Modern Pumping - Jan 2015

MODERN MODERN

TO DAY PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

JANUARY 2015

X Y LEM ’S BELL & GO SSETT SETS TH E STANDARD AT LE V I’ S STA DI UM

PROGRESSING CAVITY PUMPS GET AGGRESSIVE HOW TO CHOOSE THE RIGHT BLOWER FINDING RUGGED AND RELIABLE CONTROL SYSTEMS

®

CONTENTS 4 10

INDUSTRY N EWS TRADE S HOW P ROFILE CASE STUDIES

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Recharged Solution for Drainage Impacts CULTEC chambers provide new stormwater system for Connecticut nursery

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Game On at Levi's® Stadium Xylem's Bell & Gossett sets a new standard for conserving natural resources

WATER & WAST EWATER S OLUTIONS 16

The Pursuit of a Green Carbon Steel Corrosion Inhibitor Part 1 in a 4-part series

20

How to Select the Most Effective Blower Technology for Wastewater Applications Part 1 in a 2-part series

MAIN TEN ANC E S OLUTIONS 24

Preventing Rust Formation with Electronic Water Treatment

PUMP S OLUTIONS 30

Progressing Cavity Pumps Get Aggressive Offshore solution underlines Moyno versatility

32

The Key to a Good Pumping System Landia's know-how helps meet wastewater facility needs

DEWATERING S OLUTIONS 36

From Reaction to Taking Action The Mine Performance solution increases throughput and availability

MOTOR S OLUTIONS SM

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Motor Don't be anDecisions energy dinosaur Matter

JANUARY 2015

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POWER G ENERATION SOLUTIONS

@ModPumpMag

40 Seeking New Territory

JEFF FLETCHER Associate Publisher

Onset's handheld data loggers provide baseline measurements for prospective Delaware River Basin site

PROCESSING S OLUTIONS

42 Using Coriolis Mass Flow Meters

with Positive Displacement Sliding Vane Pumps Part 1 in a 2-part series

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VALVES & CONTROLS SOLUTIONS

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48 Reliable Control Systems for a Rugged World

TONYA BROWNING Account Executive JERRY DICHIARA Account Executive DAVID MARLOW Account Executive

SEALING S OLUTIONS

CINDEE STANDRIDGE Account Executive

52 Goodbye to Tradition Metcar bearings and bushings offer advantages over traditional metals

54 MODERN P UMPING P RODUCTS Featured Product Release: FLOWSERVE Bearing Gard Bearing Isolators www.highlandspublications.com

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PUMPING T RENDS

56 How Do You Gauge Success? HDI Instruments' Will Condon speaks to the importance of field tests, certifications, and meeting customer needs

TIM GARMON

CEO/President RUSSELL HADDOCK

COO/Publisher

EDITORIAL ADVISORY BOARD Terry Bell Drives and Motion Solution Engineer Baldor Electric Company

Michael Mancini Consultant and Trainer, Mancini Consulting Services

Heinz P. Bloch, P.E.

John M. Roach

Consulting Engineer, Process Machinery Consulting

Engineering Manager for New Product Development, Trebor International, Inc.: A Unit of IDE X

Robert G. Havrin

Director of Technology, Centrisys Corporation

Lisa Riles Business Development Manager, Wastewater Pumps Xylem Inc.: Flygt

Greg Towsley Director of Regulatory and Technical Affairs, Grundfos

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

CHRIS GARMON

General Manager

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff Modern of Pumping Today, or who are not specifically employed by Highlands Publications, Inc., are purely their own. All Industry News material has either been submitted by the subject company or pulled directly from their corporate website, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected]. For address changes, please contact Lindey Scott: [email protected]

INDUSTRY news ABB AND STADLER COLLABORATION WORTH $40 MILLION IN US, EUROPE ABB, the leading power and automation technology group, received orders worth $40 million from Swiss train manufacturer Stadler Rail for train projects in Europe and the United States, extending the c ompanies’ long partnership. The orders were booked in the last quarter of 2014. ABB will supply its newest traction converters with integrated onboard power supplies as well as roof-mounted traction transformers. The equipment converts electricity from overhead power lines to the voltage levels needed by train motors as well as auxiliary power systems, including lighting, heating, ventilation, passenger information systems and automatic doors. “These orders are an affirmation of the successful partnership between Stadler Rail and ABB,” says Pekka Tii tinen, president of ABB’s Discrete Automation and Motion division. “It underscores the importance of long term pa rtnerships based on industry expertise a nd leading innovation.” In Switzerland, the order includes four powerful new electrical mountain trains for the Jungfraubahn that transports visitors to Europe’s highest rail station at 3454 meters above sea level, beneath the famed Eiger, Moench and Jungfrau mountains. T he Jungfraubahn will be driven by the sam e generation of ABB traction converters as eight additional trains currently being refurbished by Stadler and ABB. ABB will also supply lightweight, tailor-made compact traction converters with integrated onboard power supplies for electric and diesel-electric Stadler trains destined for Bay Area

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Rapid Transit (BART) in California, for an expansion of the rail system linking cities including San Francisco and Oakland. Other transportation authorities that will receive equipment in this order are Spain’s Ferrocarrils de la Generalitat Catalunya (FGC); the train line that operates be tween the cities of Alphen and Gouda in the Netherlands; and the city of Aarhus, Denmark, which will receive twenty-four light rail vehicles. This new business follows previous orders from rail operators around the globe to further expand their large fleets of Stadler FLIRT regional trains. T hese include Finland’ s Junakalusto O y and Switzerland’s Swiss Federal Railways (SBB). Since the two companies began working together in 2002, Stadler Rail has ordered ABB traction equipment for more than 1500 regional trains and m ore than 300 light-rail vehicles. ABB is among the world’s largest independent suppliers to rolling stock manufacturers, generating annual sales of more than $1.5 billion in its rail bu siness. ABB has a long history of providing innovative and energyefficient technologies to the rail sector, manufacturing and servicing all components and sub-systems used in urban, intercity and high-speed networks, both for rail infrastructure and for rolling stock. ABB also provides life cycle service support including maintenance and retrofit for its large, global installed base.

SPI SUPPORTS EFFORTS TO CLEAR WATERWAYS OF POLLUTION SPI: The Plastics Industry Tr ade Association advocates on behalf of programs designed to pursue zero waste. In response to the

w w w . mo d e r n p u mp i n g t o d a y . c o m

INDUSTRY news Five Gyres Institute’ s recent release of a study that estimates the quantities of plastics in the world’s oceans (“Plastic Pollution in the World’s Oceans: More than 5 Trillion Plastic Pieces Weighing over 250,000 T ons Afloat at Sea”), SPI President and CEO William R. Carteaux released the following statement: “Marine debris is a serious pollution problem that impacts our environment, the economy and our way of life. As responsible plastics manufacturing professionals, SPI and its members are firmly committed to addre ssing marine litter issues with sound solutions that achieve our goal of pursuing zero waste. “Operation Clean Sweep, an international product stewardship program launched by SPI in 1994 and currently administered in conjunction with the American Chemistry Council, is credited with reducing the concentration of pellets in the waterways by 80 percent. We are extremely proud of our success in this realm and plan to continue working with our peer organizations as well as our me mbers to make greater strides in the future. “Along with similar-minded organizations around the globe, in 2011 SPI signed T he Declaration of the Global Plastics Associations for Solutions on Marine Litter, a public commitment to address plastics in the marine environment. SPI is one of sixty associations representing thirty-four countries that have signed the declaration to promote policies and practices that rid our waterways of ugly, harmful marine debris. “Plastics are renewable resources that are too valuable to lose as litter. Because of this, we’ve invested heavily in a broad range of recycling projects geared toward encouraging the

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public to reuse and recycle plastics products. Most recently, SPI became an inaugural member of the Recycling P artnership, a grant fund established by the Curbside Value P artnership (CVP) to support and transform public recycling performance. In this role, we advocate for expansion of programs in communities that have the capability to maximize recovery of plastic products including rigids, thermoforms and other non-bottle packaging materials. “By supporting efforts to close the loop on all plastics materials so that none reaches the marine environment or the landfill, SPI and its partners are helping to combat marine debris and look forward to a day when plastics in the marine environment are a thing of the past.” GRAPHET DATA MINING LAUNCHES NEW INTERACTIVE WEBSITE

Graphet Data Mining proudly launched its new interactive website recently. The website serves as an interactive resource for clients as well as an informative summary for p rospective clients. T he website highlights Graphet’s data mining pr ocess, its focus on energy conservation and the sustainable cost savings that can be achieved a s a result of the company’ s services. Numerous articles and case studies are posted on the new website as well, providing visitors with an overview of the proven processes and the knowledge and experience Graphet Data Mining professionals can bring to its clients. The value of energy conservation and the resulting savings leads to a sustainable ROI.


INDUSTRY news JET EDGE NOMINATED FOR 2015 BOLD AWARDS Waterjet systems manufacturer Jet Edge Inc. was named one of sixty-three Minnesota businesses nominated for awards recognizing bold corporate g rowth strategies. Presented by ACG Minnesota, the BOLD Awards celebrate and honor the very best in corporate growth strategies. Winners will be announced at a February 24 reception. Based in St. Michael, Minnesota, Jet Edge is a worldleading manufacturer of ultra-high pressure waterjet systems for precision cutting, surface preparation and coating removal. Jet Edge waterjet s are used by a wide range of industries around the world to cut everything from auto parts and titanium joint implants to food products and diapers. For more information about the BOLD Awards, visit www.acg.org/minnesota/boldawards.aspx .

SMART H2O SUMMIT ISS UES CALL FOR PAPERS Smart H2O Summit, scheduled for August 17 though 19 in San Francisco and targeted to municipalities and other key water stewards, has issued a Call for Papers. The comprehensive Conference Program is focused on providing solutions to challenges regarding water and sewer infrastructure, longterm water supply re-use and desalination, financing for

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capital improvements, the impact of big data on managing this resource, and public understanding of water resources, systems and services. Abstracts are currently being accepted for the following five subjects: Executive Management Track: Financing change in the network; Water pricing strategies; Building a sustainable network; Reducing non-revenue water losses; Innovation in the publicly-owned and privately-owned utilities. AMR/AMI/Big Data: Using big data, smart meters, and new forms of communication to improve the efficiency of the water network; New technologies and their applications. Water Recycling and Reuse: Scale of the opportunity , practical realities; Strategy for implementing non-potable water recycling and reuse; Key targets for projects; Getting financing for projects. Desalination, Limits and Opportunities: Current state and future of desalination in North America. Beyond desalination, using multiple water sources for desalination including industrial effluent; agricultural water; rainwater and urban runoff. Managing Public Perceptions of Smart Water Innovations: Practical advice on user reactions to the smart meters and other new technologies; Delivering information to consumers; Managing crises. Special Sessions and Topics: Proposals for special 1.5 hour sessions or workshops are also welcome. The deadline for submitting a 250 word abstract is April 15, 2015. Submissions can be made online at tinyurl.com/mlmm4wb or emailed to Sebastian Bizzari at [email protected]. ■


TRADE SHOW profile

METS 2015 The third Middle East Turbomachinery Symposium continues to reach high standards

U

nder the patronage of His Excellency Dr. Mohammed bin Saleh Al-Sada, Minister of Energy and Industry and Chairman of Qatar Petroleum, the third Middle East Turbomachinery Symposium (METS 2015) will be held February 16 through 18, 2015, in Doha, Qatar. The T urbomachinery Laboratory (Turbo Lab) of the Texas A&M Engineering Experiment Station (TEES) is organizing METS 2015, which will feature a worldclass educational forum in combination with an i nternational exhibition. T echnical sessions cover topics on machinery maintenance, design, and troubleshooting, and case studies describe in-the-field problems and their real-world solutions. FEA TURED SESSIO NS

Attendees will benefit from a wide range of technical sessions and case study presentations. In one featured session, “Combustion, Fuels and Emissions for Industrial Gas Turbines,” many types of gaseous and liquid fuels that can be used in gas turbines will be discussed, as will be the two basic types of combustion systems employed—“conv entional” and “dry low emissions”—along with the flexibility of these systems to accept different types of fuel. Some of the common contaminants found in fuels are discussed along with the impact these have on the operability and maintenance of industrial and aero-derivativ e gas turbines In a separate tutorial, “Stability Considerations: A Simplified Approach, ” presenters propose a simplified stability check for turbocompressor rotors based on the gas swirl in the labyrinth seals. With this approach only a minimum of operational and design data is required to gain a realistic picture of the stabili ty behavior of the investigated machine. The proposed method is compared to analytical and measurement data and very good correlation is shown. REAL-WORLD SOLUTIONS

One of the highlights of METS 2015 includes t he presentation of in-the-field problems and their real-world solutions through the three separate case study sessions. Over the course of three sessions, attendees will learn from seventeen unique presentations from leading global companies in the fiel d. Presenters for this year’s line-up include GE Oil & Gas, EagleBurgmann, Flowserve, and others. A GLOBAL CONNECTION

Since 2011, METS has proved to be the premier turbomachinery event in the Middle East, combining a world-class technical conference with an i nternational exhibition and this year’s version will continue the excellence. T he event offers an exciting occasion for industry leaders to share ideas, exchange technical knowledge, and to discuss ongoing industry related issues. This unique and comprehensive business platform will bring together hands-on users, manufacturers, buyers, and developers from the oil and gas, petrochemical, and power generation industries to meet in the Middle East. ■

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CASE Studi es

Recharged Solution for Drainage Impacts

CULTEC chambers provide new stormwater system for Connecticut nursery

By CULTEC technical staff

hemin Nurseries, Inc. is a wholesale supplier of

landscape

S

and nursery supplies. The company also stocks a wide assortment of trees, shrubs, perennials, annuals and irrigation and drainage products. With twenty-eight locations across fourteen states, Shemin has been a top-performing wholesale landscape supply company for over fi fty-five years. UP CLOSE: SHEMIN NURSERIES

In 2008, the company pursued the subdivision of its entire Greenwich, Connecticut, based location, splitting the property into five lots with a private right-of-way roadway . Under this new arrangement, four lots would be marketed and sold as separate residential properties and the fifth would be the nursery . A significant portion of the property is wetlands; however , a majority of the upland areas will be part of the new residential lots. At the beginning of 2014, Shemin Nurseries implemented the design and began construction on the common improvements of the approved subdivision. With the addition of the roadway and other impervious surfaces, Stamford, Connecticut, based Redniss & Mead, Inc. engineers needed to include a new stormwater management system to mitigate the increased stormwater runoff. In addition, the roadway leading into the development had to be mitigated for peak flows and stormwater volume. Th e project required

that the team provide detention on the

site using a subsurface

stormwater management system. RECHARGER 330XLHD CHAMBER

Given the requirements of the site, the team chose CULTEC, Inc.’s Recharger ® 330XLHD, an efficient chamber that has a relatively low volume in the early stages of a storm. T he chambers were supplied by the client, Shemin Landscape Supply, and installed by White Contractors of Old Greenwich, Connecticut. A stormwater system, which includes 204 chambers, was placed beneath Shemin’s current employee parking lot of approximately fifty parking spaces. T his location was chosen because during the approval process, the T own of Greenwich ruled that the wetlands were not to be used as a volume control function for the drainage. “In the T own of Greenwich, we are particularly mindful of drainage impacts associated with development and while the Wetlands and Watercourses Agency always promotes natural alternatives to maintaining existing flow rates, we have been pleased with the results stemming from the growing use of recharge chambers,” says Michael Chambers, director of Greenw ich’s Wetlands and Watercou rses Agency. “In an industry that is ever-ev olving, recharge chambers appear to

For More Information CULTEC’s technical staff offers free design assistance including preliminary calculations and job-specific CAD details. For additional information about Shemin Landscape Supply, visit www.shemin.net or follow them on Facebook. For more information about CULTEC’s stormwater chambers, call 203.775.4416 or visit www.cultec.com.

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be a storage system that has remained the preferred means of controlling rates of runoff, and in this case, CULTEC’ s chambers met our strict stormwater drainage requirements.” “Of the 44-acre site, 19 percent is made up of wetlands, which encouraged us to consider a low-impact solution for the stormwater management system,” says Lou DiMarzo, P.E., Redniss & Mead. “The unique feature about this project is just how close those wetlands are to the development. W e really took precautions to preserve the site from an environmental perspective.” MAXIMUM CAPACITY, MINIMUM FOOTPRINT CULTEC’s Recharger 330XLHD has a capacity of over 400 gallons (1514.16 liters), making it one of the largest CULTEC chambers available. T he unit itself measures 52 inches wide by 30.5 inches high (1321 by 775 millimeters) and has an installed length of 7.5 feet (2.29 meters) long with a bare chamber capacity of 7.5 cubic feet per linear foot. The CUL TEC system provides a total of 17,429 cubic feet (493.53 cubic meters) of storage, maximizing storage capacity within a small footprint to best satisfy the requirements of the site. In addition, a Vortechs ® Model 2000 and a VortSentry ® HS unit produced by another manufacturer are placed upstream from the pipes leading to the CULTEC system. These oil-grit separators pre-treat stormwater runoff before it flows into the chambers using a cyclonic separation method to control pollution. Another two hydrodynamic separators will be placed in the roadway to provide pre-treatment for the pipes that wil l be in-letting into a rain garden and a surface water quality detention basin.


The CULTEC chambers are encased with an impervious liner supplied by LidT ech to stop the system from infiltrating due to the presence of seasonal high ground-water. T he liner is located beneath the CULTEC chambers and spans the entire width of the bed. In addition, CULTEC’ s No. 410™ Filter Fabric encases the entire bed and prevents soil intrusion into the chamber bed. RIGHT ON TIME “One important consideration for this installation was the project timeline,” says T om White, president and manager of field operations for White Contractors. “ We needed to have the work done before the spring gardening season began, so the employees could use their parking lot and have access to the yard to start stocking supplies and plant material. Most of the work was completed in the company’s offseason, but that presented its own set of challenges because we had such a harsh winter. In the end, we were able to provide the client with a high-quality installation by the deadline.” CULTEC manufactures several chamber sizes ranging from 8.5 to 48 inches (216 to 1219 millimeters) to accommodate almost any site parameter. T he chambers’ perforated sidewalls and fully open bottoms promote maximum infiltration capability and allow for the transfer of high volumes of water at a low velocity. In addition, CULTEC developed its own in-line side portal manifold system, which eliminates the need for a conventional pipe header system, and water quality unit f or maintaining CULTEC chamber systems. CULTEC products are currently modeled in HydroCAD ®, Bentley Systems, Inc.’s PondPack ® V8i, Autodesk’ s Storm & Sanit ary Analysis in Civil 3D, and Streamline Tec hnologies' ICPR ®. ■

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CASE Studi es

B&G products installed in Levi's Stadium.

Xylem’s Bell & Gossett sets a new standard for conser ving natural resources By Mark Handzel, Bell & Gossett

T

he new $1.3 billion Levi’s ® Stadium in Santa Clara, California, home to the NFL’s San Francisco 49ers is a model of sustainability, from its 27,000-square-foot (2508 squaremeters) green roof and its owners suites decked out in recl aimed wood, to its farm-to-table concessions offerings. But none of the green features is more crucial to its operations than its use of recycled water for the flushing and irrigation systems.

need to use freshwater to flush toilets and to irrigate the natural grass field, green roof and other areas, which is of particular concern in droughtridden California. A recycled-water pressure booster system ensures adequate water is available when everyone goes to the bathroom at one time, like halftime at a football game. The “Super Flush,” a test of the system, was Volunteers coordinate plans for the “Big Flush.” conducted in April 2014 to make sure the system was fully operational before the stadium opened. During the test, hundreds of workers and volunteers simultaneously flushed every toilet and PREPPING FOR THE “SUPER FLUSH” urinal and turned on every sink in the stadium for about thirty Up to 85 percent of all water use in the 68,500-seat stadium minutes. will be from recycled water used for toilet flushing and playing The B&G/CHC system solution handled it with flying colors. field and green roof irrigation. The recycled-water pressure booster system built by California Hydronics Corp. (CHC) using INNOV ATIVE AN D HIGH-PERFORMING Xylem’s Bell & Gossett brand products, taps into the Santa Clara There are twice as many toilets in Levi’s ® Stadium as there Valley Water District water recycling system. This eliminates the were in Candlestick Park, the 49ers’ former stadium, and

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

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Goulds Water Technology e-SV multistage centrifugal pumps proved a good fi t for L evi’s Stadium ’s recycledwater pressure booster system. Goulds Water Technology e-SV pumps installed in Levi's Stadium.

the expectation is for significant water savings due to more efficient infrastructure. According to stadium water assessment estimates, 84 percent of all of the water used will be recycled water, which amounts to more than 42 million gallons (nearly 159 million liters) a year. All of the Bell & Gossett products that went into the stadium are noted for their efficiency and were selected by Turner-Devcon, who drafted design development drawings and specs, along with the support of M-E Engineers. Plumbing contractors ACCO and FW Spencer completed the permit packages, which included the selection of Bell & Gossett centrifugal pumps and Goulds Water Technology e-SV multistage centrifugal pumps for t he recycled-water pressure booster system. “The system needed to be both innovative and high-performing,”


The selection of Bell & Gossett centrifugal pumps and Goulds Water Technology e-SV multistage centrifugal pumps for the recycled-wat er pressu re boo ster s ystem was an impo rtant co mponen t in th e new stadium’s sustainability plan.

says Kevin Coyne, vice president, FW Spencer . “Based on our successful history working with CHC, we knew the Bell & Gossett products would deliver on both f ronts.” A CLOSER LOOK AT EFFICIENCY

ACCO, the mechanical contractor for the project, procured a variety of Bell & Gossett products, including Rolairtrol air separators, Series 60 inline pumps, 1510 end suction base mounted pumps, and VSX double suction pumps for the hydronic systems. Xylem Bell & Gossett brazed plate and GPX gasketed plate and frame heat exchangers were specified and supplied for the project, offering t he highest level of thermal efficiency for t he condenser water system since majority of the air-conditioning equipment and food

service coolers are water-cooled. The stadium received Leadership in Energy & Environmental Design (LEED) Gold certification, a first for a NFL stadium. “Every detail regarding environmental sustainability was addressed during planning and construction,” says CHC’s Ken Carey. “This project is a bellwether for others to follow.” READY FOR GAME DAY

The 49ers made their debut in Levi’s ® Stadium during the NFL preseason in August 2014. The stadium is scheduled to host Super Bowl 50 on February 7, 2016, to a crowd of more than 70,000 people. With an increased focus on sustainability and efficiency , Levi’s Stadium will be ready for the f ans. ■

JANUARY 2015| 15

WATER & WASTEWATER solutions

The Pursuit of a Green Part 1 of 4 Carbon Steel Corrosion Inhibitor By Matthew LaBrosse and Donovan Erickson, U.S. Water Services, Inc.

orrosion control of carbon steel heat exchange components is becoming increasingly more important as energy costs rise and the demand for environmentally friendly chemicals is on the water technology forefront. This series of articles explores the effectiveness of both inorganic and organic inhibitors to control carbon steel corrosion in open system cooling tower water that is both corrosive and scaling. Pilot-scale corrosion testing is used to generate results from corrosion coupons and corrator electrodes under synthetic water conditions. Several carbon steel corrosion inhibitors are examined. Carbon steel corrosion inhibitor packages are discussed and compared in terms of environmental friendliness,

hexavalent chromium compounds are considered to be known human carcinogens (see reference 1) and the overall non-biodegradability of the metals is considered undesirable as they tend to accumulate in the environment (see reference 2). Molybdate has come under scrutiny because of the apparent negative response of lactating dairy cows to high levels of dietary molybdenum (see reference 3). Phosphate can form algae blooms that limit the oxygen in lakes and streams from agricultural run-off and other means causing the death of aquatic life (see reference 4). Even though these materials have worked well to prevent expensive corrosion of carbon steel, they are becoming less and less available or the amount that

susceptibility to chlorine, even at low levels (see reference 5). This presents a problem because oxidizing biocides are a necessary part of any successful water technology program for control of potentially harmful bacteria, such as legionella. Organic inhibitors based on the phosphate molecule may result in unexpected phosphorous in the open cooling system due to reversion of some of the organic phosphonate to orthophosphate. Reversion of the organic phosphorous molecule may render it less effective as an inhibitor but may be a good biological food source. Finally, organic inhibitors can be deactivated by cationic microbiocides such as the quaternary ammonium compounds and other cationic substances that may be

corrosion rate minimization, and cost effectiveness.

can be used for this purpose has been limited substantially. In light of these environmental and safety restrictions, newer nonmetallic corrosion inhibitors have become commercially available. These organic inhibitors are often based on low molecular weight polymers, phosphonates, and amino phosphonates. Some of these organic molecules have proven to be successful carbon steel corrosion inhibitors (see reference 5). Although they show improved environmental ac ceptability, they too may have some technical concerns. For instance, organic molecules may be more susceptible to oxidizing biocides than inorganic molecules. Many azole-based copper corrosion inhibitors are susceptible to degradation by oxidizing biocides. Hydroxyphosphonic acid has shown

present (see reference 6). It should be noted that tin is one inorganic inhibitor recently available that is less regulated than other metals. It can be used in drinking water, carries some Food and Drug Administration (FDA) accepted food uses, is considered quite safe for the environment (see reference 7), and for human safety in general (see reference 8). Tin used for corrosion inhibition in cooling towers currently has patents associated with its use (see reference 9). Green Chemistry has become a design criterion in water treatment programs and the chemical industry over the past dec ade. The definition of Green Chemistry is constantly evolving to include new environmental regulations and customer expectations. In general, it may be assumed that

C

INTRODUCTION

Metals have been used for many years to minimize carbon steel corrosion. Inorganic compounds such as chromate, zinc, and molybdate, often times combined with phosphate or polyphosphate, are added to aqueous systems to provide corrosion protection for carbon steel. Prevention of costly metal loss due to general corrosion and pitting is accomplished by the use of these anodic and cathodic inhibitors. In the last several years, these materials have been regulated more stringently by the Environmental Protection Agency (EPA) and other governing agencies due to their perceived negative impact on the environment or other safety concerns. For example,

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

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Inhibitor

Biodegradability

Ecological Toxicity

Molybdate

1

1

1

Zinc

1

1

1

1

Tin

1

2

4

4

NPDES Status 4

Heavy Metal

Drinking Water

1

3

45.8

4

2

41.7

4

2

Phosphate / Polyphosphate

1

1

1

4

4

3

Polyaminophosphate

2

3

3

4

1

3

Safety

Total (%)

70.8 5

8.3 66.7

Hydorxyphosphonic Acid

2

3

3

4

1

3

Phosphonocarboxylic Acid

2

4

3

4

1

3

Aspartic Acid Polymer

4

4

4

4

1

4

87.5

Coffee Extract

4

4

4

4

3

4

95.8

66.7 7

0.8

Table 1:Evaluation of corrosion inhibitors based on six criteria previously outlined. The total score for an inhibitor has been normalized to 24, the maximum possible green score. Values of 1/2/3/4 represent poor/fair/good/excellent scores, r espectively.

Green Chemistry is environmentally friendly, but may have other connotations that apply to safety, good manufacturing practice, and even efficiency. GREEN CHEMISTRY CRITERIA

In our pursuit of a green carbon steel

corrosion inhibitor, we strive to be as green as possible, and yet perform adequately for the purpose intended. For the purpose of these articles, the inputs that are used to determine green status for an inhibitor fall into six categories. A summary of the evaluation is shown in Table 1. The

values are the subjective interpretation by the authors. Biodegradability Inorganic materials are not usually considered biodegradable but instead they tend towards bioaccumulation, implying a negative situation, thus

bigger jobs, bigger Brown Bears Equipment to match the size of the job Dry sludge to reduce volume and weight before transporting. Why haul water? Save time, fuel, expense. Compost sludge to create a beneficial reuse product and reduce volume and weight. We have small inexpensive units for small jobs, mid range units for farm tractors and the larger self propelled machines for the large jobs. Bigger machines for bigger sludge drying or composting projects.

D E L L E P O R P F L E S

S T N E M H C A T T A

E P O R P F L E S

COMPOSTING

COMPOSTING


D E L L



D E L L E P O R P F L E S


DRYING SLUDGE

COMPOSTING

DRYING SLUDGE

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JANUARY 2015 17

WATER & WASTEWATER solutions their green rating for this criterion is low. An organic chemical substance is said to be biodegradable if it can be broken down by the metabolic action of living microorganisms such as bacteria, fungi, algae, and yeast. Biodegradation is one of the most important processes governing the fate of a chemical after its release into the environment. A highly biodegradable material is considered greener than more persistent counterparts. Ecological Toxicity Toxicity testing can be done to determine the effects of a material on aquatic species like fish, water flea, and algae. The less ecologically toxic a material is, the greener its status is considered to be. NPDES Status The National Pollution Discharge Elimination System (NPDES) issues permits regulating chemical discharge for the protection of the environment. The materials that are regulated on these permits and the concentrations allowed for discharge to the

environment will affect the green ranking of a material. Heavy Metal Status The EPA has established a list of heavy metals, also called Target Analyte Metals, that are used to determine environmental assessments such as NPDES permitting. Materials listed as Target Analyte Metals are considered less green than others. Drinking Water Additive Certain additives are allowed by the EPA as corrosion inhibitors in drinking water systems. These normally carry a maximum allowed use level. These materials usually carry a third party certification from the National Sanitation Foundation (NSF) confirming they are safe for use in drinking water. A drinking water additive could be considered greener than materials that cannot be added to drinking water. Safety Materials are rated for safety by several factors: the Occupation Safety

and Health Administration (OSHA) through a Material Safety Data Sheet, the United States Department of Transportation (USDOT) t hrough the Hazardous Materials Table, the FDA through a Generally Regarded as Safe (GRAS) status, and others sources as they apply. A higher safety rating translates to a better green s tatus. CHEMICAL INHIBITORS

The additives chosen for our pilot testing are common inhibitors that are available in industry. T he list is not exhaustive but gives a fair representation of the kinds of technology currently available. Descriptions of various corrosion inhibitors can be found in the AWT Technical Reference and Training Manual (see reference 5). Molybdate Molybdate is a precipitation inhibitor at anodic sites of carbon steel. Molybdate is often combined with other corrosion inhibitors. The molybdate source was sodium molybdate dihydrate. Zinc Zinc inhibits corrosion of carbon steel by forming hydroxide or hydroxycarbona te compounds on the surface. Zinc is often combined with other corrosion inhibitors. A solution of zinc chloride was used. Tin The mechanism for tin corrosion inhibition of carbon steel is not well understood. A 50 percent tin chloride solution was used. The use of this material as a corrosion inhibitor in cooling towers is patented (see reference 9).

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Orthophosphate Orthophosphate forms ferric phosphate at anodic sites of carbon steel forming a protective film. Both monosodium phosphate (MSP) and disodium phosphate (DSP) salts were used. Polyphosphate The mechanism of polyphosphate inhibition is complex, but can be generalized by precipitation at cathodic carbon steel sites. Polyphophate is often combined with other corrosion inhibitors. The polyphosphate source was tetrapotassium pyrophosphate (TKPP). Polyaminophosphonate Polyamino phosphonate (PAP) is a phosphonate inhibitor that precipitates a general protective film at both anodic and cathodic sites on carbon steel. A liquid solution of PAP was used. Hydroxyphosphonic Acid Hydroxyphosphonic acid (HPA) is a phosphonate inhibitor that precipitates a general protective film at both anodic and cathodic sites on carbon steel. A liquid solution of HPA was used.

corrosive environment. Later installments will build on these observations to determine acceptable green corrosion inhibitors for use in open system cooling waters by examining the effect of oxidizing biocide on their performance and, finally , to select the most appropriate and cost effective product for use as a green corrosion inhibit or. ■ REFERENCES

1. Report on Carcinogens, Twelfth Edition, National Program, Department of HealthToxicology and Human Services, 2011. Web. May 17, 2012. 2. Qishlaqi and F. Moore, “Statistical analysis of Accumulation and Sources of Heavy Metals Occurrence in Agricultural Soils of Khoshk River Banks, Shiraz, Iran”, American-Eurasian J. Agriculture and Environmental Science , 2, 565-573 (2007). 3. J.T. Huber, N.O. Price, and R.W. Engel, “Response of Lactating Dairy Cows to High Levels of Dietary Molybdenum”, Journal of Animal Science , 32, (1971). 4. B. Oram, Water Research Center, B. F. Environmental Consultants Inc., 2012. Web. May 17, 2012. “Phosphates in the Environment.”

5. Association of Water Technologies Technical Reference and Training Manual , 2nd ed, chapter 5.10, (2009). 6. P. Puckorius et al., “Phosphonates-Part II-Corrosion Control- Cooling Water”, A Practical Guide to Water Treatment Chemicals Newsletter , Volume 2, Issue 1, 1st quarter (1998). 7. P. Howe, M. Wood, and P. Watts, “Tin and Inorganic Tin Compounds”, Concise International Chemical Assessment Document, 65, World Health Organization Geneva, (2005). 8. J. Fawell and R. Mascarenhas, “Inorganic Tin in Drinking-water”, Background document for development of WHO Guidelines for Drinking-water Quality , World Health Organization, (2004). 9. W.E. Stapp and G. Westlund, “Corrosion Inhibition Compositions and Methods for using the same”, U.S. Patent 7,910,024, issued March 22, 2011. 10. V.V. Torres et al., “Inhibitory action of aqueous coffee ground extracts on the corrosion of carbon steel in HCl solution”, Corrosion Science , 53, 2385-2392 (2011). 11. B.P. Boffardi, “Corrosion and Fouling Monitoring of Water Systems”, The Analyst Technology Supplement, spring (2010). 12. Rohrback Cosasco Systems, Inc., “Model 9020 &9020-OEM Corrater Transmitter User Manual”, November (2004).

Phosphonocarboxylic Acid Phosphonocarboxylic acid (PCA) works similarly to HPA as a corrosion inhibitor, but is claimed to have higher resistance to chlorine degradation. A liquid solution of PCA was used. Aspa rti c Aci d Pol ymer The mechanism for aspartic acid polymer (AAP) inhibition of carbon steel corrosion is not well known. Manufacturer testing has claimed carbon steel corrosion inhibition under certain synthetic brine conditions. A liquid solution of AAP was used. Coffee Extract It is unknown which chemical components of coffee extract directly contribute to carbon steel corrosion inhibition (see reference 10). A viscous coffee extract material was used in the experiments. A LOOK AHEAD

In next month’s installment in this series, we will detail the experimental procedure’ s test apparatus, with controlled flow rates and temperature to simulate both a scaling and www.modernpumpingtoday.com

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JANUARY 2015 19


How to Select the Most Effective Blower Technology for Wastewater Applications PART 1 OF 2 By Aerzen USA

G

iven numerous variables when selecting an aeration blower system for wastewater applications, and equally numerous claims by technology providers, it is not surprising that confusion exists. Worse than confusion is the disappointment that results when a blower technology fails to perform as anticipated — and operating cost and efficiency benefits go unrealized. This guide explains three blower technologies and, using examples from actual wastewater plants, describes the most effective technology for particular applications and why. Of cour se there is no substitute for a consultation specific to your application; however, the guide can help raise the right questions and ensure a productive vendor and technology evaluation process. INTRODUCTION

Energy consumption and cost have been the key drivers behind the development of more efficient aeration blower systems. These systems ca n account for as much as 60 percent of the total energy consumption of a wastewater treatment plant (WWTP). Therefore, the payback on greater energy efficiency is significant. Technological advancements in aeration blowers are providing new options for reducing energy

For More Information Aerzen USA offers a wide array of Positive Displacement Blowers, High-Speed Turbo Blowers, Screw Compressors, Rotary Lobe Compressors, and Vacuum Pumps for various industries. For more information, visit www.aerzenusa.com.

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consumption. However, these options also require greater understanding of the overall system and fluctuations in operating conditions in order to optimize the total cost of ownership and maximize return on investment. If the choice of an aeration blower was simply based on the energy efficiency or initial cost of the technology—irrespective of the operating conditions—it would be easy to select the most effective aeration blower. However, once installed, the cost-benefit intended is not likely to be achieved if the technology is misapplied. An accurate cost-benefit analysis must include the capital expenditure of the aeration blowers themselves, and the operating variables. Consider daily and seasonal swings in oxygen demand, fouling and aging of diffusers, air flow control and turndown capabilities, total blower efficiency and energy consumption over time, mode of operation, blower accessories, and plant set up when making your decision.

Operating variables can significantly affect cost and benefit. With energy efficiency the primary driver of aeration blower technology, the goal of this paper is to illustrate the most efficient and cost-effective way to achieve energy efficiency based on real-world applications and right-sizing blower technologies.

AN OVERVIEW OF CURRENT BLOWER TECHNOLOGIES

There are four main blower solutions for wastewater aeration applications: positive displacement blowers, turbo blowers, hybrid blowers, and combination blower technologies. The following sections provide brief introductions to these approaches and outline the benefts and limitations of each.

PD BASIC DESIGN PRINCIPLES • •

• •

• •

Constant volume against varying pressure Flow changes by varying speed with variable frequency drive (VFD) Large turndown (typically 4:1) Adapts naturally to changes in pressure and temperature Widely used Low initial cost

PD L IMITATIONS •

• •

Slip between rotors increases with differential pressure Efficiency drops at lower speed Efficiency drops at higher pressure


JANUARY 2015| 21


TURBO BLOWE R ADVANTAGES

TURBO BLOWER LIMITATIONS

•

•

• •

Higher efficiency than conventional rotary lobe technology Small footprint reduces cost to design new and retrofit blower rooms Integrated package including blower, motor, and controllers makes installation easier

•

Limited operational range relative to pressure and airflow (typically 2:1 turndown) Limited on/off cycling due to airfoil bearing limits, and limited wear on electronic components

despite changing conditions; the PD blower has a lower initial cost than its turbo and hybrid counterparts. However, the PD blower's lower cost can be offset by higher energy consumption, depending upon the operating conditions. When it comes

Positive Displacement (PD) Blowers These blowers are defined as rotary lobe blowers with straight or twisted lobe rotors without internal compression. Often, they are referred to as "the workhorse" for its flexibility to perform well Chart 1

0.68

yc n iec if f E ci ta

0.66 0.64 0.62 0.6 0.58

0.56 iab 0.54 d A 0.52 0.5 0

500

1000

1500

2000

2500

Inlet Flow - ICFM PBIG 8

10 PBIG

12 PBIG

Chart 2

Specific Power Comparison Delta Hybrid D62S, GM 60S,

20.0

and TB100-1.0

3%

6%

18.0 25.8

16.0 kW / FM14.0 C S

21.9

19.1

20.7

11.8

D 029 3M 605

12.0

TB 100-1.0 10.0 400

800

1200

1600

Flow 8 GPM (Inlet T1=68F, P1=14.5 PSIA, RH=0%) P2=11.6 PSIG

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2000

to turndown, PD far exceeds turbo blower technology by achieving ratios as high as 4:1.

Turbo Blowers When operating near its design point, the turbo technology may be the most efficient ad therefore performs cost-effectively in applications with narrow swings in turndown. Turbo has a higher initial cost than its rotary lobe and hybrid counterparts. However, in applications with less variation in operating conditions, the additional cost can be compensated for in lower energy consumption. Centrifugal design principles include dynamic compression, a “sweet zone” of highest efficiency, as well as a guideline to operate on a performance map. If the flow is too low or pressure too high, users can expect a surge. Conversely, if the flow is too high or pressure too low, users can expect a choke. Also, performance varies with air density: summer means high loads in low air density, and winter means low loads in high densi ty. Hybrid (Rotary Lobe Compressors) Blowers This technology provides energy efficiency comparable to turbo and the flexibi lity of PD technology. T he hybrid uses a low-pressure screw rotor instead of a straight or twisted rotary lobe rotor. In applications with large swings in flow and pressure, hybrid blowers can achieve rates as low as 25 percent of the srcinal design point. Hybrid design principles include constant volume against varying pressure with a large turndown (typically 4:1). Also, flow changes by varying speed (via use of a VFD) and rotors mesh, compressing air inside housing. www.modernpumpingtoday.com

HYBRID ADVANTAGES

HYBRID LIMITATIONS

• • •

•

Comparable efficiency to turbo High efficiency throughout range Tolerant of variations in pressure

Combination Blower T echnologies For large WWTPs, applying a combination of blower technologies at various points in the treatment process can improve overall energy efficiency and reduce initial and long-term operating costs. This solution can be especially effective in a retrofit application and in processes where the duty cycle on the blower can be as low as running only one hour per day. Turbo blowers are ideal for applications where they can run at the same speed all day—they are less efficient when used in applications with regular fluctuations. The best way to optimize a system is to combine a turbo (for base load) with a hybrid (for peak load and low flow conditions). It is critical that the turbo is able to tolerate the introduction of the hybrid without surging. The idling


• •

Less efficient at very low pressure than rotary lobe blowers Higher capital cost (10 percent higher than PD) Larger footprint than turbo

feature and the current-based inverter control easily facilitate this combination. It is also critical that the PD or hybrid be equipped with pulsation attenuation, to minimize the disturbances in the system while operating with the turbo. Overall energy efficiency can be higher with this approach, and the overall turndown range can be extended to 6:1 or more.

A LOOK AHEAD Next month, we’ll take a closer look at case studies illustrating the results that can be achieved by implementing turbo, hybrid, and combination blower technologies in wastewater treatment plants. After seeing the results in action, most wastewater professionals feel more confident in making their next blower selection the right one to fit their needs. ■

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MAINTENANCE solutions

Preventing Rust Formation with Electronic Water Treatment By Jan de Baat Doelman, Scalewatcher North America Inc.

T

he growing demand for water for industrial applications, power production and water supply has resulted in an increasing need for water treatment. The water used in industry comes from a range of sources such as rivers, lakes, wells and oceans and contains dissolved and suspended solids. In addition the industrial world has to

reuse water which in turn causes it to be highly concentrated in silicate, iron scale and calcium carbonate that cause limescale build up and rust. Limescale deposition results in t he need for regular shut down in order that build-up can be r emoved. Sometimes, this shutdown will be part of a planned maintenance

About The Author Jan de B aat Doelm an is pr esid ent of S calewatch er North Ameri ca I nc. The Scal ewatch er i s an environme ntally friendly alternative to chemical and mechanical descaling. Launched in the 1980s it has successfully treated hard water problems for industrial manufacturers as well as water companies, oil producer s, farmers, horticulturists, shipping companies, shopping centers, school, universities and government establishments. For more information, call 610.932.6888, email [email protected], or visit www.scalewatcher.com.

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program but on other occasions the system may become severely or even completely blocked with limescale, making it necessary to remove the equipment from service until the blockage is cleared. Scale deposits can also increase corrosion. T his is due to entrapped oxygen and also because scale itself is sometimes corrosive to the surface with which it is in contact. Also, scale will interfere with the action of inhibitors in the system, keeping them from reacting with the surface below the scale. If the scale is patchy , the differential aeration between the clean surface and the scale surface may cause a corrosion cell to set up. RUST THROUGH OXIDATION

One of the chemical characteristics of iron i s its chemical reaction to oxygen. When there is more dissolved oxygen in water, iron is easily oxidised and grows into rust (Fe 2O 3). In addition this ferrous iron is a catalysis that continuously accelerates the anode action so that rusts grows inside the pipe.

Generally , this is called red rust but electronic water treatment (EWT) devices such as Scalewatcher changes it into black rust shown as below 3Fe 2O 3 · nH 2 O + e-

⇒

2Fe 3O 4 + 1/2O 2 + 3nH 2O

This cathode action gradually changes red rust into brown and then into dark brown rust ( Fe 3O 4). Called magnetite it makes it possible to extend the life span of pipe material by forming a film on the inside of the pipe wall which prevents rust growth. Red rust accelerates scale deposition, but the transformation into black rust by EWT means that the red rust is removed together with t he scale in the water flow. ELECTRONIC SCALE REMOV AL

To explain the effect of electronic scale removal it is fir st important to understand the major f actors that cause scale. Whilst scale can be a complex of many minerals, calcium carbonate is the most prevalent in i ndustrial processes. SUPER SATURATION

When rust grows through iron bacteria its can be expressed as follows: Fe + 2OH ⇒ Fe(OH) 2 2Fe(OH) + 2H ⇒ 2O + ½ O 2 2Fe(OH) 3 2Fe(OH) 3 ⇒ Fe 2O 3 + 3H 20


progress

Aqueous solutions can become supersaturated, which means that they contain higher concentrations of dissolved solute than their equilibrium concentration. Such solutions are not stable and are easily triggered into dropping back to saturation level, forcing the dissolved compound to precipitate. Even when a bulk solution is less than fully saturated, scale formation can occur spontaneously due to localized super saturation, on a surface for example with a drop in calcium carbonate solubility, leading to the

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MAINTENANCE solutions formation of mineral scale deposits. In RO, the raw water and its components pass through the membrane filtering the pure H 2O. Therefore there is a steady process of supersaturation and precipitation of the water through the membrane. Within this environment electronic water conditioners, such as

Scalewatcher is the ideal solution for removing and preventing the membranes being clogged with scale. As electronic water treatment (EWT) changes the shape of the molecules from rough to smooth, they do not form a matted structure and are washed away thereby preventing the membranes from being clogged

which in turn reduces maintenance shutdown and energy costs. ELECTRONIC WATER CONDITIONING

EWT is a non-invasive system utilizing a solenoid coil or coils wrapped around the pipework to be treated. A continuously frequency changing signal generator, within a specified range, supplies current to the coils. The pulse shaped current creates an induced electric field, concentric around the axis inside the pipe. As a consequence to this arrangement, any charged particle or ion moving within the field experiences a socalled Lorentz force generated by the interaction between charged particles and magnetic and electric fields. The treatment influences the initial nucleation, resulting in crystals that do not "stick" together . Untreated water builds up matted structures that continuously grow. This treatment creates idiomorphic, scattered crystals, which do not form matted structures. They have a rotundas shape, which means that t hey have a larger volume in relation to a smaller surface. Th is feature makes them sensitive to water currents and they are easily flushed out of the pipeline. As no new scale layers are formed, the sheer force of the water f low will gradually remove existing layers of scale. The ability to adjust power, frequency and coil configurations of products like the Scalewatcher on site enables performance to be optimized with no downtime and no pipe replacement. TWO EXAMPLES

River W ater Used in a Compressor for Cooling Water Line The pipe work was clogged with scale which resulted in a safety device automatically stopping the compressor which had overheated. The main composition of the scale was calcium carbonate and iron scale. When the temperature of cooling water was over 194ºF, the compressor stopped automatically. The river water, gathered in a water pond cools the compressor after passing through a strainer . After cooling the compressor , the river water gathers at the return sump and then it is sent to the water pond by a circulation pump. It was difficult to pull up the screen of the strainer because 0.2 inches ( 5.08 26

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millimeters) in diameter of rust adhered to the screen case of the strainer. Scalewatcher was installed on the discharge side of the pump. After about three weeks, red rust inside the screen case of the strainer disappeared and remaining rust was changed into a black color. And then it became easy to pull up the screen. In the compressor , the temperature of the cooling water didn’t go up to more than 176 degrees Fahrenheit (80 degrees Celsius) and it made it possible to operate the compressor safely without interruption. Iron Scale Caused by Chlorine in Power Plant Seawater was used in a pipeline supplying analyzing


equipment. The line was clogged with microorganisms and iron scale. The strainer had to be cleaned every week. The main composition of the scale was Fe 2O3 and micro-organisms. The object of the Scalewatcher test was to examine whether Scalewatcher is effective on scale caused by dissolved Chlorine. Scalewatcher was installed on the line between the water pump and the strainer. After a month, the rust and hard scale inside the pipeline was softened. After a further three months t he rust (Fe 2O 3) was changed to black colored Fe 3O 4, the strainer was not clogged and the microorganisms had disappeared. T his means that black colored Fe 3O 4 is effective for prevention of corrosion by ionized chlorine. ■

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t ytsr u h dni g gnip i ost mu l sp t ecca dei oysae dwrol .

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JANUARY 2015

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PUMP solutions

Progressing Cavity Pumps Get

By Chip Strickland, Moyno

T

he wide variety of applications that can be accommodated by Moyno progressing cavity (PC) pumps has been highlighted by an offshore application. Ten of Moyno’s 2000 Series pumps have been ordered for a new fleet of offshore supply vessels that will be used to service drilling rigs worldwide.

BIG JOB OFFSHORE The 2000 Series pumps will be fitted to ten new HOS M AX 320 supply vessels that Miss issippi-based VT Halter Marine is building for Hornbeck Offshore. The pumps will transfer up to 24-pound (HH kilogram) liquid mud to and from the vessels, which will be off-loaded when they reach the drilling rigs.

IN THE MUD, BUT NOT STUCK This is a very demanding application for any pump. Drilling mud is a very aggressive substance that can have high solids content, so the pumps must be able to withstand this.The ability to operate at sea was another important consideration. For example, centrifugal pumps require a fairly stable level of pumped media to work efficiently. T he motion of the sea can cause the mud levels in the vessels to fluctuate constantly and this would have reduced the efficiency of a centrifugal pump, leading to longer offloading times and expensive delays. However, the progressing cavity action of the Moyno pumps isn’t affected by these changing mud levels and they

About The Author Chip Strickland is techincal services manager for Moyno, a brand of National Oilwell Varco. Moyno manufactures progressing cavity pumps, grinders, screens and aftermarket spares and services, across a broad spectrum of industrial sectors including water and wastewater, oil and gas, chemical, pulp and paper, food and beverage and agriculture. For more information, visit www.moyno.com or call 877.486.6966.

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2000 SERIES FEATURES The Moyno 2000 gear joint pump offers best value and application versatility. The proprietary gear joint design effectively handles radial and thrust loads for maximum perfor mance an d long life.

GEAR JOINT DESIGN: The uniform design of the ring gear and gear ball components create greater surface contact leading to less wear and better overall performance. MATERIALS OF CONSTRUCTION: Available in cast iron or stainless steel, with a choice of rotor and stator materials to suit individual applications (e.g. hard chrome plated rotor or natural rubber stator). LOW RUNNING SPEEDS: Reduced wear for a longer working pump life which extends the periods between routine maintenance— realized savings on abrasive applications.

can work perfectly well in these circumstances. T his allows the vessel operator to accurately predict the time needed for off-loading and get the vessels heading back to shore for the next load as soon as possible, without any costly delays. HIGH VOLUME AND HIGH PRESSURE

In addition to these predictable offload times, our 2000 Series pumps are also well-proven in this type of challenging duty. T hey offer the high volume and high pressure capabiliti es which the customer requires, plus the ability to operate in reverse so that mud levels in the t anks can be adjusted to add extra stability while the vessels are at sea. Moyno’s high-performance 2000 Series pumps offer an outstanding combination of low maintenance, minimal downtime and long service life, which all combine to create a low cost of ownership. Th eir proprietary 2000 Series gear-type universal joint design minimizes wear and accommodates both radial and thrust loads with ease. This allows the pumps to handle abrasive materials with over 80 percent solids, while still maintaining a steady and consistent flow. The 2000 Series range also offers performance capabilities to 4500 gallons (17,034 liters) per minute, with pressure to 1500 psi. www.modernpumpingtoday.com

VARIETY TO MEET APPLICA TION N EEDS

Both cast iron and stainless steel models are available, with a choice of materials and coatings for rotors and stators, to suit individual applications. The 2000 Series pumps also have a low running speed capability which extends both the maintenance intervals and the overall working life. That pays particular dividends on an application like this where the pumped media is so abrasive. The pumps will transfer mud at volumes up to 1000 gallons (3785 liters) per minute, handling pressures of 200 psi. The order was secu red through Moyn o’s partner company, Chemetec Engineered Equipment. Other pumps in the Moyno range offer proven solutions for many other oil and gas applications, such as multiphase fluid transfer , lease automatic custody transfer, crude oil transfer and produced water handling duties. ■

VISCOUS PRODUCTS AND HEAVY SOLIDS: Minimizes shear and crush damage to the pumped product, while maintaining a steady flow when pumping products with a high solids content. DURABLE COATINGS: Rotors can be supplied w ith specialized coatings to help extend the life of the rotors through improved wear and corrosion resistance. HIGH PRESSURE/LONG HAUL PUMPING: Can offer considerable pro ject cost savings by utilizing small borehole pipework and eliminating the need for series of pumps when pumping over long distances or with high head requirements.

JANUARY 2015| 31

PUMP solutions

THE

KEY

GOOD

TO

A

PUMPING

SYSTEM

Landia’s know-how helpsfacility meet wastewa needs ter By Soren Rasmussen, Landia, Inc.

T

he average citizen in the modern world consumes around 34 gallons (130 liters) of household water every day—and most of it is contaminated because we use it for cleaning, washing clothes, showering, or flushing the toilet. The manufacturing sector also consumes a lot of water—and in addition a large quantity of rainwater is ducted to the wastewater treatment plant via t he sewers. Enormous amounts of water therefore have to be treated every day to keep streams, lakes and the sea clean. For wastewater professionals, a common difference heard between industrial wastewater plants and municipal plants

is that one exists for p rofit, the other for nec essity. In both cases, however, reliable and efficient pumping systems are a must. One of the keys to a good pumping system is a good design: placing quality components where they are needed. With voluminous experience with a diverse client base, Landia has positioned itself to assess any pump user’s needs and presc ribe the right compo nent from their products. Landia has supplied equipment to public and private water treatment plants since the 1980s, and has gained practical experience from small and large plants throughout the world.

About The Author Soren Rasmussen is the director of Landia, Inc. For more information Landia’s range of applications, call 919.466.0603, email info@landiain c.com, or visit www.landia.com.

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JA NU A RY 2 01 5


The initial standard propeller mixer was constantly fouling and tripping on overload and was also causing foaming, which worsened the unwanted surface matt build-up.

Two recent success stories highlight the constraints and demands placed on wastewater professionals around the globe, and the need for designed solutions. The following case studies—one from North America, one from Europe— are representative of issues facing wastew ater treatment facilities for public and private concerns, and also illustrate the benefits a global pump manufacturer like Landia can provide from their varied experiences.


The additional Landia unit pumps into a manifold to create a spray action along the floor of the basin, moving any settled material to the pump suction area.

CASE 1: GENTL Y DOES IT WITH NOC TURNAL PUMPS

While workers from a l andmark building in Canada are at home sleeping, Landia’s pumping and mixing equipment quietly goes to work removing highly concentrated sewage at a flow rate of just 0.58 gallons (2.2 liters) per second from an 8189 gallon (31,000 liter) cistern. In fact, due to a lack of existing sewage capacity, the authorities in this city could only allow the prestigious

JANUARY 2015| 33

PUMP solutions

Tullamore Wastewater Treatment Works

seven-storey CAD $100 million building to go ahead if such an overnight wastewater removal system could be put securely into place. Supplied by Engineered Pump Systems of Port Coquitlam, who have worked in close conjunction with Landia and professional services firm WSP to bring about the most effective low-flow design, L andia’s chopper pumps and mixers are in operation from 11pm until 6am, removing sewage from the cistern that serves the third to seventh floors. Eric C. Pettit, P.Eng, projec t manager for WSP, provided consulting services through for the project. “To meet the strict low-flow rate of just 0.58 gallons (2.2 liters) per second that was required for the overnight time slot, we’ve had to throttle the Landia pumps down substantially with a variable frequency drive (VFD) as part of this complex installation. We start the pumps at 100 percent speed, and then ramp them down to the restrictive flow rate. We then ramp them back up to 100 percent just before shut-off to ensure that the pump is clear.” “We are also using an additional Landia chopper pump as a mixer. Initially a standard propeller mixer was used, but it was constantly fouling and t ripping on overload due to high concentrations of sanitary products that were causing a floating matt problem,” Pettit adds. “It was also causing foaming, which worsened the unwanted surface matt build-up. We use the additional Landia unit to pump up and into a manifold so as to create a spray action along the floor of the basin, moving any settled material to the pump suction area. This also pre-chops the materials, effectively eliminating the chances of jamming when we are running the VFD-controlled pumps to discharge.” “This has been an unusual, challenging yet very rewarding project,” adds Earl Masse for Engineered Pump Systems. “The Landia chopper pumps have conclusively proved their non-blocking capability and their ultra-reliability. The specification of a good pumping system to the successful operation of this new building has been crucial.” CASE 2: THE RIGHT BLEND AT TULLAMORE

Landia’s externally-mounted GasMix digester mixing system is proving to be an integral part of EPS Water’s successful design-build-operate (DBO) package at the recently expanded wastewater treatment works in T ullamore, home of the celebrated Irish whiskey, Tullamore Dew. EPS Water’ s process for the wastewater treatment works, which caters for a population equivalent (PE) of 45,000 and a sludge treatment capacity of 80,000 PE, includes two 34

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Landia's externally mounted GasMix AD digester mixing at Tullamore Wastew ater Treatment Works.

sludge digesters with duty/stand-by CHP , sludge holding tanks, sludge drier and all associated works. A leader in infrastructure support services, including design and build f or the water sector, EPS Water introduced Landia’s GasMix for its reliability, gas yield enhancement and easy maintenance. “For our client, Irish Water , Landia’s GasMix not only produces more methane than other systems, but it does so much quicker because it mixes the whole tank properly, leaving no crust on the surface,” EPS Regional Operation Manager Gerald Buckley explains. “We have found the GasMix unit to be extremely reliable. Easy access to the pumps ensures staff carry out routine maintenance efficiently and safely, thereby avoiding downtime,” Buckley adds. “At EPS we deliver mission-critical products for the very best, long-term technical solutions— and Landia’ s GasMix meets that requirement as a system we know can rely upon for its efficiency and performance.” ■ www.modernpumpingtoday.com


JANUARY 2015| 35

DEWATERING solutions

From Reaction to Taking Action The Mine Performance solution increases throughput and availability

By GE Intelligent Platforms

rocess variability and surprise equipment failure are common hindrances facing mine operators around the world and prevent them from optimizing throughput, recovery , and asset availability . Operators need the right information at the right time to catch problems early and maximize your mining operations. Mine Performance, from GE Predictivity™ (formerly Proficy MaxxMine), is an advanced and proven remote monitoring and diagnostic software solution that combines process and asset optimization in a single offering. The software helps mine operators make timely and accurate decisions that balance process performance with equipment health. The following three cases highlight some of the Mine Performance solution’ s benefits in helping users shift from costly reactive maintenance to efficient planned maintenance.

P

pump had exceeded its operating limits was increasing above historic values. In further analyzing the pump operational history , it was found that there were periods of time when the pump was operating at 100 percent speed when it was expected, given the loading conditions of the pump, to operate at 80 percent speed. During the time the pump was being run at full capacity, it was found that a suction level was returning flat line values. T he Availability & Performance Center and the South African Monitoring team investigated this issue and discussed it with the client on the next weekly call. When the client investigated this issue, it was found that a level sensor was malfunctioning and this was causing the level sensor to return flat line values. T his level indication, which is part of the pump control system, caused the pump to operate at a higher speed than previously required for the same flow rate. The client had the opportunity to correct a faulty level

CASEA 1: FAULTY SYSTEM SENSOR DETECTED ON PUMPING

indication before secondary damage was done to their equipment. Running the pump at full speed, when the operation did not require it, cost t he client unnecessary production costs and could result in unnecessary wear on the pump. In addition, a faulty level indication, if not corrected, could have resulted in pump cavitation which would have resulted in additional maintenance costs to the pump.

In this example, the Mine Performance solution detected that a pump was not operating at the speed that was expected based on previous historical data. The Mine Performance solution identified that the percentage of time a PID Control loop for a 100

Manual Auto Cascade Shutdown % Limits Exceeded

8.0 80 ) % ( e g a t n e rc e P

7.0

6.0

60 40 20

5.0 0 11 Dec 12

12 Dec 12

13 Dec 12

14 Dec 12

15 Dec 12

16 Dec 12

17 Dec 12

Screenshot depicting actual values (blue) and expected values (green). Mill gearbox lube oil cooler outlet temperature shown in top graph. Mill gearbox lube oil flow shown in second graph. Mill gearbox lube oil inlet pressure shown in bottom graph.

CASE 2: PERFORMANCE LOSS DETECTED ON PUM P AT MINING FACILITY In another case, the Mine Performance solution detected an increase in the speed of a pump at a mi ning facility. Given load and operational conditions, pump speed was expected to remain around 82 percent of full speed operation. Actual pump speed was seen to be rising as high as 90% of full speed operation. At the same time, the estimated pump driver power was seen to be increasing from expected values of 120 horsepower (89 kil owatts) to values as high as 150 horsepower (112

For More Information GE's Intelligent Platforms Business has built a where machines, data, and people combine to

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range of Predictivity solutions™ that connect to the power of the Industrial Internet drive unprecedented value. For more information, visit www.ge-ip.com/predictivity .


Mill Gearbox Oil Heat Exchange Outlet, Temp, C 50.0 C

30.0 10.0 3/14/2013

220

3/16/2013

3/18/2013

Mill Gearbox Oil Flow, l/min

3/20/2013

3/22/2013

up and ultimately affect the lubricating quality of the oil. This could have caused damage to the gearbox bearings or gears, resulting in an unplanned outage of the mill and a subsequent loss of production.

200 in m l/

CONCLUSION

180 160 140 3/14/2013

3/16/2013

3/18/2013

Mill Gearbox Oil Inlet Pres, kPa 300 a P k

100 3/14/2013

3/16/2013

3/18/2013

kilowatts). T he Availability & Performance Center notified the client and began tracking the issue on the regularly scheduled weekly calls. When the client completed their investigation, they confirmed that the liners in the pump had degraded and needed to be replaced. The client had the opportunity to proactively

The Mine Performance solution is a proven technology that reduces 3/20/2013 3/22/2013 process variability and inefficiency, improves product consistency, increases throughput by allowing operations to push constraints to the limits, and achieves higher return on assets. The Mine 3/20/2013 3/22/2013 Performance solution is currently monitoring over 12,000 critical rotary, reciprocal, and fixed assets around the world, a depth of experience in large industrial-equipment monitoring and predictive analytics encompasses hundreds of milli ons of machine hours. ■

schedule a maintenance action on this pump at the time that minimized their maintenance and lost production costs. Continuing to run this pump with degraded performance caused the client to incur excess production costs.

CASE 3: LUBE OIL PUMP OPERATION AL ISSUE DETECTED In this example, the Mine Performance solution detected that a lube oil flow and a lube oil inlet pressure to a mill gearbox were not operating as expected, as the mill came out of outage. Values for the oil flowing to the mill gearbox were expected to operate around 42 gallons (160 liters) per mi nute, given operating conditions. However actual values were seen to be operating as high as 52 gallons (200 liters) per minute. At the same time, lube oil i nlet pressure was expected to be operating around 140 Kilopascals, but was actually operating as high as 315 Kilopascals. The A vailability & Performance Center sent a high priority notification to the client and began tracking this issue on the regular weekly calls. When the client investigated this issue, it was found that a startup lube oil pump had not been turned off once the main lube oil pump and the mill were in steady state operation. The client had the opportunity to correct an operational issue before secondary damage was done to the mill gearbox. In addition to saving the unnecessary expense of running two lube oil pumps instead of one, the operation of a second lube oil pump resulted in an over pressurization and excessive flow of the lube oil system. T his increased pressure and additional flow could have resulted in system lube oil leaks. If not corrected, this over pressurization will cause the lube oil to slowly heat www.modernpumpingtoday.com

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JANUARY 2015 37

MOTOR solutions

MOTOR DECISIONS M ATTER Don’t be an energy dinosaur

SM

By Walker Larsen, Consortium for Energy Eff iciency

P

lant managers, who may be d eterred by the initial cost of variable frequency drives (VFD), may find a new fact sheet released by Motor D ecisions Matter a useful way to assess the many benefits of this technology. VFDs are devices that improve the efficiency of electric motor-driven systems by varying motor input frequency and voltage to control motor speed. Energy costs are 95 percent of the mo tor total cost of ownership, but VFDs can dramatically reduce the electricity

by controlling the frequency (Hz) to the motor.

and Volts/Hz ratio supplied

SHRINK THE ELECTRICITY PIE A whopping 95 percent of the cost-of-ownership of a motor is the cost of electricity. When implemented correctly, VFDs reduce these costs and can provide other benefits as well. Improved process controls can bypass capability in an

a motor system uses. In order to achieve these savings, plant emergency or failure and also offer protection from overload managers need appropriate information to match VFDs to the currents. Other benefits include noise reduction and extended motor system application. motor equipment life. That’s where the fact sheet Electricity costs Upfront cost of the motor comes in handy. The following MATCH CORRECTLY TO information is targeted to ACHIEVE OPTIMAL SAVINGS business decision makers as A variable frequency drive must well as staff at other levels. be paired correctly with existing It simplifies what could be equipment in order to achieve a complex decision given optimal electricity savings. competing business priorities, Generally, VFDs have lower by laying out the situations in savings potential in applications which VFDs are most beneficial. that require constant torque and For facilities that move air or constant speed. Lower savings water, it’s worth the time to take potential also exists for high a look at this fact sheet and static pressure installations and Electricity is the vast majority of motor life cycle cost, a cost not usually factored into operating considerations. assess the costs and benefits of soft start only applications. VFDs.

GETTING STARTED MODERNIZE YOUR MOT OR SYS TEMS Running motors at full sp eed when it’ s not required is a waste of energy and money. A variable frequency drive is a widely used device that reduces motor sp eed to match a driven load

Many operations managers are unaware that some utilities offer technical and financial assistance for variable frequency drives on fans and pumps used in HVAC, chillers, pumps, and many other applications. A good next step would be for prospective

About The Author Walker Larsen is CEE's industrial program manager and can be reached at [email protected]. Motor Decisions Matter SM is a sponsored project of the Consortium for Energy Efficiency. Email questions to [email protected], and visit the Motor Decisions Matter website at www.motorsmatter.org to see other fact sheets, read case studies, or learn more about how VFDs can help boost your bottom line.

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users to ask their local utility, motor service center, or motor distributor to help identify opportunities for VFDs in their plant or facility . Online resources, such as those found on the MDM website ( www.motorsmatter.org ) can also provide VFD case studies, assessment tools, and links to utility programs throughout the United States and Canada. Many market segments are already benefiting from the energy Savings and cost savings of variable frequency drive technology. The range of applications include all aspects of the HIGH economy and all types of users. VFDs can be found at work in commercial buildings, food processing, grocery stores, cold storage, MEDIUM hospitals, schools and universities, industrial processes, water and wastewater treatment, and irrigation. For any facility LOW routinely moves air or water, it is worth the time to assess the costs and benefits of installing a VFD.


CASE IN POINT: LAYFIELD GROUP

Potential By Application

Layfield Group, a large plastic manufacturer, worked with utility BC Hydro in 2012 to im prove the efficiency of its facilities. Using a BC Hydro incentive program, Layfield Group replaced several single-speed air compressors with one variable frequency drive model. The VFD model was projected to save 120,000 kWh of energy and about $7400 per year.

• Centrifugal fans and pumps Lower speed operation results in significant energy savings, • Blowers as shaft power of the motor • Axial fans theoretically drops with the cube of the rotational speed • HVAC systems • Mixers • Conveyors • Compressors

Lower speed operation saves energy in direct proportion to the rotational speed

• Lathes • Milling machines • Punch presses • Printing presses • Machine tools

No energy savings at reduced speeds. Nonenergy benefits that may result in cost savings can be realized

CONCLUSION Managing a plant requires multiple decisions to achieve business goals. Optimizing motor systems to reduce costs is jus t one of them, but considering appropriate use of VFDs can significantly reduce costs. Many utilities throughout the US and Canada offer financial incentives to end users who install these devices to improve the efficiency of motor-driven systems. ■

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POWER GENERATION solutions

Seeking New Territory By Evan Lubofsky, Onset

Onset’s handheld data loggers provide baseline measurements for prospective Delaware River Basin site athering water quality data at potential natural gas fracking sites is important work. For environmental impact to be accurately measured, the baseline needs to be accurate and the testing thorough. However, for some managers, the pressure to provide reliable baseline water quality data while also staying

G

fracturing, commonly known as “fracking,” also brings risk of environmental contamination from salty fl ow-back water containing potentially toxic and carcinogenic chemicals. To protect against negative byproducts of hydraulic fracturing, the Delaware River Basin Commission (DRBC) turned to cost-effective

under budget and making best use of available workers can seem daunting. One solution can be found in Onset’s handheld data loggers. Portable, accurate, and cost effective, devices like these can provide baseline data when and where it’s needed.

HOBO U24 Conductivity Data Loggers from Onset, a Massachusettsbased company. Although gas development in the Marcellus Shale continues to remain outside the Delaware River Basin, in 2011 the DRBC began using the data loggers to measure the baseline water quality in rivers in anticipation of future work there. T hen, when gas development does begin, the DRBC can quickly identify any changes and react if problems arise.

®

QUALITY MEASUREMENT NEEDED Hydraulic fracturing, the process of injecti ng water and chemicals into shale to release natural gas, holds promise for addressing both energy and employment challenges in the United States. Experts estimate that the Marcellus Shale in New York and Pennsylvania alone could satisfy as much as fourteen years of U.S. natural gas consumption and create nearly a quarter million jobs. However, hydraulic

MEET THE HOBO

The DRBC chose the HOBO data loggers for their accuracy , reliability, and affordability. Since deploying the loggers

About The Author Evan Lubofsky is a writer and communications director for Onset, a leading supplier of data loggers. Based on Cape Cod, Massachusetts, Onset has sold more than 2.5 million data loggers since the company’s founding in 1981. For more www.onsetcomp.com . information, call 800.564.4377, email [email protected], or visit

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in January 2011, they have performed consistently while tolerating harsh weather conditions, branches, and other objects moving do wnstream. As of October 2 014, the loggers had collected nearly 500,000 specific conductance measurements in water bodies in the Delaware River Basin, with the data indicating that different streams in the same region have different conductivity distributions. “The loggers have proven to be an inexpensive solution for high-risk deployment,” says John Yagecic, environmental engineer and section supervisor at DRBC . He adds, “The HOBO Waterproof Shuttle’ s optical interf ace allows us t o easily download data in the field.” The HOBO U24 C onductivity Logger is a high-accuracy , cost-effective data logger for measuring conductivity and temperature in streams, lakes, and other freshwater sources. In particular, electrical conductivity levels in water can indicate contamination. By defining t he range and variability of specific conductivity measurements before gas development occurs, the DRBC will have the information to take immediate corrective action if water resources in the Delaware Basin are affected by future hydraulic fracturing. LEADING THE WAY

“The Delaware Rive r Basin Commission is taking a leadership role in monitoring the potential impact of natural gas development to help preserve area rivers,” says Paul Gannett, Onset product marketing manager. “We are excited to be able to provide the DRBC with a reliable and affordable way to measure water conductivity levels prior to natural gas drilling.”


KEY ADVANTAGES • Non-contact capacitive sensor provides long life • Easy acc ess to sensor for cleaning and shedding air bubbles • HOBOware Pro software provides compensation for fouling using calibration points from the start and end of each deployment • Optical interface provides high-speed, reliable data offload in wet environments • Compatible with HOBO Waterproof Shuttle f or easy and reliable data retrieval

Expected next steps for the DRBC include possibly adding more monitoring sites. “When gas development does commence, data from the HOBOs will be invaluable for knowing the pre-gas condition,” says Y agecic. Onset’s HOBO data logger and weather stat ion products are used around the world in a broad range of applications, including building energy performance monitoring, water resources management, and ecological and agricultural research. ■

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PROCESSING solutions

Using Coriolis Mass Flow Meters with Positive Displacement Sliding Vane Pumps PART 1 2 OF

By Jeff Sietsema and Richard E. Foster, Blackmer

ositive displacement flow meters have long been the technology of choice for applications requiring very

Figure 1: Emerson Mass Flow Meter installed horizontally on propane (LPG) system

THEORY OF OPERATION

Coriolis mass flow meters do not

measure flow directly in 3

P

precise delivery of h igh-value liquid produ ct. Recently , mass flow meters (also called Coriolis Flow Meters for the French scientist, Gustave Coriolis, who pioneered the technology in the 1830s) have increased their presence in the marketplace. T hese meters h ave been successfully utilized in a wide range of both rotodynamic and pos itive displacement pump systems. While rotodynamic pumps generate relatively smooth flow, positive displacement pumps such as p iston pumps, gear pumps and s liding vane pumps generate pressure pulses during operation. Since mass flow meters utilize vibrations to measure fluid flow we questioned h ow well they would work with equipment that generates pressure pulses during operation. This study focuses on flow measur ement in positive displacement pump systems that utilize rotary sliding vane pumps as the means of flow generation. Fur ther, we narrowed our s cope of interest to relatively thin liquids. T he transfer and change of custody of high-value liquids (fuels) is the primary focus of the study. W e tested the meters on 30-SSU solvent and LPG (liquefied petroleum gas) to simulate one of the most common app lications of our sliding vane pumps. Higher viscosity liquids were no t considered and are outside the scope of this investigation.

terms of gallons per minute or cubic meters per hour (m /hr) . Instead, fluid density and the Coriolis forces (mass flow) are measured, which are then used to calculate flow rates. There are typically two measuring tubes in a Coriolis meter, which are formed into a slightly bent tube or a more dramatic “U” shape. The measuring tubes through which the fluid flows are constantly expected to oscillate at their resonance frequency . The resonance frequency is the frequency a t which the measuring tubes are “ most willing” to oscillate. Any change in the density of the fluid produces a corresponding change in the resonance frequency of the entire vibrating system (measuring tube and fluid). The resonance frequency , therefore, is a function of fluid density—the higher the density, the lower the resonance frequency. T he resonance frequency is then compared to the empty-tube resonance frequency , allowing the mass of the fluid in the tubes to be calculated. Since the volume of the tubes is known, the density of the fluid can be calculated. Typically, the two tubes in the meter are vibrated 180 degrees out of phase with each other. As flow (mass) passes through the meter, the phase angle between the tubes changes. T he phase-angle change of the tubes is caused

About The Authors Jeff Siet sema is the Rese arch & Develo pment Lab Manager, an d Richard E. Foster is Director of E ngin eering for Blac kmer®, the leading global brand of innovative and high-quality rotary vane and centrifugal pump, and reciprocating compressor technologies for the transfer of liquids and gasses. Part of PSG ®, a Dover Company, Blackmer pumps and compressors are used in a multitude of applications in the Process, Energy, and Military and Marine markets. For more information, visit www.blackmer.com.

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by the Coriolis Effect and is proportional to the mass flow rate of the fluid in the tubes. Using the mass flow rate and dividing by the density provides a volume flow rate. Both t he density and the mass flow rate are measured directly and are therefore independent of the temperature, pressure, viscosity, conductivity and flow profile of the f luid passing through the meter. This means that, in theory, a Coriolis mass flow meter can be used to measure any type of fluid flow. T he meter output can be corrected to a st andard reference temperature if desired. There are several significant advantages to using Cori olis mass flow meters: • Because the flow passes through smoo th tubes with no moving parts, there is no mechanical wear of the measuring elements. T here are also no parts subject to abrasion, erosion or corrosion.

• Accuracy is typically listed as 0.1 to 0.2 pe rcent of the flow rate being measured. T his is much more accurate than mechanical meters, which are listed as being within 0.5 percent of full-scale flow. Because other types of meters also need to have pressure and temperature compensation, additional error in these measurements can increase the overall flow error to as much as 3 percent. • Because of their very precise accuracy, the Coriolis ow meters have a turndown ratio of about 100:1 or more. This means that if a meter is rated for a maximum ow rate of 200 gallons (757 liters) per minute, it is still accurate down to 2 gallons (7.57 liters) per minute. Typical mechanical meters have a turndown ratio of 10:1. An orice plate’s turndown ratio is more like 5:1.

• Particulates nearly as large as the measuring tube diameter can pass through the meter without issue. Typically , the measuring tubes have a diameter onehalf that of the meter’s piping connections for a twotube meter and are approximately equal to the piping connections for a s ingle-tube meter.

• There is minimal pressure drop through a Coriolis mass flow meter with lower-viscosity fluids. T he only pressure losses are caused by the splitting of the flow into the two measuring tubes. Orifice plates, flow nozzles, venture tubes and positive displacement meters can have significant pressure losses associated with the meter.

• Coriolis meters are not affected by temperature o r pressure. T hey measure mass flow directly , which does not change even if the temperature or pressure of the fluid changes. T herefore, no pressure or temperature compensation is required.

• Coriolis meters are unaffected by changes in viscosity during a process or batch run. Orifice plates and the other pressure-differential meters need to be calibrated for various viscosities and the viscosity needs to be measured during operation to ensure accurate metering.


JANUARY 2015| 43

PROCESSING solutions Admittedly, there are also a few disadvantages to using Coriolis mass flow meters that must be considered: • Pressure drop through a Coriolis meter may increase significantly with increasing viscosity when compared to other technologies such as ultrasonic or magnetic

flow meters. The pressure drop is caused by the split of flow into two or more smaller pipes that are not straight. The smaller bent pipes can increase pressure drop when compared to the straightthrough flow of ultrasonic or magnetic flow meters.

• Typically , a mass flow meter has a higher initial cost than that of other technologies for similar applications. • Depending on the amount of “bend” in the measuring tubes, the space required to locate a Coriolis flow meter can become significant. However, this is offset by a reduction in the amount of straight pipe (flow straightening) usually required on the inlet and discharge sides of many types of flow meters. MASS FLOW METER EXPERIENCE

To understand how Coriolis mass flow meters might interact with Blackmer ® sliding vane pumps, two flow meters were purchased. The first meter, from Endress+Hauser, was a 3 inch (76.2 millimeter) Mod el 83F. This meter was used for performance testing of various pumps on 30-SSU through 2,000-SSU fluids. The second meter, an Emerson™ Micro Motion 2 inch (50.8 millimeter) Model CMF200, was installed on Blackmer’s propane test loop. Meters were evaluated for setup and installation, pressure pulses and flow precision. SETUP AND INSTALLA TION

The Endress+Hauser meter was installed on a mobile cart. A 3 inch (76.2 millimeter) 100-mesh strainer was installed on the inlet side. The piping looped around on the cart with an elbow directly on the inlet side of the meter. This was done because, per the recommendations of both manufacturers, no straightline inlet piping is required on the inlet or the outlet side of the meter for straightening. Manufacturer recommendations were to install the meter vertically to allow easier removal of air when the meter is started empty. However, the meter was deliberately installed horizontally to investigate the effects of improper meter mounting orientation. Typical usage for this meter was to test a pump with a specified fluid and viscosity, drain the pump and piping system, and then set it up with another pump with a specified fluid. The Endress+Hauser meter has a flow capability of 800 gallons (3028 liters) per minute of water. The Emerson meter was also installed in the LPG test loop 44

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horizontally. However, in keeping with LPG custody transfer protocol, a vapor eliminator and back-check valve were installed with the meter. This system is also used in a similar manner: a pump is tested, piping is drained and the pump is removed for the next pump installation. The Emerson meter has a flow capability of nearly 400 gpm of water. The following observations and lessons were learned from using the meters: • Both meters have pressurepulse dampening software available. Both meters had this feature deactivated; testing indicated that it was not nece ssary. • Flow readings were unexpectedly smooth on both meters, much less than with any PD meters that were used previously. Fluctuation of the Emerson meter on LPG was observed to be ±0.1 gallons per minute for flows to 40 gallons (151.42 liters) per minute. The Endress+Hauser meter fluctuation was similar, with fluctuations up to perhaps ±0.3 gallons (1.14 liters) per minute on flows up to 300 gallons (1136 liters) per minute, and greater. • The Coriolis mass flow meters are acoustically much quieter than PD meters. This was especially noticeable with the meter on the LPG system. Because there are no moving parts there is no vibration generated to resonate with associated piping. However, when the meters are powered and not filled with liquid, they do emit a high-pitched hum. The humming ca n be eliminated by keeping the meters filled with liquid or by de-energizing the meters. www.modernpumpingtoday.com

Figure 2: 120-Hz Sliding Vane Frequency

Frequency (period)

ON Cycle

25

4.0 3.5

20 3.0 ) s tl o 15 (V

2.5

l a n ig S 10 w o l F

2.0 1.5 1.0

Minor voltage variation of both signals is electrical noise in ) s system t l o (V l a n g i S e r u s s e r P

5 0.5 0 0.020

0.0 0.030

0.040

0.050

0.060

0.070

0.080

Time (Seconds)

0.090 OFF Cycle

Flow Pressure

Figure 3: 200-Hz Sliding Vane Frequency

Frequency (period)

ON Cycle

25

4.0 3.5

20 3.0 ) s tl o 15 V ( l a n g i S 10 w lo F

2.5 2.0 1.5 1.0

Minor voltage variation of both signals is electrical noise in ) s system t l o V ( l a n g i S e r u s s e r P

5 0.5 0 0.050

0.055

0.060

0.065

Time (Seconds)

0.070

0.075

0.0 0.080 OFF Cycle

Flow Pressure

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JANUARY 2015 45

PROCESSING solutions vertically and the recommendation was proven correct. Above flow rates of 100 gallons (378.54 liters) per minute, air was successfully removed in a very short time (less than one minute). At lower flow rates (less than about 75 gallons [284 liters] per minute), a valve was used to throttle the outlet of the meter to increase pressure in the meter. T his allowed the trapped air to dissolve in the test fluid and flush out of the meter after several minutes. Below about 30 gallons (113.56 liters) per minute it was not possible to completely get rid of the air.

The EMCO Chemical Distributors facility located in Pleasant Prairie, WI, USA, reports excellent results using Blackmer sliding vane pumps in systems that use Coriolis flow meters for flow measurement.

• The LPG meter , with the vapo r-elimination system, experienced no difficulties reading flow when started empty. Since the back-pressure and vapor-elimination valves eliminated vapor quite well, the meter filled with liquid as quickly as the PD meter used earlier . • There was difficulty getting rid of air from within the Endress+Hauser meter, which had been intentionally mounted horizontally on the mobile cart. Both manufacturers recommended the meters be installed

• Air in the meter c reate s turb ulence and reduces the accuracy of the density measurement. Air in the meter also causes the density measurement to become unstable, which could be observed on the meter register. When functioning properly, density fluctuation was typically ±.0005 SG or less - the fluctuation was out to the fourth decimal point, or in the ten-thousandths range. When air was in the system the SG varied approximately ±.05, or two orders of magnitude greater than without air. • The Endre ss+Haus er mete r was r e-ori entate d vert ically to test the air-elimination process. At a flow rate of less than 3 gallons per minute, (on an 800 gallons [3028 liters] per minute meter) after about five minutes of operation, it was possible to flush the air out of the meter without using a throttling valve on the outlet side of the meter. With more flow rate, or by throttling the outlet of the meter, air removal was accomplished in less time. PRESSURE PULSES

A point of concern when utilizing Coriolis mass flow meters with positive displacement pumps is that PD pumps generate pressure and flow pulses that a Coriolis meter might respond to. PD pumps move fluid by filling a fixed-volume chamber and then forcing the fluid out of that chamber . The PD pump could have as few as one chamber, such as a single-piston pump, or twenty or more, as in a gear pump. T he pressure pulses are generated by each individual pumping chamber being filled and emptied, and the frequency of the pulses is a function of the number of chambers in the pump and the speed at which the pump is operated. Coriolis mass flow meters measure vibration of the tubes and frequency variation of the tubes in order to measure flow. We wanted to understand if the vibrations generated by Blackmer sliding vane pumps would interfere with the flow-meter measurements. Distortion of flow-meter vibration measurements would, in theory, tend to be maximized near the frequency at which the flow meters operate. From discussion with the mass flow meter manufacturers, the resonant vibration of the mass flow meters is approximately 200 Hz. To evaluate possible interference of pressure pulses with flow measurement, several sliding vane pumps were tested at a nominal 100 psi with varying shaft speeds to create a range of vane frequencies from 80 Hz to 260 Hz. High-speed pressure and flow data was collected and minimum and maximum pressures and flows were recorded. T he results indicated that there was no correlation between the vane frequency, pressure pulsing and meas ured flow at the meter. Another attempt was made to look for possible interference between the pump and the flow meter. A 46

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pump was operated at sliding vane frequencies of 120 Hz and 200 Hz (figure 2 and figure 3) for comparison, with pressure on the pump outlet and in the flow meter held at a nominal 100 psig. The flow and pressure signals from the flow meter and the pressure transducer were monitored with a digital-signal processing oscilloscope. The Coriolis flow meter used for the test provided a frequency output signal, producing a 50 percent on/off square-wave function between 0.5 VDC and 22.5 VDC. The number of on/off cycles produced by the meter per unit of time is proportional to the flow passing through the meter. While operating at the conditions outlined above, the signal from the flow meter was inspected for distortions of voltage values, shape of the output function and the timing of each signal step over time. Other than minor pressure and flow fluctuation that were within the expected values of the system, no significant output-wave from distortions were found. Figure 2 and figure 3 show samples of the results. The final investigation pursued was to operate a sliding vane pump with the vane-pass frequency the

Figure 4: Comparison of Flow Signals for 19.5 gallons per minute – Vane Pump and Rotodynamic Pump

25

Vane pump operated at 200 HZ 4.0 vane pass frequency and 100 3.5 PSID

20 3.0 ) s lt o 15 V ( l a n ig S 10 w o l F

2.5 2.0 1.5 1.0

) s tl o V ( l a n g i S e r u s s e r P

5 0.5 0 0.000

0.0 0.010

0.020

0.030

0.040

0.050

0.060

0.070

0.080

Time (Seconds) Rotodynamic Pump Vane Pump

Rotodynamic pump operated at same flow rate and 100 SPID

same as the Coriolis mass flow meter’s resonant frequency and record that output wave form from the meter and then compare it to the same conditions with nonpulsed flow from a rotodynamic flow source. The vane pump was operated at a sliding vane pass frequency of 200 Hz to maximize the opportunity for meter resonance. The flow rates and operating conditions for both pumps were held equal at 19.5 gallons (73.82 liters) per minute and 100 psig on 30-SSU solvent. The results (figure 4) show that the wave forms are identical. The meter handled both types of flow (pulsed and non-pulsed) with equal precision. A LOOK AHEAD In next month’s concluding article, we will examine the test result across different flow rates as well as observations from the field. As the analysis will show, the goal of greatly improved measurement accuracy and very good reliability in a production environment can be achieved and documented. ■ www.modernpumpingtoday.com

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VALVES & CONTROLS solutions

RELIABLE ControlforSyst em s a Rugged Worl d By Jack Baldwin

In APC’s workshop, skilled technicians design, assemble, and

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n a quiet, leafy street on the outskirts of the Adelaide CBD sits APC Technology. The peaceful exterior and Managing Director Scott Begbie’s laid-back attitude don’t give much away. “We have ‘MythBusters’ moments in the car park, making things like explosion proof PCs for oil rigs. We were pressure testing a particular unit - we blew the back off it and stripped

test components for a range of applications.

16 hefty bolts right out of the back,” Begbie says. “A lot of the time we just try and break something. The neighbors don’t really know what w e do.” APC Technology spe cializes in making components rugged enough for extreme conditions and industries. Whether it’s for the bottom of a mine, a surveillance plane’s cockpit, or the interior of a tank, the job is to make it work.

Long-term, experienced staff helps APC increase efficiency.

HISTORY IN PROGRESS This year, APC Technology are marking thirty years in bu siness, a testament to their ability to quickly adapt and iterate, the esteem their customers hold them in, and the staying power of their workforce. Begbie points out the various facets of APC’s workshop. T here are people designing, assembling and testing components. Consoles for Australia’ s

For More Information APC Technology is a leading designer, manufacturer, and supporter of computer/control and innovative sub-system technology www.apctechnology.com.au. packages for a diverse range of demanding operational environments. For more information, visit

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It’s easier to go in to the industrial arena with a defense

When Begbie first joined the APC Technology, military and defense contracts made up the majority of work. Now it sits at around a quarter of their total workload, though the total turnover of the business has greatly increased. “As a percentage it’s not huge— but in dollar terms i t’s probably twice what it was before, along with mining, rail, oil and gas, farming,

food, pharmaceutical and all of those industries too.” INCREASED DEMAND, EXPANDED REACH The spread of industries ensures that APC has a steady stream of business no matter what happens outside. “At any given time at least three or four of those are pretty buoyant. This

pedigree behind you. We did it for a tank, what’s so hard about a train?

Air Warfare Destroyer project lie hidden under a tarp. “We’re testing i n a range of conditions. Th ings are getting submerged; they’re operating at 185 degrees Fahrenheit (85 degrees Celsius); they’re freezing. We’ll freeze them and then put them in the ovens to thermal shock them. It’s generally hardcore stuff,” Begbie explains. There are stacks of equipment and components, testing chambers for humidity, temperature, shock resistance, and more. It’s not far removed from a mad scientist’s laboratory—just better organized. APC started out in the mid-80s making rugged things like control panels and switches for industrial automation. “They were in harsh environments where computers wouldn’t normally work. The industries couldn’t find anything that would. So we thought we’ll go and make our own computers,” Begbie says. RUGGEDIZED COMPONENTS Before long, the defense industry caught on to the fact t hat they didn’t need to buy expensive, custom built systems - they could just up spec industrial components. “APC were one of the first to ma ke ruggedized military systems from commercial equipment,” he says. “It’s easier to go in to the industrial arena with a defence pedigree behind you. We did it for a tank, what’s so hard about a train? It gives you tha t cred ibility.” www.modernpumpingtoday.com

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VALVES & CONTROLS solutions manufacturing. He had a passion for CAD. He was good at it. Now, when he designs something, he knows how to think from a manufacturing perspective—so that’ s inherent in the design now.” An external review of the company pointed out a very low turnover rate. Begbie says it was around two years since the last person left; before that it was another two years. Their longest serving staff have over twenty years with the company. “People are here and they’re here for a while. We try and have some fun and two days are never the same.” GLOBAL EXPERIENCE Managing director of APC Technology , Scott Begbie.

year there’s been a lot of defence work come in. The dairy guys are having a record year. We’ve landed a significant domestic rail contract. The good thing is w e’ve more than doubled turnover and we’ve only got one extra person,” Begbie says. APC’s advantage is their flexibility. They’re small and can adapt their workflow to quickly cater to customers’ needs. “One business we worked with in the United States—we generated a prototype for them faster than they approved the minutes of the meeti ng about building that prototype,” Begbie says. “That’s what happens when you’re a big company burdened by process.” Begbie attributes a lot of their success to the fact that the customer determines the timing of the project. THE ROLE OF 3D PRINTING

As the technologies that they ruggedize

“You can

Begbie’ s previous work at BAE is probably what keeps APC Technology fresh for him—instead of working for years on one project, they service a wild variety of jobs. “We’ve got a dairy customer, he buys 500 units a year. That’s one of the most challenging things. Fo r some reason dairy keeps breaking things. People generally come to us for one or two units. The P3 Orion job was twenty-two, around that. We’re making drive through units for fish and chip shops. We have computers in battle tanks, trying to survive the shock pulse of the main guns,” Begbie says, “not even a human can survive that. When I first came on, it was submarines. We had that turned around in eight weeks - designed, made, certified and installed.” APC Technology recentl y brought on Rear Admiral Kevin Scarce AC, CSC, RANR—the previous governor of South Australia and head of the Defense Materiel Organization (DMO)—on get to board to help them navigate complex projects.

change, so do the company’ s processes. The DMO is responsible for the entire Singapore faster That introduces plenty of challenges—but Australian Defense Force’s mili tary it makes some things easier. platforms and equipment. The next big than a remote “Display technologies change. project on the horizon is a bid at the Everything is faster, everything Land 400 in partnership with Singapore Australian mine site.” is smaller. Faster motherboards company ST Kinetics, an arm of have different electromagnetic Singapore T echnologies Engineering Ltd. vulnerabilities and frequency ranges,” “That’s a company transforming Begbie explains. “But along comes a project—obviously if you win it. We’re 3D printer and suddenly it’s easier to playing against some seriously big show the customer what they’re going to get. We had one companies. T hey’ll have one department that’s bigger than our customer sit here wanting the door of one of their units to company, just set aside for this project.” be a little different. They’re relying on ST Kinetics to prime the project. APC “I excused myself, came back a little later and finished will act as their Australian branch in many respects. the meeting. One of our CAD guys came in with a new 3D “We treat Singapore as essentially just another state. printed door, asking if that was what the customer wanted. They’ll call a meeting and we’ll just go. If it ’s tomorrow, He just said, ‘I’ll take twenty-five of them!’” we’ll fly tomorrow. It freaks them out a bit. It’s often hard for That technology has also helped their prototyping work. It our clients to come to terms with the flexibil ity you can get,” typically takes APC only a day or two to design a unit, but Begbie explains. the metalwork can take several weeks. Often they’ll send “It’s a seven hour plane ride, so you can get to Singapore a 3D printed prototype ahead of time to ensure that the faster than a remote Australian mine site. So they’re mounting, wiring and placement works as promised. concerned as to how we’ll support them - well, if we can “3D printing has been pretty good for us,” Begbie admits. support a mine site, we can certainly support you in a capital city with direct flights!” INGENUITY AT WORK That is how APC have stayed in the game for thirty Their staffing practice has also helped them increase their years; work smarter, get it done faster, and build it to your efficiencies by a significant amount—as mentioned, they’ve customer’ s exacting standards. doubled their turnover with only one extra set of hands. “If you’re the customer, we endeavor to get really close “When we need people, we always attempt to promote to you,” Begbie says. “If you need something, someone people internally. So the latest CAD guy worked in will be there.” ■ 50

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SEALING solutions

Goodbye to

Tradition

Metcar bearings and bushings offer advantages over traditional metals

By Matthew Brennan, Metallized Carbon Corporation

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il or grease lubricated bearings and plastic bearings can cause problems for users needing high temperature applications. However, there are alternatives. Metallized Carbon Corporation manufactures oilfree, self-lubricating, carbon-graphite materials for severe service applications, includ ing bearings specially designed for dry run ning in high temperature applications. DRY RUNNING AT HI GH TEMPERATURES

The Metcar high temperature bearings are designed for use at temperatures ranging from 350 to 1000 degrees Fahrenheit (176 to 537 degrees Celsius) in oxidizing atmospheres, and from 350 to 6000 degrees Fahrenheit (176 to 3315 degrees Celsius) in non-oxidizing atmospheres. At these high temperatures, oilgrease lubricated ball, roller, and sleeve bearings are problematic because the oil-grease lubricants can melt, volatilize or carbonize. P lastic and composite bearing materials can soften, deform or melt at such high temperatures. Because Metcar carbon-graphite bearings rely on graphite for their self-lubricating prop erties, they are not subject to the sho rtcomings associated with petroleum-based lubricants at elevated temperatures. They are dimensionally stable, and are not subject to melting, softening, or deformation. Metcar bearings are ideal for use in continuous dryers, high temperature conveyors, kiln cars, and high temperature ventilation dampers. They are also a great choice for other high temperature equipment, including continuous bakery ovens, screw conveyors, valves, and paint dryers. Several Metcar Grades have received FDA approval for use in contact with foods and pharmaceuticals.

Carbon-Graphite bearing for running at high temperature.

About The Author Matthew Brennan is president and CEO of Metallized Carbon, an ISO certified and producer of the Metcar brand of solid, oilfree, self-lubricating materials. For additional information about the company and its services, visit www.metcar.com or call 914.941.3738.

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Metcar bearings for dry running can be provided to customer prints or customdesigned for specific application dimensions and tolerances. Standard pillow blocks and flange blocks with Metcar bearing inserts are available with cast iron, stamped steel, or stamped stainless steel housings. Metcar high temperature bearings are also available shrink-fitted into metal housings or metal retaining rings. CARBON-GRAPHITE BUSHINGS FOR AIRCRAFT

Carbon-Graphite aircraft fuel pump bearings.

ENGINE FUEL PUMPS

Another example of Metallized Carbon Corporation’s new approach are Metcar carbon-graphite bushings for use in gear pumps that pump aviation fuel for aircraft engines. T his unique material offers n umerous advantages over traditional metals. T he carbon-graphite bushings are us ed to support both the drive gear shaft and the idler gear shaft. Metcar carbon-graphite bushings are preferred for this application because they can use aviation fuel as the bushing lubricant. Aviation fuel is a low viscosity liquid that produces only an extremely thin hydrodynamic film, too thin to provide adequate lubrication for traditional metallic


bushings. But since Metcar’s carbon-graphite material— in contrast—has no atomic attraction to a metallic shaft, the thin fuel film is sufficient to lubricate metallic shafts running in the carbongraphite bushings. A second major advantage of carbon-graphite bushings is that they are selflubricating—they can run dry for short periods of time without catastrophic pump failure or significant wear. In addition, Metcar carbon-graphite bushings are dimensionally stable, which permits the close bushing to shaft running clearances that are required in gear pump applications. Finally, these carbon-graphite bush ings have a relatively low elastic modulus. While elastic enough that they can be press-fit into the metallic gear pump hou sing with no difficulty , after being prop erly press-fit, the Metcar b ushings are pre-stressed in compression. Therefore, they exhibit nearly the same coefficient of thermal expansion as the metallic gear pump housing material. T his assures that the running clearance between the shafts and the bush ings will remain the same throughout the entire o perating temperature range of the pump. ■

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MODERN PUMPING products FLOWSERVE

Featured Product Release

Bearing Gard Bearing Isolators

Designed to offer superior protection for your bearing housing, Bearing Gard bearing isolators directly assist equipment reliability by creating a strong barrier against external contamination. • Static protection is assured by an internal O-ring between the rotor and stator. • Dynamic protection is provided by a tortuous labyrinth that effectively repels severe environmental conditions. • Static sealing quickly transitions to non-contacting operation for consistent performance and will not wear on the shaft or equipment.

Working to keep industry running, Flowserve offers the Bearing Gard with same day shipping of equipment-specific and made to order designs. We are continuously expanding our product range and custom engineered solutio ns. Your local Flowserve representative will guide you through the selection and ordering process. Bearing Gard isolators fit a wide range of rotating equipment. Typical applications include pumps, motors, gearboxes, and general lip seal replacements. Equipment-specific Bearing Gard designs are available or Flowserve will rapidly design a custom solution. In addition to extensive in-house hurricane simulation testing, the Bearing Gard meets or exceeds the following industry standards and certifications: • API 610 • IEEE-841 • IP-66 • ATEX

To find your local Flowserve representative and

find out more about Flowserve Corporation visit

www.flowserv e.com.

RF SYSTEM LAB AA Battery Powered Video Borescope

Some of the most important features companies look for when investing in a high-quality video borescope are portability and a reliable, long-lasting power source. RF System Lab, a world-wide leader in remote visual inspection technology, introduces the VJ-Advance video borescope; an extremely portable, high-end inspection camera that runs on standard AA batteries. The VJ-Advance video borescope from RF System Lab is compact in size and weighs in at only 23oz, making it ergonomic and extremely lightweight. Lower-quality borescopes are bulky and, in some cases, require access to an electrical outlet to operate. The VJ-Advance is easily transported and, while a direct AC-110 power adapter comes with the VJ-Advance for non-stop, continuous power, the video borescope’s main power source is standard AA batteries. For more information, call 231.943.1171, email [email protected], or visit www.rfsystemlab.us .

WATSON-MARLOW PUMPS GROUP 120 Peristaltic Pump

With development based on extensive feedback from customers, Watson-Marlow Pumps Group has launched its 120 cased peristaltic pump range. The 120 pumps are perfectly suited to singleuse systems where no contamination can be accepted. Ultimately the 120 pumps have been developed to increase the low-flow capabilities of the company's product range for applications in the biopharm sector. The market need for the 120 range is well understood, with customers voicing their own mantra, "keep it small, keep it simple." As a result, Watson-Marlow has produced a pump that is focused on size, performance and ease-of-use. Biopharm processes require accurate and repeatable pumping that is easy to validate. With an exceptional 2000:1 speed range (speed accuracy ±1 percent) and a selection of USP Class VI tubes, the 120 delivers the flexibility and purity so vital to drug trials. For more information, contact Doreen Goodrich, marketing communications manager, at 978.988.5309 or [email protected].

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HAYWARD FLOW CONTROL “Plug & Play” Instrumentation Hayward Flow Control announces the launch of its innovative and corrosion resistant “Plug & Play“ Instrumentation products and solutions featuring easy to install designs, thermoplastic construction, high accuracy, and measurement of processes. The Hayward “Plug & Play” Instrumentation now includes in-line and insertion style paddlewheel flow meters, pressure gauges, level sensors, displays & controls, as well as surge suppressors. All products are made with high performance thermoplastic materials to measure and regulate your system’s performance in the most demanding corrosive environments and chemical systems. Additionally, this revolutionary line of flow meters, level sensors and gauges expands Hayward’s industry leading range of thermoplastic fluid handling products and the applications they serve today. For more information, call 888.429.4635, email [email protected], or visit www.haywardflowcontrol.com .

GREYLINE PDFM 5.1 Portable Doppler Flow Meter Greyline's new PDFM 5.1 Portable Doppler Flow Meter employs the latest technology in Doppler signal processing with an improved ability to filter out noise and produce flow measurement accuracy far greater than previously possible. Mount the ultrasonic sensor on the outside of a pipe and this new PDFM 5.1 Portable Doppler Flow Meter shows flow rate instantly . It works from outside metal or plastic pipes. Simply enter pipe diameter with the 5-button keypad and the PDFM 5.1 will display, totalize and data log in your choice of gallons, liters or any engineering units. The PDFM 5.1 is recommended for wastewater, sludge, slurries, chemicals, and abrasives. Use it for flow troubleshooting, spot checks or balancing flow. For more information, email [email protected], or visit www.greyline.com/pdfm51.htm .

WILDEN

430 and 830 Advanced™ FIT 316 Stainless Steel AODD Pumps Wilden ®, part of PSG ®, a Dover Company and a worldwide leader in air-operated double-diaphragm (AODD) pump technology, releases the 430 and 830 Advanced™ FIT 316 stainless steel AODD pumps. Featuring superior corrosion resistance in aggressive chemical applications, Wilden 430 and 830 Advanced FIT pumps have been specifically designed to be direct replacements for existing Wilden 1-½ inch (38 millimeter) and 2-inch (51 millimeter) advanced pump installations. Wilden Advanced FIT pumps feature superior flow rates and easier installation compared to other brands. Advanced FIT pumps precisely “fit” bolt-to-bolt and pipe-to-pipe in existing fluid-handling piping systems to provide increased performance with no repiping necessary. have been engineered to beThey an easy, cost-effective way to enhance and upgrade existing pump performance with superior bolted product containment. For more information, contact Carrie Halle, director of global marketing, at 630.282.7338 or [email protected] or visit www.wildenpump.com .


DeZURIK Four Knife Gate Valves DeZURIK is pleased to announce that four knife gate valve product lines have earned Safety Integrity Level (SIL) Certification per the requirements of the IEC 61508:2010 standard. The IEC 61508 international standard on functional safety assures that safety-related systems provide risk DeZURIK’s reduction required to achieve safety forthe thenecessary equipment. KGC Knife Gate Valves, KSV Severe Service Knife Gate Valves and KUL Urethane Knife Gate Valves have been certified as SIL 3 capable; KSV Double Block and Bleed Valves have been certified as SIL 2 capable. The SIL certification means that these valves styles are suitable for use in critical applications up to the SIL rating. The SIL rating reflects the level of risk reduction the device can provide when used as part of a safety instrumented system. For more information, visit www.dezurik.com .

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PUMPING trends

How Do Y ou Ga uge Suc ces s? HDI Instruments’ Will Condon speaks to the importance of field tests, certifications, and meeting customer needs ill Condon is a project manager

for HDI Instruments,

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a leading provider of battery-powered, stand-alone gauge systems based in Houston, T exas. Recently, HDI released their Certified 2000P Mud/Standpipe Gauge System, a digital gauge specifical ly designed to handle the rugged and hazardous environment of the rig floor, which is the culmination of over twenty years of field testing. Mr. Condon spoke with Modern Pumping T oday about the critical role that such field tests play for their products and why certifications are one of the most important criteria his customers look for. Modern Pumping Today: How important is field testing for your products? Will Condon: Field testing is immensely important to us. We’ve got a platform—our electronic pressure gauge platform—and digital instrumentation in general that i s twenty-years field proven. HDI Instruments was started roughly twenty-five years ago, and,

regulations being tightened up and customers seeking higher quality , which is a large part of why we expect our role as an equipment provider to the oil industry to grow. We’re constantly striving to produce equipment that is more robust, more solid every day to keep up with these standards. They are rigorous. They are demanding. Th ey require investment. But they are necessary! MPT: How often does a product innovation begin with meeting a customer’s need from out in the field? Will Condon: With perhaps only one or two exceptions, literally every product HDI has produced started out in response to a customer’ s need. For example, our 2000B Panel Gauge was creat ed due to many industry voices telling us they needed something more than the existing hydraulic, liquid-filled pressure gauges. The old gauges would lock up because of friction, and then they would

as you can imagine, there were many concerns produce inaccurate readings or cause injuries in the industry about introducing a new to workers or provide the driller with improper platform back then. People would look over feedback. electronic instrumentation and were somewhat When we attend conferences, like OTC or resistant to changing what they were familiar the SPE/IADC Drilling Conference, we meet with. face to face with our clients or people who However , it was through the fiel d testing— stop by our booth, and we’re always asking, these people seeing the toughness and “What do you need from us? Look at our The HDI 2000P began in response to offshore users’ needs. durability of our equipment—that we built our technology… Look at what we do… Where reputation. For that reason, we take immense can we extend our offerings to bett er meet pride and place intense focus on our fiel d your needs?” Many times, we find avenues that testing, because without the certificat ion and the ruggedness of make perfect sense within our family of products. our equipment we would not be where we are today . We’re always looking, always building, and creating products based on customer needs. Our customer’ s voice is criti cal to our research and development practices, so our products are MPT: What are some of the criteria you rely on in setting up a designed with that thought in mind—and we’ve been doing that field test? for over twenty-five years. Will Condon: Certifications are huge component of what we do. Because our equipment is on the drill floor in Class 1, Zone MPT: What customer needs brought about the 2000P? 1 intrinsically safe environments, certifications are necessary for most of the work they’re need ed for. As I said, HDI Instruments is approaching its second decade of providing this type of equipment, so we’ve worked closely with the certifyi ng bodies for many, many years. We have a very good working relationship with CSA, ATEX, DNV , and other third-party certification groups to ensure our products are in compliance. It’s important for us not only that our equipment works from a practical standpoint but also is engineered to meet industry standards—both for today and the f uture. Many things have changed over the past five to ten years with regard to both 56

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Will Condon: In particular, the 2000P is based on our existing, field-tested M100—which has been successful for pumping trucks on land applications for ten to fif teen years. However, the M100 lacked the critical certifications needed for the offshore theater. W e took the same internal components as our Certified 2000B Pa nel Gauge and created a solution for these offshore users—who need that certification for use with t heir pipes, mud pumps, and so on. The certification process is very diligent and thorough, so we’re proud to offer a product that can meet their needs. ■ www.modernpumpingtoday.com

Modern Pumping - Jan 2015

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