Modern Pumping - 062014

modErN
todAy
ProvidiNg SolUtioNS for thE WorldWidE PUmP iNdUStry
NEW CONTROL
VALVES
PROTECT VITAL
WATER SUPPLY
JUNE 2014
4 Ways to
Reduce Nox
emissioNs
makiNg
Waves iN
a global
maRket
RecycliNg
PRocess
coNtRol
equiPmeNt
CoNtENtS
4
10
JUNE 2014
industry News
trade Show Profile
Case Studies
12 New Control valve is an overnight

Success
EOV control valves protect vital water supply
14 making a Big Splash
Sphero S underwater pelletizing machinery system makes waves in China
Water & Wastewater

Solutions
12
18 Uniform distribution in headers

and distribution Systems
Part 2 of 2
maintenance Solutions
24 Know your Pump Base Plate

installation options
Part 2 of a 3-Part Series
Pump Solutions
26 A revolution in Pumping Eff icieny
42
All-Flo's A200 pump reduces energy costs, improves performance

Part 3 in a 4-Part Series
dewatering Solutions
30 Controlling All the variables
VLT AQUA Drive produces huge water savings from food processor's deep well
motor Solutions
36 the Next generation of Premium

Efficient gearbox
Two stage helical-bevel design adds bite to food and beverage industry
50
www.modernpumpingtoday.com
P.O. Box 660197 | Birmingham, Alabama 35266
Power generation
Solutions
40 Utilities Are frightened of a "death Spiral."

they Shouldn't Be.
Industry and regulators need a more accurate and adaptive view of tomorrow's energy market
Processing Solutions
42 Short design means Big innovation

Splitted gear box and improved maintenance possibilities for plunger pump
valves & Controls

Solutions
46 4 Ways to Achieve Nox reductions

without turbine damage
Reduction in emissions isn't just desiredit's required
Sealing Solutions
50 Safe and Efficient Bolting
Russell haddock COO/Publisher

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Superbolt makes easy work for boiler feed pump workers
52
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modern Pumping
Products
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kRisti Neil Account Executive
Featured Product Release: MILTON ROY Primeroyal X Metering Pump
Pumping trends
56 going green (And Earning Some too)

Automation Service's Steve Ploudre explains how recycling process control equipment improves
the environment and the bottom line
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tim gaRmoN
President
EditoriAl AdviSory BoArd

Terry Bell
Michael Mancini
Drives and Motion Solution Engineer

Baldor Electric Company
Consultant and Trainer,

Mancini Consulting Services
Heinz P. Bloch, P.E.
John M. Roach
Consulting Engineer,
Process Machinery Consulting
Robert G. Havrin
Director of Technology,
Centrisys Corporation
Engineering Manager
for New Product Development,
Trebor International, Inc.:
A Unit of IDEX
Lisa Roe
Business Development Manager,

Wastewater Pumps
Xylem Inc.: Flygt
Greg Towsley
Director of Regulatory and

Technical Affairs, Grundfos
Trey Walters, P.E.
President, Applied Flow Technology
laRRy daughety
Vice President
deNNis daughety
Vice President
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INDUSTRy news
NETZSCH ANNOUNCES
R.F. MACDONALD PARTNERSHIP
Netzsch, the
worlds largest manufacturer of
progressing cavity pumps,
rotary lobe
pumps and
now multiple screw
pumps for
the industrial market,
announces the signing of R.F. MacDonald Company as their
distributor in Southern California to service the Industrial
marketplace in this region.
R.F. MacDonald Co. will represent Netzsch in all industrial
markets as well as oil and gas downstream. Our new
distributor has been in business since 1956 with a strong
presence selling industrial boilers as well as a broad range of
industrial products that complement the Netzsch offerings.
GIW INDUSTRIES EXPANDS OPERATIONS

WITH KSB BRAND
GIW Industries announces a new look and logo as the

company unites under the KSB corporate brand. All slurry
4 | JUNE 2014
products have been rebranded under the umbrella of GIW

Minerals. The primary GIW Minerals world class products
are specially designed centrifugal pumps used to transport
a mixture of liquids and solidscommonly referred to as
slurry. What this means to customers is well over a century's
worth of experience in pumps and hydrotransport. The
KSB global mining team strives to be an innovative partner
that provides customers with the best slurry and process
solutions. GIW is a global business with the majority of its
customers located outside of the USA.
The previous few years have seen a variety of expansion
projects designed to improve production efficiencies at
KSB's GIW Industries manufacturing facility. As the result
of a recent growth in production, sales, and product
endorsement in the mining market, KSB is moving forward
with a three-year multimillion dollar expansion project
encompassing its Grovetown and Thomson, Georgia,
production facilities. Started in January of this year, the
expansion project includes additional foundry and heat
treat capacity, along with a new distribution center at the
Grovetown production facility. The Thomson production
facility will receive upgrades in process flow and the
installation of larger equipment. When completed, this
expansion will more than triple the company's capabilities
and provide customers with one of the most advanced slurry
pump manufacturing facilities.
The markets served will continue to expand as the need
for raw materials increases due to population growth and
urbanization. Part of this growth is the need for larger
INDUSTRy news
equipment sizes. The current expansion will ensure that
KSB's GIW Minerals products will be ready for growing
market demands. This investment in large casting capacity
will provide for the most efficient plant to handle sizeable
castings. The expansion will meet the requirements
needed for the handling of larger components to allow
the company to increase efficiencies while continuing to
uphold its world class quality and safety standards.
Why expand? Richard Sterzen, industrial engineering
manager at KSB's GIW Industries facility, explains, "In
the entire world, only 10 percent of iron foundries make
white irons, and nobody can make the materials we
do. In addition, there are only a few foundries that can
manufacture the large casting sizes our customers need."
The economic impact of KSB on the Grovetown
community in Georgia is far reaching. GIW Industries
has been in business for well over a century and its
facilities have been located in Grovetown and Thomson
for forty-nine years and forty years respectively. The
current expansion will provide new permanent employee
positions, along with a large number of temporary
construction jobs, over the next three to four years.
This project is a large investment for the KSB
subsidiary, GIW Industries. Long term, this expansion will
give GIW Minerals products a significant advantage in
the global mineral processing industry. It will allow the
KSB global mining team to continue to provide market
leading quality products, services, and solutions for its
customers.
6 | JUNE 2014
DEMATIC SPONSORS
FIFTH THIRD RIVER BANK RUN
Dematic, a global supplier of logistics systems for the

factory, warehouse and distribution center, is supporting the
companys hometown through its sponsorship of the 5K race
at the Fifth Third River Bank Run. The event was held May 10
in downtown Grand Rapids, Michigan. This is the first year
Dematic has sponsored the race, which includes walk and
run distances of 5K, 10K and 25K.
"We are proud to support our community with event
sponsorships like the Fifth Third River Bank Run," says
president and CEO of Dematic North America, John Baysore.
"With more than 1300 Dematic employees and many local
business customers based in the West Michigan area, it
is vital that we be involved in making Grand Rapids an
economically strong, healthy and desirable place to live and
work."
Dematic provided more than 100 event volunteers,
participants and spectators, including approximately
80 runners. In its 37th year, the River Bank Run drew
approximately 38,000 onlookers, 2000 volunteers, and over
21,000 contestants.
TV RHEINLAND INDUSTRIAL SOLUTIONS GOES

WIRELESS WITH PORTABLE X-RAY DETECTOR
TV Rheinland Industrial Solutions (TRIS), a full-service

inspection, testing and certification company, expands its
digital radiography capability with a portable X-Ray detector
using wireless and battery-operating technology. The wireless
INDUSTRy news
capability will allow TRIS to provide faster results at reduced
costs to the companys oil and gas, power generation,
construction and other industrial clients.
Designed to operate in the harshest industrial
environments, the portable X-Ray detector can be wirelessly
connected or tethered to a laptop computer. TRIS technicians
can quickly set it up in some of the most challenging field
conditions and survey hard-to-reach areas such as pipe
racks.
Digital radiography improves field safety and productivity
through the advantages of reduced exposure and shooting
times. It eliminates the need for film and chemical
components necessary for traditional radiography, reducing
costs. Instant radiographic inspections and review help TRIS
clients receive results faster while digital storage makes for
easy documentation and retention of inspection records.
TRIS provides both field and laboratory inspection
services, including all NDT methods, QC/QA functions,
proof loading, calibrations, tensile testing (including
ultimate strength, yield, elongation and reduction of area),
compression, shear testing and slow bend testing.
FLUID TRANSFER, INC. LAUNCHES NEW WEBSITE
Fluid Transfer, Inc., an aftermarket parts supplier of plunger,

piston, and reciprocating pumps for the hydro blasting, oil,
gas, and fluid transfer industries and also a supplier of OEM
parts, has launched a new website at www.fttipumpparts.
com. Based in Norton, Ohio, the new site provides both
regional and national customers an easy-to-use resource
8 | JUNE 2014
for consulting on service to a variety of manufacturers,

including American Aero, Aqua Dyne, Armco, Butterworth,
FMC, Gardner-Denver, GASO/Wheatley, General, Geoquip,
Haliburton, Hammelmann, Jet Tech, Jetstream, Kamat, Kerr,
Myers/Aplex, National, NLB, Oilwell, Partek, Tritan, Union,
Uraca, Weatherford, and WOMA.
HI, FSA COLLABORATE ON WEB SEMINAR
The Hydraulic Institute, in collaboration with Henri Azibert,

technical director of the Fluid Sealing Association and
associated HI committee members, has developed a new
webinar session focused on how dual gas seals improve
pump system reliability and performance.
Henri Azibert, FSA technical director and pump industry
consultant, remarks, HIs new webinar session on Dual Gas
Seals is the most complete course available in the pumping
industry. Engineers from a diverse array of industries will
learn about the in-depth influences. The Fluid Sealing
Association has collaborated extensively with HI to develop
this new session and will jointly promote its benefits to the
pump user community.
The June 24 webinar will begin at 1:00pm EDT and will
be led by Jason Ferris, manager of product development,
Flowserve Corporation. Cost is just $99.00, with HI members
receiving an additional 25 percent discount, along with
attending earning one (1) Professional Development Hour
(PDH) credit after the session. HI also offers corporate group
webinar site licensing for the lowest prices in training larger
groups.
TRADE SHOW profile
ASHRAE 2014
Annual Conference
Setting the Standard, Raising the Bar
or over one hundred years, the American Society of

Heating, Refrigeration, and Air-Conditioning Engineers
better known as ASHRAEhas set the standard as the
foremost source of technical and educational information and
the primary provider of opportunity for professional growth
in the related fields of heating, ventilating, air conditioning,
and refrigerating. Each year, the ASHRAE Annual Conference
provides a launch pad for innovative ideas, skilled instruction,
and industry camaraderie.
TECHNICAL PROGRAM
A mainstay of the ASHRAE Annual Conference, the technical

program addresses broad topics in the application of technology
to practice, specific applications in ground source heat pumps,
O&M and indoor environmental quality, as well as new reports
on research taking place worldwide. The conferences technical
program features various tracks, each speaking to current needs
that professional engineers face in the field.
The complex relationship between indoor and outdoor
environmental conditions, coupled with the impacts of
climate change, requires buildings that are comfortable and
healthy for the occupants yet also energy efficient. The
Indoor EnvironmentHealth, Comfort and Productivity
Track highlights the state of knowledge of the balance of
environmental health and energy efficiency in buildings and
research directions.
The Ground Source Heat Pumps State of the Art: Design,
Performance and Research Track addresses all aspects of
design that lead to optimally performing systems in addition
to avoiding common pitfalls that lead to poorly performing
systems.
With low energy and zero energy buildings becoming more
prevalent, there are many issues that arise with installation,
startup, commissioning and operations and maintenance
(O&M). The Installation, Commissioning, Operation,
Maintenance of Existing Buildings Track focuses on lessons
learned, improvement of process and team communications
and efforts to improve the installation, startup, operations and
maintenance, and commissioning of HVAC systems.
The Refrigeration Track emphasizes global perspectives
on new refrigerants, variable refrigerant flow applications,
magnetic bearing compressors, and refrigerant management.
Non-comfort cooling applications in food preservation and
medical cryogenics also are highlighted
ASHRAE is known for its standardstheir development and
their adoption worldwide. The Standards, Guidelines and
Codes Track highlights the applications of ASHRAEs standards
to practice as well as European (CEN) and ISO standards that
support building performance.
10 | JUNE 2014
RESEARCH SUMMIT
AND BOOKSTORE
The second annual ASHRAE Research

Summit presents innovations in HVAC&R
research with particular emphasis on
high performance building design and
its role in a clean energy economy,
and brings together researchers to
present and discuss the latest research.
Researchers will present papers,
seminars and forums or participate in
panel discussions. Also, highlights on
ongoing ASHRAE funded research are
presented. Join us in this comprehensive
compilation of research-related papers
and programs that peer into what the
future holds.
Authors of some 200 conference
paper abstracts have been invited
to submit papers for the Research
Summit and conference. More than
300 books, meeting papers, and other
recent publications will be available for
purchase in the ASHRAE bookstore. The
bookstore provides HVAC&R technical
literature from ASHRAE and other
popular industry publishers.
EDUCATIONAL SEMINARS
The two full-day seminars include

Introduction to Buildings Enclosure
Commissioning, which introduces
the Building Enclosure Commissioning
(BECx) process by outlining key quality
based activities that achieve a successful
building enclosure. The seminar will
include overviews on such design
phase BECx activities as developing
the Owners Project Requirements, the
BECx plan, and critical building science
and architectural issues to address in
the design review and specifications,

and construction phase BECx activities
such as construction observation and
performance testing. The seminar
will aid in understanding how BECx
contributes towards commissioning
goals and requirements and LEED.
The other full-day seminar,
Introduction to Buildings Enclosure
Commissioning, provides guidance on
how to perform commercial building
energy audits. Best practices and
other information relevant for building
owners, managers and government
entitles are covered. The seminar
includes a summary of materials
essential for performing ASHRAE Level
1, 2 and 3 audits, time-saving tips for
every auditor, how to hire an auditor,

what to ask for in a comprehensive audit
report, and how to build a successful
energy efficiency retrofit team.
Numerous half-day short courses
include Designing High-Performance
Healthcare HVAC Systems,
Designing Toward Net Zero Energy
Efficiency Commercial Buildings,
Troubleshooting Humidity Control
Problems, Building Demand
Response and the Coming Smart Grid,
Commissioning for High-Performance
Buildings, Application of Standard
62.1-2013: Multiple Spaces Equations
and Spreadsheets, and Exceeding
Standard 90.1-2013 to Meet LEED
Requirements. Each course earns
three professional development hours
(AIA LUs) or .3 CEUs. Attendees
are encouraged to check with their
state for their continuing education
credits requirements and to bring all
identification numbers to the course to
ensure they receive proper credit.
THE PATH TO
PROFESSIONAL GROWTH
With access to varied offerings and

unmatched expertise, attendees of the
ASHRAE Annual Conference continue
to distinguish themselves among their
peers and develop new approaches to
the growing challenges of efficiency,
power, and sustainability that are the
driving forces of the HVAC&R industry.
This years conference promises to build
on the wealth of ASHRAEs resources
and encourage current professionals to
promote new ideas.
JUNE 2014 | 11
CASE Studies
New Control Valve Is

an Overnight Success
EOV cOntrOl ValVEs prOtEct Vital watEr supply
By Craig Stanners and martyn redman, ivl flow Control
The 23.62 inch (600 millimeter) EOV

control valve installed and running.
urther to investigations of Pin

Holes by non-destructive testing
of a strategic flow control valve
at Dwr
Cymru Welsh Waters Pontsticill
WTW near Merthyr Tydfil, it was found
that in fewer than five years, cavitation
had caused extensive detrimental
and potentially fatal wear to the
plug valve, which was in danger of
imminent failure. Should this have failed
completely, the Water Treatment Works
would have flooded and reinstatement

would probably have taken several days,
placing 70,000 customers at risk of
losing supply.
Although there was a replacement
plug valve on hand, Dwr
Cymru Welsh
Water sought advice from Industrial
Valves technical specialists (IVL Flow
Control) as to the suitability of this
type of valve in this environment. On
studying the available data it was proved
that the pressure differentials present

could not be handled by this type of
plug valve, and it would inevitably lead
to a repeat of the cavitation problems
and another potential loss-of-supply
situation. IVL recommended a series
300, 23.62 inch (600 millimeter) EOV
control valve as an alternative, along
with a technical assessment which Dwr
Cymru Welsh Water were happy to
accept.
About the Author

Craig Stanners is the director at IVL Flow Control and can be reached 07772.699313 or craigstanners@ivlflowcontrol.co.uk.
Martyn Redman is the technical director at IVL Flow Control. Contact him by calling 07972.194965 or via email at
martynredman@ivlflowcontrol.co.uk. IVL Flow Control provides solutions for a range of water utilities and industrial markets.
For more information, visit www.ivlflowcontrol.co.uk or meet the team this year at WEFTEC.
12 | JUNE 2014
WORKING THROUGH
THE NIGHT
The difficult replacement

was carried out overnight,
and the removal of the
existing valve and reinstallation of the new
valve was achieved
within an eight hour
overnight shutdown
period between 8pm and
4am, with IVLs engineers
on hand to assist.
Thankfully this type of
work goes unnoticed by
the general public, but
when dealing with such
large volumes of water
from a health and safety
and water quality point
Above: The new 23.62 inch
of view, the planning
(600 millimeter) EOV control
valve is already showing that
and effort that goes
it is resistant to cavitation.
into ensuring a smooth
Right:
The Pontsticill
transition has to be
Reservoir, an important water
absolutely meticulous.
source to local residents.
This was another
example of teams working
together to protect
essential services and an
excellent example of a
positive intervention that will benefit
The detailed planning, competent
both customers and the company.
risk assessment and above all,
The new 23.62 inch (600 millimeter)
leadership and teamwork to get the
job done in such a short space of time
control valve is already showing that
overnight is highly commendable,
it is resistant to cavitation at Pontsticill
adds Dwr
Cymru Welsh Waters chief
WTW, performing within an accuracy of
operating officer, Peter Perry. The
0.5 percent and controlling flows from
commitment, proactive approach and
0 gallons per day (when closed) up to
long-term solution for this essential
around 25.1 million gallons (95 million
work have been first class.
liters) per day.
FIRST CLASS ALL THE WAY
Furthermore, in this situation the new

control valve will have a lifetime of
twenty to thirty years, when serviced
and maintained regularly.
IMPROVED OPERATION
We had noticed a problem with the

old valve when we were carrying out
regular checks of the raw water valve,
add Chris Holloway, production asset
engineer at Dwr
Cymru
Welsh Water. There
was water spraying out
of very small holes in
the valve body. When
it came to changing the
valve (and the capital
team told us they were
going to change the type
of valve), I was a bit
concerned that that the
operation of it would
change and we would
not be able to restart
the works in the way we
normally would.
He continues, On
the night after the new
valve was installed
and everything was
ready to go we decided
to try to bring on the
works using the normal
method, where we have
to bring the flow on
very quickly for the first
10.6 million gallons
(40 million liters) per
day to make sure the
DAFs get a decent flow
to start with. I was surprised that the
flow came on so smoothly and did
exactly what I was hoping it would do.
All changes following this were much
smoother than we were getting with the
old valve.
Since the install of the new valve
we have noticed that the changes to
the flow required by network and the
high lift pumps (which can be as much
as 5.3 million gallons [20 million liters]
per day at any one time) have been a
lot smoother than before. The control
of the chemicals, which are flow-paced
from the front-end has also improved
enormously.
JUNE 2014 | 13
CASE Studies
By Chris laurent, maag
Sphero S underwater
pelletizing machinery
system makes waves
in China
About the Author

Chris Laurent is the marketing communications manager for Maag, the worldwide leading manufacturer of gear pumps,
pelletizing systems, and filtration systems for demanding applications in the plastics, chemical, petrochemical, and food
industries. Its subsidiary Automatik Plastics Machinery has been manufacturing innovative pelletizing systems of the
highest quality for several decades. It is the world leader in underwater strand pelletizing systems. He can be reached at
ChrisLaurent@maag.com or 41.44.278.8349. For more information about the Sphero S, visit www.sphero-s.com.
14 | JUNE 2014
APPLICATIONS
Compounding/masterbatch/recycling based on:

Polyolefins, e.g. LDPE, HDPE, PP
Styrene polymers, e.g. PS, SAN, ABS
Acrylic resins, e.g. PMMA, APN
Polyesters, e.g. PET
Polyamides, e.g. PA 6, PA6.6
Polyurethanes, e.g. TPU
Hot-melt adhesives
uilding on over
sixty years of
technological and
industry experience,
Automatik Plastics
Machinerya subsidiary of Maag, a
member of Dover Corporation's Pump
Solutions Group (PSG )launched
its innovative design, the Sphero
S underwater pelletizing system,
before the scrutiny of attendees
at the Chinaplas 2014 technical
conference this past April. As one
of the largest and fastest growing
industrial sectors on the globe, the
Chinese market provides a proving
ground for new designs and ideas and
the Chinaplas conference annually
brings together a wide variety of

leaders from the plastics and rubber
industries. Specifically designed and
engineered for the mid-tier polymer
production market, the Sphero S is
ideally suited to meet the demands
in compounding, masterbatch, and
recycling applications.
ITS PUBLIC AWAITS
Chinaplas was the perfect venue for

us to introduce our new Sphero S
System, says Andreas Weidner, China
sales director for Automatik Plastics
Machinery. Launching
the Sphero S in front of
the over 40,000 visitors
to Chinaplas was a great
experience, and we received
an overwhelmingly positive response
from everyone at the event. We look
forward to showcasing the Sphero S
at other upcoming shows.
PERFECT PELLETS FOR THE

PERFECT PRODUCTS
Automatiks new Sphero S underwater

pelletizing system is designed for
the medium-throughput polymer
production market and engineered to
perform in compounding, masterbatch
and recycling applications. The system
JUNE 2014 | 15
CASE Studies
Urs Gull,
director of
sales for Maag,
with the new
Sphero S
underwater
pelletizing
system at
Chinaplas
2014
16 | JUNE 2014
delivers exceptional value through industry leading

bypass design has also been fine-tuned resulting in a
technology, production proof components, reputation and
speedier start-up. In addition, special attention has been
design innovation.
given to the design of the cutter head to guarantee process
Specifically designed to be a cost-effective alternative
integrity and ensure the production of evenly shaped, highto larger and more customizable systems, the Sphero
quality pellets. System options include a flow meter with
S incorporates a
shut-off valve, sight
variety of innovative
glass, stroboscope,
features suited for
water blow out device,
visual indicator for
medium throughputs,
FEATURES & BENEFITS
heating cartridges
typically between
1500 to 6600 pounds
performance
Upgraded water by-pass design for utmost process
(roughly 700 to 3000
integrity and fast start-up
kilograms) per hour.
READY FOR
Enhanced cutter-head produces quality, evenly cut
The major technological
TODAYS
pellets
advancements include
PRODUCTION
new pneumatic diverter
PROCESS
Ergonomic design for minimized cleaning and die
valves that optimize
Pelletizing is one of
plate changing times
the flow channel and
the most important
Single mobile-frame structure for superior
ease the cleaning of the
steps in the production
alignment and reduced footprint
cutting chamber, and a
process of a wide
user-friendly, ergonomic
variety of plastic and
design for easy cleaning
rubber products,
and quick changes of the
Andreas Weidner
knives and die plates.
adds, and Automatik
Other improvements to the Sphero S include a new
pelletizing systems have been designed to integrate
frame that allows it to be mounted on a single mobile
perfectly into the production line to simplify operations
structure, which guarantees a perfect alignment and a
and maximize output in the most efficient manner possible.
reduced footprint. Starting the system is almost instant,
The new Sphero S will continue this tradition, only now
accomplished with a simple press of a button. The water
with a simpler and more cost-effective design.
JUNE 2014 | 17
WATER & WASTEWATER solutions
By david l. russell, global Environmental operations, inc.
n part one of this article, we examined two common

systems, one using compressible gasses, and the other
using non-compressible liquids, that provide uniform
distribution of cooling fluid in both cooling applications
and many spray applications. In this months concluding
installment, well take a closer look at the benefits of the
calculations for compressible flow as well as for expansion
factor as it relates to the change in the density of an ideal
gas. As you will see, accurate measurement and thoughtful
calculation can save operators many hours of regretnot to
mention a boon to the bottom line.
OLD NEWS IS GOOD NEWS
An old article in a text book from the 1960s provides a

good answerin that, they suggested that with a pipe of
constant diameter, the head losses through the nozzle were
approximately equal to the friction losses equal to about
one-third the frictional flow in the pipe.
Put in scientific terms, the friction head or h f is equal to
the value shown in equation 2:
Equation 2
Hf = (KQo2/L2)(I-I2/L + I3/L2)
Where:
K is the hydraulic coefficient equivalent to the head
losses in the total length of the pipe at full flow
conditions;
L is the length of the pipe,
l is the fractional length of the pipe where the losses
are occurring, and
Qo is the total flow in the pipe at maximum
conditions.
Remember that you will need to have the head greater

than the hydraulic head on the outside of the pipe.
Another way to look at the solution to the problem is to

perform an analysis across the orifice. In a simple case we
have
qn = CAo2(2gh)0.5
If the value of C is 0.60, and the value of the large pipe
flow is Q and the individual orifice value is q, and the
hydraulic head differential between the inside of the pipe
and immediately outside the pipe is hd which accounts for
the submergence of the pipe. If you set the nozzle losses
greater than the pressure head against the pipe plus the pipe
friction, the design works.
An example will help. I have a 3-inch (76.2 millimeter)
pipe 300 feet (91.44 meters) long. I want to distribute 100
gallons (378.54 liters) per minute through it uniformly. Head
losses through the length of the pipe are 4.47 feet of head
loss per 100 feet. The pipe is submerged by 3 feet of water.
The total head loss is then 4.47 * 3+3 = 16.41 feet of head
or just about 5 PSIG.
I want to use 30 nozzles or orifices, and each one should
take about 3.33 gallons per minute.
The nozzle size should be
q = 0.60 A2(2gh)0.5
In the proper units q = 7.42*10 -3 cubic feet per second,
g is 32.18 square feet per second and h is 16.41 feet.
Running the numbers that gives A 2 is 5.381*10-4 square feet
or 0.0775 square inches.
That translates to a hole of approximately 0.0987 inches
in diameter or a 3/32 inch hole. The water will flow out
uniformly. The water will also flow in uniformly, under
vacuum conditions. If the system is going to be a free
draining system with no vacuum in the pipe, then the
available head with be that on the outside of the pipe less
the friction losses in the pipe, meaning that a larger opening
will be required.
About the Author

David L. Russell, P.E., is a chemical and environmental engineer and the founder of Global Environmental Operations, Inc., a
specialty environmental consulting firm serving clients all over the world. Mr. Russell is an in-demand consultant for projects
ranging from environmental process designs and hazardous wastes to water systems and wastewater treatment. He can be
reached at 770.923.4408 or by visiting www.globalenvironmental.biz.
18 | JUNE 2014
Warning: If you are trying to use this design for developing

a uniform draining system, remember that the maximum
vacuum you can reliably have on the system, is about
negative 13 psig or about 30 feet of suction. Beyond that you
will start to get cavitation in your pump.
CALCULATION OF EXPANSION FACTOR
The expansion factor Y, which allows for the change in the

density of an ideal gas as it expands isentropically (no net
change of energy through the nozzle or orifice), is given by:
For values of (ratio of orifice diameters) less than 0.25
COMPRESSIBLE FLOW
Compressible flow occurs in air and other gases. The formula

must account for a few more variables such as the initial and
final states and temperatures. As the air crosses the orifice it
changes temperature, decreasing sharply as it expands from
the nozzle. In order to prevent the moisture in the gas from
freezing and possibly plugging the nozzle, one needs to
account for the change in temperature across the orifice.
The equations for compressible gas flow across a nozzle
are a bit different.
For this we need to introduce an entire new set of terms:
Equation 2 above needs to be modified by introducing the
expansion factor to account for the compressibility of gases.
Y = r 2/ k
1-r(k-1)/k
1-r
1-4
1-4 r2/k
4 approaches 0 and the last bracketed term in the above

equation approaches 1. Thus, for the large majority of orifice
plate installations:
Equation 4
Y = r 2/ k
Equation 3
m = 1 Q = C Y A2 2 1 (P1-P2)
k
k-1
k
k-1
1-r(k-1)/k
1-r
Where:
Where:
Y is the expansion factor, dimensionless
Y is 1.0 for incompressible fluids and it can be

calculated for compressible gases.
r is P 2/P 1 (Absolute pressures)
k is specific heat ratio (cp/cv), dimensionless*
JUNE 2014 | 19
WATER & WASTEWATER solutions

NOTE: For air, it is 1.4, which is good enough for most
cases, unless one really has a heavy vapor concentration in
the gas. Or get Cv and Cp from online tools and references
such as those found on EngineeringToolbox.com.
Substituting equation 4 into the mass flow rate equation
(equation 3), and making a few substitutions using the Gas
Law, we get:
And make sure all the units are consistent, if using English
units, then the temperature is in Rankine degrees. And thus,
the final equation for the non-choked (i.e., sub-sonic) flow of
ideal gases through an orifice for values of less than 0.25.
2ZRT1
M
k
k-1
P2
P1
2
k
Where:
T 1 is the initial temperature
Where:
k is specific heat ratio ( ), dimensionless
m is mass flow rate at any section, kg/s
Q 1 is upstream real gas flow rate, m/s
20 | JUNE 2014
A 2 is cross-sectional area of the orifice hole, m

P1 is upstream gas pressure, Pa with dimensions of
kg/(ms)
P2 is downstream pressure, Pa with dimensions of
kg/(ms)
M is the gas molecular mass, kg/mol (also known as the
molecular weight)
R is the Universal Gas Law Constant is 8.3145 J/(molK)
T1 is absolute upstream gas temperature, K
Z is the gas compressibility factor at P1 and T1 and
dimensionlessbut most of the time it is 1 for air at
environmental temperatures generally encountered.
Equation 5
Q1 = C A2
C is orifice flow coefficient, dimensionless
P2
P1
k+1
k
A final check of the velocity of the gas through the

orifice should be made to insure that it is not supersonic
(exceeding the speed of sound) and it should be checked
for temperature to insure that the gas vapor which contains
water will remain above freezing. This is important for both
vacuum extraction and vapor venting.
The entire program can be easily arranged on an Excel
spreadsheet, and the total orifice size and pressure drop
and gas flow can be easily calculated. Then using the
same essential data, select a drill size and a spacing which
is suitable to the length of the horizontal well. A brief
calculation of the total orifice size and appropriate area is
very straight forward and easily performed.
EXPERIENCE
TODAY
1990
We recently came across a two decades old photo of some young

up and coming engineers that were part of our drive engineering team at the time.
Guess what?
All those people are still with us. In fact, they are among our company leaders today.
Imagine. Twenty years of experience from each of them going to work for you every day.
Incredible knowledge. Penetrating insights. Real results.
Yaskawa puts all of that to work for you every day. Think of what you can do with a partner like that.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A
YA S K A W A . C O M
Follow us:
For more info:
http://Ez.com/yai632
2014 Yaskawa America Inc.
MAINTENANCE solutions
Know Your Pump Base Plate

Installation Options
Part 2 of a 3-Part Series
n part 1 of this series, we looked at many of the ways in

which pumps can be mountedintroducing some of the
practical and financial considerations for best practices
in base plate installation options. In this installment, well
examine more closely some of the Best-in-Class users
decisions and an important exception to the general guidelines
for secure-in-place installation.
By heinz P. Bloch,
Process machinery Consulting
In the size range up to about 5 feet by 8 feet (1.5 meters

by 2.5 meters), conventional grouting procedures are being
phased out in favor of base plates pre-filled with an epoxy
resin or grout (see reference 3). The epoxy filling process
includes five successive stages, all done under controlled
conditions. The entire process is most often done before
shipment to the site; at other times a competent work team is
entrusted with items 3 through
5 at the destination or owners
plant site:
EPOXY-FILLED OR FULLYfigure 4
MOLDED EPOXY BASE PLATES
Best-in-Class users often
specify and generally insist
1. Base plate fabrication.
on full epoxy or epoxy pre(No pour holes are needed
filled steel base plates. Both
for pre-filled base plates,
full epoxy and epoxy pre-filled
although figure 4 shows
base plates dispense with the
these large openings)
labor-intensive conventional
2. Stress relieving
grouting procedures that will be
3. Pre-grouting (grit blasting
needed with old-style hollow
followed by primer
base plates. Much labor and
application) in preparation
corrective maintenance can
for pre-filling. (If there
be eliminated by buying either
are large pour holes, the
solid epoxy or steel base plates
inverted base plate must
pre-filled with epoxy. The latter
be placed on a sheet of
can also be fabricated inplywood, figure 4)
plant. The conventional hollow
4. Fill with epoxy grout and
Underside of a base plate after a prime coat has been applied. It is
ready to be filled with epoxy. The large pour holes identify it as an
base plate in figure 4 is being
allow it to bond and cure
old-style conventional base plate being converted to pre-filled style
prepared for filling with epoxy.
5. Invert and machine the
(Source: reference 4)
Once filled, this base plate
mounting pads to be flat;
becomes a monolithic block that
then verify flatness before
will never twist and never get out of alignment (see reference
shipment. Protect and shippossibly even with pump,
4). The overall cost of this superior mounting is usually below
coupling and driver mounted and final-aligned.
that of conventional leveling and grouting methods. In other
words, the life cycle costs of full epoxy or epoxy pre-filled
The advantage of pre-filling is notable. Jobs with pumps in
steel base plates can be overwhelmingly attractive (see
the 750 kilowatts category and total assemblies weighing over
reference 3).
24,600 pounds (~11,000 kilograms) have been done without
Since about 2000, Best Practices Companies (BPCs) have
difficulty on many occasions. In contrast, a conventionally
increasingly used monolithic (all-in-one, and/or epoxy
grouted base plate requires at least two pours, plus locating
pre-filled steel) base plates in sizes approaching about 5 feet
and repair-filling of voids after the grout has cured. Epoxy
by 8 feet (1.5 meters by 2.5 meters). Larger sizes become
pre-filled base plates travel better and arrive at the site flat and
cumbersome due to heavy weight.
aligned, just as they left the factory. Their structural integrity is
About the Author

Heinz P. Bloch, P.E., is one of the worlds most recognized experts in machine reliability and has served as a founding
member of the board of the Texas A&M University's International Pump Users' Symposium. He is a Life Fellow of the ASME,
in addition to having maintained his registration as a Professional Engineer in both New Jersey and Texas for several straight
decades. As a consultant, Mr. Bloch is world-renowned and value-adding. He can be contacted at heinzpbloch@gmail.com.
24 | JUNE 2014
better because they

do not require grout
holes. Their installed
cost is less and their
long-term reliability
is greatly improved.
figure 5
combination (see
reference 3). A
decade-long rule of
thumb for horizontal
pumps aims for a
foundation mass
of 3 to 5 times the
combined mass of
pump, driver and
base plate.
SECURING PUMPS
IN PLACEWITH
ONE EXCEPTION
Again, and for
general emphasis:
A LOOK AHEAD
Proper field
In the conclusion of
installation of pumps
this series, we will
has a measurable
look at what pump
positive impact on
users need to know
pump life. Even a
about with regard
superb design will
to the best-practice
give poor results
specifications for
if poorly installed.
alignment jacking
A moderately
provisions and
good pump
create an adaptable
design, properly
checklist for base
installed, will give
plate installation
good results (see
options and
reference 2). Proper
guidelines. No
installation refers to
installation checklist
a good foundation
can cover the
design, no pipe
entirety of pump
strain and good
users experiences
shaft alignment, to
and specifications,
name just a few. No
but some concerns
pump manufacturer
remain worthy
designs its pumps
of attention in
strong enough to act
the majority of
as a solid anchoring
applications.
point for incorrectly
supported piping, or
REFERENCES
piping that causes
1. Bloch, H. P., and
A. R Budris. Pump
casings and pump
Users Handbook:
nozzles to yield
Life Extension, 4th
and deflect. Also,
Edition (2013).
pumps have to be
Fairmont Press (ISBN
0-88173-720-8).
properly secured to
their respective base
2. Bloch, H. P., and F.
K. Geitner. Major
plates and these
Process Equipment
base plates have
Maintenance and
to be well-bonded
Repair, 2nd Edition.
to the underlying
Gulf Publishing
Company (ISBN
foundation. Epoxy
0-88415-663-X).
grout is used to
3.
Bloch, H. P. Pump
do this bonding in
Vertical in-line pumps are not to be bolted to the foundation. They should be allowed to move with the
Wisdom: Problem
connected pipes
modern installations.
Solving for Operators
There is one
and Specialists
exception, however:
(2011). John Wiley & Sons (ISBN 978-1-118-04123-9).
Vertical in-line pumps (figure 5) are not to be bolted to the
4. Monroe, Todd R. and Kermit L. Palmer. Methods for the Design and
foundation. They are intended to respond to thermal and other
Installation of Epoxy Pre-filled Base Plates (1997 Marketing Bulletin).
Stay-Tru Services, Inc., Houston, Texas.
growths of the connected piping and must be allowed to float
5. Barringer, Paul, and Todd Monroe. How to Justify Machinery
or slide a fraction of an inch in the x and y-directions. The
Improvements Using Reliability Engineering Principles, Proceedings
foundation mass under vertical in-line pumps can be much less
of the Sixteenth International Pump Users Symposium (1999).
than that under the more typical horizontal pump. For vertical
Turbomachinery Laboratory, Texas A&M University, College Station,
in-line pumps it is acceptable to make the concrete foundation
Texas.
about one-and-a-half to twice the mass of the pump-and-driver
JUNE 2014 | 25
PUMP solutions
A Revolution in Pumping Efficiency

All-Flos A200 pump reduces energy costs, improves performance
PARt 3 in A 4-PARt SERiES
By Paul mcgarry, All-flo Pump Co.
ll air-operated double diaphragm pumps (AODDPs)

are not created equal. In fact, significant differences
in performance, efficiency, and total cost of ownership
exist from one manufacturers pump to another. Sometimes
these differences are so pronounced that they can add up to
losses of hundreds of thousands of dollars every year.
If AODDPs were truly the interchangeable commodity
products as some believe, would this be the case? The
answer is an emphatic no. There is still room for innovation
and improvement in the field of AODDPs. One example of
where these ideas have found a homeas weve seen in the
first two installments of this seriesis All-Flos A200 pump.
The A200 stands apart from other AODDPs on the market.
As you read this months article, the importance of choosing
the right pump for your application will become abundantly

clear.
A QUICK RECAP
Before we move on, lets take a moment to look back at

how we got here. The first two articles in this series covered
how AODDPs work, how to read performance curves, and
how to calculate pump operating costs. We also delved into
how All-Flos new A200 model drastically improved upon
its predecessor and has raised the bar for performance and
efficiency across the entire industry.
Please reference the prior installments if you need a
refresher, but for your convenience, heres a reminder of
the primary takeaway: All-Flo seriously advanced pump
Total Head in Feet (Meters)
Pressure Inlet/Outlet PSIG (Bars)
Discharge Flow - Liters/Min.
Discharge Flow - U.S. Gals./Min.

Figure 7
About the Author

Paul McGarry is the All-Flo sales and marketing manager for North America. To learn more, visit www.all-flo.com, and
www.aoddpumpefficiency.com.
26 | JUNE 2014
performance and efficiency with

the A200. This was achieved by
reducing and optimizing dead
space on the liquid and air
sides of the diaphragms and by
improving the timing of the main
air valve.
SETTING THE
COMPARISON CRITERIA
Redesigned
Pumps
Original
Pump Model
Brand A
Brand B
Brand C
Brand D
Required air pressure (psi)
90
82
81
100
120
97
Required SCFM
70
122
108
135
125
175
$ Per hour
$0.91
$1.59
$1.41
$1.76
$1.63
$2.28
$ Per 8-hour day
$7.31
$12.71
$11.28
$14.10
$13.06
$18.28
$ Per five-day week

(8 hours per day)
$36.55
$63.71
$56.40
$70.50
$65.28
$91.39
To get a fair apples-to-apples

$ Per year (52 weeks)
$1,901
$3,313
$2,933
$3,666
$3,394
$4,752
comparison underway, we
will start with some specific
Table 1: The operating requirements of the redesigned A200 AODDP and other pumps.
assumptions. First, the
application scenario. For our
purposes, we are going to
suppose that the AODDP being evaluated needs to transfer
All-Flo customers run four hundred pumps or more at any
8000 gallons (30,283.29 liters) of liquid every hour, for eight
given time, so imagine extending these savings across an
hours a day, over the course of a year. It will do this with a
entire operation! You dont have to be a mathematician to
liquid discharge pressure of 20 PSI. Second, 8000 gallons
understand that those kinds of numbers can dramatically
(30,283.29 liters) per hour is equivalent to a flow rate of 133
impact a companys bottom line. Thats why its so important
gallons (503.46 liters) per minute. This means that the pump
to know exactly what youre getting intoexactly what
in our example operates at 133 gallons (503.46 liters) per
youre getting for your AODDP investmentbefore you make
minute against a discharge pressure of 20 PSI.
a purchasing decision. The numbers dont lie.
Using the performance curve shown in figure 7, we can
find out how much air is required to run the pump. Simply
COMING UP
find 133 gallons (503.46 liters) per minute on the horizontal
In our next, and final, article in this series, we will discuss
axis and then look to see where that value intersects with
how to make sure you get the ideal AODDP for your needs.
20 PSI on the vertical axis. You can see that they meet
Well clue you in on what to look for when evaluating
between the two blue lines that represent 80 and 100 PSI.
AODDP performance and give you the right questions to ask
This means that the required operating pressure is around 90
pump manufacturers.
PSI. The intersection point also lies between the red lines that
represent 60 and 80 SCFM. This tells us that we can estimate
the air consumed by the pump to be 70 SCFM.
WHAT DOES THIS MEAN?
To put it all together to calculate operating costs, we use the

following equations:
70 SCFM x 1 hp/4 SCFM = 17.5 hp

17.5 hp x 0.746 kW/hp = 13.06 kW
13.06 kW x $0.07/kWh = $0.91 per hour
As you can see, in our example, this particular pump can

transfer 8000 gallons (30,283.29 liters) per hour at a cost
of $0.91 per hour. This makes the extended annual cost
somewhere in the neighborhood of $1900.
ONE OF THESE PUMPS IS NOT LIKE THE OTHERS
The impressive pump performance used in the previous

example belongs to All-Flos A200. In Table 1, weve put
those numbers (found under A200 Redesigned Pumps)
up against the operating costs of the A200s own All-Flo
predecessor (Legacy Pump Model) as well as AODDPs
currently sold by other manufacturers. As you can see, the
A200 beats the competition in every single category.
Sure, the differences in operating costs demonstrated here
are stark, but rememberthis is just for one pump. Some
JUNE 2014 | 27
DEWATERING solutions
Controlling All the
vaRiables
VLT AQUA Drive produces huge water savings from food processors deep well
By James Klauer, danfoss
ood processing plants

require a dependable
source of water in large
quantities for the washing
and rinsing, steaming,
cooking and cooling of food,
and during plant sanitation
operations. Thats why a
large Midwest food processor
wanted full control over its
water supply by constructing
a private water well on its
own property. However, what
looked like a simple solution
was quite complex below
the surfaceas the well
driller discovered when he
embarked on the project.
"The food processor's water
production requirements and
the utilization of local wells
meant our first and second
drilling choices wouldnt
work," says Roger Renner,
owner of E.H. Renner and
Sons, a leading well-drilling
firm located in Elk River,
Minnesota, near the Twin
Cities metro area. "In fact,
I'm the fourth generation in
our family firm, and I can
truly say this was the most
challenging job I've ever
had."
DIFFICULTIES WITH A
DEEP AQUIFER
From the start, Renner

realized the project would
be difficult when there
The Danfoss VLT AQUA Drive
were objections to using a

desirable shallow aquifer.
An aquifer is a water-bearing
layer of permeable sand,
gravel or rock that channels
water to a well. In this case,
the first choice aquifera
shallow sand and gravel
formation located from 112
to 442 feet (34.14 to 134.72
meters) deepcould not be
used, because local residents
were concerned that their
wells would dry up.
"That meant we had to look
at deeper aquifers in two
geological formations known
as the Jordan formation
and the Franconia-IrontonGalesville (FIG) formation,"
says Renner. "A nearby city
was drawing water out of
the Jordan formation. That
forced the processing plant
to go deeperdown 705 feet
(214.88 meters), over a tenth
of a mile. At that depth, the
bedrock is the FIG formation,
which dates to the Cambrian
Era. This water was deposited
millions of years ago before
the dinosaur age. Yet, the
water quality is generally
acceptable for all types of
use today."
Although drilling a deep
well is difficult, Renner's
main challenge was that the
FIG formation has extremely
low well productivity, which
About the Author

James Klauer is regional sales manager for Danfoss, a world leader within energy-efficient and climate-friendly solutions for
selected industries. For more information, visit www.danfoss.com.
30 | JUNE 2014
Deeper aquifers proved to be necessary.
was measured at a specific capacity of 1 to 2 gallons (3.79

to 7.57 liters) per foot of drawdown compared to a specific
capacity of 20 gallons (75.71 liters) per foot drawdown
in the sand and gravel formation. Also, the FIG formation
would max out at a relatively low 350 gallons (1324.89
liters) per minute. The food processing plants operation,

however, needs a dependable 350 GPM flow rate running
24 hours a day, 7 days a week. That adds up to 10 to 12
million gallons (37.9 to 45.4 million liters) per month, 150
million gallons (567.8 million liters) per yeara larger
JUNE 2014 | 31
volume of water than used by small
cities.
"The plant depends on that rate of
flow to process food around the clock
all year long," Renner emphasizes.
"At the same time, we had to respect
the low specific capacity to avoid
over pumping the well and prevent
excessive drawdown. Plus, the state
Department of Natural Resources

requires the pumping water level to
be monitored and controlled to keep
the pumping water level above the
existing horizon of the formation. That
meant we needed an intelligent pump
control system that could monitor
and adjust a lot of different factors to
ensure reliable water production."
VFD INTELLIGENCE AT WORK
Considering the challenges, Renner

contacted Brian Peterson of Schwab,
Vollhaber and Lubratt, Inc., (SVL)
of Shoreview, Minnesota, near St.
Paul. As a provider of technical
and engineering services for HVAC
and pump applications, Peterson
recommended a Danfoss VLT AQUA
Drive to operate the pump motor.
"This facility is extremely dependent
on maintaining a variable water flow
between 150 to 350 gallons (567.81
to 1324.89 liters) per minute at a
constant pressure of 65 pounds per
square inch (psi)," says Peterson.
"The Danfoss VLT AQUA Drive is
a variable frequency drive (VFD)
that is built in Loves Park, Illnois,
and is specifically dedicated to
water and wastewater applications.
They come off the shelf with the
onboard intelligence to handle all the
monitoring and control parameters this
job required."
The VFD was employed in a
closed control loop. The control and
monitoring programming included
A wake-sleep sequence that, upon
waking, ramps up the GPM of the
32 | JUNE 2014
pump to provide a minimum flow

of water to cool the motor. As the
plant needs more water flow, the
VFD increases motor speed to the
required pre-set pressure of 65
psi. The typical production flow
rate is 185 to 285 gallons (567.81
to 1078.84 liters) per minute,
with process cleaning peaking at
the 350 gallons (1324.89 liters)
per minute limit.
To control the flow rate, the VFD
monitors a pressure transducer
that sends a 4-20mA signal
back to the drive. The drive
intelligence ensures a constant
65 psi, but also limits the flow
to 350 gallons (1324.89 liters)
per minute by monitoring
the flow meter. Even with
fluctuating pumping levels over
the 12-month period the VFD
adjusts the speed of the motor
to compensate for the changing
pumping levels. During the initial
VFD programming, adjustments
were made that limited the 100
horsepower motor to only 56 Hz
to avoid possible over pumping in
the event of a water main break.
"This was the most challenging job I've ever had," says Roger Renner, owner of E.H. Renner and Sons.
A pressure transducer was also

installed in the well to control
the maximum amount of water
drawdown. If the pumping water
level in the well falls below the
preset 520-foot (158.5 meter)

depth, the VFD would limit or
hold the speed of the pump
to avoid severe pump damage
created by cavitation. This
JUNE 2014 | 33
over pumping mode protection
feature is particularly needed in
the autumn when well pumping
levels are lowest and when the
processing plant's production is at
its peak.
Finally when plant water demand
falls below the minimum GPM
needed to cool the submersible

motor, the VFD stops the pump
and enters the sleep cycle. When
the plant calls for water while
the VFD is in the sleep state, the
water pressure falls below a preset
minimum pressure of 50 psi, then
restarts the pump and ramps up
to the preset 65 psi. Thus, the
wake/sleep sequence protects

the motor against overheating if
the minimum flow rate cannot be
maintained and shuts off the flow
when the plant does not call for
water.
Peterson notes that "the VFD's
extended closed loop function can
handle three distinct control sensors:
the flow meter, drawdown gauge and
the pressure. The VLT AQUA Drives
built-in intelligence can process all
those inputs simultaneously. Plus,
the system incorporates phase failure
protection, under-voltage and overvoltage protection that protects the
drive and the submersible motor,
pump and bearing. This protection can
provide some water production even
with a loss of a three-phase power
down to two-phase current."
The plant is so dependent on
maintaining water flow that the
customer also added an identical
VFD housed in a NEMA 1 enclosure.
It hangs on a wall inside the plant,
beside the original Danfoss VLT
AQUA Drive.
"The spare is a redundant backup,"
says Peterson. If there were a
catastrophic failure due to a utility
issue, lightning, physical damage or
other unforeseen event, the spare drive
can be put into service by just a flip
of the switch. For the same reason,
the plant also wanted a replacement
submersible motor and pump on the
shelf. But the system has been so
reliable since it went into service in
2010 that the redundant measures
have not been needed."
GIGANTIC PAYBACK, PLUS

GREAT SUPPORT
Along with reliable water production,

the processing plant benefited from
tremendous water savings by operating
its own well.
"Maintaining variable flow at a
constant pressure of 65 psi is job
number one," says Renner. "The
reliability of the VLT AQUA Drive
is critical to keep this plant running.
Plus, by enabling the use of their own
water source, the VLT AQUA Drive
makes it possible to run the plant very
profitably."
Renner calculates that the plant
consumes about 12 million gallons
(45.4 million liters) a month. If they
did not have their own well and
were paying a local price of about
34 | JUNE 2014
Savings in water costs will quickly pay back this complex well job.
two dollars per 1000 gallons

(3785.41 liters), the water cost
alone would have been $24,000
a month, nearly $250,000
dollars a year.
For a processing plant whose
business depends on high,
reliable quantities of water,
"Saving a quarter of a million
dollars a year certainly justifies
a complex well project like this,
because the payback is so fast,"
Renner concludes. "The well has
been operating since 2010. The
entire project, including well
drilling and lining, was paid
back in less than two years."
"And SVL and Danfoss
have been a pleasure to work
with. The level of support
was unbelievable. All of the
parameters required a lot of
programming. If we had an
issue, the Danfoss application
engineer was available, even
on a Sunday. It's hard to find
that level of support in a VFD
manufacturer. The Danfoss team
was instrumental in making this
project a huge success."
JUNE 2014 | 35
MOTOR solutions
The Next Generation of

Premium Efficient
Gearbox
By John Shanesy, Nord gear Corporation
Two stage helical-bevel design

adds bite to food and beverage
industry
NORD 92.1 Series Gearbox
About the Author

John Shanesy is the product marketing specialist for NORD Gear Corporation, a part of NORD Drivesystems. NORD provides
a wide range of products with gearboxes ranging in torque ratings from 90 to 2,200,000 pound inches, and electric motors
rating in power from 1/6 to 250 horsepower. In addition, the product line consists of high-performance AC Vector Drives and
AC Drives for panel mount or distributed mount. For more information, visit www.nord.com.
36 | JUNE 2014
NORD 93.1 Series Gearbox
ince 1965, NORD Drivesystems

has been providing applicationspecific concepts and solutions,
which include energy-saving drives,
and now the next generation of
premium efficient gearbox has arrived
for the North American market.
The two stage helical-bevel design,
referred to as the 92.1 and 93.1
series, offers high-performance, up
to 97 percent efficiency and a 60
percent increase in torque to weight
ratio over the previous series. Both
series are available in five gear
case sizes and are characterized
by an open, smooth, self-draining
outer surface, and are the result of
thorough research assessing the needs
of todays users. Across a range of
industries, but particularly in food
and beverage processing, users
are searching for increased power
without sacrificing efficiency. NORD
Drivesystems believes the two stage
helical-bevel design is the answer.
MEETING THE NEEDS THE FIELD

Designed using FEM (Finite Element
Modeling Technology), this highstrength aluminum alloy housing
is manufactured using NORD's
UNICASE Design. The UNICASE
design consists of a one-piece
housing where bores and mounting
faces are machined in one step,
producing precise tolerances that

ensure accurate positioning of gear
teeth, bearings and seals. Internal
reinforcements inside the gear case
increase the strength and rigidity
of the gearbox, resulting in a highstrength housing. This, in turn,
provides for larger, high-capacity
output bearings, increased overhung
load capacity and increased hollow
bore capacity. By NORD offering
a leak-free design, longer gear and
bearing life, quiet operation and
high output torque capabilities,
the customer benefits from high
efficiency, low maintenance and a
long service life.
Providing exceptional modularity
and adaptability for all mounting
positions, numerous possibilities exist
for input, output and motor options.
Input and output options are stocked
at the factory to guarantee quickshipment upon order. Available with
either a NEMA or IEC input, a NORD
motor or brake motor, the 92.1 and
93.1 are well suited for applications
in the conveyor industry, material
handling, car wash, and the food &
beverage industry, including wash
down environments.
THE 92.1 SERIES
The 92.1 series, easily identified by

its high-strength lightweight design, is
a universal housing offering foot, face

(B14) and shaft mount as standard.
An optional B5 mount is available.
The 92.1 series is cost effective when
compared to the 93.1 and is ideal for
cooling, due to its large surface area.
Universal foot and flange-mount
housings
Easy wash-down solution
Cost effective design
Foot, face (B14) and shaft mount
External surfaces connected
with large radius and generous
mold release slopes provide for a
cleanable, drainable housing
THE 93.1 SERIES
The 93.1 series is characterized

by the closed design and comes
as shaft and flange mount (B14)
as standard. Optional drilled and
tapped holes can be provided for foot
mount requirements. In addition,
an optional through-bolt, B5-flange
is readily available. Because there
are no cavities to this design, NSD
tupH surface conversion system is
available.
Closed gearbox design
No hidden chambers (cavities) for
material build-up
Optimal for NSD tupH Surface
Conversion System
JUNE 2014 | 37
MOTOR solutions
OPTIMIZED FOR THE FOOD
INDUSTRY
The 93.1 Series is optimized for

the food industry because of the
lightweight, aluminum housing
incorporating the newest technology.
Designed and manufactured with
inclined surfaces guarantee the
draining of cleaning liquid in all
mounting positions. By adding NORD's
NSD TupH surface conversion system,
washdown liquids always run off.
The benefits of NSD TupH include no
peeling, flaking or blistering of paint by
providing a higher level of corrosion
resistance.
The 93.1 series is much lighter and
offers better thermal conductivity
than stainless steel. The design is
optimized for use in the food and
beverage industry and complies with
international guidelines and standards
such as EHEDG, ANSI, and ANSI /
NSF. For sealing lubricants inside
and keeping contaminants outside
the reducer, NORD's four component
QUADRILIP sealing system, is
standard for both hollow and solid shaft
unit types.
FOCUSED ON EFFICIENCY AND

THE CUSTOMER
As the world continues to strive for

increased efficiency, the new 92.1
and 93.1 units are the answer. While
a typical worm gear type drive may
be only 70 percent efficient, the 97
percent efficiency of the 92.1/93.1
series are truly the premium efficient
gearbox. Dramatic energy savings
and a much lower cost of ownership
are accomplished which, in turn,
improves the bottom line. While
some manufacturers in the power
transmission industry claim an
improved bevel design but attach
a lesser efficient hypoid gear stage,
others sell the customer a high efficient
motor but attach an inefficient worm
gear drive.
This gear cutting technology allows
for the production of gear sets with
a higher maximum ratio per stage
than many other speed reducer
manufacturers. This allows for a
true helical-bevel, double reduction
gear unit with a maximum ratio of
70:1. With a company-wide focus
on design, innovation and a superior
product, customers and end users
around the world rely on NORD for
performance, efficiency, and superior
dependability.
38 | JUNE 2014
POWER GENERATION solutions
Utilities Are Frightened

of a Death Spiral.
They Shouldn t Be.
Industry and regulators need a more accurate and
adaptive view of tomorrow s energy market
By Steven Nadel, American Council for an Energy-Eff icient Economy
he electric and gas utility industries are facing substantial

changes. For decades, rising sales have contributed to
increasing revenues and profits, but the combination
of improved energy efficiency with the growing use of solar
electric systems and other
forms of distributed energy
has reduced growth rates,
which could lead to small
declines in future sales. But
these potential small declines
will not lead to the kind of
death spirals claimed by
some industry alarmists, as our
new report, The Utility of the
Future and the Role of Energy
Efficiency, shows. Still, the
industry and their regulators
will need to make substantial
changes in the next few years
in order to continue providing
quality service at a reasonable
price, while providing utilities
reasonable returns on their
investments.
THE FORECAST FOR

UTILITY SALES
According to the alarmists,

utility sales could plummet,
requiring utilities to raise rates so they can recoup their fixed
costs (such as the cost of the current distribution system), and
these rising rates would drive additional customers to leave
the system, a phenomenon they call a death spiral. Our study
examines three potential sales scenarios, employing increasing
levels of energy efficiency, solar electric power and electric

vehicles.
The most extreme scenario includes levels of energy
efficiency now being achieved in only a few states plus the
use of solar electric power
that eventually uses nearly
all available roof space.
Under this extreme scenario,
national electricity sales
decline about 10 percent by
2040, an average reduction
of 0.39 percent per year.
Under a more likely mid-range
case, sales grow 0.04 percent
per year, while under the
reference scenario, developed
by the Energy Information
Administration, sales grow 0.7
percent per year.
ENERGY EFFICIENT
OPTIONS FOR A NEW
WORLD
In our view, a 10 percent sales

decline over twenty-five years
is far lower than what would
be required to initiate a death
spiral. Under the more likely
scenario, sales are essentially
flat. In such a scenario, utilities that have relied on rising sales
to fuel profits will need to pursue new business models if they
want to see profit growth. To address this finding, our report
recommends that utilities offer optional energy-related services
to their customers, including energy efficiency and technical
About the Author

Steven Nadel is the executive director of the American Council for an Energy-Efficient Economy (ACEEE), a nonprofit,
501(c)(3) organization, that acts as a catalyst to advance energy efficiency policies, programs, technologies, investments,
and behaviors. Read the ACEEEs newest report, The Utility of the Future and the Role of Energy Efficiency, in full at
www.aceee.org/research-report/u1404.
40 | JUNE 2014
help and financing for larger customers

installing and operating high-efficiency
combined heat and power systems. Such
efforts can contribute to utility profits,
reduce customer bills (since consumption
is lower) and also provide services that
customers value, positioning the utilities
to offer additional services.
cuts in carbon dioxide emissions from the

power sector, but provides utilities and
states with the flexibility to use energy
efficiency programs and policies to help
achieve those reductions. An earlier
ACEEE report from April 2014 found that
energy efficiency could achieve all of the
needed reductions while also increasing
GDP and employment.
In summary, if we can get the rules

right and continue to develop the
technologies and systems we will need,
utilities can maintain profitability,
customers can receive the services they
need, bills can be kept to reasonable
levels, and we will all enjoy a cleaner
environment.
To support this effort, we also

recommend that regulators
adjust rates so that fixed costs
are fully recovered as sales levels
change,
provide utilities financial incentives
for meeting energy efficiency goals,
reform ratemaking so that costs are
fairly allocated and price signals
encourage efficient use of energy,
and
develop rules to improve the ability
of utilities to offer optional services
in ways that provide a level playing
field relative to non-utility providers.
Quite a few states have taken some of
these steps, but only a few states have
taken most of them. In addition, we
recommend upgrading management of the
electric grid to better handle increased
amounts of variable and distributed
generation.
STOP DIGGING, START CLIMBING
Our research also identifies several things

not to do. In our view, the first rule of
holes applies: When youre in a hole, the
first thing to do is stop digging. If sales
are level or declining, then utilities and
regulators need to be careful of investing
too much in new generation, transmission
and distribution. Our report notes how
Australian utilities invested so much in
transmission and distribution that rates
doubled, and how German utilities overinvested in generation, contributing to a
steep drop in stock prices. While some
investments in fast ramp-up generation,
transmission to link control areas, grid
hardening, and grid control will be
needed, these should be prioritized so
costs and rates are kept to reasonable
levels.
Our call for increased utility investment
in energy efficiency fits in well with
proposed regulations (see the EPAs Clean
Power Plan Proposed Rule on their
site: www2.epa.gov/carbon-pollutionstandards/clean-power-plan-proposedrule) on existing power plants published
last week by the Environmental Protection
Agency. The proposal calls for substantial
JUNE 2014 | 41
PROCESSING solutions
Short Design
Means
By thomas Bkenbrink,
lewa gmbh
Splitted gear box and improved

maintenance possibilities for
plunger pump
Lewa skid with plunger pump

and ATEX-compliant diesel engine.
ewa plunger pumps according to API 674 are used

consumption, and a long service life. The new structure with the
wherever high hydraulic power is needed, especially in
splitted gear housing and the fully balanced crankshaft doesn't
the oil and gas sector and the process industry. These
just reduce wear, but also particularly facilitates maintenance.
pumps are characterized by their compact construction and
The design of the pump also permits the maintenance of
low weight, which is particularly significant for offshore
components without disassembling the process pipeline. The
installations. To meet the special requirements of customers
crankshafts are drop-forged and shot-blasted, leading to a
homogeneous grain structure and low
even better, Lewa now offers a new
generation of pumps with splitted
stress level. The integrated gear unit is
gear housings. This special feature
self-adjusting and both the crankshaft
significantly facilitates maintenance,
and the pinion shaft are practically free
New quintuplex pumps
of axial load.
permitting the use of a fully balanced
crankshaft which generates less noise
with drive powers of up
and vibration, thus reducing wear. The
G5K 500 AND G5K 800
power range was also extended with
Lewa plunger pumps are very powerful
to 800 kilowatts.
two quintuplex plunger pumps.
and work with volumetric accuracy.
Their large valve cross-sections
A CLOSER LOOK
make the suction pressures required
The very short design of Lewa plunger pumps is made possible
comparatively small. This mostly eliminates the need of a
by the special alignment of the plunger and crosshead.
booster pump. Starting at a power of 15 kilowatts, flexible
These pumps also have outstanding efficiency, low energy
use is possible at different drive speeds up to 800 kilowatts, at
About the Author

Thomas Bkenbrink is a product manager for Lewa GmbH, the world's leading manufacturer of metering and process
diaphragm pumps as well as complete metering systems for process technology. The company, headquartered in Leonberg,
Germany, has developed over just a few decades into an international group, and its position in the world market was further
strengthened by its integration into the Japanese Nikkiso Co. Ltd. in 2009. For more information, visit www.lewa.com.
42 | JUNE 2014
pressures of up to 3500 bar and a maximum flow

rate of 76,600 gallons (290 cubic meters). They
are especially used for uncritical fluids
like glycol, methanol, or inhibitors that
are similar to water in terms of their
viscosity.
Now both quintuplex variants,
the G5K 500 and G5K 800, are
available with maximum power of
up to 800 kilowatts. By increasing
the number of plungers, the size
of the individual components can
be reduced for the same hydraulic
power. That leads to a reduction
in weight, in turn facilitating
maintenance. They also achieve a
low residual pulsation of about seven
percent, thanks to the five plungers.
The pump head is equipped with an innovative

plunger seal. Pressure and/or spring support of
the seal packing allows a long service life
and high availability. The gland packing
is entirely maintenance-free; it never
requires adjustment of pretensioning
or repacking. Any packing leaks are
returned internally, so no external
pump is needed for returning the
leakage back into the suction line
and no monitoring is necessary.
Due to the modular
construction, a pump can
be configured that meets the
requirements resulting from the
application. Different pump head
designs and valves are available
for this purpose. The pump head
The divided gear housing of the new quintuplex
design makes it possible to exchange
pump permits the use of a fully balanced
the conversion kit, that is, the plunger
SIMPLE MAINTENANCE
crankshaft and facilitates
and stuffing box, thus adjusting the volume
AND GREAT FLEXIBILITY
maintenance.
conveyed and the discharge pressure over a certain
To protect the gear unit from low oil levels and
range. All pumps are optimized for operation with speed
excessive temperatures, the pump is monitored by default
controlled electric motors and/or diesel engines, but of course
by a temperature and pressure switch. In the oil and gas
industry, this is often implemented using transmitters. Within
they can also be operated without a frequency converter. The
the gear housing, the crosshead pins and plain bearings are
maximum regulation range is between ten and one hundred
percent of the rated speed. Depending on the application
supplied by an integrated pressure oil lubrication system, so no
additional systems are required. Because all the oil seals are
and/or the fluid, a wide variety of materials is available for
accessible from outside, no gear oil needs to be drained during
selection. A number of different connection geometries and
maintenance tasks, which has a beneficial effect on downtime.
several options for monitoring and flushing are also offered.
JUNE 2014 | 43
VALVES & CONTROLS solutions
4 Ways
to Achieve NOx Reductions

without Turbine Damage
Reduction in emissions isnt just desiredits required.
By Eric yax, imi Sensors
overnment regulations require

emissions without damaging the
all industries who rely on
turbines necessary to keep industry
gas-powered turbineswhich,
moving. Before we begin, though, it
in the industrialized world, means
may prove helpful to ask yourself a
nearly all industriesto reduce their
few questions about your companys
NOx emissions. Companies who fail
emission reduction strategy:
to reduce their
emissions to
the prescribed
On-Turbine
rate must be
Instability Sensor
prepared to incur
harsh financial
penalties.
Furthermore,
since emissions
standards change
over time, the
quest for new
strategies and
technologies
to reduce NOx
emissions is
unending.
In the following
article, well
briefly discuss
the causes and
consequences of
Remote Sensor
NOx emissions,
(located outside of
plus explore four
turbine room)
techniques for
reducing NOx
Can you identify your NOx

emissions and how they relate to
combustion instability?
What can your operators do to
control combustion dynamics?
What ways are available to
Gas Turbine
Combustor
"Infinite" Coil
Close
Coupled
Sensor
Suggested Sensor Placement
About the Author

Eric Yax is the director of sales and marketing for IMI SensorsEnergy and can be reached at eyax@pcb.com. IMI Sensors, a
division of PCB Piezotronics, is the pioneer of ICP technology and a global supplier of accelerometers, vibration transmitters
and switches. PCB Piezotronics was founded in 1967 as a manufacturer of piezoelectric quartz sensors, accelerometers,
and associated electronics for the measurement of dynamic pressure, force, and vibration. For more information, visit
www.imi-sensors.com/reducenox or call 800.959.4464.
46 | JUNE 2014
monitor combustion instability?

What measures have you
implemented to reduce NOx
emissions?
Are you protected against
potential catastrophic failures
that result from NOx reduction
strategies?
What does your condition
monitoring look like?
For decades, gas turbine operators

have used pressure sensors and
specialty accelerometers to monitor
pressure and vibration levels within
very demanding, high temperature
environments. This technology is
designed to detect and measure
dynamic pressure spikes, pulsations
and surges in gas turbine engines.
4 WAYS TO MONITOR
COMBUSTION DYNAMICS
The use of remote sensors is the first

method of monitoring combustion
dynamics in an industrial environment.
Remote sensors have the advantages
of relatively low cost while providing
accurate pressure measurements.
In their design, remote sensors also
You may not have the answers to all

of those questions right now, but they
should place you in the proper mindset to improve your NOx reduction
strategies and address your need for
better condition monitoring.
THE PROBLEM OF COMBUSTION

INSTABILITY
What is NOx, and how does it

relate to combustion instability? The
production of NOxthe common
term for mono-nitrogen oxides NO
(nitric oxide) and NO2 (nitrogen
dioxide)emissions occurs in the
combustion process of any gas-fueled
turbine. In common practice, NOx
emissions are kept low by using lower
combustion temperatures and burning
leaner fuel mixtures. However, this
combination can lead to combustion
instability.
This instability can damage
components in the combustion
chamber such as nozzles, baskets,
and transition pieces, as well as
downstream components, such as
blades. The damage invariably results
in downtime, loss of production, and
costly repairs. Further, a breakdown
of one turbine component, such as a
blade, has a domino effect on many
other parts, resulting in serious repair
costs.
Turbine operators who utilize NOx
reduction strategies use sensors to
measure dynamic pressure to obtain
early warning of conditions that can
lead to excessive pulsations and cause
instability.
HOW TO CONTROL
COMBUSTION DYNAMICS
In order for your industry to continue

be profitable, you must develop
a strategy to control combustion
dynamics while reducing NOx
emissions. Strict emission laws and
regulations make it difficult for many
gas turbines to continue operation
with old combustion technology
producing high NOx emissions.
JUNE 2014 | 47
VALVES & CONTROLS solutions

offer a good deal of flexibility to meet the specific
monitoring needs, with either portable or permanent
installation options available.
Close coupled sensors present another option for
operators looking to control combustion dynamics.
When compared to remote alternatives, close
coupled sensors offer an even higher degree of
accuracy and provide precision pressure sensor
technology. This higher performance comes at
a price, however, with close coupled sensors
method 2
Pressure Sensor
(Series 171)
Combustor
Tube
Length approx. 5m
"Infinite"
Coil
method 1
Gas Turbine
Pressure Sensor
(Series 121)
Sensor
Enclosure
"Infinite" Coil
Tube
Length approx. 10m
48 | JUNE 2014
generally being the higher cost alternative to remote sensor

choices.
The third method of monitoring combustion dynamics is
the use of on-turbine instability sensors. These sensors, as
depicted in the explanatory diagram, are mounted directly
on the combustor. Although these types of sensors have
the highest initial cost, because they are also the most
reliable, they present the greatest advantage for longterm measurements and improvements in reducing NOx
emissions. Industrial operators who are searching for longterm choices in their strategies would be wise to consider
the upfront investment of this alternative.
method 3
method 4
045M19 Cable to
Charge Amplifier Enclosure
Length approx. 10m
Series 176
High Temp
Pressure Sensor
Combustor
Charge Amplifier
(Series 422M182)
(located inside the turbine room)
Inner Wall
of Can
The last method on our list is

represented by operators who turn
to high temperature accelerometers,
which have the ability to measure
vibration of the combustion
machinery. Some of these devices
can withstand temperatures up to
1300 degree Fahrenheit (740.44
degrees Celsius), meaning they can
withstand the heat of most industrial

applications.
WHATS NEXT?
Bottom line, regardless of the method

your industry turns to in order to
better control combustion dynamics,
reduction in NOx emissions
is required to comply with the
environmental legislation worldwide.

Since it causes combustion instability
that leads to machine breakdown,
its imperative to have a condition
monitoring program to ensure troublefree operation, prevent catastrophic
failures, unscheduled downtime,
loss of productivity, and even worker
safety.
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ITS A CHECK-ALL
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absolute precision and reliability. They
work like they should. Plus, most lead times
are less than one week. Thats what makes
Check-All the only choice.
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JUNE 2014 | 49
SEALING solutions
Superbolt makes easy work for boiler feed pump workers

By Steve Buslacchi, Nord-lock, inc. / Superbolt, inc.
uts and bolts are one of the most basic and

commonplace components in any piece of assembled
equipment. At larger diameters, they can also be one
of the most challenging. Part of the problem is that while the
strength of a screw fastener increases with the square of its
diameter, the torque required increases by the third power.
That means, with larger diameters, achieving proper preload
levels typically
figure 1
requires some form
of high energy
equipment.
A NEW WAY
NEEDED
For this boiler feed

pump (see figure
1), the 5-inch (127
millimeter) studs
were previously
tightened with a
very large wrench
in conjunction
with heating
rods. This method
required 1-2 shifts
(sometimes three)
with three workers
for installation
or removal.
Occasionally a
nut would seize
and would require
destructive removal.
Three workers
were required because it took two to manipulate the tool
and one to operate the overhead crane. Excessive bolting
time during an unscheduled pump repair can cost the utility
hundreds of thousands of dollars in lost generation. For these
types of applications, making this job safer and faster is highly
beneficial to both the workers and the utility.
THE SOLUTION
The ideal bolting method would be one that allowed you
to achieve accurate tension, safely, and quicklywithout

the use of any special tooling. One solution that meets
these criteria and offers a purely mechanical approach to
tightening is the Superbolt multi-jackbolt tensioner (MJT).
This technology utilizes a number of smaller jackbolts
threaded through the tensioner body to achieve preload,
rather than turning one large nut or bolt. The result is that
this tensioner can
be installed or
removed using a
hand-held electric
or air-powered
torque wrench.
A CLOSER LOOK
A Superbolt
tensioner is
comprised of three
componentsa
hardened washer, a
tensioner nut body,
and jackbolts. To
install (see figure
2) the hardened
washer (3) is
installed first to
protect the joint
surface. Then
the tensioner
body (2) is spun
on hand tight,
for positioning.
The jackbolts
(1) push the
nut body up, tightening the existing bolt or stud in pure
tension (5).
For this particular boiler feed pump, MJTs were installed
using -inch (12.7 millimeter) impacts for initial tightening,
and calibrated torque wrenches for the final torqueing step.
Two workers were utilized for the installation which required
about fifteen minutes to spin the tensioners into position,
and one hour and twenty-one minutes to tighten. This was a
significant time savings versus the previous method.
About the Author

Steve Buslacchi is the global product manager for Nord-Lock's Superbolt Division. For more information, visit
www.nord-lock.com. Additional information on Superbolt tensioners can be found at www.superbolt.com.
50 | JUNE 2014
WHAT IS SUPERBOLT?
Superbolt tensioners are designed as
direct replacements for conventional
nuts and bolts. These devices can
be threaded onto a new or existing
bolt, stud, threaded rod or shaft. The
main thread serves to position the
tensioner on the bolt or stud against
the hardened washer and the load
bearing surface. Once it is positioned,
actual tensioning of the bolt or
stud is accomplished with simple
hand tools by torquing the jackbolts
which encircle the main thread.
The jackbolts transfer the preload
evenly into the main thread and,

consequently, onto the joint. The main
thread is tightened in pure tension.
How Superbolt tensioners work:
figure 2
1. By tightening the jackbolts,

a strong thrust (axial) force is
generated. This thrust force is
directed against a hardened
washer. Jackbolts have a small
friction diameter and can
therefore create a high thrust
force with relatively little torque
input.
2. The loads are transferred through

the nut body which is positioned
on the main thread by hand.
3. A hardened washer is used to
transfer the force while protecting
the flange face.
4. The thrust (axial) force of many
jackbolts and the opposite
reaction force of the main bolt
head create a strong clamping
force on the flange.
5. The thrust (axial) force from the
jackbolt creates an equally strong
reaction force in the main bolt.
PROVEN TECHNOLOGY
Multi-jackbolt tensioners have been around for quite a while. Boiler feed
pumps are a particularly ideal application, and many plants have used
these tensioners with excellent results. Another such example is for a
boiler feed pump with 6-inch (152.4 millimeter) studs (see figure 3). This
plant experienced similar problems with the previously time consuming
and unsafe bolting method. The MJTs were installed in two hours and
this proved most fortuitous as one pump repair had to be assembled and
disassembled three times due to a rotor setup problem. It was estimated
that the plant saved as much as 220 man hours by using the MJTs.
figure 3
The Superbolt principle.
JUNE 2014 | 51
MODERN PUMPING products

miltoN roy
Primeroyal X
metering Pump
Featured Product Release
Milton Roy, the worlds largest manufacturer

of controlled volume pumps, and a brand of
Accudyne Industries, is launching the industrys
most powerful API 675 pump yet, Primeroyal
X. The addition of the Primeroyal X pump to
the companys extensive pump range brings
extended capabilities and economic savings
to oil and gas operations. The new pump is
designed specifically for the deepest subsea
wells and gives operators greater power and
more accurate control to improve flow and
deliver consistent product quality. Efficient in
chemical and energy usage, the pump increases
reliability within a smaller deck footprint and
has exceeded API 675 compliance. In addition
to its superior power rating, Primeroyal X
comes with the accuracy of control necessary
to chemically dose wells consistently while
adapting to the changing conditions of the
wells lifecycle. Milton Roys Primeroyal series
of process pumps combines design excellence,
modular installation and flexible application to
deliver truly exceptional safety, reliability and
performance.
For more information about Milton Roys Primeroyal X, visit www.primeroyalpumps.com.
grEyliNE iNStrUmENtS
dfm 5.1 doppler flow meter
Greyline's new DFM 5.1 Doppler Flow Meter measures flow from outside a pipe. It
employs the latest technology in Doppler signal processing. Faster processing, higher
data resolution and an improved ability to filter out noise, all combined to produce data
accuracy far greater than previously possible. The clamp-on ultrasonic sensor mounts
on any pipe inch ID or larger. The DFM 5.1 is designed for difficult liquids like
wastewater, sludge, slurries, abrasives or any liquid with bubbles or suspended solids.
Calibration and start-up is simple with the built-in 5-button keypad. Standard features
include a large, backlit display and totalizer, isolated 4-20mA output and 6 control relays.
Options include a built-in data logger and reporting system with USB output, Windows
software and intrinsically safe sensor. No other flow meter currently offers the DFM 5.1's
combination of ease of use and highly repeatable, accurate, flow measure. This makes it a
natural choice for anyone measuring flow in industrial, municipal, oil and gas and other
challenging environments. For more information, visit www.greyline.com/dfm51.htm.
AShCroft iNC.
1305d Portable deadweight tester

The Ashcroft 1305D series portable deadweight tester is a pressure calibration
system that includes a low range and high range piston assembly, weight set, a
hydraulic (oil) test pump to generate test pressures, metal carrying cases, tools
and other accessories. Depending on the weight set provided, the 1305D is
capable of establishing test points from 15 to 10,000 psi in an accuracy of 0.1
percent of Reading. As a primary standard, the 1305D will provide years of
accurate calibration measurement, helping to ensure that pressure instruments
operate safely and reliably. For more information, visit www.ashcroft.com.
52 | JUNE 2014
A.W. ChEStErtoN ComPANy

442C Cartridge Split mechanical Seal
Innovation drives performance, and the Chesterton 442C Cartridge Split

Seal is the latest innovation in split seal technology, combining superior seal
performance with the ease of installation of a cartridge split seal. The design
simplifies seal repair by using a standard spare parts kit, enabling you to lower
costs, enhance operation flexibility and minimize equipment turnaround.
With only two seal components, the 442C is easy to install, offers the greatest
installation flexibility and is engineered to enhance sealing reliability like no
other cartridge split seal. For more information, visit www.chesterton442C.com
or e-mail 442C@chesterton.com.
NidEC motor CorPorAtioN

WPi inverter duty motors
Nidec Motor Corporation has redesigned its WPI Inverter Duty motors to
meet NEMA premium efficiency levels in response to new Department of
Energy regulations, scheduled to take effect in 2015. The redesign of the 1530 horsepower vertical high thrust motors includes features to protect against
harmful effects when the motors are used with a VFD. These features include
a shaft grounding ring to discharge shaft current without harming the bearing
and winding thermostats to protect the motor from incidental over heating
when operated at low speeds for extended periods of time. Nidec has also
added extra high thrust options for all Inverter Duty motors 100 horsepower
and greater. For more information, visit www.nidec-motor.com.
ANKo ProdUCtS iNC.

mityf lex 850 Peristaltic Pump
Anko Products, a leading provider
of peristaltic pumps introduces its
new Mityflex series disposable
pump. The highly anticipated 850
pump is dynamic, durable, and
disposable. This small, new pump,
offers a low flow pump alternative
at an extremely competitive price.
Designers at Anko Products have
created the 850 series pumps in
response to calls for an easy load,
low flow, compact pump. They took
this one step further and eliminated
the need for replacing the tubing
by making the pump head totally
disposable. The new 850 is available
in multiple colors and voltages and
is both attractive and functional with
flow rates up to 300 ml/min. For
extra pump head longevity only high
performing materials are used to
provide chemical/detergent resistance
as well as longer tubing with high
grade stainless steel roller pins and
self-lubricating Nylon rollers. For
more information, contact Tim Smith
at 800.446.2656 or via email at
tims@ankoproducts.com.
hArvArd APPArAtUS
Pump 11 Elite glucose Clamp
infusion System
Harvard Apparatus is pleased to announce the release of

the NEW Pump 11 Elite Glucose Clamp Infusion System
for academic euglycemic or hyperglycemic glucose clamp
studies. The Pump 11 Elite Glucose Clamp Infusion System
is a time saving syringe pump enhancement that offers quick
and simple set-up using an innovative touch screen display.
The built-in software capabilities reduce the potential for
error by providing the most accurate fluid delivery available.
Harvard Apparatus is a global developer, manufacturer, and
distributor of innovative and specialized products to enhance
bioresearch. For more information, call 800.272.2775 or
508.893.8999, email techsupport@harvardapparatus.com, or
visit www.harvardapparatus.com.
JUNE 2014 | 53
MODERN PUMPING products

QUiKSPrAy, iNC.
Carrousel Pump 15010hP-3

The new Carrousel Pump model 15010HP-3 designed for commercial coatings industry.
This Carrousel Pump is manufactured for high production patching work or for small
complete high production applications. Whether stucco, cement textures, shotcrete,
waterproofing, concrete repair products or most heavy bodied products, this pump will
deliver and spray them all! The peristaltic action allows for low/no maintenance and
it is extremely easy to operate with unskilled labor. The time proven easy flow Q & Q
couplings are a standard on this pumping system, so high material flow can be expected
with less power necessary. The unit is electrically powered with a 220 VAC motor and
variable speed controls. This model Carrousel Pump is also available with a hydraulic or
pneumatic motor with the same production, or a 110 VAC system is also available with a
little less production for those areas that do not furnish 220vac. For more information, call
419.732.2611 or visit www.quikspray.com.
ElECtro-ChEmiCAl
dEviCES
hydra Nitrate Analyzer System

Offering a precision nitrate ISE electrode sensor with
an integral self-cleaning sprayer, the new Hydra Nitrate
Analyzer System from Electro-Chemical Devices, Inc.
(ECD) is ideal for nitrate monitoring in wastewater
treatment aeration basins. The Hydra Nitrate Analyzer
System monitors the nitrification process in aeration basins
at wastewater treatment plants, a process during which
toxic ammonium ions are oxidized into much less toxic
nitrate ions using an aerobic activated sludge process.
De-nitrication reduces the nitrate ion to nitrogen gas
by an anoxic reaction in the same treatment basin or in
a separate anaerobic digester. The rugged ECD HYDRA
Analyzer nitrate sensor offers 1.25-inch NPT rear facing
threads for attaching an extension/immersion tube for
easy installation from catwalks or handrails. Internal
signal conditioning allows the sensor to be mounted up
to 200 meters from the analyzer. The sensor is extremely
low-maintenance, featuring a movable electrode guard to
facilitate easy electrode replacement when necessary. For
more information and to download product literature, visit
www.ecdi.com/products/hydra_analyzers.html.
www.ecdi.com/products/hydra_analyzers.html
vAl-mAtiC
v
QuadroSphere trunnion Ball valve

Val-Matics QuadroSphere Trunnion Ball Valve is able to handle the demands of many
industries such as Oil & Gas Production and Pipelines, Refining, Geothermal, Power,
Chemical, Pulp & Paper, Cryogenic and Mining/Steel. Multiple flow paths through the
valve and the four recessed surfaces of the ball provide self-flushing to prevent clogging
by avoiding high scale and solids build up. The self-flushing feature makes this valve
stand out in the Geothermal, Mining, Power and Oil and Gas industries where the
media flowing through the valve has a tendency to collect and solidify causing other
valves to fail. The special machining of the ball substantially reduces the ball to seat
surface contact, creating less resistance during cycles, lowering the torque to operate
the QuadroSphere Ball. The QuadroSphere comes standard as fire safe for flammable
materials such as natural gas, oxygen, gasoline and oil. Contact Val-Matic for optional
component materials to use the QuadroSphere Ball Valve in your particular industry
application. For more information, visit www.valmatic.com.
54 | JUNE 2014
BAldor ElECtriC ComPANy
Super-E motors with Baldor Shaft

grounding Brush
Baldor Electric Company is proud to announce a new line of electric motor

Super-E motors with Baldor Shaft Grounding Brush. Stock ratings available
include 1 through 50 HP in Totally Enclosed Fan Cooled (TEFC) or Open Drip
Proof (ODP) Foot Mounted designs along with 1/2 through 5 horsepower in
TEFC, C-Face Foot Mounted designs. The new Super-E Motor with Baldor
Shaft Grounding Brush is designed with a carbon brush mounted internally to
divert shaft currents away from motor bearings, thus increasing the life of the
bearings. While the use of across-the-line motors is still common, the use of
drives to control motors has become more prevalent in recent applications.
However, when motors are controlled by a drive, it can create the potential
for common mode voltage, which can cause voltage spikes in the rotor. The
internally mounted Baldor Shaft Grounding Brush can prevent the voltage
spikes from damaging the bearings. For more information, contact Brad
Chrudimsky at brad.chrudimsky@baldor.abb.com or 479.788.8532, or visit
www.baldor.com.
ChECK-All vAlvE
mfg. Co.
Butt Weld (B4) Check valve

Check-All Valve introduces the Butt Weld (B4)
check valve for use with schedule 40 pipe
(other schedules on a per quote basis). The
one piece body is machined from bar stock
eliminating porosity concerns and providing
uniform density for more consistent welds.
Standard materials of construction are 316SS
and carbon steel with many more exotic
materials also available. With their rugged,
dependable Check-All trim, this valve will
stand up to the most rigorous conditions. With
many series available, Check-All Valve provides
check valves for practically every service
application. Valves are offered with metalto-metal or soft seats in sizes ranging from
1/8 inch NPT to 20 inch flanged connections.
Pressure ratings are available from full vacuum
to 10,000 PSI. We are ISO 9001 certified
and most styles comply with NACE, ASME/
ANSI, API, CE, CRN, and other standards. Most
options are available for fast delivery. For more
information, visit www.checkall.com.
WAtSoN-mArloW PUmPS
Peristaltic Chemical metering Pumps
Watson-Marlow offers the widest range of peristaltic chemical

metering pumps and tubes, capable of handling flows from
0.0015 GPD to 17.6M and up to 100 psi. Watson-Marlow
cased pumps have no seals or valves to clog, leak, corrode or
replace. They successfully handle the harshest fluids, stand
up to the toughest industrial environment, and pump with
extraordinary accuracy and flow control up to 875,000:1 in
one pump. The duty fluid is contained within a chemically
resistant tube; there is no contamination of the pump and no
contamination of the fluid. Watson-Marlow cased pumps
combine the toughness industry demands with the features
vital to todays highly tuned economic production techniques.
Our pumps are easy to install, maintain and clean and are
configured for industrial integration: PLC remote control,
analog, SCADA and Profibus network control. With more than
one million pumps in the field, our peristaltic pumps give our
customers maximum reliability and minimum downtime. For
more information, visit www.watson-marlow.com.
JUNE 2014 | 55
PUMPING trends
Going Green (and Earning Some Too)

P
Automation Services Steve Ploudre

explains how recycling process
control equipment improves the
environment and the bottom line
lants have long faced

the dilemma of
replace versus repair
for industrial equipment.
However, even after users
decide to replace equipment,
they face another choice:
scrap or recycle. We asked
Steve Ploudre, raw materials
manager for Automation Service, a global
leader in remanufactured process controls,
to discuss the growing trend of recycling
process control equipment. To contact
Steve with your own questions, visit
www.automationservice.com.
Modern Pumping Today: How
are companies like Automation
Service influencing the choice
to recycle process control
equipment? Are more plants
choosing to by recycle their parts
instead of scrapping them?
Steve Ploudre: Automation Services

instrument and valve reclamation
program is the right thing to do for
the environment as we focus on truly
extending the life of these products as
opposed to filling a landfill (with plastic
cased items) or grinding them for scrap metal.
Just as important, and regardless of the current method of
disposal, our program promises to offer our customers the
maximum value available for their unwanted, used, or obsolete
equipment with no additional effort on their part.
Pitching a transmitter in an unsorted metal scrap bin might
yield somewhere between .06 and .08 cents per pound. That
means a typical instrument will not even generate one dollar
from the scrapyard. Controllers and positioners that are plasticcased items have zero scrap value. In our evaluation process,
there are factors that affect the overall value of items like
condition, material of construction, generation of equipment,
and completeness of the item, just to name a few. But if our
program allowed merely $10 or $15 per piece on any of these
items it would be considered a huge windfall. The truth of the
matter is that, in most cases, you can expect five to ten times
that amount with our reclamation program.
MPT: When considering the huge volume of old, used control
valves, transmitters, flow measuring equipment, and process
controls, what are some of the current recycling trends in the
industry?
Steve Ploudre: Being environmentally conscience and recycling
all that you can have become priorities in every aspect of what
we do. For that very reason many companies have established
their own investment recovery departments to try and recoup
56 | JUNE 2014
as much of their assets as

possible. The internet has also
made it very easy to sell/buy
used equipment. Unfortunately
there are many drawbacks to
disposing of used and obsolete
material in that fashion.
The cost, knowledge and
manpower required to market
an extremely wide variety of
industrial material can be overwhelming and
is time consuming. Its very common to
move much of this equipment to brokers or
auctioneers who make it impossible for the
seller to realize the full value potential of
these items for themselves. Even worse,
there can be liabilities involved when
you have no control of where your
serialized used equipment is going
to end up. These concerns are
nonexistent for our customers.
MPT: What are your customers
telling you on why they choose to
recycle their old control valves and
instrumentation?
Steve Ploudre: There are numerous

reasons why customers choose to recycle
their instruments and control valves. The
green aspect is definitely one factor. We have
some customers who recycle their items with us with
zero expectation of any value in return purely because they
recognize its just the right thing to do for our environment.
Still, having said that, value is always going to be one of the
top reasons for participation. One of the best aspects of the
credits we issue for the materials we receive is the fact that our
customers, who are responsible for maintaining these types of
items within their facilities, are allowed to retain the value of
that asset for their department, as opposed to losing that value
to a general fund fed by the scrapping or liquidation of that
material. We have even heard comments that the credits earned
through this program have made upgrades and/or projects
that originally seemed unlikely due to budgetary restrictions
possible.
Another favorite reason is our unique rewards program.
Automation Services Reclamation Road Trip rewards program
allows participants to accumulate points (or miles in this
case) to have popular regional foods shipped to them from all
over the country. These miles are for select items they recycle
and are in addition to the credits they receive. Its a great way to
provide a celebration or holiday party for an entire department.
Participants also have an option to convert their miles into a
cash donation to a charity of their choice, in the event that a
food option does not work for their purpose. Its a great bonus
to an already rewarding program.

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modErN

12 New Control valve is an overnight

14 making a Big Splash

Sphero S underwater pelletizing machinery system makes waves in China

Water & Wastewater

18 Uniform distribution in headers

24 Know your Pump Base Plate

26 A revolution in Pumping Eff icieny

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

30 Controlling All the variables

36 the Next generation of Premium

P.O. Box 660197 | Birmingham, Alabama 35266

40 Utilities Are frightened of a "death Spiral."

42 Short design means Big innovation

valves & Controls

46 4 Ways to Achieve Nox reductions

50 Safe and Efficient Bolting

Russell haddock COO/Publisher

Superbolt makes easy work for boiler feed pump workers

cuRtis fRost Account Executive

RaNdy mooN Account Executive

Featured Product Release: MILTON ROY Primeroyal X Metering Pump

56 going green (And Earning Some too)

312 Lorna Square | Birmingham, Alabama 35216

EditoriAl AdviSory BoArd

Drives and Motion Solution Engineer

Consultant and Trainer,

Heinz P. Bloch, P.E.

Business Development Manager,

Director of Regulatory and

Trey Walters, P.E.

President, Applied Flow Technology

No part of this publication may be reproduced or transmitted in any form or by any

GIW INDUSTRIES EXPANDS OPERATIONS

GIW Industries announces a new look and logo as the

products have been rebranded under the umbrella of GIW

Dematic, a global supplier of logistics systems for the

TV RHEINLAND INDUSTRIAL SOLUTIONS GOES

TV Rheinland Industrial Solutions (TRIS), a full-service

FLUID TRANSFER, INC. LAUNCHES NEW WEBSITE

Fluid Transfer, Inc., an aftermarket parts supplier of plunger,

for consulting on service to a variety of manufacturers,

HI, FSA COLLABORATE ON WEB SEMINAR

The Hydraulic Institute, in collaboration with Henri Azibert,

TRADE SHOW profile

or over one hundred years, the American Society of

A mainstay of the ASHRAE Annual Conference, the technical

The second annual ASHRAE Research

The two full-day seminars include

the design review and specifications,

every auditor, how to hire an auditor,

With access to varied offerings and

New Control Valve Is

The 23.62 inch (600 millimeter) EOV

urther to investigations of Pin

would have flooded and reinstatement

that the pressure differentials present

About the Author

The difficult replacement

FIRST CLASS ALL THE WAY

Furthermore, in this situation the new

We had noticed a problem with the

About the Author

Compounding/masterbatch/recycling based on: