe
weather event. He says it gives them a current snapshot of
what is occurring at the stations.
When we had a wind storm, we were having problems
with power bumps to one of our stations, Baxter says.
Using the real-time SCADA software, we were able to see
how the pumps were performing to determine whether
we needed to call in sta during the night.
Service personnel can also troubleshoot stations at
multiple locations. The software providers real-time data
and alarms have prevented pump failure when a pump
started to get plugged.
Baxter regularly uses a pump runtime variance report

and weekly communication management report. The
pump runtime variance data has allowed him to ag
abnormal runtimes at one or more pumps.
He says the real-time viewer application and trending
data help him decide whether or not to schedule
maintenance ahead of normally scheduled rounds if he
nds an issue.
Two or three problems are averted every month because
of the report.
Im really happy that our new SCADA provider has
been eager to listen to our feedback and prompt to
address any concerns we have had, Baxter says. That has
been a real positive benet of working with the company
and their local distributor.
Lauryn Colquitt is the marketing coordinator

for Mission Communications, a managed
SCADA provider. She may be reached at
laurync@123mc.com or 877-993-1911.
For more information, visit 123mc.com.
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49
he SWPA Webinar Series Continues
Diagnose & Solve

Cavitation & Air Entrainment
MAY 28, 2015 | 1 P.M. EASTERN | Free
This advanced level course focuses on two common problems
encountered with centrifugal pumps: cavitation and air entrainment.
Although usually unrelated, both can cause big operational problems
that lead to frequent failures and costly maintenance.
Attendees will learn:

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The effects of these problems
How to test for them
How to repair systems that have them
Register today!
pumpsandsystems.com/webinars
EARN
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SWPA and Pumps & Systems are proud to present this webinar, the rst in a two-part series for 2015.
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50
SPECIAL SECTION

Outreach and the LifePump
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51
THE GIFT OF
C L E A N WAT E R
52
PUMP
TECHNOLOGY
CHANGES
COMMUNITIES
ARTICLE & PHOTOS BY
AMELIA MESSAMORE
PUMPS & SYSTEMS
Reporting from Zambia & Malawi
n the heart of the Kasungu District in the Central Region of

Malawi, a 45-year-old grandmother of six stoops to slice fresh
okra into a large woven basket. The red brick behind her glows
against the backdrop of lush green Acacias, banana trees and broad
tobacco leaves. It is the end of the rainy season, and soon the crops
will be harvested and dry air will suck the life out of the ground.
Even during Malawis driest days, the bucket of clear, cool water
sitting in the red dust by this womans feet will be lled again and
again. Children will continue to drink, and gardens will still grow.
For Vickness Nyirenda and her neighbors in Zolomondo village, a
simple hand pump has changed everything.
The Gift of Clean Water

In November 2013, Zolomondo received a gift that transformed the
entire community: a deep-well, progressive cavity (PC) hand pump
known as the LifePump.
Provided by humanitarian engineering nonprot Design
Outreach in partnership with World Vision and private donors, the
LifePump is engineered to reach depths of 325 feetmore than
twice that of a typical hand pump. It supplies a consistent ow of
clean water, which for this community, is life-saving.
Supplied by SEEPEX, a German-based pump manufacturer,
the LifePumps PC pumping elements work to continuously and
eciently move water to the surface with every turn of the handle.
Unlike piston pumps that lift the entire column of water with one
push of the lever, this design allows virtually anyoneregardless of
strength or sizeto access safe water.
Nyirenda no longer has to wait for hours or hack away at the
earth with a hoe to ensure her family has enough water to survive.
She no longer has to fear for her life.
54
THE GIFT OF
CLEAN WATER
Even if I come to the pump late or there are others gathered, Nyirenda
says in native Chewa, my family and I are certain we will get water.
This design gives her condence that she can easily pump the water
herself and that there will be enough.
Reaching New Depths

The LifePumps outer components, including the concrete mounts, spout
assembly, base, gearbox and handles, are connected to the PC pump and
foot valve at the bottom of the well by riser pipe and drive rods.
The weight of the rod and water in the column in a LifePump are
supported by bearings, says Mike Dillon, SEEPEX president. In a
conventional hand pump, the mechanism and the water have to be lifted
with each stroke. Thats a lot of unnecessary work. Plus, with reciprocating
equipment there are a lot of high moment loads, plus hinges and chains
with sprockets that are all moving and wearing. Fewer parts and fewer
moment loads means that it lasts longer.
The LifePump consists of a single helix metallic rotor that turns inside a
double-helix elastomeric stator. Each turn of the handle rotates the drive
rod, which turns the PC pump element to create cavities that draw water to
the surface.
The sealing lines between the rotating and stationary parts have to be
carefully designed to allow the pressure capability to lift the column of
water, but at the same time not be excessive to require high torques that
would make it dicult to turn the handles, says Kamran Mirza, SEEPEX
director of business development. This challenge is overcome by the
geometry of the helical design, selection of materials and processes during
manufacturing that help reduce friction between the parts.
A critical feature of the LifePump is its depth capacity. The current
LifePump is designed to reach 325 feet, and another in research and
development will reach 500 feet. In mountainous areas such as Malawi,
this is crucial. You can nd water in just about any part of the world if
you drill far enough, says Dr. Greg Bixler, CEO and co-founder of Design
Outreach. But most pumps only go 150 feet. If theres no water there, the
pump wont work. This is part of the untold story.
Before the LifePump came to Chilekwa village in Malawi, this was their
fate. A borehole was drilled to the standard 150 feet, but it wasnt deep
enough to hit water. Unsuccessful, the operators packed the drill truck and
left, devastating and disappointing the villagers.
But when Design Outreach returned to the same borehole a few weeks
later and drilled deeper for the LifePump that stretches to greater depths,
hundreds of villagers saw clean water for the rst time.
The celebration lasted for a long time, with villagers singing and passing
around clean water to everyone in the village, Bixler says. It was a very
moving celebration, watching the joy and sharing, and it made it very
evident what a dierence clean water makes.
The Power of Water
Water, as Nyirenda knows, is a powerful thing. Her village is living proof.
Less than two years ago, the lives of Nyirenda and her neighbors ticked
away as they waited at a watering hole that produced just a trickle of water.
Clockwise from top left: Dr. Greg Bixler, CEO & co-founder
of Design Outreach, offers training in Zambia; Children at
Kafwikamo Community School show off clean water from the
LifePump; A woman in Malawi gathers water from a polluted
water source that serves 1,100 people.
55
pump minder conducts inspections for leakage,

discharge, loose nuts and bolts, and any other
unusual behaviors or problems.
The women would walk two kilometers deep into the

African grassland in the afternoon, only to return the
next morning with dirty water laden with disease.
The women, already exhausted from only three to
four hours of sleep every night, would often bring hoes
to increase their chances of nding water. Since water
is life, Nyirenda says, we had no option but to dig
down to get it.
While they waited as long as 12 hours for water to
ow, wild animals from a nearby national park would
sometimes wander beyond their territories to drink
from this same water source. Sometimes wed be
chased by hyenas, Nyirenda says. We were afraid that
wild animals would kill us.
The water they returned with was rarely sucient for
daily needs. Nyirenda and her family would often go
without food, because rice and nshimaa corn-based
staple in Malawi and Zambiarequire water.
This is not an isolated story. More than 750 million
people worldwide lack access to a safe and reliable water
source, and women and children spend an estimated
140 million hours every day collecting water. Of the
water that is gathered, much of it is so dirty that a child
dies every minute of water-related disease.
In addition, Design Outreach uses satellite data

loggers provided by SonSet Solutions to monitor
pump performance. So far, the max amount
pumped per day was 1,980 gallons.
But in places like Zolomondo, Design Outreach and its

partners are working to reverse these statistics. Every
LifePump installed means more time and opportunity
for people like Nyirenda.
Solutions to a Crisis
Design Outreach was born ve years ago when Bixler
and co-founder Abe Wright decided to use their
engineering expertise to provide innovative solutions to
help break the cycle of poverty.
While working with Water for Good in the Central
African Republic, Bixler says he began learning about
hand pumps and the challenges they pose for rural
communities. Many of the worlds hand pumps often
last six months or less before needing repairs, and some
estimate that about a third are broken. Because most
hand pumps reach depths of only 150 feet, drilled wells
in some places hit water about 68 percent of the time.
56
THE GIFT OF
CLEAN WATER
Having seen rsthand the devastating eects of lack of access to clean

water, the two engineers wanted to build a pump that would reach deeper
and last longer.
Inspired by a PC pump designed in the 1970s that was still operating
in some places 30 years later, the Design Outreach team engineered an
improved PC hand pump and installed a prototype in 2011. The prototype
had some major issues we just couldnt work around, Bixler says. It needed
to be created custom for this application. We needed to make an optimal PC
pump element, or the project was not going to work.
Through a random series of events, Bixler was introduced to Dillon, who
worked on the PC hand pump project in the 1970s and 80s.
Something else funny was happening. We had a team of engineers
looking for a supplier to make this part. One of the suppliers was SEEPEX,
Bixler says. When we described the project to Mike, his jaw about hit the
ground because he was so happy to see this project come back to life.
Now, SEEPEX manufactures and provides the PC pumping elementthe
rotor and the statorfor the LifePump. Its not just a job for them, Bixler
says. You can tell they really want to make it work.
In addition, the SEEPEX team has funded a LifePump installation in
Malawi and is working on their second campaign. Having been to parts of
Africa himself, Dillon sees the need for a pump that wont break down.
Its just absolutely heartbreaking to see the suering people go
through, he says. When you see something like that you think, I really
wish I could do something.
Engineered for Life

An hour ight west of Malawis capital city in a Jetstream 32 turboprop
and a bumpy ride in a Land Rover lead to the heart of Zambia, where nearly
80 percent of people live in poverty. In the Mumbwa District, Kafwikamo
Community School, developed in part by World Vision, seeks to improve
the lives of about 400 children through education.
In December of 2014, a LifePump was installed on the school grounds,
serving the students and the surrounding homes. The communitys
previous pump was dicult to use and faced frequent breakdowns. Women
needed to assist each other, and the water they did draw was polluted.
Aggrey Shanzala, Kafwikamo school manager, says the previous pumps
pipes would leak and parts would wear out within a few months.
You would expect some to come back without water, he says. Now
everybody drinks. Even the nearby community can draw water, and weve
never experienced trouble. The kids are very grateful.
The school has planted a garden of papaya, carrots, tomatoes and other
vegetables, and they no longer fear that a pump breakdown would waste
their investment in seed during the dry season. School attendance has also
improved. With breakdowns, we couldnt prepare meals, Shanzala says.
Now, more children come because they have food to eat.
Kafwikamo School is just one example of the innovative technology
that makes the LifePump work. The PC pump design minimizes stress and
wear on parts, and durable, corrosion-resistant materials ensure resilience
even during continued use. The lack of frequent maintenance makes the
LifePump aordable for local communities to operate without constantly
relying on outside funding.
Clockwise from top left: Children in Malawi drink from the

LifePump; Nyirenda, her sister and grandson in front of a
brick home built after the installation of the LifePump; Amelia
Messamore, Pumps & Systems managing editor, (second from
left) with the Design Outreach and World Vision teams in Malawi;
Children in Zolomondo Village in Malawi
58
1 OUT OF 9 PEOPLE
lacks access to improved sources
of drinking water.
About 140 million hours a day are spent collecting water.

water /
$1 spent on
sanitation
= $4 economic return
Increase In Water
Withdrawals By 2015:
18%
50%
DEVELOPED COUNTRIES
DEVELOPING COUNTRIES
80% OF
WASTEWATER
is not collected or treated.
Nearly out of every

deaths before the age of 5 is
due to a water-related
disease.
1 out of 3 people lacks
IMPROVED SANITATION.
At least
750 million
lack access to clean water.
To learn how to help, visit

giftofcleanwater.
APPROXIMATELY
3.5 million die each year due
to inadequate water supply,
sanitation and hygiene.
Sources: UN-Water |WHO/UNICEF | Water.org
The New York Times
THE GIFT OF
CLEAN WATER
Pump Industry Improves

World Water Access
COMPILED BY PUMPS & SYSTEMS EDITORS
Atlas Copco
Atlas Copco
Pump companies and nonprot organizations are

teaming up to give clean water to communities
worldwide. The following pages highlight how
technology and resources are being used to
provide developing countries with sustainable
access to clean water.
Atlas Copco
In 1984, Torgny Rogert and Peter Hkansson saw a
striking documentary about the ongoing drought in
Peru and the harsh living conditions that followed.
After seeing the countrys hardships, they decided to
take action.
Rogert and Hkansson successfully engaged their
Atlas Copco co-workers to contribute with voluntary
donations to support a project giving droughtstricken areas of Peru access to clean
drinking water.
The project was so impactful that Atlas Copco
joined the cause and promised to match its
employees contribution.
More than 30 years later, what once was a onetime project, grew into an initiative with projects
implemented all over the world. All projects are
funded and driven by voluntary Atlas Copco
employees acting on their commitment to global
sustainability.
During the past three decades, Atlas Copcos
employee-run Water for All organization has helped
more than 1.5 million people gain access to clean
drinking water. The initiative has helped more than
10,000 people gain access to safe, clean water and
sanitation and has donated more than $500,000
to 15 projects around the world in just the past
four years.
In honor of Water for Alls 30th anniversary,
Atlas Copco USA recently held a membership drive that
resulted in a 10 percent increase in employee participation.
Participants also voted for the next proposal the program
Franklin Electric
will fund: a $50,000 project in the Tigray region of

Ethiopia that will bring clean water to 2,500 people
through the building of ve community-drilled wells.
atlascopco.com
59
60
THE GIFT OF
CLEAN WATER
Franklin Electric
In 2014, the Franklin Wells for the World Foundation
(FWWF) completed a project in the Chibombo District
of Zambia, Africa. The project consisted of water well
installations at ve schools in the community.
The groups mission is to provide safe, reliable and
cost-eective water supplies to suering communities,
focusing on Africa. The goal is to provide fundraising and
technical resources for water projects, as well as facilitate
global partnerships for charitable organizations.
FWWF is principally funded by Franklin Electric, its
a liates and its employees. | fwwf.org
Grundfos
Grundfos partners with Water Missions International
to organize an annual Walk for Water event. Grundfos
employees join family, friends and corporate partners
to take part in the non-competitive, educational event
that mimics the trek of those who walk almost four
miles per day to provide their families with what is often
contaminated water. Halfway through the 3.5-mile
walk, participants ll three-gallon buckets with water,
simulating the true burden of life in a developing nation.
Since Grundfos rst Walk for Water in 2012, nearly
$170,000 has been raised and thousands of people
now have daily safe water access in Haiti and Uganda.
Each year, Grundfos hopes to continue the tradition of
reaching entire areas through safe water community
development projects.
In August 2014, Grundfos hosted three Walk for
Water events in North America to raise money for Water
Missions International. Walks were held in Kansas City,
Missouri; Chicago, Illinois; and Toronto, Canada.
The funds raised by Grundfos in 2014 will impact
projects in ve Ugandan communitiesAyilo I, Birra
Health Center III, Nyumanzi Health Center II, Boroli and
Odubu. | grundfos.us
ITT
ITT Corporation partners with Engineers Without
Borders (EWB) to construct irrigation systems, schools
and to bring clean water technology and education to
communities all over the world.
ITT announced on Feb. 24, 2015 that they would
extend their partnership with EWB through December
2015. The expansion comes after a successful yearlong
partnership between ITT and the University of
Washingtons EWB chapter that helped fund an energy
infrastructure project in Mekelle, Ethiopia.
ITT launched its ocial partnership with EWBa
nonprot organization that supports community-driven
development programs worldwidein 2012. Since

then, ITT has helped fund projects in communities
around the world. | itt.com.
Pentair
Pentair created The Pentair Foundation in 1998 to
use its technology and resources to help communities
across the globe. The Pentair Foundation provides
funding for water access, sustainability and
education. The Pentair Foundation has donated more
than $50 million to provide clean water to more than
500,000 people.
In 2006, The Pentair Foundation started Project
Safewater in Coln, Honduras. The goal of Project
Safewater was to use Pentair technology and support
from their partners to give sustainable access to clean
water to the people of Coln.
Pentair partnered with Water Missions International
to install more than 200 water treatment systems and
more than 15,000 latrines in Coln. The systems can
produce clean water for $3-6 per person per year.
Project Safewater included a microenterprise
business model in which the community owns the
water treatment systems and users pay a nominal fee
for potable water. Education programs were put in place
to increase awareness of the importance of safe
drinking water.
In March 2015, Pentair announced that it has
implemented numerous Project Safewater programs
around the world, helping to deploy water systems to
provide clean water to more than 1 million people.
Pentair also partners with organizations such as
WorldServe International and Action Against Hunger to
give communities access to clean water. | pentair.com
Xylem Inc.
Through its corporate citizenship and social investment
program, Xylem Watermark, Xylem Inc. works with
nonprots to provide nancial support, technology and
education to communities worldwide. Xylem Watermark
delivers sustainable solutions, combining communitybased interventions with regular monitoring to ensure
projects meet local water needs. Xylem Watermark works
in areas across the globe partnering with organizations
like PlanetWater and MercyCorps.
One of Xylem Watermarks current projects is
constructing wells in Syrian refugee camps.
Inside the Zaatari refugee camp in northern Jordan,
there is no access to modern-day conveniences for nearly
100,000 Syrians who have ed their home country, which
has been torn apart by civil war since 2011.
61
Grundfos
Xylem
This once vast desert is

now the worlds second
largest refugee camp, which
is quickly exhausting its
water supply in an already
water-scarce region of the
world. With the camps two
wells overburdened, storage
tanks and pumps have been
distributing water brought
in daily by truck, but its not
enough to keep up with the
increasing demand.
Xylem Watermark
turned to Mercy Corps, an
international humanitarian
organization and one of
Watermarks partners, to
seek a solution. With initial
funding from the United Nations and a $150,000 grant
from Xylem Watermark, Mercy Corps worked to create
major water infrastructure improvements for Zaatari.
The eort began with the construction of two new
deep wells within the Zaatari camp. The wells are tted
with submersible pumps, backup generators in case of
power grid interruptions, a chlorination facility, adequate
on-site water storage, booster pumps, site security and
amenities to increase access to fresh water. By the end
of 2014, at full working capacity, the two existing wells
could provide enough water to meet the daily needs of
approximately 68,570 Syrian refugeesabout 68 percent
of the maximum population of the camp.
To further develop new infrastructure, Xylem
employees from the U.S., Poland and Italy worked with
Mercy Corps to drill a third well in the camp. Xylem
Watermark also allocated an additional grant of $100,000
to support the well construction. The well began
operation in late March 2015 and is expected to provide
enough clean water for cooking, cleaning and drinking for
refugees of the Zaatari camp and local Jordanians.
Franklin Electric
Working together, Xylem Watermark and Mercy Corps

have and will continue to help people in need around the
world by providing access to advanced ltration systems,
water-saving network improvements and improved
sanitation tools. | xyleminc.com
Zoeller
Zoeller Companys distributor in South Africa,
Maskam Water, has partnered with Absolute
Ablutions to create a self-contained sanitation unit
utilizing Clarus Environmentals Fusion wastewater
treatment technology.
This mobile bathroom unit consists of showers, sinks
and toilets, and the euent from these amenities is
treated and partially recycled on-site for the toilet
ushing process.
The system has the exibility to be solar-powered
or plugged in electrically, allowing for a multitude of
possible applications. In South Africa, these units will
provide clean, low-maintenance facilities for informal
housing developments. | zoeller.com
62
THE GIFT OF
CLEAN WATER
WaterStep Teaches
Pump Maintenance
BY STEVE SIKKEMA & LAUREN HACK, WATERSTEP
Out of the millions of hand pumps that have

been installed around the world to provide
water to developing communities, some
estimate that more than half are broken. For
communities that rely on a hand pump as their only source
of clean water, a broken pump can be the dierence between
life and death.
While drilling a new well is often the go-to solution, this
processwhich takes three to ve dayscan cost $7,500 to
$15,000 in addition to the price of the drilling rig, which can
be as much as $250,000. For a community in need of water,
the cost can be an insurmountable obstacle. With the right
tools and repair knowledge, however, a broken hand pump
can be xed in two to four hours at a cost of $5 to $250.
Three types of hand pumps are commonly used throughout
the world: India Mark II/III, African Bush Pump and Afridev.
Although these pumps look dierent, the principle of how
they work is the same. These pumps work by moving a handle
In 2012, two General Electric (GE) engineers in

Louisville, Kentucky, led a team of GE and other
volunteers to design and develop a chlorine generator
that could be used to chlorinate water and save lives in
developing countries. In partnership with WaterStep,
the team developed the M-100 Chlorine Generator,
which uses table salt, a 12-volt car battery and
electrolysis to generate chlorine gas.
The M-100 is about the size of a football, weighs
approximately 15 pounds and can chlorinate up to 50
gallons of water per minute or 10,000 gallons per day.
The GE Foundation has provided financial support to
help build and distribute the M-100 to more than 30
countries. | ge.com
attached to a chain which moves a rod up and down within a

pipe that has a cylinder at its bottom. The rod is attached to a
plunger and has a top valve. A foot valve at the bottom of the
cylinder allows water to enter from the aquifer. As the handle
moves down and the rod moves up, water is drawn into the
cylinder and then stacks on top of itself in increments of 9 to
12 inches until it reaches the surface. This kind of pump can
be installed on wells from 25 to 250 feet.
The India Mark II/III, Afridev and African Bush Pumps
are closed systems designed to prevent contamination of the
water supply and provide high volumes of water from great
depths. These economical pumps use fewer parts, need little
maintenance and require no electricity, which make them
ideal for communities in developing countries.
As with any mechanical device, some maintenance is
required. While replacement parts are widely available
and relatively cheap, this is where many projects fail. If
communities are not trained in maintenance, no one can x
the pump when it breaks months or years later. Communities
must have the tools and training to repair broken pumps.
WaterStep, a nonprot organization in Louisville,
Kentucky, has recognized this need and works to provide
training and resources to keep hand pumps operating. The
organizations three-day, hands-on training course teaches
students to assemble and disassemble pumps, troubleshoot
common problems, and use critical thinking to get broken
hand pumps back up and running. The course also teaches
students the subtleties of working with other cultures and
the importance of training those in the community.
Training locals is key to the sustainability of well repair
projects. Leading a team of North Americans to x hand
pumps is a matter of addition: With each repaired pump, a
working well is added. WaterStep goes beyond by teaching
students about the multiplication eects of training. Imagine
that a team of six people trains six more people at every
community well they visit. Then those six trained people can
each train six more people. Before long, more hand pumps
are xed, and the response time for repairs is shorter.
WaterStep works alongside local people, not simply xing
their problem, but joining them as a partner to provide the
tools and training they need to be able take care of their own
water supply. | waterstep.org
63
Water Professionals
Ride to Raise Money
BY ALECIA ARCHIBALD,
People who work in the water industry

understand the importance of the gift of clean
water. When you get a few water professionals
together, and they happen to enjoy riding
motorcycles, the result is the Water Buffaloes.
The Water Buffaloes ride together for fun and
to raise money for Water For People.
The group travels each year to the Annual
Conference and Exhibition of the American
Water Works Association (AWWA ACE) and
Water Environment Federation (WEFTEC)
shows, taking a different route each time and enjoying the
countryside as they go. Along the route, new riders join
those who start the journey, and before its done, as many
as 70 bikers are riding together.
We have raised more than $650,000 for Water For
People since we started 10 years ago, says Water Buffalo
Tom Caraker, Jr. Our goal this year is $100,000. Some of
our riders will log in well over 10,000 miles before they
return home from ACE.
The Water Buffaloes are a volunteer group with only a
fraction of costs going to administrative fees. That means
that almost 100 percent of the money they raise during its
Ride With Purpose goes to benefit Water For People.
The vast majority of our membership are water
professionals in production/distribution, engineering,
sales and service, Caraker says. Our membership rides
the full gamete of motorcycles, from on/off road endurance
motorcycles to Harley Davidsons. Some of us pull trailers
and travel great distances to participate in the AWWA
ACE show each year. And now we also have an active group
participating in the WEFTEC annual conference.
About 10 years ago, Ken Howe and Bill Persich in Seattle
decided to ride their bikes to the ACE in San Francisco.
Meanwhile, Harold Thomas and and Mark Stratton in
Tuscon had begun riding to water operations events
together and dubbed themselves the Water Buffaloes. The
groups merged and grew, and they keep growing.
This will be the second year the group has put forth a
concerted effort to have a large showing at WEFTEC in
Chicago, Caraker says. We will be soliciting a different
group of riders to participate in the Dirty Water Buffaloes.
This part works in both industries, and sponsors operate in
either water or wastewater industries.
Caraker said to become a full member of the group, you
must take the Buffalo oath led by our fearless leader, the
Grand PooBah,
followed by
the ceremonial
smoking of the
cigar. Members
dont seem to
take themselves
too seriously but
are serious about
raising money for their water charity.
The group is greeted with open arms everywhere they
go. We are invited to gatherings and parties during the
conferences and treated like celebrities at each and every
one of them, he says. The group usually has a booth at the
conference.
Through the years, they have traveled all over the
country, seeing such sites as the Tail of the Dragon at Deals
Gap. This road along the border of the Smoky Mountains
National Park is known for its 318 curves in 11 miles.
Its one of the most famous roads for motorcycling and
sports car enthusiasts in the country, Caraker says. This
road lives up to its name with 180 switchbacks and nearly
constant turns the entire 11 miles. All I can say is what
a ride!
In 2015, the Buffalo herd will snake its way around the
U.S. to meet again at WEFTEC. They will again be greeted
with open arms and smiles and, most important, will again
contribute the money they raise to Water For People. For
the Water Buffaloes, it truly is a Ride With Purpose.
For more articles, images, slideshows, videos

and information on how you can help, visit
pumpsandsystems.com/giftofcleanwater.
64
TRADE SHOW PREVIEW
American Water Works Association

Annual Conference & Exposition Exhibition Hours
June 8 10, 2015
Anaheim Convention Center

Anaheim, California
he American Water Works

Association Annual Conference
& Exposition (AWWA-ACE15)
is an annual event for water industry
professionals. he conference provides 12,000 attendees
with the opportunity to network and learn about upcoming
regulatory updates and actions and to stay current with water
sector trends. he event also features more than 900 expert
speakers, professional sessions, pre-conference workshops,
opportunities to earn continuing education credits or
professional development hours, and more than 450 exhibitors.
he AWWA-ACE15 professional program will focus on water
sector issues, such as infrastructure renewal and replacement,
potable reuse applications and drought response. Some
examples of topics include small systems management and
operations, water quality challenges and advances in
water treatment.
Public oicials have opportunities for networking and
specialized training, including three sessions covering water
and sewer environments and infrastructure.
AWWA also holds several competitions to showcase operator
skills. Water professionals can demonstrate their talents in pipe
IDA World Congress 2015

Aug. 30 Sept. 4, 2015
San Diego Convention Center
San Diego, California
he International Desalination
Association (IDA) World Congress
is one of the premier global events
in the desalination and water reuse
industry. Since its irst meeting in 1987, the
Congress has been ofering participants the
opportunity to expand their knowledge of current and
emerging desalination and water reuse technologies.
End users, researchers, consultants, academics, manufacturers
and suppliers attend the Congress for networking and
educational opportunities.
he theme of 2015s World Congress is Renewable Water
Monday, June 8
Tuesday, June 9
Wednesday, June 10
10 a.m. 5 p.m.
10 a.m. 5 p.m.
10 a.m. 3 p.m.
tapping, water meter assembly and water

treatment knowledge. Every two years,
the World Water Cup competition rotates
between three locations.
In 2015, it will be a part of ACE15 in Anaheim, California.
his competition is an international drilling and tapping
contest among teams from North America, the United Kingdom
and the Netherlands.
AWWA ofers several special events and activities as well.
For young professionals or students, workshops, a scavenger
hunt, poster competition, job fair and several networking
opportunities are available.
Attendees can also participate in touring diferent water and
wastewater facilities in the area, including the Disney Parks
and Anaheim Water Recycling Facility. Other special events
for speciic groups include the International Reception and the
Womens Networking Lunch.
For those looking to explore solutions in an interactive
setting, AWWA exhibitors and sponsors will lead Roundtable
Solution Sessions. Participants will hear from industry experts
and have the opportunity to network with professionals facing
similar issues. For more information, visit awwa.org.
Exhibition Hours
Monday, Aug. 31
Tuesday, Sept. 1
Wednesday, Sept. 2
Thursday, Sept. 3
9 a.m. 6 p.m.
9 a.m. 6 p.m.
9 a.m. 6 p.m.
9 a.m. 4 p.m.
Resources to Meet Global Needs. It will

continue to include technical sessions,
lectures, roundtable discussions and
workshops. For the irst time, the event
will feature an interactive plenary session
in an open forum format.
he events exhibition will cover more than 190,000 square
feet. It ofers exhibitors the opportunity to interact with
conference attendees from all over the world. his years
conference will include the Innovation heater, a venue for
ilms and company presentations, for the irst time. For more
information, visit wc.idadesal.org.
ONE WORLD.
ONE WATER.
ONE EVENT.
COUNTLESS
OPPORTUNITIES.
WEFTEC 2015 is the event for water professionals, industry experts, and the most innovative
companies from around the world to gather together for the advancement of water.
STAY COMPETITIVE
AND RELEVANT
WEFTEC offers the
highest-quality, most
comprehensive
educational sessions
available today.
DISCOVER
THE NEWEST
INNOVATION AND
SOLUTIONS
WEFTEC features the
largest water quality
exhibition in the world
with more than 1,000
exhibiting companies.
ACCESS GLOBAL
BUSINESS
OPPORTUNITIES
EXPERIENCE
SPECIALIZED
PAVILIONS
WEFTEC is your gateway to global water,

wastewater & resource
recovery and the
only water show
selected to be a part
of the U.S. Commercial
Service International
Buyer Program.
See the latest equipment, services and presentations in focused

areas on the exhibit
floor, including: the
Stormwater Pavilion,
Innovation Pavilion and
more than 10 Country
Pavilions.
88th Annual Water Environment Federation

Technical Exhibition and Conference
September 26 30, 2015
McCormick Place, Chicago, Illinois USA
MAKE VALUABLE
CONNECTIONS
WEFTEC hosts more
than 22,000 attendees from around the
world and all sectors
of water quality.
Register Today!
www.WEFTEC.org
pu 115
mpsa
om | Ma y 2015
Circle
onndsyst
card orems.c
visit psfreeinfo.com.
66
SPECIAL REPORT
TheThe
CostCost
of Clean Water
Challenges, opportunities and the role technology plays in the
water-energy nexus
of Clean
Water
BY MICHELLE SEGREST
PUMPS & SYSTEMS
How pumps play a role in the

WATER-ENERGY NEXUS
ater is life.
It is essential to the production of electricity
and other energy, to agriculture and
industrialization, to comfort and progress.
But in a world of climate change and population
growth, a world in which natural and man-made
disasters demand better, smarter and more sustainable
technologies, the availability of water and energy will
determine the future of life itself.
Will there be enough?
As we face this monumental question, government
regulators, industry leaders and citizens of the world
are beginning to think dierently. Energy and water
systems have historically been developed, managed
and regulated independently and solutions have been
considered separately.
Today, there is a growing understanding of the natural
nexus between water and energy. To nd sustainable
solutions, we must start with the basics. We all know the

price of a gallon of gas, and we track this cost daily.
But what is a gallon of water worth?
Most people dont have a common tendency to place a
value on water, Xylem President and CEO Patrick Decker
said. This is becoming more and more understandable
by our policy and thought leaders around the world that
some of the biggest demands on the environment in
terms of energy production are the demands placed on
water and the scarcity of water.
In many areas where oil is the most abundant,
water is the most scarce. It is simply not going to be
sustainable until we have as much of a focus and debate
around the value of waterwhether that be sources
of clean water, the climate of the energy cycle or
management of the wastewater.
An integrated, strategic approach can guide technology
research, development, demonstration and deployment
67
(RDD&D) to address regional water-energy issues and

also make national and global impacts, according to a
2014 report from the Department of Energy (The WaterEnergy Nexus: Challenges and Opportunities).
The World Health Organization predicts that by 2050
two-thirds of the nearly 10 billion people on Earth will
live in developed cities, which will create great pressure
on global energy and water resources.
In the Middle East, produced water from oil and gas
operations wastes more than 73 million barrels per day.
In regions characterized by unconventional production of
oil, such as tight oil and oil sands, a single well can require
up to 5 million gallons of water.
This is clearly not sustainable, Decker said. We need
resilience for water infrastructure. Water variability
is resulting in a rising economic risk for communities
around the world. Floods disrupt power plants, oil
reneries and other critical energy infrastructure.
Managing the movement of water around energy facilities
during these times is crucial for maintaining resilience.
In arid environments, there are some no-regret moves
that can immediately be made, such as water reuse.
These are common in the Middle East, Singapore,
Australia and the U.S. Reuse can help close the gap
between supply and demand.
The Role of Technology

Energy sustaining partners should realize the need for
less stringent thinking in terms of technology.
With regard to pump-related technology, the key is
energy eciency and having more data to measure the
eciency. And we need to use partnerships to accomplish
this, Decker said. Partnering is the ultimate catalyst to
create water security for the world.
Climate change, population growth and rising sea
levels all lead to a higher requirement for water treatment
and pumping tasks, said Franz Bosbach, Technology
Foresight, KSB Group.
We enter a vicious circle, Bosbach said. Renewable
energy sources need water. Plants for biogas production
need irrigation. Wind generators have to be cooled. Water
production and energy generation both depend on each
other and the use of resources.
Pumps account for 20 percent of the global energy
demand. Energy ecient pumping systems reduce the
impact on both energy and water consumption.
Higher eciency at machine level (new motor design,
new pump design, speed control), combined with the even
larger leverage eect of pump system optimization is the
logical response here and will reduce the impact on our
16 gallons
The amount of water used to operate a 60-watt light
bulb for 12 hours
405,868 gallons
The amount of water withdrawal per person per
year in the U.S.
3.5 to 6 gallons
The amount of water it takes to produce one gallon
of ethanol
Source: U.S. Department of Energy
environment, Bosbach said. The water-energy nexus will

force us to change the types and sizes of pumps we are
using. The waste of water in the energy generation process
has to be reduced by water recycling and reuse.
This means, for example, fewer intakes from the sea or
rivers, improved circulation concepts with a high level of
optimization and local water treatment as an integrated
step in reusing water, Bosbach explained. In industrial
processes for chemical products, there is progress in
optimization from sealing water circuits to zero liquid
discharge. Energy generation will, and has to, follow suit.
More innovation is the key, Decker said.
There is no one single technology that is going to
solve all the issues here. We need to partner together and
realize that we all have some level of risk aversion. None
of us wants to make changes with technology that will
put our public health at risk. Having greater cooperation
and opening the research capabilities together and having
trust in the partnerships is key. Education and awareness
will also be dierence makers.
Sustainability is the Future

The world is in the middle of a paradigm shift brought on
by technology, innovation and basic needs, said H.E. Dr.
Abdullah Abdulaziz Al-AlShaikh, President, International
Desalination Association (IDA) and CEO, Advanced Water
Technology Deputy Governor, Saline Water Conversion
Corporation (SWCC) Saudi Arabia.
Sustainability is not just our futureit is our present,
he said. We are shifting away from an old-model of
consumption toward sustainability. Sustainability is a
must in the water sector, thus our focus needs to be in
68
SPECIAL REPORT
THE COST OF CLEAN WATER
how to accelerate it. First, we need policy and regional

agreement that encourages sustainability. Second,
nancial and economic incentives for corporations that
promote sustainability are needed. Third, we need to
share technology and innovation and support continued
involvement in regional policy.
We no longer say You need to conserve water. We

now say You need to use every drop wisely, Lovell said.
It is often cheaper on a total life-cycle cost basis
and can be a more energy ecient alternative to
lower energy costs and greenhouse gas emissions,
Decker said.
A perfect example here is the Kuwaiti government
demonstrated forward-thinking in this area by building
the worlds largest reuse and reclamation facility. We used
our suite of products to help them build that capability
which now has an expansion plan underway. The
projections are that this plant will generate $11 billion in
cost saving benets for the Kuwaiti government over the
lifetime of the project.
Oil operators are also nding creative ways to reuse
available water sources.
Every oil eld is dierent, and every one of them has
a dierent quality of produced water, explained Anna
Halpern-Lande, Senior Management Upstream Business
Development, Shell, Netherlands.
Oil operations are both big users and big producers
of water. Often, water is injected into the drilling well
to maintain the pressure needed to produce the oil. We
also have large camps that are fully-funtioning cities that
Learning from Other Regions

In reaction to the recent droughts in California, there
is a lot of talk at the federal level in the U.S. about the
growing importance of water infrastructure, Decker said.
But utilities are local, and water is always a global issue.
Unfortunately, its only when the crisis occurs that we get
a meaningful dialogue. Whats happening in California
right now is all about the appropriate pricing of water, the
regulation of waterespecially on the industrial side
and its all about water reuse.
Climate change in Australia has generated action in
the way the people in that region think about water,
says Adam Lovell, Executive Director, Water Services
Association of Australia (WSAA). Parts of Australia have
declared regulations in which people do not use water
one day a week or at certain times of the day. By 2022
Perth will be a climate independent city in terms of water
supply, desalination and plans of
reuse for agriculture.
Water eciency for
HOW TO ADDRESS THE WATER-ENERGY NEXUS
residential customers has
STRATEGIES
TECHNOLOGIES
dropped from around 350
liters per person per day to
Decrease water heat in power
Optimize the freshwater efficiency
plants through combined power and
of energy production, electricity
around 200, and thats without
desalination plants
generation and end-user systems
restrictions, Lovell said.
Customers in Australia have
Optimize the energy efficiency of water Recover dissipated energy within water
now locked in their behavior and
pumping and piping systems
management, treatment, distribution
they see this as a permanent way
and end-user systems
of treating water positively.
Enhance the reliability and resilience of Improve systems with sensor, data
Politics often get in the way,
collection, analysis and reporting
energy and water systems
Lovell said, but the Australian
government has enacted policies
Use non-freshwater sources, such as
Increase safe and productive use of
at the local and federal levels
brackish water, seawater or wastewater,
nontraditional water sources
as cooling water
that have made an impact,
including a labeling scheme
Find alternatives to freshwater in
Promote responsible energy operations
in Sydney, which requires all
with respect to water quality, ecosystem unconventional oil & gas
appliances to have a water
and seismic impacts
eciency label indicating
Focus on plant integrations, including
Exploit productive synergies among
compliance with minimum
water reuse and renewable energy
water and energy systems
standards. Manufacturers
systems
cannot ship equipment to
Source: U.S. Department of Energy, The Water-Energy Nexus: Challenges and Opportunities, Overview and Summary
Australia that does not meet
the standards.
69
For every barrel of oil we pull out of the ground, we use 10 barrels of water
and that water needs to be dealt with and reused.
- Anna Halpern-Lande, Senior Management Upstream Business Development, Shell, Netherlands
have potentially 5,000-10,000 people living there who are

using water and producing wastewater.
Shell partnered with the Global Municipal Water
Authority to build a wastewater treatment plant in
Canada. The water o take from the treatment plant is
now used in Shells oil operations.
By working with regulators on a case-by-case basis, we
can create ways to take water into the next reuse, and we
can determine how we can use these assets in a circular
way, Halpern-Lande said.
Budgeting the Use of Water

A critical paradox in the Gulf Cooperation Council (GCC)
is the high per capita consumption patterns, despite the
high cost of water consumption. In Abu Dhabi, the per
capita water consumption is about three times the
world average.
Given the current water scarcity in our region,
which will only be exacerbated by growing population
and dwindling groundwater reserves, business as usual
is not a satisfactory response, said H.E. Razan Khalifa Al
Mubarak, Secretary General, Environment Agency Abu
Dhabi (EAD), UAE. What we need is business
as unusual.
The GCC is now discussing the concept of a water
budget, at the heart which is the principal that a
xed volume of water per person will be specically
determined. This should create a decent sustained supply
in the long term, and the GCC population must nd ways
to live within this predetermined amount, Her Excellency
Al Mubarak explained.
Unlike the business as usual model, we must not
continue to meet increasing demand by increasing supply.
Of course, this does not mean that our population and
our economy cannot grow. It simply means that we must
be more productive, more competitive and more ecient
in the ways we use our water. We must think carefully and
debate about how we allocate our water by developing a
sophisticated system that recognizes scarcity.
This broad switcha mental switchfrom the
continuous reliability on conventional desalination
to greater eciency and greater water reuse will
have substantial benets in terms of health,
environment, reduction of carbon dioxide emissions and

other air pollutants.
Forty percent of the worlds population is expected to
live in water-scarce regions by 2025. Globally, 70 percent
of water sources are used for agriculture and irrigation
and only 10 percent for domestic use. It is a natural
connection that 1.3 billion people have unreliable or no
access to electricity.
Opportunities
In simple terms, the water-energy nexus is the
relationship between how much water is used to generate
and transmit energy and how much energy it takes to
collect, clean, store and dispose of water. Shortages and
supply disruptions to one directly impacts the other.
Managing water and energy as an integrated
system will unlock water-energy synergies and reduce
consumption of both.
Many challenges and opportunities existfor
example, hydraulic fracturing in North America where
the management of water in and around that technology
is critical. In the mining industry, there is more money
spent on getting water to and from the mining site than
there is on the core mining operation, Decker said.
We look at this as an opportunity to create social and
economic value, not just through the obvious role that
pumps playwhich is the ecient movement of water,
whether its getting it out of places it shouldnt be or
getting it to places where it is needed.
The energy eciency aspect of pumps is important
because the pumps themselves demand so much energy
consumption. Its also about the treatment and the
testing of the water, both before and after its use in the
energy cycle. Summits around the world will continue to
raise the consciousness of energy as it relates to water,
which is arguably our most precious resource.
Michelle Segrest is the editor of Pumps &

Systems. She may be reached at
msegrest@pump-zone.com.
70
SPECIAL SECTION
WATER HANDLING
Water Loss Audits

Decrease Costs
Intelligent tracking and pressure adjustments can
protect aging infrastructure.
BY EDWARD R. OSANN
NATIONAL RESOURCE DEFENSE COUNCIL
ach day billions of gallons of treated drinking

water are lost from the leaking distribution
systems of public water suppliers. The U.S.
Environmental Protection Agency (EPA)
estimates that water losses are responsible for more than
$2.8 billion in lost revenue each year for water suppliers
across the nation. In an effort to shed light on these water
losses that water engineers, maintenance professionals
and pump operators often experience firsthand, the
National Resources Defense Council (NRDC) launched
Cutting Our Losses: State Policies to Track and Reduce
Leakage from Public Water Systems, an interactive
website that highlights how states and utilities are
adopting water loss accounting to more accurately assess
this nationwide problem.
States and utilities face the following challenges that
perpetuate the loss of billions of gallons of water and
associated revenue every year because of leaky pipes:
Aging and failing infrastructure: The condition of our
nations drinking and wastewater infrastructure has
been given a failing grade of D by the American
Society of Civil Engineers. To continue to provide safe
drinking water, EPA estimates that community water
systems will need approximately $384.2 billion during
the next 20 years. EPA includes expanding, replacing
or rehabilitating existing infrastructure, as well as
constructing new infrastructure in that estimate.
Climate change: Extreme weather events, sea-level rise,
temperature changes, and shifting precipitation and
runoff patterns challenge the abilities of states and
utilities to protect water quality and quantity. These
changes can impact a utilitys ability to access reliable
water supplies, provide effective flood management

and maintain affordable rates. These changes also can
impact a utilitys customer base, causing fluctuations
in demand and patterns of use.
Accounting for and controlling water loss helps utilities
address these dual challenges, first by helping them to
better manage their existing infrastructure and control
costs. Water loss programs can help utilities identify
water losses that are economically recoverable and that
are cost-effective to identify and eliminate. One study
quoted by EPA estimates that up to 75 percent of losses
are cost-effectively recoverable.
In addition to infrastructure investment, utilities
face other costs associated with leaky and aging pipes.
Water main breaks typically come with costly emergency
repairs, street closings, traffic disruptions, loss of water
pressure, curtailment of service and boil-water advisories.
Conversely, water loss reduction increases system
resiliency, reduces weather-related risks, protects water
resources and shields residents from excessive utility
rate increases.
The American Water Works Association (AWWA)
developed a standardized method to conduct water audits
and help water utilities track their distribution system
losses. Once a water system accurately identifies losses, it
can implement strategic controls to reduce them.
A Pivotal Role for Pressure Management

As any drinking water professional knows, maintaining
adequate pressure in the distribution system is essential
for public safety (fire protection), public health (backflow
71
WATER LOSS ACCOUNTING: THE BASICS

Water loss accounting is a cost-effective, systematic
additional energy and chemical usage required
approach that helps utilities detect, locate and
to treat lost water, and apparent losses (water
correct leaks. It is strongly endorsed by the
that is used but not billed). These are the primary
American Water Works Association (AWWA) and
components of non-revenue waterwater the utility
presented in AWWAs Manual M-36, Water Audits
spends capital and operating dollars to obtain, treat
and Loss Control Programs. The manual offers
and transport, but which generates no revenue.
standard methods and terminology to perform water
These costs, along with the costs of repairing the
audits and to assist water utilities in tracking their
damage caused by water main breaks and leaks,
distribution system losses. AWWA also provides free
are simply passed along to rate payers in the form
audit software available for any utility to download.
of higher water charges. Until a utility identifies
Water loss accounting helps utilities identify
and categorizes its losses, it cannot effectively
two types of loss from their systems: real (physical)
implement the distinct strategies necessary to
losses, which include costs to a utility from the
reduce them cost-effectively.
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72
SPECIAL SECTION
WATER HANDLING
CUTTING OUR LOSSES

Cutting Our Losses: State Policies to Track and Reduce
Leakage from Public Water Systems is an interactive
website that highlights how states and utilities are
addressing distribution system water loss through
water loss auditing. NRDCs website tracks the policies
leading states have adopted to standardize the
reporting of water losses and set goals for its reduction.
The site answers the following questions:
How is your state doing compared to other states?

What is your states grade for the strength of its
water loss reporting policies? Does it require more
than rudimentary water loss reporting? If so, does
your state set targets for water loss reduction?
What states are leading the way on water loss
accounting? What can other states learn

from them?
What does a validated water loss audit look like?
What key questions are consumers asking about
how their utility is addressing water loss?
What are upcoming training opportunities?
Where can you get the latest research on
water loss?
Cutting Our Losses is frequently updated to track

the adoption of new state policies, provide links to
actual water audits of additional systems, highlight
developments in the eld of water loss auditing and
control, and provide additional resources about water loss
auditing. For more information, visit the site at nrdc.org/
water/water-loss-reduction.
prevention) and customer

satisfaction. Even though sufficient
water pressure is essential for good
system operation, more is not
always better.
Excessive pressure can
contribute to water hammer,
with the potential for damaged
plumbing and customer
annoyance.
Pressure directly affects the
running rate of all leakage, so
unnecessarily high pressure
produces an extra increment of
water loss. Elevated pressures also
raise the floor from which pressure
transients arise. These microbursts
of pressure, often at multiples
of average system pressure for
fractions of a second, are thought
to exacerbate the more gradual
effects of age, corrosion and
vibration that attack the integrity
of buried piping.
New work now links water
distribution system pressure to
the frequency of water main
73
breaks. The upcoming Fourth Edition of AWWAs

Manual M-36, Water Audits and Loss Control
Programs, due to be released in December 2015, will
have an expanded discussion of pressure management,
including more specific guidance for determining
average system pressure.
The new manual will also include formulas for relating
changes in system pressure to changes in main break
frequency. Tamping down unnecessary and excess
pressure is likely to emerge as a leading tool for saving
water and for cost-effectively extending the life of
distribution system piping.
The implications of this development for operators are
substantial. Water main breaks are the most visible and
objectionable manifestations of water infrastructure
failure. In cities like Los Angeles where water pressure
in more than half of the citys 113 pressure zones is
unnecessarily high, water managers and their governing
boards will want to learn more about where pressures are
excessive and how they can be reduced.
Specific steps will vary from system to system.
Pressure reduction can start with
relatively simple adjustments
to tank levels, pump controls
and existing pressure reducing
valves (PRVs). More advanced
interventions would involve the
placement of additional PRVs in
the system and evaluation of flowmodulated pressure control valves.
Hydraulic modeling might
also suggest the division or
recombination of certain pressure
zones to remove pockets of
excess pressure. New attention to
transients can also be expected,
including deployment of transient
monitoring sensors and revised
operating procedures to better
ensure that valve openings and
closings and pump operations are
properly attenuated to reduce
the frequency and severity of
pressure transients.
are reluctant to aggressively self-audit and have not

implemented water audit best practices described by
AWWA. Fortunately, the tools already exist to address
water loss. By embracing them, states can help achieve
real monetary savings for public water utilities and
their customers and taxpayers. To know when and
where to deploy these solutions, annual, standardized
water loss auditing should be undertaken by all public
water suppliers.
Edward R. Osann is a senior policy analyst with NRDCs

Water Program. He oversees an eight-member team
working to advance regional, state and national
policies and technologies that improve
the efficiency of water use. He holds a
masters degree in urban and regional
planning from George Washington
University and a B.S. in international
relations from Georgetown University.
State Action Is Essential

Unfortunately, without direction
from state regulators or auditors,
many public water utilities
74
SPECIAL SECTION
SPECIAL SECTION
WATER HANDLING
Wisconsin Nonprot
Works to Achieve Global
Freshwater Sustainability
The Water Council uses partnerships and research
to address water challenges.
BY DEAN AMHAUS
THE WATER COUNCIL
ith the two largest Great LakesLake

Michigan and Lake Superiorand
the Mississippi River forming three of
Wisconsins borders, plus 15,000 lakes
within the states boundaries, access to freshwater has
been viewed as one of the states greatest attributes. This
abundance of freshwater has contributed to an economy
driven by water-related technologies.
Wisconsins water-related assets include higher
education programs and resources, public-private
partnerships and a facility that provides companies
with a physical space to advance their offerings. Nearly
300 companies throughout Wisconsin are working to
strengthen the states growing water technology industry.
These companies employ nearly 37,000 and account for
$5.7 billion in annual sales. Thirty-eight water technology
companies have headquarters in Wisconsin, and five
of the 11 largest water companies in the world have
operations in the state.
The Water Council

The Water Council is an industry-led nonprofit dedicated
to achieving global freshwater sustainability through total
water-cycle solutions. The Water Councils membership
includes industry, academic, utility and private-sector
leaders. The council has worked to create opportunities
for Wisconsins water industry participants by building
partnerships, supporting education and facilitating access
to capital investments. The Water Councils members

are managing stormwater with green infrastructure,
extracting renewable energy from waste products, and
mitigating and adapting to climate change. Its members,
including Baker Manufacturing, Xylem and Grundfos, are
charged with helping solve the worlds water challenges by
offering solutions through water stewardship.
Global Water Center

The Water Council established the Global Water Center to
further research and business development. The center
houses water-related research facilities for universities
and existing water-related companies and offers
accelerator space for emerging companies.
In June 2014, The Global Water Center was named the
North American headquarters for the Alliance for Water
Stewardship (AWS), a global collaboration of leaders in
sustainable water resource management. AWS connects
companies from a variety of industries to demonstrate
leadership and mitigate water risk for their businesses,
communities and investors.
The Water Council is responsible for administering
AWSs International Water Stewardship Standard 1.0
certification program in the U.S. and Canada. In April
2014, AWS released the standard as a global framework to
promote sustainable use of freshwater resources. Through
the standard, AWS plans to engage regional stakeholders
in AWS governance.
75
The implementation of this agreement will have implications for a broad

array of business, public sector and civil society interests across North
America. For the first time, companies headquartered in the U.S. and
Canada can become AWS members, enabling them to receive exclusive
benefits and mitigate water risk. Now, in partnership with AWS, The Water
Council will provide North American water users with a road map to a
comprehensive approach to water stewardship and sustainability.
Extending the Reach

To support the development of new talent and innovation, The Water
Council knew it needed to bring together wide-ranging, complementary skill
sets within a single location to spur industry collaboration. Entrepreneurs,
in particular, needed both financial and operational assistance from
industry partners in order for their ideas to flourish. The Water Council,
in partnership with the Wisconsin Economic Development Corporation
(WEDC), established the first global freshwater seed accelerator program,
known as the BREW (Business Research Entrepreneurship in Wisconsin).
Vegetal I.D., a manufacturer and designer of green roof systems in both
Europe and North America, was accepted into The BREWs inaugural
program in 2013. A subsidiary of French company Le Prieure, the company
established a foothold in North America in 2011 with its Batavia, New York,
headquarters. Vegetal I.D.s green roof solution, Stock & Flow, helps control
stormwater runoff to protect municipal water management systems.
The exposure and networking weve experienced through The BREW
are the biggest benefits weve received from the program, says Brennon
Garthwait, stormwater management specialist with Vegetal I.D.
In addition to space in the Global Water Center in Milwaukee and a
$50,000 grant from WEDC for startup costs, Vegetal I.D. received access to
top industry and business talent. The University of Wisconsin-Milwaukee
also is helping the company test the products efficiency, while the
University of Wisconsin-Whitewater is assisting with a cost-benefit analysis
that can be used to market Stock & Flow to building owners.
Before entering The BREW, we were not expecting to maintain a
presence here long-term, Garthwait said. However, given a projected
industry growth rate of 20 percent per year, Garthwait can imagine Vegetal
I.D. moving its headquarters to Milwaukee.
Dean Amhaus has served as the president and CEO of The Water Council since
March 2010. His 30-year background in multiple sectors encapsulates a wide
range of expertise in government relations, branding, fundraising, economic
development and nonprofit management in Washington, D.C., and Madison,
Wisconsin. Amhaus has also served as the president of The Spirit
of Milwaukee, which is dedicated to enhancing Milwaukees
image, the president of Forward Wisconsin, the states economic
development organization, and executive director of the
Wisconsin Sesquicentennial Commission.
76
EFFICIENCY MATTERS
How Automated Optimization Can

Push the Limits of Efficiency
With the right setup, this software can open new possibilities for system and
pump design improvements.
By Mark R. Anderson
Concepts NREC
utomated methods first

emerged from the aircraft
propulsion industry and
became available to a wider
audience in the mid-1990s. The first
optimization products promised
radical improvements in the design
process but were expensive. With
time, competition in the software
market and a better understanding
of the inherent limitations of the
technique provided the industry
with a more balanced perspective.
While the revolutionary nature
of automated optimization may
have been overstated initially,
many industries have adapted
and evolved the technique in
recent years. Today, automated
optimization is widely used in
engineering design and has moved
into many spheres that have
been late adopters of advanced
numerical analysis.1
Optimization
Many optimization algorithms and
commercial offerings are available
to the engineering community.
Some of the most prominent
solution techniques include
simulated annealing, genetic
algorithms and neural networks.
As the name implies, simulated
annealing methods are derived
from the natural annealing process
of metals and glass. Generic
algorithms mimic the process of

natural selection.
Neural networks are based on
a network of processors similar
to the neurons of the brain.
Despite the sophisticated naming
conventions and schemes, the
basic goal is simple: find the
combination of input values that
yields the best result.
The automated optimization
process is highly dependent on
what is defined as best, often
referred to as the objective
function. The best schemes for
optimization depend on the nature
of the results and how they are
distributed across the numerical
space. Figure 1 shows a simulated
annealing method in a simple twodimensional variable space.
Various optimization schemes

have been widely published.
Although proprietary schemes
do exist, most schemes available
in commercial software packages
are not restricted. The key
functionalities provided by
commercial optimization products
are the ease of setup and control
of information flow. The input
and output flow of information
between the optimization program
and the external solvers is one
critical area. Advanced formatting
and text parsing functions enable
this flow. Advanced plotting and
display functions that enable the
user to see the progression of the
solution across a complex and
multi-faceted range of variables
is also important. Software also
Figure 1. Simulated annealing response surface for a two-parameter

example (Courtesy of Frankfurt Consulting Engineers GmbH)
77
and are common in practice. Most

real-life manual designs require some
compromise of several competing
factors, and MDO methods can
account for this in optimization.
Special attention is required to
constrain the model input and to
scrutinize the model output for
validity. A poorly chosen input range
can force the model outside the valid
range of results and render the
process moot.
A CFD solution that is not
converged or has failed will give
bad signals to the optimizer. Other
constraints are often needed to ensure
a rational result. A user can easily
find that the result dutifully produced
from the optimizer is either not
manufacturable or has been driven
maximum stress level from an FEA
to astronomical size if the proper
analysis. Such approaches are called
multidisciplinary optimization (MDO) constraints were not provided.
Figure 2. Three-dimensional volute (Courtesy of Concepts NREC)
provides control of calculations across

distributed computing nodes.
Solution Methods
Anything that can be quantified
through a model and has multiple
inputs affecting the result can be
used as the basis for optimization.
In pump design, a typical option
might be efficiency determined
through a computational fluid
dynamics (CFD) solution. However,
any model such as meanline
analysis or streamline curvature
could be used to quantify
performance, and finite element
analysis (FEA) could be used to
determine stress levels. Other
more esoteric models can be also
used in the objective function.
Variables such as casting,
machining or assembling costs
can be used, provided they
can be discretely quantified.
Other phenomena such as noise,
vibration and lifespan can also
be studied.
Combinations of analyses
can be used to define the
objective function. A common
combination might be efficiency
from a CFD solution and
78
EFFICIENCY MATTERS
Figure 3. Flow field result for the baseline and optimized volute. Note the more uniform
velocity distribution after the tongue. (Courtesy of Concepts NREC)
Examples
This article will examine two
CFD-based optimizations that
demonstrate the optimization
process (see Figure 2). The first
study is an optimization of a
three-dimensional volute. In the
study, the flow rate was fi xed
and the overall head rise was
predominantly determined by
the impeller, which was also
unchanged.
The study used three separate
parameters to control the shape of
the tongue region of the volute.
The objective function was taken to
be the total-to-total efficiency
of the stage.
Figure 3 shows the results of the
baseline design and the optimized
result. The baseline design shows
a large separation region after the
tongue, while the optimized design
shows a well-developed flow field
with no separation. A total of 150
CFD solutions were called by the
optimizer. Each CFD solution was
comprised of about 388,000 grid
cells and ran for 30 minutes.
Efficient parameterization
of the inputs is a critical factor in
the success of an optimization.
The case is a good example of how a
system-level approach is the most
cost-effective.
The design space must be
explored as efficiently as possible
to ensure that a reasonable number
of iterations are needed to actually
get to the optimum. Systems using
parameters that define a wide
variety of coherent shapes with
a minimal number of inputs are
superior to other methods.
The second study also used
CFD, but this time to optimize the
impeller. A snapshot of the grid
used to analyze the baseline design
is shown in Figure 4. The analysis
included 14 input variables. Ten
Figure 4. Cross-section of the structured grid example for the pump impeller optimization
(Courtesy of Concepts NREC)
Figure 5. Solution for the pump impeller optimization (Courtesy of Concepts NREC)
79
AMERICAN TRAINCO
Real World Training...for Real World Needs
different outputs were considered from the solver,

either as constraints or included directly in the
objective function.
The result of the process yielded a design with
1.2 percent higher efficiency at the design point,
with no penalty at the off-design flow rates. Head
rise went from 99 to 104 feet at the design point.
About 450 CFD solutions were required by the
optimizer (see Figure 5).
Conclusion
Automated optimization is becoming more widely
used in the turbomachinery industry at many
levels. While commercial offerings have improved
the process significantly, making effective use of
optimization still requires expertise on the part
of the user.
That said, a properly designed optimization
exercise can both streamline the entire design
process and discover improved performance from
regions of the design space that the user might
never have considered previously. Expanded
capability in modeling methods and reduced cost
in high-powered computing resources both point
to the increasing use of advanced optimization
methods in the pump industry.
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Acknowledgements
Dr. Edward P. Childs of Concepts NREC performed most of the
optimization setup and analysis shown in this article and laid
much of the ground work for the optimization system shown.
References
1. Japikse, D., and Platt, M. J., Optimization in Component
Design and Redesign, 10th Intl Symposium on Transport
Phenomena and Dynamics of Rotating Machinery
(ISROMAC-10), Honolulu, Hawaii, March 7 11, 2004.
2. Anderson, M. R., Optimization of Turbomachinery
Validation against Experimental Results, CDK Nov
Energo, 2009 Current Trends in Design and Computation
of Turbomachinery, June 2 4, 2009.
Mark R. Anderson is Chief Technology Officer

at Concepts NREC. He received his B.S. at
Northeastern University and his M.S.
at the Massachusetts Institute of
Technology, both in mechanical
engineering. He has authored more
than 25 papers throughout his
career.
80
MAINTENANCE MINDERS
Remote Monitoring Solutions Prevent Valve

Failure at Combined-Cycle Power Plants
Specialized software helps end users address problems before they happen.
By Cynthia Stone
t combined-cycle power plants, a problem

in even the smallest piece of equipment
can cause signicant downtime and lost
production. Valves, in particular, must operate
at peak performance to ensure consistent plant
operation. With the help of remote monitoring
software solutions and related support, power
plant management teams can ensure that all
equipment is operating eciently and address
potential problems before they result in
costly downtime.
Failing Servo Valve

In the summer of 2013, a remote monitoring
software solution detected a small increase in the
dierence between the command and feedback of a
valve on a combustion turbine at a combined-cycle
power plant.
The dierence in feedback increased from
approximately 1.6 percent to about 2.9 percent.
At the same time, the dierential on the other
gas valves appeared to be stable and tracking
around 0.5 percent (see Figure 1). The software
solution company notied the end user of this
issue in a weekly report and began tracking this
measurement on weekly calls.
Figure 1. Fuel gas control valve 2 differential shows the variance between the
position feedback of the valve and the servo command. (Graphics courtesy of
GE Intelligent Platforms)
81
Figure 2. A screenshot shows actual values (blue) and expected values (green). Decreases in actual
hydrogen gas pressure (blue) versus expected (green) are shown in bottom graph.
The site initially attempted to

calibrate the gas valve, but after
the calibration, the dierence
between the feedback and demand
reached approximately 4 percent.
The site then determined that
either the servo for the valve was
failing or debris had accumulated
on the servo.
Regardless, the servo needed to
be replaced. After the site replaced
the servo, the dierence between
the actual and feedback of the valve
returned to expected levels.
If the dierence between
the demand and the actual had
reached 10 percent, the unit would
have tripped, resulting in lost
production and a decrease in the
life of the engine.
Early notication of this issue
provided the end user with time
to schedule a second maintenance

action to solve the problem.
This allowed the prevention of
production loss.
Tripped Purge Valve

In early November, this same
software solution detected that
the hydrogen gas pressure on a
generator was dropping rapidly.
Values were expected to operate
at approximately 31 pounds per
square inch gauge (psig) (3.2 bar).
Actual values, however, were
measured as low as 28 psig (2.9
bar) (see Figure 2). The software
company sent a high-priority
notication to the end user and
began tracking this issue on
weekly calls.
The user immediately
investigated the issue and
discovered that a hydrogen

purge solenoid valve had tripped
and was releasing hydrogen from
the generator.
The user was able to reset and
correct a tripped purge valve. If
this issue had not been detected,
the low hydrogen gas pressure
could have caused a trip of the
unit, resulting in signicant
production losses.
The low hydrogen pressure
could also have resulted in seal
oil leaking into the generator,
endangering the generator
windings and/or the bearings.
Read more Maintenance

Minders articles from GE at
mmgeip.
Cynthia Stone is a product

marketing manager for Industrial
Data Intelligence at GE. With
nearly a decade of experience
working in predictive analytics
for power, oil and gas,
mining and aviation.
Stone may be
reached at cynthia.
stone@ge.com.
82
MOTORS & DRIVES
How to Prevent the 2 Most

Frequent Causes of Motor Failure
Protecting these two components can lead to longer equipment life.
First of Two Parts
By Rob Amstutz
GE Power Conversion
ndustry estimates assert that

50 percent of all electricity
usage and up to 70 percent
of electricity usage in industrial
plants is the direct eect of the
energy used by motors.1 In the
petroleum and chemical industry,
average downtime costs $87,000
per hour.2 Given that the initial
cost of a 60-horsepower motor, for
example, is less than $6,000, the
reliability of motors is much more
critical than the initial cost.
This series discuss the two most
frequent causes of motor failures:
bearings and windings. It also
identies some steps that motor
manufacturers and motor users
can take to reduce downtime and
increase reliability and motor life.
Many end users specify a certain
L10 bearing life in an attempt
to ensure that their motor will
have a long bearing life, which
implies a long motor life. Institute
of Electrical and Electronics
Engineers (IEEE) 841 also species
a required minimum L10 life.
Requiring an L10 life (within
reason) may help ensure long
bearing life, but other parameters
are also necessary.
L10 as dened by American
Bearings Manufacturers
Association (ABMA) is a measure
of bearing fatigue life, with the

assumption that other critical
aspects such as operating
temperature, t and lubrication are
adequate. In essence, it means that
under ideal conditions, 10 percent
of bearings will fail because of
metal fatigue in service conditions
with ideal operating conditions.
In practice, most bearing failures
are not related to metal fatigue.
These failures are usually caused by
contamination, vibration, heat, too
much or too little lubrication, or
other environmental factors.
Keeping a bearing isolated from

the environment, both outside
and inside of the motor, is a good
rst step to protecting it from
contamination. A close running
t between the end shield and the
shaft, along with a recessed slinger
or labyrinth seal, can help keep
contaminants out of the motor and
the bearing from the outside.
Keeping grease inside the bearing
cavity and outside of the internal
area of the motor is also important.
Although motor bearing greases
are selected to be compatible with
Labyrinth Seal
Gasketed and rabbeted
bearing cap
Close running ts
Image 1. A properly designed bearing cavity protecting the bearing from contamination
(Images and graphics courtesy of GE Power Conversion)
83
winding materials and insulation, in

service grease contamination on the
windings will collect dust and debris,
which is often electrically conductive
and can lead to degradation of the
insulation system.
A close running fit between the
motor bearing cap and the shaft
helps ensure that contaminants
arising inside the motor do not
migrate into the bearing cavity.
A further improvement can be
created by having a bearing cap
gasket and a rabbeted closely
machined fit between the bearing
cap and the end shield. A labyrinth
seal can also increase protection.
Image 1 shows some things
that can be done to ensure the
bearing cavity is protected from
contamination.
Figure 1. Common causes of motor failure
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84
MOTORS & DRIVES
Lubrication
Lubrication is the second issue
to generate premature bearing
failures in motors. Over-lubrication
and under-lubrication can both
cause bearing failures.
The motor manufacturers
installation manual should
be consulted for frequency of
lubrication, amount of lubrication
and type of lubrication.
In addition to the frequency
and the amount of lubrication, the
type of lubrication is critical. Many
bearing failures happen because
of the incompatibility of greases.
Again, the installation manual
and the motor nameplate should
be consulted.
Some manufacturers stamp
the grease type on the motor
nameplate to help end users
ensure that they are using the
correct grease.
Figure 2 is a compatibility chart
comparing the compatibility
of various grease types.4 Many
plants re-lubricate with whatever
grease is available. This can lead
to fast failures if the grease
is not compatible with the
grease supplied by the motor
manufacturer.
Vibration
High vibration can be a cause of
bearing failures in motors as well.
Petroleum and Chemical Industry
Committee (PCIC) Paper No. PCIC2005-9 states that a 50 percent
reduction in vibration can result in
a doubling of bearing life.
Specifying low motor vibration
can greatly increase the motor
bearing life.
The National Electrical
Manufacturers Association
(NEMA) standard vibration level
for 140-449 frame motors is 0.15
inches per second.
Figure 2. Compatibility of various grease types with other grease types
The IEEE 841 committee

recognized low vibration as a way
to increase bearing life, and they
specied a level of 0.08 inches
per second, roughly half of the
NEMA standard.
Some motor manufactures are
able deliver motors with overall
vibration levels of 0.04 inches
per second.
The overall vibration level of
the motor should be a strong
consideration where maximum
reliability and uptime is desired.
Low vibration can also increase
the life of the bearings in the
pump and the life of the pump
seal. Specifying a maximum of
0.04 inches per second of vibration
should make bearing life seven
times longer according to the
PCIC paper.
Part 2 of this article, which will
appear in Pumps & Systems June
2015s cover series, will discuss
winding failures, another common
cause of motor failure.
References
1. http://www.reliableplant.com/
Read/25199/methods-optimize-electricmotor Methods to optimize electric
motor eciency
2. http://www.reliableplant.com/
Read/22766/test-methods-motorreliability The impact of condition on
motor eciency and reliability
3. IEEE Petro- Chemical Paper PCIC-94-01
4. http://www.acculube.com/lubricantacculube-compatibility.html Acculube
Compatibilty Chart for Commercial
Greases
Rob Amstutz is a senior

application engineer with GE
Power Conversion focusing on
1-1,000-horsepower motors. He
holds a Bachelor of Science degree
in mechanical engineering from
Purdue University and
a Masters of Business
Administration from
Indiana Wesleyan
University.
SEALING SENSE
How To Avoid Compression Packing Failure

Waiting to replace packing in centrifugal pump service can lead to downtime and safety issues.
By Carl H. Jones
FSA Member
ompression packing has been

around since the beginning of
the industrial revolution and
is still used extensively in types of
equipment in which a stung box
seal is required to prevent loss of
process uids to the environment.
While advanced sealing solutions
for rotary applications, such as
mechanical seals, emerged over
time, compression remains an
important industrial tool.
often requiring further gland

adjustment. Gland pressure
is regulated to provide the
optimum lubrication to seal and
prevent overheating.
Over time, loss of the lubricant
and wear of the packing rings
contribute to gradual decreased
eectiveness, leading to the need
to replace the packing.
S
T
A
M
P
S
Size What are the stung

box dimensions?
Temperature What is the
temperature of the medium?
Application What type of
equipment is it?
Media What medium is
being sealed?
Pressure What is the
internal pressure being sealed?
Shaft speed What is the
surface speed of the shaft?
Packing Material
The choice of packing material
aects the operating costs of
Gland Pressure
Compression Packing Failure
centrifugal pumps, but little is
A compression packing seal is
One common mistake is the
known about the relationship. The
established by installing the
tendency to maximize the packings
Fluid Sealing Association (FSA)
packing ring set into the stung
time in service to a perceived
and European Sealing Association
box (see Figure 1). Then, the gland
point of failure before replacing it.
(ESA) began to address this lack
on the back of the stung box is
Dening failure is more a matter of
tightened to compress the packing of data by developing industry
between the shaft and stung box standard test methods to shed light opinion than science.
Signs that the packing has failed
wall. Once compressed, the packing on how packing behaves.
include increased leakage, smoke
The acronym STAMPS
expands, exerting a radial force to
at the stung box or uncontrolled
can be used to remember key
the sides of the stung box and
considerations that can determine leakage at the gland.
against the shaft.
Safety-conscious operators service
Built-in lubricants are released
which packing material and
the pump and replace the packing at
from the packing as gland pressure construction should be selected:
is applied. These lubricants are
Figure 1. Packing in a stuffing box (Graphics courtesy of FSA)
particularly important during
equipment startup.
Eventually, the process uid, or
an external ushing uid, takes
over the packings lubricating
function and provides a continuous
lm of uid to reduce friction.
Heat dissipates through the shaft,
packing, pump housing and
process uid.
Built-in lubricants are gradually
lost during pump operation,
85
86
SEALING SENSE
regular intervals. However no

common criteria for determining
the replacement frequency or
relating it to the packing material
are available. An acceptable
replacement cycle time is heavily
dependent on the application, the
equipment and the packing.
The confusion occurs because of
the forgiving nature of compression
packing. Pump operation is not
impaired until the packing fails. It
should be replaced long before this
occurs. For any type of packing,
operating costs are relatively xed
when it is functioning correctly.
As performance deteriorates,
operating cost increases are much
larger than the initial cost of the
packing ring set.
Based on the way packing works,
three factors aect costs:
1. Power loss, shaft/sleeve
abrasion and material wear
caused by friction
Figure 2. Heat dissipation path
2. External ush uid leak

rate from the stung box to
dissipate heat caused by friction
3. Labor to adjust gland pressure
to maintain minimal leak rate
from the stung box
The best practice is to monitor
changes at the stung box and
replace the packing before costs
increase. There are many costs,
and depending on each application
any of these costs could be the
most signicant. For example, the
cost of product loss and product
dilution could be much higher than
power consumption or ush water
losses depending on location and
the cost of labor.
Signs of Failure
After the pump and auxiliary
systems have achieved a steady
state, measure the temperature
at the stung box and record
the dierence from the ambient

temperature. For example, if
ambient is 65 F and the stung
box is 110 F, the operating baseline
dierential is 45 F.
Measure the drip rate from the
stung box in drips per minute
and record that as well. Over time,
operators will adjust the gland
follower to maintain this drip rate.
Signs that the packing is failing
and needs to be replaced are now
easier to identify and can include
any of the following:
The baseline drip rate can no
longer be controlled through
normal gland follower
adjustments.
The stung box/ambient
temperature dierential
increases dramatically relative
to the baseline reading taken
when the packing was rst
installed (+25 percent).
The packing is extruding from
the back of the pump.
The pump is shut down for
maintenance, and the packing
shows signs that the material is
becoming hard or brittle.
Following these simple steps
and replacing the packing can
improve performance and save
money by avoiding excess loss of
power and process uid. Increased
adjustments to the gland and
extending of the shaft/sleeve life
are no longer needed.
Figure 3. Sealing forces and packing
Next Month: What does the

new FSA/ESA Gasket Handbook
contain, and how was it developed?
We invite your suggestions for article topics as
well as questions on sealing issues so we can
better respond to the needs of the industry.
Please direct your suggestions and questions to
sealingsensequestions@fluidsealing.com.
87
Principles of Controlled-Volume Metering

Pumps & Advantages of Dual Seals
By Hydraulic Institute
Figure 7.3.1a. Rate of flow versus pressure (Graphics courtesy of
Hydraulic Institute)
What principles drive the pumping

action in a controlled-volume
metering pump?
The pumping action is developed by a
reciprocating piston. This reciprocating motion
develops a ow prole represented by a sine wave.
Actual rate of ow is determined by the following
formula:
Rate of flow = Displacement x
Cycles per unit of time x Volumetric efficiency
Figure 7.3.1a illustrates how changes in
discharge pressure minimally aect the rate of
ow from a reciprocating, controlled-volume
metering pump.
Figure 7.3.1c shows the rate of ow versus
stroke-length setting for a controlled-volume
metering pump at a given pressure and stroking
speed. The curve is linear, and it is not necessarily
proportional. The 50 percent stroke setting
may not equal 50 percent ow, because the
curve may not pass through zero on both axes
simultaneously. Other rates of ow versus stroke
length settings can be accurately predicted by
measuring ow at two rate-of-ow settings,
plotting both points and drawing a straight line
through them.
The relationship between the theoretical
and actual rate of ow of a controlled-volume
metering pump is illustrated in Figure 7.3.1d.
The dierence between the theoretical and actual
curves represents the volumetric eciency (VE),
the ratio of the actual pump delivery per stroke to
theoretical displacement, expressed as a percent.
For more information on controlled-volume
metering pumps, see ANSI/HI 7.1-7.5 ControlledVolume Metering Pumps for Nomenclature,
Definitions, Application and Operation.
Figure 7.3.1c. Actual flow curve, rate of flow versus stroke length
Figure 7.3.1d. Theoretical and actual flow curve, rate of flow versus
stroke length
88
HI PUMP FAQS
What are the advantages

of dual seals, and how are
they subcategorized?
Dual seals include more than
one set of sealing surfaces. Dual
seals typically require the use of
an external liquid or gas and are
operated with an auxiliary system.
They require more auxiliary
systems and monitoring than a
single seal. The total initial cost
is usually higher and requires
the installer to have additional
training. The benets are increased
reliability and safety.
Dual seals are used when one
or more of the following criteria
cannot be achieved by using a
single seal design:
Emission control of process
uid to the environment under
normal operating conditions
Emission of process uid under
upset conditions or failure of
the primary seal
Acceptable life (time
between repairs) as a result
of inadequate lubricating
properties of the pumped
medium, which may be a result
of too many solids too close
to vapor pressure, too low
viscosity in combination with
pressure and speed, or too high
pressure dierential for one set
of faces
The advantages of dual seals
include:
Dual pressurized seals can seal
products that crystallize, burn
or are otherwise unsuitable for
single seals.
Dual seals can limit loss to the
atmosphere. This feature may
be a factor in seal selection for
equipment handling hazardous
materials.
Seal life may be improved as
Variation in molten metal temperatures can also result in

variations in surface finish in a single foundry run.
the seal faces operate in a clean,

cool environment.
Seal performance can be
conrmed by monitoring the
barrier uid.
Dual seals are subcategorized

as dual pressurized and dual
unpressurized. In a dual
pressurized seal, the external uid
is at a higher pressure than the
seal chamber pressure. As a result,
all faces of the mechanical seal
are lubricated. In this design, the
external liquid is called a barrier
uid. In the dual unpressurized
seal, the external uid is at a
lower pressure or, as in most
applications, at ambient pressure.
The external uid is called a
buer uid. Dual seals come in
several congurations and with
a variety of application-specic
design features. Their faces can be
arranged face-to-back, face-to-face
and back-to-back.
The advantages of the
pressurized dual seals over the
unpressurized versions are:
The faces are lubricated using a
clean, cool liquidusually oil,
water or glycolwhich provides
low wear rates.
Dual gas seal faces are
separated with a clear inert gas
such as nitrogen.
The seal operates independently
from the pump. Consequently,
loss of product, cavitations
or other disturbances can be
better tolerated.
Zero emissions or product

leakages are released into the
atmosphere.
For more information on

mechanical seals, see the HI
Guidebook Mechanical Seals for
Pumps: Application Guidelines.
What pump component

casting properties are
affected by variations in
test tolerances, and how
can an increased level of
precision be obtained?
Various manufacturing
processes often dictate the level of
precision possible in the production
of a certain part. A large percentage
of pump components are produced
as cast parts that must be
subsequently machined, cleaned,
dressed and assembled into
stationary and rotating assemblies
prior to the pump test. Normal
manufacturing variations can have
an impact on the continuity of
hydraulic geometry and, therefore,
aect performance.
Casting dimensional variations
depend on the molding process.
Low-volume, large components
are frequently molded in sand
using manual processes. As
with most manual processes, an
inherent large variation exists in
the process, both dimensionally
and in the resulting surface
89
nish. Machine molding is used on higher

production volume components and results in
less variation in dimensions and nishes. For a
higher level of precision, some components may
be cast using an investment process that results
in the smallest variation in both dimensions
and nishes.
The variation of hydraulic surface nish
of the casing or impeller is dierent for the
various types of cores used to make the part.
Wax cores exhibit little variation in nish and
typically do not cause hydraulic performance
variations. Sand cores, particularly those that
are hand-molded, can have signicant variation
in surface nish. Variation in molten metal
temperatures can also result in variations
in surface nish in a single foundry run. The
surface nish in these types of cores can aect
head and eciency.
Minor variations in the contour of the
leading edge of impeller vanes can aect
the net positive suction head required
(NPSHR) signicantly. Because leading
edges are often thin, they can be easily
deformed. Casting shrink rates are aected
by chemical composition variations within
alloy specications, pouring temperature
and cooling rates. The resulting dimensional
variations aect head and eciency.
Casting cleaning is the process in which
a raw casting is manually or automatically
cleaned and dressed. Casting burrs, surface
imperfections and mold split lines are often
ground o and smoothened out. Hydraulic
passageways are often dressed and matched
by hand. These processes result in variations
of the local geometry of the part. An increased
level of precision can be obtained through
the introduction of more sophisticated metal
removal processes and metrology.
For more information on test tolerances, see
ANSI/HI 14.6 Rotodynamic Pumps for Hydraulic
Performance Acceptance Tests.
HI Pump FAQs is produced by the Hydraulic Institute

as a service to pump users, contractors, distributors,
reps and OEMs. For more information, visit pumps.org.

90
The Volumetric Efficiency of Rotary

Positive Displacement Pumps
Comprehensive testing revealed unexpected relationships.
By Bill Blodgett
LobePro Rotary Pumps
otary positive displacement

(RPD) pumps theoretically
displace a xed amount
of uid per revolution. However,
some loss in output is typically
caused by the uid slipping past
the rotors. The dierence between
the quantity displaced (Qd) and
the actual output quantity (Q) is
slip (Sq). The volumetric eciency
of RPD pumps depends on the
percentage of slip to the total
quantity displaced. The total
output quantity as a percentage
of the quantity displaced is the
pumps volumetric eciency. The
principle determinants of slip
in the normal range of a pumps
operation are:
ViscosityThe higher the
viscosity (V), the lower the slip.
PressureThe higher the
dierential pressure (Pd),
the higher the slip. Pressure
increases slip in pumps with
exible or compressible parts,
such as exible vane impellers
or rubber coated lobes, more
than in pumps with parts
constructed of rigid materials
such as steel.
RPD pump typeEach pump
type has dierent clearance
requirements. For example,
exible vane pumps do not
require any vane clearance
whereas a rotary lobe pump
with stainless steel lobes does
require clearance from the

housing. Within a pump type,
some manufacturers are better
able to meet tight clearance
requirements with precision
than others.
WearAs components wear,
the clearances between them
increase. At higher pressures
and lower viscosities, this
clearance dierence may
increase slip signicantly.
Slip does not increase as pump

speed increases, although the
displaced quantity does increase.
As a result, the faster a RPD
pump is operated, the greater the
volumetric eciency, as illustrated
in Table 1.
Unfortunately, operating an
RPD pump at the upper end
of its normal range may be
counterproductive. High speed
will produce rapid wear if the uid
is abrasive, creating greater slip
with time.
Shear-sensitive uids may be

adversely aected by high pump
speeds, even though RPD pumps
are generally low shear. High pump
speed operations may not provide
enough time for highly viscous
uids to ll the pumping cavities
completely. This will cause a
reduction in the output quantity.
Testing High-Viscosity Fluids

A manufacturer of rotary lobe
pumps (positive displacement
rotary pumps) produces pumps
equipped with nitrile rubber (NBR)
coated lobes, although some are
hydrogenated nitrile butadiene
rubber (HNBR), uorocarbon
(FKM) and solid metal lobes. For
many years, the manufacturer
tested each pump in a test pond to
ensure the pump met the published
curve for ow and horsepower at
the duty point for pumping fresh
water, which is close to a viscosity
of 1 centipoise (cP).
However, through 2013, this
Table 1. Pump volumetric efficiency (Graphics courtesy of LobePro Rotary Pumps)
Slip
Pump rpm
Qd
Volumetric
Efficiency
10
100
34
24
71%
10
200
58
48
83%
10
300
92
82
89%
10
400
126
116
92%
10
500
160
150
94%
91
manufacturer had not tested the

pumps to determine the eect
of higher viscosities on output
and horsepower (HP) in part
because many of its customers were
unable to supply the viscosities of
their uids.
For example, municipal
sludges viscosity depends on the
temperature, percentage of solids,
sludge type and how long the
sludge has been stationary. The slip
and HP required to move municipal
sludge are typically estimated
from practical experience
based on the type of sludge and
percentage of solids. With time and
experience, however, many end
users can provide the minimum
and maximum viscosities of
their uids. Up to 2013, the
Figure 1. Slip percentage of the maximum quantity at 25 psi
TAKE THE SURVEY
THE EFFECT OF GLOBAL FORCES

ON PUMP USERS ATTITUDES
Capital
Expenditure
(CAPEX)
plans for 2015
Frost & Sullivan and Pumps & Systems magazine are partnering to
Emerging
technology and
equipment
upgrades
I
will be published as a series in Pumps & Systems, authored
F
A
S
bit.ly/pumpsurvey
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J
92
manufacturing team estimated the

eect of viscosity using Equation 1.
S = ( K Pd )
V
Equation 1
Slip is a function (K) of the

dierential pressure divided by
the viscosity. The manufacturer
estimated K based on other pumps
published data. By the end of
2013, however, the manufacturer
decided to determine the eect
by direct testing.
In 2014, the companys quality
control manager and plant
manager, under the supervision of
the vice president of engineering,
conducted extensive tests to
determine slip using one of the
manufacturers rotary lobe pumps.
The selected pump model had a
displaced quantity of 34 gallons
per 100 revolutions. The tested
pump was equipped with new
70-durometer, NBR lobes.
The advantage of rubber-coated
lobes is that they are compressible
enough to permit a very close t

with the pump housing. This close
t permits the pump to create a
strong vacuum that results in the
ability to self-prime up to 25 feet.
The compressible rubber coated
lobes also allow the pump to pass
small hard solids without damage.
The disadvantage is that, under
high pressure, the rubber coating
will compress and increase slip.
The pump housing and wear
plates are made from hardened
metals. For all tests the pump was
operated at 300 rpm at multiple
dierential pressures from 1 to 75
pounds per sqaure inch (psi). The
test team used recently certied
vacuum and pressure gauges to
determine the dierential pressure
and recorded barometric and uid
temperature before each test.
At each psi level, multiple tests
were conducted to determine the
eect of the uid viscosity on slip.
The viscosity of the test uid was
determined by evaluating a 1-liter
sample on the viscometer spindle.
The viscosities tested ranged
Figure 2. Slip percentage of the maximum quantity at 50 psi
from 1 to 1,912 cP. Periodically,

certied viscosity uids were used
to ensure that the spindle was
properly calibrated.
Test Results
The test team kept careful track
of the barometric and water
temperature throughout the
testing process. However, when
the team members conducted
regression analysis of the
data, these variables were not
signicant. The barometric
pressure ranged from 29.86 to
30.22. The uid temperature
ranged from 12 to 22 C.
As the team expected, with the
tested pump rotating at 300 rpm
with a dierential pressure of 1 psi,
the slip is relatively low, regardless
of the viscosity. However, a small
but steady increase in slip occurred
from 2.6 percent displaced quantity
at 1 cP to 8.2 percent displaced
quantity at 207.9 cP, which was
not expected.
The team also determined slip
at 25 psi dierential pressure at
93
different viscosities. At 1 cP, the slip equaled

24.5 percent of the displaced quantity, which
was the maximum slip percentage. The
test showed a steady decline in slip as the
percentage of this maximum as the viscosity
increased (see Figure 1, page 91). At 401 cP, the
slip was 2.8 percent. The change in viscosity
explained 95.2 percent of the change in slip.
Based on the published information and
pump handbooks, the team also expected to
find a similar drop in the slip percentage as
the viscosity increased at higher pressures. The
team discovered that the higher the pressure,
the lower the drop in slip percentage as a
result of higher viscosity. For example, at a
differential pressure of 50 psi, the team found
the results shown in Figure 2.
The testing revealed that fluid viscosity
was less effective in sealing the test pump
at higher pressures. This is assumed to have
occurred because the rubber coating on the
lobes compresses more at higher pressures.
This test showed the decline in effectiveness of
viscosity sealing the pump closely correlated
with the pressure increase (R2 = 0.965) and
is, therefore, easy to model. The team plans to
conduct similar tests with metal lobes to see if
the results are different.
Read other articles by Bill Blodgett at

pumpsandsystems.com.
Bill Blodgett is president of LobePro

Rotary Pumps. He holds undergraduate and
graduate degrees in economics and finance
from University of Pennsylvania and the
University of Chicago. Blodgett is the 1987
winner of Northwood Universitys National
Business Leader Award, the former director of
Entrepreneurship and current treasurer
of Palm Beach Atlantic University
and is active in many charitable
organizations. He may be reached
at billb@lobepro.com. For more
information, visit lobepro.com.
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94
Submersible Pumps Protect Canadian

City from Dangerous & Costly Flooding
The city of Richmond, Canada, selected customized technology to suit
the areas unusual requirements.
By Bryan Orchard
KSB
here commercial
enterprises, residential
properties and
agriculture occupy low-lying land
in river deltas, the possibility of
ooding demands consideration.
Rising river and sea levels coupled
with seasonal heavy rain and
snow is a powerful and potentially
disastrous combination. The
appropriate authorities must invest
in both drainage and pumping
systems to protect assets.
Image 1. The award-winning Cambie Road

pumping station (Images courtesy of KSB)
The city of Richmond, Canada, is

an example of such a location. City
authorities have invested in a ood
protection infrastructure that
has prevented signicant ooding
in the community for more than
60 years. The infrastructure is a
combination of dikes constructed
around the 51-square-mile island
on which the city is located, a
network of streams and drainage
channels, and 41 strategically
positioned pumping stations.
Lulu Island, on which most of the

city of Richmond is located, is three
feet above mean sea level. With
continuing property development
to meet the needs of a growing
population, a greater investment
in agriculture and expanding
commercial enterprises, more than
$45 million, has been spent on
ood protection since 2008.
During the next ve years, a
further investment of $50 million
is being recommended to upgrade
95
existing facilities and install new

ones. Pumping stations are a
central element in the ood and
drainage infrastructure, and
the existing 41 stations have the
capacity to shift 18,700 gallons
per second.
Under the upgrade and new build
program, 28 pumps have been
installed and commissioned, with
nine more ordered. Twenty-four
of the pumps are 127-horsepower
(HP) units, and the remaining
four are smaller 37-HP units. The
build program is delivering one
new station per year, and the pump
manufacturer is working with
project engineers in the design of
the water intake and tubes.
Submersible motor pumps
are often used for industrial
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and agricultural water supply,

stormwater and ood prevention
stations, and for other applications
in water treatment industries (see
Image 2). The model is a closecoupled, wet-installed single
entry axial open impeller pump
in which the impeller is located
in a tubular casing immersed in
the water. Explosion protected to
Atmospheric Explosibles (ATEX) II
G2 T3, the pump has a maximum
ow capacity of up to 1,500 gallons
per second and a maximum head of
39 feet. Low vibration hydraulics
and a vortex-free ow due to the
inlet ribs and wide bellmouth
ensure the pump is hydraulically
optimized. Eciency is provided
by the slim motor that minimizes
discharge tube ow losses.
Image 2. This pump serves in many

flood control applications.
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96
Romeo Bicego, manager,

Sewerage and Drainage
Engineering and Public Works,
explains why this pump is their
preferred option. We rst brought
in these pumps around 12 years
ago, and since then, they have
proved to be durable and reliable.
We have experienced very little
downtime, maintenance is easy and
the customer service is good, plus
our sta likes working with the
pumps, Bicego says.
There is a high iron content in
the water, but this has not proved
to be a problem for these pumps.
Life expectancy for the pumps
is more than 30 years. This is
attributable to the high quality
of the pumps and our in-house
planned maintenance. We like to
keep one pump in our workshops
as a standby, and we do maintain
comprehensive stocks of spares.
Derek Hunter, foreman pump
stations, says that when a station
is upgraded, the preferred option
is to retrot with the submersible
motor pumps, which are replacing
aging long shaft pumps. Usually
we try to change out the aging
long shaft pumps rst because of
problems associated with parts and
eciencies, Hunter says. We have
not had any signicant problems
with the submersible motor pumps
over the years. We pull them out of
service once a year for inspection,
and, quite frankly, they are
bullet-proof.
When it comes to specifying
pumps, Bicego emphasizes that
once a product range has been
found to provide good operational
service and reliability, it makes
sense to stick with that product.
By standardizing on a single type
of submersible pump, we have been
able to focus our product training
and knowledge on this pump,
which makes maintenance far more
cost-eective. When you work with

a wide number of products, it can
produce diculties in terms of
inventory control, and technical
knowledge is diluted. I am a strong
believer in going for best value
when it comes to pump selection
as this provides dividends over the
long term.
Maintenance is high on the
Engineering and Public Works
agenda because it is far more costeective to invest in maintenance
than to replace products. We
spend considerable eort on
maintaining our pumping stations,
and we have a sta of 18 dedicated
to checking that the stations are
clean, odors are controlled and
intake screens are free of debris,
Bicego says. The last thing we
want is for the pumps just to be
cycling water. Through previous
storm events we know that we can
experience up to 2 inches of rain,
so we need to ensure that screens
are free of blockages ahead of
predicted storms.
Located at strategic intervals
around the island, the pumping
stations are called into service
when required, and all are tted
Image 3. Romeo Bicego and Derek Hunter

at No. 4 Road pumping station.
with ood gates and ood boxes.

During the winter months, the
pumping stations are called into
action much more frequently. The
groundwater levels can be very
high during the winter, and this
is exacerbated when rainfall and
tides are high, too. At high tides,
the pumps transfer drainage water
into the Fraser River Delta, but at
low tide, drainage water discharges
through the ood boxes via gravity
outow gates. Users also have to
consider the possibility of power
outages. The citys goal is to have all
the stations equipped with standalone generators. Currently they
have 11 on-site generators and 10
portable sets.
Pump Station Design

Water pumping stations are not
usually aesthetically pleasing
and can be noisy, which is why
they are typically located away
from residential areas. For the
pumping stations to have the
minimum visual impact on the
environment, Richmond has
given a great deal of thought to
their design and construction.
This approach was rewarded when
97
98
the Cambie Pumping station (see

Image 1, page 44), located in a light
industrial area close to a residential
development on the Fraser River,
won a design award. The station
has a vegetation-covered roof to
blend in with the environment and
is built into the dike giving walkers
a rest facility along the river. The
design also includes a sculpture
by the pump house designed to
resemble a droplet of water.
The No. 4 Road pumping station
is in a former industrial area that
is going through a residential
transition (see Image 3, page 96).
Converted from a long shaft pump
station, the design incorporated
aspects of the old station together
with the crane lifting frame that
now acts as a viewing platform.
The walls of the pump house depict
the history of the lumber business
along the Fraser River, and the
standby power generation plant is
visible though clear glass walls. By
deliberately making the pumping
station visually attractive, practical
and a community amenity,
vandalism is deterred.
The designers also considered the

outow from the pumping stations
and the eects it would have on the
surrounding area. Large volumes
of water can lead to the erosion of
river banks, creeks and beaches.
Spillways are designed to minimize
this impact (see Image 4).
Image 4. Spillways are designed to minimize the

environmental impacts of outflow from pump stations.
Image 5. Cranberries are the single largest crop grown in the city of
Richmond and the fields are flooded during the harvesting period.
Planning for the Future

The challenge that faces the city
of Richmond is unusual, with
occupancy and use being split
between residential/commercial
and agricultural activities. The
city is part of Canadas largest
cranberry growing area, and the
99
elds have to be ooded at harvest time

(see Image 5). However, water levels in the
drainage channels must be kept low enough
that other parts of the island do not ood.
It is a delicate balancing act that combines
irrigation, drainage and ood control.
Designed for a once-a-decade rainstorm,
the pumping stations are all monitored
remotely 24 hours per day using a
supervisory control and data acquisition
(SCADA) system to ensure that the pumps
are operating eectively. This provides
additional capacity to hold the surplus
drainage water resulting from a storm.
While risk pro les are changing slowly with
climate change and sea level, the citys ood
protection improvements are moving faster,
and the overall level of safety continues
to improve.
The city of Richmonds Engineering and
Public Works Department has developed a
close working relationship with one pump
manufacturer throughout several years,
and when a major investment is being made
in ood defenses, that manufacturer is the
preferred supplier.
We need our pump suppliers to provide
technical support not just when we are
designing a new or refurbishing an old
station, but also throughout the length of
a project and over the long term, Bicego
says. When it comes to selecting pumps,
we look for pump eciency and reliability.
We are very conscious of the environment
and our carbon footprint, so if we can source
pumps that satisfy our green credentials
and operating requirements, then we will
go with the company who can ful ll all the
requirements.
U N M AT C H A B L E E X P E R I E N C E
I N F L OW C O N T RO L
TRANSACTIONS
Jordan, Knauff & Company is a knowledgeable and

experienced provider of a comprehensive line of
investment banking services to the pump, valve and
PXVEXMSRMRHYWXVMIW*PS['SRXVSP
Our lines of business include: selling companies,
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To learn more about Jordan, Knauff & Company,
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XIEQ %GGIWW SYV *PS[ 'SRXVSP VIWIEVGL EX
[[[NSVHEROREYJJGSQS[GSRXVSP
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(EZMH%/EOEVIOE
Managing Principal
GN$NSVHEROREYJJGSQ

Senior Associate
HOEOEVIOE$NSVHEROREYJJGSQ

MEMBER FINRA, SIPC
Bryan Orchard is an independent technical

and environmental engineering journalist
based in the U.K. For more than 25 years, he
has reported on water treatment and supply,
energy and pump related projects in many
parts of the world. For more information,
visit ksb.com.
100
Impeller Design Prevents Vapor Lock

Specialized centrifugal pumps handle liquids with up to 70 percent gases.
By Ross Draper
Fluid Process Equipment
ir and gas entrainment

in pumped liquids is a
long-standing problem for
centrifugal pumps. A conventional
method of dealing with this issue
is using recessed, impeller-style
pumps. However, this technology is
highly inecient. Other methods
use expensive and environmentally
unfriendly defoaming chemicals.
Some facilities use too much
defoaming chemical to prevent
pumps from vapor locking or to halt
ow instabilities. Many operators
have problematic pumps that
continue to vapor lock. This is a
result of too much air entrainment
in the process.
Unconventional Solution
One particular centrifugal pump
moves liquids containing large
amounts of air and other gases. The
system can pump liquids containing
up to 70 percent gases.
In conventional centrifugal
pumping, a liquids air or gas
migrates to the impellers center.
This is because the centrifugal eect
imparted by the impeller vanes onto
the liquid causes the air or gas to
separate from the liquid. The impeller
center is an area of low pressure,
which leads to gas accumulation.
Eventually, the gases increase so
much that a bubble forms, preventing
the liquid from entering the impeller.
The pump essentially vapor locks and
no longer performs.
One specially made impeller

features teardrop-shaped balancing
holes located closer to the center
of the impeller, where the gases
accumulate. The balancing holes
allow gases to pass through the
impeller eye. By introducing a
lower pressure behind the impeller,
the balancing holes allow a removal
route for the gases accumulating
in the impellers eye. This concept
allows the pump to perform like
a normal centrifugal pump while

pumping liquids with high gas
entrainment. Two dierent pump
models use this design, but each
employs a dierent method to
create the lower pressure behind
the impeller.
Pump Designs
The rst pump design has an
external liquid ring vacuum
pump mounted next to it. This
Figure 1. An external vacuum pump is attached to the centrifugal pump.

(Images and graphics courtesy of Fluid Process Equipment)
101
In conventional centrifugal pumping, a liquids air or gas migrates

to the impellers center. This is because the centrifugal effect
imparted by the impeller vanes onto the liquid causes the air or
gas to separate from the liquid.
model has a unique stuffing box

arrangement consisting primarily
of an expeller inside the stuffing
box located behind the impeller,
a degas pipe and a recirculation
pipe. The vacuum hose from the
external vacuum pump connects to
the centrifugal pumps degas pipe,
which is attached to the stuffing
box (see Figure 1). This creates
lower pressure behind the impeller,
inducing gases to migrate through
the balancing holes and into the
degas zone, which is the stuffing
box area in conventional pumps.
The expeller mounted to the
shaft inside the stuffing box
separates any liquid carryover
from the gases. The expellers
centrifugal force moves any liquid
carryover into the recirculation
pipe. The recirculation pipe is
connected to the peripheral
portion of the stuffing box where
liquid accumulates by the expellers
centrifugal force. The recirculation
pipe is routed back towards the
centrifugal pumps suction inlet
where the liquid carryover returns
to the process.
As the gases migrate from the
impeller and into the expeller
chamber, the expellers centrifugal
force separates the liquid from the
gases. Any gases will accumulate
in the eye of the expeller just as
they did in the eye of the impeller.
This is where the removal of the
gases takes place. The degas port
extends deep inside the pump to

the expellers eye connecting the
external vacuum hose to the degas
pipe and pulls gases out of the
pump and away from the expeller.
The degas pipe and recirculation
pipe are on opposite sides of the
centrifugal pump.
The external vacuum pump
discharges its vacuumed gases from
the centrifugal pump back into the
supply tank. This allows the gas to
dissipate. Any liquid carryover goes
back into the process.
The pump models that use the
special impeller were designed in
the 1980s in Karhula, Finland.
The design facility has a test stand
with a clear tank and a modified
pump system with a see-through
volute. An air hose is inserted into
the tank and discharges near the
suction flange, dispersing air in
a manner that simulates actual
process conditions.
With the degas vacuum pump off,
the centrifugal pump is turned on,
and it pumps room-temperature
water like any centrifugal pump.
However, the demonstration
begins when air is pushed inside
the suction flange. The volume
of air gradually increases until
the pump vapor locks and stops
pumping. The external degas
pump is then turned on, and the
pump begins working normally.
The demonstration continues with
air pumped inside the centrifugal
pump and the external degas pump

continuing to run. The centrifugal
pump quickly removes the air
bubble from the impeller eye and
returns to normal performance.
Comparing Pump Models

The second centrifugal pump model
uses the same volute and impeller
as the first, but the stuffing box
chamber is different. The second
model uses a degas rotor instead
of an expeller (see Image 1, page
102). The degas rotor is similar to
the rotor used in a vacuum pump.
In fact, the pumps incorporate a
miniature vacuum pump inside the
stuffing box behind the impeller.
The second model has limitations
when compared with the first.
It can withstand a maximum of
11.5 feet of inlet pressure on the
suction flange.
This limitation is governed by
the degas rotor capabilities. The
pressure inside the degas rotor
chamber is directly related to the
amount of suction pressure at the
suction flange.
The degas rotor cannot perform
its degas function if the suction
flange is experiencing too much
liquid suction inlet pressure. The
first model described does not have
this limitation.
The second model pump
requires less space because the
vacuum pump is built into the
stuffing box. Both systems can
102
Image 1. Degassing rotor found inside internal degassing pump type 2
pump from tanks either above or

below the pump centerline.
Both designs conform to
International Organization for
Standardization 5199. Neither
pump is of American National
Standards Institute design. The
volute, impeller, expeller and
stung box are made from duplex
stainless steel grade American
Society for Testing and Materials
(ASTM) A890 Grade 3A. This
metallurgy is superior to 316
stainless steel in both corrosion
and abrasion resistance. A890
Grade 3As closest equivalent in the

U.S. and Canada is CD4MCu.
The volute, bearing unit and
adapter are the same as those used
on a similar process pump. Both
models use a single mechanical seal.
These pumping systems cost
more than conventional centrifugal

pumps of an equivalent size.
However, they oer value allowing
air- or gas-laden uids to be
predictably and reliably pumped
in situations where conventional
pumps fail.
Ross Draper works for Fluid Process Equipment (FPE), a

pump distributor in Kalamazoo, Michigan. FPE is a division of
Sunsource. FPE represents Sulzer Pump Solutions,
exclusive manufacturers of centrifugal pump degassing
technology. Draper can be reached at 269-488-2895 or
rdraper@sunsrce.com.
MEET OUR TEAM
103
The editors hope to meet you at these upcoming industry

trade shows. We invite you to stop by our booth, say hello
and tell us your success stories and topic ideas!
Houston, Texas May 4-7
San Antonio, Texas June 14-16
Frankfurt, Germany June 15-19
San Diego, California Aug. 30-Sept. 4
Anaheim, California June 7-10
We look forward to seeing you!

104
Diamond Bearings Withstand Abrasive

Fluids & Environments
These components do not have to be sealed from harsh operating media.
By Rob Judd
U.S. Synthetic
earings are a vital

component in the
wastewater industry.
Breakthroughs in bearing
technologies help wastewater
companies extend the life and
operational eciency of critical
applicationseven when those
applications are operating in harsh
conditions, with corrosive uids
and under heavy loads.
The main problem facing
wastewater applications is not
the operating uid itself. It is the
ongoing threat of seal failure that
causes bearing contamination,
ultimately leading to destructive
and costly system failure. Many
wastewater applications such
as transfer pumps, electric
submersible pumps (ESPs),
stationary pumps, vertical
turbine pumps, dredging pumps
and injection pumps can operate
in demanding and abrasive
environments. Unfortunately, a
typical sealed bearing must be
kept clean and lubricated for the
pump to function properly. Even
the smallest break in the bearing
seal can quickly ood the bearing
with abrasive and corrosive
working uids, bringing pumping
operations to a halt.
Recently, a coastal wastewater
treatment facility in Washington
demonstrated the eects of
running in a corrosive saltwater
environment. The biggest diculty

that the facility faced was the
intrusion of saltwater into its
sewage-outow pipes. If higher
water levels are able to push salty
water into the countys wastewatertreatment system, corrosion will
worsen. This has already been seen
to a certain extent with equipment
that should be lasting 50 years
breaking down after 20 (Seattle
Weekly, King Tide Shows What
Climate Change Has In Store,
January 2015).
Corrosion is a killer when it
comes to application integrity.
Bearings and seals have a direct
impact on wastewater equipment
and system performance. They
simply cannot fail. Because these
applications generally run in
corrosive conditions, wastewater
engineers design bearings and seals
that are protected from operating
uids. However, these bearings
generally require a watchful eye
and ongoing maintenance. When
a seal fails, operational uid
leaks into the bearing housing
quickly, decreasing equipment life,

increasing surface friction and
energy consumption, and aecting
equipment operation.
A New Solution
Faced with these challenges, some
companies in the wastewater
industry are discovering the
benets of advanced seal-free
bearing technologyusing
polycrystalline diamond (PCD).
PCD is an advanced engineering
material comprised of individual
diamond crystals that have been
fused together under extremely
high pressures and temperatures.
The result is a diamond bearing
surface that provides extreme
hardness, wear resistance and
thermal conductivitydelivering
a bearing that can be submerged
directly into corrosive and abrasive
process uids. This eliminates
the need for seals and lubricants
altogether. Instead of designing
around corrosive process uids,
diamond bearings can work
directly in them.
Instead of designing around corrosive process

fluids, diamond bearings can work directly in them.
105
Compared to traditional bearing technology (such as tungsten

carbide), diamond bearings offer extended bearing life by four to
ten times in the harshest real-world environments.
typically operates in silt-laden river

water and canal water.
Another large energy company
also saw remarkable results from
its adoption of diamond bearing
technology. The company reported
signicant improvements in its
chemical mixing application. The
application used a traditional foot
bearing that was typically failing
every three months. Replacing the
In our initial testing, we

threw sand and gravel into the
PCD bearing to see how it would
perform. It seemed to like it
just ground up the particles
with no problem. In some ways,
it actually worked better, said
Clayton Bear, president of New
Energy Corporation, a builder
of Marine Hydrokinetic power
generation equipment that
Table 1. Physical and mechanical property comparison of bearing materials.

Sources: Bertagnolli, U.S. Synthetic; Roberts et al., De Beers; Cooley, U.S.
Synthetic; Jiang Qian, U.S. Synthetic; Glowka, SNL; Sexton, U.S. Synthetic; Lin,
UC Berkeley, MatWeb.com, Cerco
Properties
PCD
Tungsten Steel Silicon Silicon

Carbide
(4140) Nitride Carbide
Coefficient of
friction
0.05-0.08**
0.2-0.25
0.42
--
--
Thermal
Conductivity
(W/m*K)
543
70
42.6
30
85
Fracture
Toughness
(MPam)
13-15
10-25
50
3.5-4
Hardness
(gigapascal
[GPa], Knoop)
49.8
1.8
0.2
1.8
2.4
Compressive
Strength (GPa)
6.9-7.6
2.68
--
--
2.5
Youngs
Modulus (GPa)
841
669-696
205
296
434
Tensile
Strength (MPa)
1,300-1,600
334
415
520
500
*ASI 4140 Steel, annealed at 815 C (1,500 F) furnace cooled 11 C (20 F)/hour to 665 C (1,230
F), air cooled, 25 millimeter (1 inch) round (1,100 F) temper)
** PCD on PCD in H2O, dynamic, dynamic
Tungsten carbide on tungsten carbide, static
Steel (hard) on steel (hard), dynamic
YAt 100 C
bearing was time-consuming and

dicult. Equipment had to be shut
o, tanks had to be drained and
cleaned, and maintenance personal
had to climb down into the base
of the tank to replace the bearing.
Company engineers swapped the
mixers foot bearings with diamond
radial bearings. After a six-month
test, the diamond bearings showed
no measurable wear. The chemical
mixing application bearings have
now run for four years without
failure or maintenance.
The Diamond Advantage

Compared to traditional bearing
technology (such as tungsten
carbide), diamond bearings oer
extended bearing life by four to
ten times in the harshest realworld environments. Although
diamond bearings are relatively
new in the wastewater industry
and in pumping applications, this
technology oers a reliable, costeective and proven solution to
make pump operations more robust
and maintenance free.
Reverse Moineau pump
technology used in mud motors
in the oil and gas industry
represent one application where
diamond bearings adoption is
already occurring. These motors
force particle-laden drilling uid
through diamond radial and
thrust bearings within the drill
string. In renewable energy,
marine hydrokinetic (MHK)
generators also currently use

diamond bearings in submerged
underwater environments. MHKs
have the same design as vertical
turbine pumps and benefit from
the seal-free advantages of
diamond bearings.
Diamond is known for its
high thermal conductivity,
low coefficient of friction, high
toughness, and other preferred
physical and mechanical
properties. Having a bearing
material with high thermal
conductivity reduces localized
temperature extremes that lead to
bearing degradation.
High thermal conductivity
reduces the likelihood of causing
localized welding of the surfaces
during starting and stopping,
which in turn leads to scoring

and galling of the bearing
surface. In sliding bearings, low
coefficients of friction are desired
to decrease heat generation and
reduce power losses. A bearing
material exhibiting a large fracture
toughness will decrease the
likelihood of race damage during
extreme operation conditions.
Because of its extreme hardness,
high thermal conductivity, fracture
toughness and strength, diamond
is very resistant to wear and
Figure 2. Comparative data in fracture toughness and material

hardness. (Courtesy of U.S. Synthetic)
(MPa m)
(GPa)
damage from abrasive particles in

lubricants or process fluids.
Breakthroughs in diamond
bearing technology extend the
life and operational efficiency of
critical wastewater applications.
Diamond technology can operate
in harsh conditions, corrosive
fluids and under heavy
loads. Abrasive-laden, water
environments that are challenging
to traditional sealed bearings
are generally ideal conditions for
diamond bearing technology.
Rob Judd, director of sales and engineering at US Synthetic

Bearings, has 15 years of professional experience in
engineering and new product development. Rob holds an
undergraduate degree in mechanical engineering from Utah
State University and an MBA from Xavier University.
Figure 1. Comparative data in thermal conductivity and

friction co-efficiency (Courtesy of U.S. Synthetic)
(W/m*K)
106
PRODUCTS
Ultrasonic Flowmeters
Solar Powered High Liquid Alarm
Sonic-Pro Hybrid Ultrasonic

owmeters measure ow
rate using Doppler or Transit
Time methods. Non-invasive
clamp-on transducers work
with clean and dirty uids,
with a high capacity ow
velocity range of up to 30
feet per second. Sonic-Pro can be congured and controlled
remotely via RS-232, RS-485, universal serial bus (USB)
or Ethernet. View real time ow and download data log
les remotely on a Windows computer. Additional features
include: backlit liquid crystal display (LCD); data logged to
standard secure digital (SD) card format supplied with unit;
fully congurable isolated 4-20 milliamp output.
solar powered
high liquid alarm
system is designed
for monitoring
liquid level in
remote sewage,
wastewater and
rural containment
applications.
Components are
prewired into a
NEMA 4X polycarbonate enclosure with lockable latches.
The solar circuit and internal 12VDC battery provide 24/7
constant power to the alarm system.
Rotary Vane Compressors
Panel-Mounted Calibrator and Communicator
FLSmidths
Ful-Vane rotary
vane compressors
provide high
eciency
compression for
high-pressure
vapor recovery.
Using Ful-Vane
compressors,
reneries are able to recover 200 pounds per square inch
gauge (PSIG) propane vapor and compress it to 240 PSIG to
re-liquefy product and return it to their storage vessels.
Ful-Vane compressors are available with maximum
allowable working pressures to 300 PSIG.
Beamex introduces
MC6 Workstation,
a panel-mounted
calibrator and
communicator. The
MC6 Workstation
oers calibration capabilities for pressure, temperature
and various electrical signals. It also contains a full eldbus
communicator for use with Highway Addressable Remote
Transducer (HART), FOUNDATION Fieldbus and Probus
PA instruments. It has a large 5.7-inch color touchscreen
with a multilingual user interface. The ergonomic design
of the panel-mounted MC6 Workstation makes it best for
sectors such as pharmaceuticals, energy, oil and gas, food
and beverage and the service industry.
Machinery Diagnostic Tool
Crusher Duty Motors
VibrAlign Inc., U.S. distributor of

FIXTURLASER alignment systems,
announced the ONEPROD HAWK
from ACOEM. The HAWK is a
machinery diagnostic tool designed
to give on-demand feedback of the health of rotating assets.
It can identify machine defects, provide trouble-shooting
advice and generate a detailed report on machine health.
The HAWK display unit is an industrial tablet with a color
touchscreen to guide users through a three-step process.
Built-in tools include: a stroboscope, used to pinpoint
the revolutions per minute of a rotating machine, a laser
pyrometer and a camera for documenting sensor placement
or machine defects. The HAWK was designed for any
industrial environment, from small shops to large reneries.
Baldor Electric Company

introduced a new line of crusher
duty motors. The crusher duty
motor platform is available in
frame sizes 180T to 449T and
in the power range of 5 to 350
horsepower. The entire product
line is available from stock and
meets current premium eciency energy standards as
well as future eciency standards outlined by the Integral
Horsepower Rule, which goes into eect June 1, 2016.
Baldor raised the breakdown and locked rotor torque values
across the entire product platform. Motors with roller
bearings as standard are eld changeable to ball bearings
and suitable for across the line starting or inverter duty.
See Water Inc.s
To have a product considered for our Products page, please send the information to Amy Cash, acash@cahabamedia.com.
107
108
Advertisers
Advertiser Name
Page RS#
ACHEMA . . . . . . . . . . . . . . . . . . . . . . . . .47
Advanced Engineered Pump, Inc. . .108
Advanced Technical
Staing Solutions, Inc. . . . . . . . . .110
All-Flo Pump Co. . . . . . . . . . . . . . . . . . .16
American Trainco . . . . . . . . . . . . . . . . .79
Automationdirect.com . . . . . . . . . . . . .21
American Water Works Association
(AWWA) . . . . . . . . . . . . . . . . . . . . . . .48
Bal Seal Engineering, Inc. . . . . . . . . .111
Baldor Electric Company . . . . . . . . . . .11
Blue-White Industries . . . . . . . . . . . . .13
Blue-White Industries . . . . . . . . . . . .111
Colfax Corporation . . . . . . . . . . . . . . . . . 7
Continental Pump Company . . . . . .111
Crane Pumps & Systems . . . . . . . . . . .23
Dan Bolen & Associates . . . . . . . . . . .110
DSI Dynamatic. . . . . . . . . . . . . . . . . . . .44
Electrical Apparatus Service
Association (EASA) . . . . . . . . . . . . .95
Engineered Software, Inc. . . . . . . . . . .34
Frost & Sullivan . . . . . . . . . . . . . . . . . . .93
Fullo Specialties Co.. . . . . . . . . . . . . . .19
GE Intelligent Platforms . . . . . . . 80-81
Gorman-Rupp Company . . . . . . . . . . .15
Hydraulic Institute . . . . . . . . . . . . . . . .99
Hyundai Heavy Industries . . . . . . . . . 17
Jordan, Knauf & Company . . . . . . . .99
KSB, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . .42
Load Controls . . . . . . . . . . . . . . . . . . . . .32
Load Controls . . . . . . . . . . . . . . . . . . . .111
LobePro . . . . . . . . . . . . . . . . . . . . . . . . .111
LUDECA. . . . . . . . . . . . . . . . . . . . . . . . . .14
Magnatex Pumps, Inc. . . . . . . . . . . . . .89
MasterBond Inc.. . . . . . . . . . . . . . . . . .111
Meltric Corporation . . . . . . . . . . . . . .110
Milton Roy,
an Accudyne Company . . . . . . . . . .12
MISSION Communications. . . . . . . . .31
Motion Industries . . . . . . . . . . . . . . . .IBC
Nachi America, Inc.. . . . . . . . . . . . . . . .83
National Pump Company. . . . . . . . . . .37
Neptune Chemical Pump Co., Inc.. . .25
Nidec Motor Corporation . . . . . . . . . .22
NSK Americas. . . . . . . . . . . . . . . . . . . . .43
Pentair Fairbanks Nijhus. . . . . . . . . . .27
Phoenix Contact. . . . . . . . . . . . . . . . . . .33
Pinnacle-Flo, Inc.. . . . . . . . . . . . . . . . .108
PPC Mechanical Seals. . . . . . . . . . . . .109
Raven Lining Systems . . . . . . . . . . . . .45
Rosedale Products, Inc. . . . . . . . . . . . .89
Ruthman Companies . . . . . . . . . . . . . .72
120
155
154
122
146
100
123
172
101
102
156
103
157
104
173
124
125
126
147
127
128
105
148
106
149
129
130
159
158
131
150
160
161
121
132
107
133
134
135
136
137
108
109
162
163
138
151
142
Advertiser Name
FREE PRODUCT INFORMATION

Visit psfreeinfo.com to request more
information from these advertisers.
Page RS#
Scenic Precise Element, Inc. . . . . . . .110

Schaeler Group USA Inc. . . . . . . . . . . . 3
SEEPEX. . . . . . . . . . . . . . . . . . . . . . . . . . .50
SEPCO . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Sims Pump Co. . . . . . . . . . . . . . . . . . . . .97
Sims Pump Co. . . . . . . . . . . . . . . . . . . .109
Sims Pump Co. . . . . . . . . . . . . . . . . . . .110
Singer Valve. . . . . . . . . . . . . . . . . . . . . . .73
SJE-Rhombus. . . . . . . . . . . . . . . . . . . . .41
St. Marys Foundry, Inc. . . . . . . . . . . .109
Stancor Pumps Inc. . . . . . . . . . . . . . . . . . 9
Summit Pump Inc . . . . . . . . . . . . . . . .109
TF Seals . . . . . . . . . . . . . . . . . . . . . . . . . .71
Titan Flow Control, Inc. . . . . . . . . . . . .93
Titan Manufacturing, Inc.. . . . . . . . . .75
Titan Manufacturing, Inc.. . . . . . . . .109
Trachte, USA . . . . . . . . . . . . . . . . . . . . .109
Tuf-Lok International. . . . . . . . . . . . .109
Vanton Pump & Equipment Corp . . .35
Varisco USA Inc.. . . . . . . . . . . . . . . . . .110
Vaughan Company . . . . . . . . . . . . . . . . . 5
Vertilo Pump Company. . . . . . . . . . . .79
VescoPlastics Sales . . . . . . . . . . . . . . .108
Watson Marlow Fluid
Technology Group. . . . . . . . . . . . . .IFC
WEFTEC . . . . . . . . . . . . . . . . . . . . . . . . .65
WEG Electric Corp. . . . . . . . . . . . . . . . BC
Yaskawa America, Inc . . . . . . . . . . . . . . . 1
Zoeller Pump Company.. . . . . . . . . . . .20
164
110
111
139
118
174
175
143
144
165
119
166
141
152
145
167
168
169
112
170
113
153
171
114
115
117
116
140
he Index of Advertisers is furnished as a courtesy, and no

responsibility is assumed for incorrect information.
Solve
dry start
problems with
Vesconite Hilube
bushings

Increase MTBR
No swell
Low friction = reduced
electricity costs
Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite@vesconite.com
www.vesconite.com
109
Your Best Value in

Self Priming Pumps
Model SN
Green Bay, WI
www.SUMMITPUMP.com
The Cryogenic
Worlds next
generation of sealing
technology is here
U-iv>}}Eiv
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U}ii
x*-
U>V
>i`
UV
U}i`
Come out of the Cold and

see what PPC is all about.
1.800.731.7325
www.ppcmechanicalseals.com /cryogenic.html
/vi>>
*i\ n{n U www.tuflok.com
A seal that can handle liquids, gas, and

phasing states. PPCs leap in technology
over the competition is the result of:
years of real world testing, premium face
materials: treated tungsten carbide &
a custom polymer face (developed by
NASA and O2 approved),
with a new engineered
bellows core.

110
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6" Ukornkgu"PHRC"92G"eqornkcpeg
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HTGG"Ucorngu"Cxckncdng
800.433.7642 meltric.com

EXECUTIVE SEARCH/RECRUITING
Mktkxgr"Sgtgmkx"Suzux"Ykx|oik"gtj"Xkvgox
Vxuj{izout"Sgtgmkx"ul"Iuor","Xuzux
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Otyzx{sktzgzout","Iutzxury"Ktmotkkxy".Vu}kx/
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Vxuikyy"Ktmotkkxy".SK"ux"InksK/
Ynovh{orjotm"3"Ktmotkkxy5Vrgttkxy5Gxinozkizy
Serving the Pump &

Rotating Equipment, Valve,
and Industrial Equipment
Industry since 1969
Domestic & International
Specializing in placing:
General Management Engineering
Sales & Marketing
Manufacturing
DAN BOLEN JASON SWANSON
CHRIS OSBORN
9741 North 90th Place, Suite 200
Scottsdale, Arizona 85258-5065
(480) 767-9000 Fax (480) 767-0100
Email: dan@danbolenassoc.com
REPS WANTED
Sims Pump, a fast growing structural
composite pump, pump parts, and
mechanical seals manufacturer is
seeking ambitious, aggressive, and
self-motivated representatives for
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 facilities, oil
and gas, as well as chemical and
industrial markets. A background in
pumps, mechanical seals, or any
rotating equipment is required.
Please fax your resume to
1-201-792-4803, or email to
Simsite1@aol.com.
www.danbolenassoc.com
111
GO WITH THE PROS!! LOBEPRO ROTARY PUMPS
pull out all

the stops
Important Properties of
LobePro Rotary Lobe Pumps

Chemical Resistant Epoxy

Room Temperature Curing EP41S
Capacities 0- 2, 656
Low shear
GPM (0-604 m/hr)
Measured Flow
Self priming to 25 wet Low pulsation
Discharge pressure to Space-saving,
compact design
175 psi (12 bar)
To learn more or get a custom quote, email PumpSales@lobepro.com

912-466-0304
www.LOBEPRO.com
Made in USA
Withstands alcohols and fuels
Fast curing
MONITOR PUMP PERFORMANCE
Abrasion resistant
For high strength coatings,
liners and sealants
FlowRate
PumPCondition
dRyRunning
Cavitation
Hackensack, NJ 07601 USA

+1.201.343.8983 main@masterbond.com
BeaRingFailuRe
www.masterbond.com
univeRsalPoweRCell
OneSizeAdjustsfor
AllMotors,FromSmall
upto150HP
WorksonVariableFrequency
Drives,3Phase,DCand
SinglePhase
10timesmoresensitivethan
justsensingamps
4-20Milliamp,0-10Volt
CallnowFoRyouRFRee30-daytRail
888-600-3247
Less downtime.
Longer seal life.
More predictability.
The Bal Seal spring-energized seal
for critical upstream and downstream
applications.
800.366.1006 www.balseal.com

112
PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch

By Jordan, Knauff & Company
Figure 1. Stock indices from April 1, 2014, to March 31, 2015
he Jordan, Knauf &

Company (JKC) Valve Stock
Index was down 20.6 percent
over the last 12 months, while the
broader S&P 500 Index was up 9.6
percent. he JKC Pump Stock Index
also decreased 18.4 percent for the
same time period.1
he Institute for Supply
Managements Purchasing
Managers Index (PMI) decreased
to 51.5 percent in March from
52.9 percent in February. he New
Orders Index also decreased to
51.8 percent from 52.5 percent
in February. he Prices Index
increased to 39.0 percent from
35.0 percent. Ten of the 18
manufacturing industries surveyed
reported growth in March with
paper products, wood products,
transportation equipment and
fabricated metal products leading
the growth. Apparel, textile mills,
petroleum and coal products, and
electrical equipment were all on the
contraction side.
Lower oil prices have had both
positive and negative efects,
depending on the industry. A food
and beverage respondent noted that
falling energies have helped on
the cost side, while sales are getting
a boost through improvements
in consumer disposable income.
At the same time, a computer
and electronic products company
suggested that oil prices are

having a major efect on energy
markets and, as a result, their
business is slowing down.
In 2015, consumer
expenditures on motor fuel
are expected to be at their
lowest levels in more than 10
years. Based on the U.S. Energy
Information Administration
(EIA) gasoline price forecast,
Source: Capital IQ and JKC research. Local currency converted to USD using
the average U.S. household
historical spot rates. he JKC Pump and Valve Stock Indices include a select list of
is expected to spend about
publicly traded companies involved in the pump and valve industries weighted by
market capitalization.
$700 less on gasoline in 2015
compared to last year. During
twice the petroleum and natural gas
Reference
this years summer driving season,
produced by Saudi Arabia last year.
1. he S&P Return
the EIA is forecasting that gas
For both the U.S. and Russia, total
igures are provided
prices will average $2.45 per gallon, production is almost evenly split
by Capital IQ.
compared with $3.59 last year.
between petroleum and natural gas,
Crude oil production in the U.S.
while petroleum makes up most of
has increased in each of the last
Jordan, Knauf
Saudi Arabias output.
& Company is an
six years. Output in 2014 rose by
On Wall Street, all indices were
investment bank
1.2 million barrels per day, or 16.2
down for the month of March. he
based in Chicago,
percent, the highest percentage
Dow Jones Industrial Average fell
Illinois, that
growth rate since 1940. his follows 2.0 percent, the S&P 500 Index
provides merger and
acquisition advisory
a period from 1985 to 2008 in
was down 1.7 percent, and the
services to the
which crude oil production fell
NASDAQ Composite declined 1.3
pump, valve and
in every year except one. Since
percent. Investors were concerned
iltration industries.
2012, the U.S. has been the worlds about the irst quarter earnings of
Please visit
largest producer of petroleum
jordanknauf.com for
multinational companies due to the
further information.
and natural gas hydrocarbons
strength of the U.S. dollar.
Jordan Knauf &
combined, exceeding the output
For the irst quarter of the
Company is a member
of both the second and third
year, the Dow Jones Industrial
of FINRA.
largest producersRussia and
Average lost 0.3 percent, the
Saudi Arabia, respectively. With
S&P 500 Index gained 0.4 percent
increases in production in both
These materials were
and the NASDAQ Composite rose
prepared for informational
areas, the U.S. produced almost
3.5 percent.
purposes from sources that
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
Figure 3. U.S. PMI and manufacturing shipments
Source: Institute for Supply Management Manufacturing

Report on Business and U.S. Census Bureau
are believed to be reliable

but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or completeness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
any investment offering or
deployment of capital.
For more than 80 years, Autogard products have

led the industry in overload protection. Autogards
full line of torque limiters can be customized to fit
customers ever changing application needs and are
ideal for use in heavy-duty and specialty engineered
components. Autogard Torque Limiters provide
equipment protection, accurate torque limitation,
instantaneous disengagement, rapid reset, reduced
downtime and increased life of system components.
And, you can find Rexnord Autogard Torque Limiters
at your local Motion Industries location. Our
local sales and service specialists are experts in
application and technical support, providing
the parts and the know-how you need to stay up
and running.
Scan this code with your smartphone
for more information
http://esp.to/wFnb8Q
The brands you count on from the people you trustthats Rexnord and Motion Industries.
Call. 800-526-9328
Click. www.motionindustries.com
Visit. Over 550 Locations
2015 Motion Industries, Inc.
Motors | Automation | Energy | Transmission & Distribution | Coatings
WEG Rolled Steel Line

Great WEG quality and flexibility in a new LIGHTER frame
Investing over 2.5% of our revenue in R&D for electric motors every year, WEG takes pride in engineering and
manufacturing motors that run cooler, last longer, and are easy to install and maintain.
Available in Open Drip and Totally Enclosed designs our WEG Rolled Steel line is the perfect example of these efforts.
A product line with superior features that make a big difference for our customers.
Features that make a difference:

"Dual
rated for 60 Hz and 50 Hz @ 190-220/380-415 V
"Optimized
ventilation system for cooler operation
"Robust
feet design for the toughest applications
"Frames
182/4T and larger have two eyebolts for easy mounting in any position
"Oversized
diagonally split aluminum terminal box that exceeds IP55 requirements. (Ideal for easy
installation and tough environments).
"Terminal
"AEGIS
"IP55
box is rotatable in 90 degrees increments for easy installation
ring inside (optional) to extend bearing life when used with VFDs
ingress protection is standard
"Suitable
"Color
"Motor
for VFD operation per NEMA MG1 part 31.4.4.2
coded leads for easy installation

paint resistance exceeds 500 hours of salt spray test
Please contact your authorized WEG distributor or go to weg.net/us for further

information or additional specifications.
1-800-ASK-4WEG
Transforming Energy into Solutions
www.weg.net/us

May 2015

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SYSTEMS

The Leading Magazine for Pump Users Worldwide

EXCLUSIVE COVERAGE FROM ZAMBIA & MALAWI

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The right amount of water pressure and flow is critical to

2015 Yaskawa America Inc.

For more info:

Get personal with Yaskawa.

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From the Editor

or most of us, our access to safe

Editor, Michelle Segrest

PUBLISHER: Walter B. Evans Jr.

P.O. Box 530067

M a y 2 0 1 5 | Pum ps & S ys tem s

1900 28th Avenue South, Suite 200

2126 McFarland Blvd. East, Suite A

Schaeffler Introduces a Genuine Breakthrough

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59 PUMP INDUSTRY IMPROVES WORLD

TRADE SHOW COVERAGE

AMERICAN WATER WORKS ASSOCIATION ANNUAL

Pumping Machinery, LLC

PUMP SYSTEM IMPROVEMENT

70 WATER LOSS AUDITS DECREASE COSTS

74 WISCONSIN NONPROFIT WORKS TO ACHIEVE GLOBAL

First of Two Parts

FROM THE EDITOR

See videos, drawings, and details at ChopperPumps.com or call 888.249.CHOP

Circle 113 on card or visit psfreeinfo.com.

REMOTE MONITORING &

28 EMBEDDED HUMAN MACHINE INTERFACES EXPAND THE REACH

36 CONTROLLERS MANAGE EQUIPMENT UNCERTAINTY

82 MOTORS & DRIVES

40 3 THINGS END USERS SHOULD CONSIDER WHEN OPERATING INTELLIGENT

How to Prevent the 2 Most

46 MONITORING BRINGS RELIABILITY TO WASTEWATER COLLECTION SYSTEM

PRACTICE & OPERATIONS

EDITORIAL ADVISORY BOARD

BRYAN S. BARRINGTON, Machinery Engineer,

M a y 2 0 1 5 | Pum ps & S ys tem s

104 DIAMOND BEARINGS

CANADIAN CITY FROM DANGEROUS

ROBERT K. ASDAL, Executive Director,

Principles of ControlledVolume Metering Pumps &

94 SUBMERSIBLE PUMPS PROTECT

THOMAS L. ANGLE, P.E., MSC, Vice President

How To Avoid Compression

ROTARY POSITIVE DISPLACEMENT

EXCLUSIVE COVERAGE FROM ZAMBIA & MALAWI

WILLIAM E. NEIS, P.E., President, Northeast

LEV NELIK, Ph.D., P.E., APICS, President,

DAVID A. DOTY, North American Sales Manager,

MIKE PEMBERTON, Manager, ITT Performance

WALT ERNDT, VP/GM, CRANE Pumps & Systems

SCOTT SORENSEN, Oil & Gas Automation

JOE EVANS, Ph.D., Customer & Employee

ADAM STOLBERG, Executive Director,

LARRY LEWIS, President, Vanton Pump and

JERRY TURNER, Founder/Senior Advisor,

TODD LOUDIN, President/CEO North American

KIRK WILSON, President, Services & Solutions,

JOHN MALINOWSKI, Sr. Product Manager, AC