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2 May 2014 www.pump-zone.com PUMPS & SYSTEMS

From the Editor

PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and additional mailing offi ces. Subscriptions: Free of charge to qualifi ed industrial pump users. Publisher reserves the right to determine qualifi cations. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and possessions $5, all other countries $15 US funds (via air mail). Call 630-739-0900 inside or outside the U.S. POSTMASTER: Send changes of address and form 3579 to Pumps & Systems, Subscription Dept., 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. 2014 Cahaba Media Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descrip-tions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine. SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media Group, Inc., permission by an irrevocable license to edit, reproduce, distribute, publish and adapt your submission in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Volume 22, Issue 5.

is a member of the following organizations:

The global water crisis claims 5,500 lives each daymore than war, natural disasters,

AIDS or hunger. It is a sobering problem but not an impossible one to solve.

Wine to WaterDoc Hendley was a 30-year-old bartender who spent his work-ing hours pouring expensive wine for wealthy patrons. He woke up one night with a vision that led him to research the life-threatening e ects of poor sanitation and bacteria- lled drinking water. e vision turned into his lifes missionto provide clean water access to one person, one family, maybe even a whole village. He realized that he could make a di erence by asking the fortunate, wine-drinking popula-tion to contribute to the cause. en he turned wine into water. During the past 10 years, his passion to help solve the worlds water crisis has pro-

vided clean water to more than 250,000 people in 17 countries. He is not stopping there. ere are still 780 million people who do not have access to clean water or proper sanitation. Hendleys nonpro t organization, Wine To Water, brings clean water to the people who need it. Some major pump companies are doing their part, too.

Water to PeopleGive clean water to people, and their lives will change. Only 10 percent of the worlds wastewater gets treated. e rest goes into lakes, rivers and oceans. UN Water estimates that 10 percent of the global disease burden could be reduced with improved water supply, sanitation, hygiene and water resource management.By merging philanthropic e orts and pump technology with human compassion and

involvement, pump companies like Grundfos make a di erence. Grundfos involves its employees through programs such as Walk for Water. e company developed strate-gic partnerships and created technology and programs to enhance the e orts.

People to Life e gi of clean water brings people to life. Access to clean water and proper sanitation lowers the risk of disease. It allows women opportunity because they no longer spend their days collecting water. Children can play and go to school. Time spent collecting water is greater than the combined hours worked in a week by employees at Wal-Mart, United Parcel Service, McDonalds, IBM, Target and Kroger, according to Gary White, cofounder of Water.org.Xylem Watermark partners with nonpro t organizations to develop clean water

solutions, hygiene education and disaster recovery in water-deprived communities. Pumps & Systems is proud to bring you special coverage this month of e Gi of

Clean Water (page 22). is is just three chapters of a huge global story. If we can turn wine into water, we can give water to people, which brings people to life. Visit www.pump-zone.com for more coverage and resources on how you can help.

EDITORIAL

EditorMichelle Segrest

[email protected] 205-314-8279

Managing EditorLori K. Ditoro


Associate EditorAmanda Perry


Assistant EditorSavanna Lauderdale

[email protected]

Contributing EditorsLaurel DonohoJoe Evans, Ph.D.

Lev Nelik, Ph.D., PE, APICSRay Hardee

CREATIVE SERVICES

Senior Art DirectorGreg Ragsdale

Art DirectorJaime DeArman

Web Content Editor & Web Advertising Traffi cRobert Ring

Print Advertising Traffi cLisa Freeman


CIRCULATION

Audience Development Manager Lori Masaoay


Circulation CoordinatorJeff Heine


ADVERTISING

National Sales Manager Derrell Moody


Mary-Kathryn [email protected] 205-345-6036

Mark [email protected] 205-345-6414

Addison [email protected] 205-561-2603

Vince [email protected] 205-561-2601

Administrative AssistantsAshley Morris


Sonya [email protected] 205-314-8276

Publisher Walter B. Evans, Jr.

VP of Sales Greg Meineke

VP of Editorial Michelle Segrest

Creative Director Terri Jackson

Controller Tim Moore

P.O. Box 530067, Birmingham, AL 35253

Editorial & Production1900 28th Avenue South, Suite 200

Birmingham, AL 35209205-212-9402

Advertising Sales2126 McFarland Blvd. East,. Suite A

Tuscaloosa, AL 35404205-345-0784

Doc Hendley turns wine into water and impacts developing communities.

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Table of ContentsMay 2014

Volume 22 Number 5

Cover photo courtesy of Wine to Water

24 WINE TO WATER A bartender serves hope.

T H E G I F T O F

C L E A N W A T E R

36 Smart Couplings Enhance a Failing Hot Oil Pump at a Wastewater Treatment PlantBy Marc W. Yarlott, P.E., & M. Azeem, C.Eng., Veolia Environnement North America Vibration and maintenance were reduced with the installation of carefully selected equipment.

42 Intelligent Water Capabilities Improve San Franciscos Aging Infrastructure By Alan Hinchman, GE Intelligent Platforms Fully integrated systems are critical for utilities when upgrading equipment and instrumentation.

44 Pressure Sensor Specifi cation for Operation in Residential, Commercial, Municipal & Irrigation PumpsBy Greg Montrose & Karmjit Sidhu, American Sensor Technologies Material of construction, environmental conditions and IP ratings should be considered to maintain operating effi ciency.

48 Cloud-Based Monitoring & Control Is an Alternative for Irrigation Systems

By Edward Desalle, Net Irrigate With fewer technical requirements, they provide lower-cost options for underserved industries.

Water Handling Systems

36

SPECIAL

SECTION

28 WATER TO PEOPLE Pump technology makes a diff erence.

32 PEOPLE TO LIFE Clean water builds communities.

The Triton Screw Centrifugal Pump combines the benefits of Vaughans UNMATCHED

RELIABILITY with the advantages of highly efficient, non-clog performance. Tritons screw

centrifugal impeller is ideal for handling thick sludges, large solids, shear sensitive fluids

and delicate or highly abrasive material.

- Steep performance curves

- Heavy-duty power frames

- Expedite pumps and parts availability

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



Thomas L. Angle, P.E., MSc, Vice President Engineering, Hidrostal AG

Robert K. Asdal, Executive Director, Hydraulic Institute

Bryan S. Barrington, Machinery Engineer, Lyondell Chemical Co.

Kerry Baskins, VP/GM, Milton Roy Americas

Walter Bonnett, Vice President Global Marketing,

Pump Solutions Group

R. Thomas Brown III, President, Advanced Sealing International (ASI)

Chris Caldwell, Director of Advanced Collection Technology, Business Area Wastewater Solutions,Sulzer Pumps, ABS USA

Jack Creamer, Market Segment Manager Pumping Equipment, Square D by Schneider Electric

Bob Domkowski, Business Development Manager Transport Pumping and Amusement Markets / Engineering Consultant, Xylem, Inc., Water Solutions USA Flygt

David A. Doty, North American Sales Manager, Moyno Industrial Pumps

Walt Erndt, VP/GM, Crane Pumps & Systems

Joe Evans, Ph.D., Customer & Employee Education, PumpTech, Inc.

Ralph P. Gabriel, Chief EngineerGlobal, John Crane

Bob Langton, Vice President, Industry Sales, Grundfos Pumps

Larry Lewis, President, Vanton Pump and Equipment Corp.

Todd Loudin, President/CEO North American Operations, Flowrox Inc.

John Malinowski, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group

William E. Neis, P.E., President, Northeast Industrial Sales

Lev Nelik, Ph.D, P.E., APICS, President, Pumping Machinery, LLC

Henry Peck, President, Geiger Pump & Equipment Company

Mike Pemberton, Manager, ITT Performance Services

Scott Sorensen, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector

Adam Stolberg, Executive Director, Submersible Wastewater Pump Association (SWPA)

Jerry Turner, Founder/Senior Advisor, Pioneer Pump

Kirk Wilson, President, Services & Solutions, Flowserve Corporation

James Wong, Associate Product Manager - Bearing Isolator, Garlock Sealing Technologies

Editorial Advisory Board

Table of Contents

Practice & Operations

Departments 2 From the Editor

8 News

52 Trade Shows

54 Business of the BusinessBy Paola Conti & Anand Gnanamoorthy,

Frost & Sullivan

Equipment Demand Increases to Solve the

US Aging Water Infrastructure Problem

58 Effi ciency MattersBy Paul McGarry, All-Flo Pump Co.

With Minimized Compressed Air Usage, AODDPs

Provide an Energy-Effi cient Solution

63 Maintenance MindersBy Todd Loudin, FLOWROX

Guidelines for Progressive Cavity & Peristaltic

Pump Maintenance

68 Motors & DrivesBy Mark W. Harshman, Siemens

Determine Total Cost of Ownership When

Selecting Medium-Voltage Drives

72 Sealing SenseBy FSA member Randy Wacker, P.E.

Prevent Gasket Blowout

Whats Most Important?

75 HI Pump FAQsBy Hydraulic Institute

NPSHR & Booster Pumps

84 Index of Advertisers

84 Pump Users Marketplace

88 Pump Market Analysis

Columns12 Pump Ed 101

By Joe Evans, Ph.D.

Test Submersible Wastewater Pumps & Motors Frequently to Accommodate for Changing Conditions

14 Pumping PrescriptionsBy Lev Nelik, Ph.D., P.E.,

Pumping Machinery, LLC

Suction Valve Throttle Versus Vacuum

16 Pump System ImprovementBy Ray Hardee, Engineered Software, Inc.How a Piping System Works

76 Progressive Cavity Pumps Provide Optimized Operation in Multiple Pulp & Paper ProcessesBy Nimish Sheth, UniqueFloThe addition of a cardan joint helps resolve wear and failure and delivers improved angularity and smooth transmission of radial and axial loads.

80 Some Chemical Applications Require the Range of a Positive Displacement PumpBy Edison Brito, Pump Solutions GroupMany positive displacement pumps deliver the same fl ow rate regardless of static head.

52

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NEWS


NEW HIRES, PROMOTIONS & RECOGNITIONS

XYLEM Wins Corporate Excellence AwardRYE BROOK, N.Y. (April 7, 2014) Xylem Inc. received the 2014 Corporate Excellence Award from Charities@Work in recognition of their employee engagement activi-ties. Each year, Xylem Watermark o ers employees ways to help with the global water crisis. Xylem Inc. is a global water technology provider, www.

xyleminc.com. Xylem Watermark is the global corporate citizenship and social investment program of Xylem Inc., www.xylemwatermark.com. Charities@Works purpose is to provide employers with an e cient way to enhance their employee engagement programs, www.charitiesatwork.org.

MADS NIPPER & DIETER SAUER, GrundfosDOWNERS GROVE, Ill. (April 7, 2014) Grundfos named Mads Nipper CEO and group president. He will be joining the company August 1, 2014. e company also appointed Dieter Sauer as president and general manager of its Water Utility business. Grundfos provides pump solutions water technology.

www.grundfos.com

GORDON VAN DYKE, QuantumFloDEBARY, Fla. (March 31, 2014) Gordon Van Dyke was named Turf and Landscape sales manager for QuantumFlo.QuantumFlo manufactures and distributes

packaged pump systems. www.quantum o.com

RICHARD BURMESTER & AUSTIN AMOS, Motion IndustriesBIRMINGHAM, Ala. (March 24, 2014) Motion Industries announced that Richard Burmester has been named senior vice president and group executive for the realigned Southwest sales group. Austin Amos has been named senior vice president and group executive of the newly formed Midwest sales group.Motion Industries is an industrial parts distributor.

www.motionindustries.com

TIM GRIFFIN, Wood Group MustangGREENVILLE, S.C. & HOUSTON (March 19, 2014) Wood Group Mustang promoted Tim Gri n to vice president, industrial opera-tions, leading the companys North American industrial division based in Greenville, S.C. Wood Group Mustang provides services to

the global energy industry. www.woodgroup.com

ABAKANs CermaClad Awarded Innovation of the Year by NACE InternationalMIAMI (March 13, 2014) Abakan Inc. announced that its 72-percent owned subsidiary, MesoCoat, Inc., received the National Association of Corrosion Engineers Materials Performance Corrosion Innovation of the Year Award in the Coatings and Linings category. Abakan develops, manufactures and markets nanocomposite materials, fabricated metal products and metal composites. www.abakaninc.com

GEIGER PUMP & EQUIPMENT COMPANY Receives ISO 9001 Certi cationBALTIMORE (March 13, 2014) Geiger Pump & Equipment Company announced that its SK Systems Division received approval for ISO 9001 Registration. Geigers SK Systems Division works in engineering,

design, project management and fabrication. www.geigerinc.com

Gordon Van Dyke

Dieter SauerMads Nipper

Richard Burmester

Austin Amos

Tim Grif n

MERGERS & ACQUISITIONS

SAINT-GOBAIN SEALS acquired LS Kunststo echnologie GmbH March 31, 2014

PROCESS & POWER, INC.acquired Jack Tyler Engineering March 30, 2014

HOOVER CONTAINER SOLUTIONSacquired Container Company Ltd. March 10, 2014

EXONEacquired MWT - Gesellscha fr Industrielle Mikrowellentechnik mbH March 6, 2014

EXONEacquired Machin-A-Mation March 6, 2014

TV RHEINLANDacquired Ristek Solutions March 6, 2014

For details about industry M&A activity, subscribe to Pump Industry Insider and visit www.pump-zone.com.

PUMPS & SYSTEMS www.pump-zone.com May 2014 9

DARRYL MCCORMICK &

MARK MONROE,

Asahi/America

MALDEN, Mass. (March 3, 2014) Asahi/America, Inc. added two new mem-bers to its sales teamDarryl McCormick and Mark Monroe. e company will also

move its corporate head-quarters to Lawrence, Mass., in October 2014.Asahi/America, Inc. specializes in

providing solutions for uid handling systems. http://asahi-america.com

KERRY BASKINS, Milton Roy Americas

IVYLAND, Pa. (Nov. 1, 2013) Kerry Baskins has been named vice president, general manager for Milton Roy Americas. Milton Roy produces highly engineered products and equip-ment. www.miltonroy.com

AROUND THE INDUSTRY

IDA Selects San Diego for 2015 World

Congress

TOPSFIELD, Mass. (May 21, 2013) e International Desalination Association (IDA) announces that it has selected San Diego as the site for its 2015 World Congress. Dates are Aug. 29-Sept. 4, 2015, and the Congress will be held at the San Diego Convention Center. is will be the rst time since 1999 that the IDA World Congress will take place in North America.IDA is a nonpro t association that

serves more than 2,400 core members in 60 countries and reaches an addi-tional 4,000 a liate members. IDA is associated with the United Nations. www.idadesal.org.

To have a news item considered, please send the

information to Savanna Lauderdale,

[email protected].

Darryl McCormick

Mark Monroe

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NEWS

MAYOFFSHORE TECHNOLOGY CONFERENCEMay 5 8, 2014

Reliant Park

Houston, Texas

301-694-5243 / www.otcnet.org

WINDPOWER CONFERENCEMay 5 8, 2014

Mandalay Bay Convention Center

Las Vegas, Nev.

202-383-2500 / www.windpowerexpo.org

IFATMay 5 9, 2014

Messe Muchen, Germany

+49 89 949-11358 / www.ifat.de

INDOWATER May 7 9, 2014

Grand City Convex

Surabaya, Indonesia

+49-40-3999905-25

www.indowater.merebo.com

JUNEECWATECHJune 3 6, 2014

Moscow, Russia

+7-495-225-5986 / www.ecwatech.com

AWWA-ACEJune 8 12, 2014

Boston Convention & Exhibition Center

Boston, Mass.

800-926-7337 / www.awwa.org

PUMP SCHOOLJune 11 12, 2014

Atlanta, Ga.

770-310-0866 / www.pumpingmachinery.com

SIEMENS AUTOMATION SUMMITJune 23 26, 2014

Walt Disney Worlds Contemporary Resort

Orlando, Fla.

www.usa.siemens.com

EASAJune 29 July 1, 2014

Hynes Convention Center

Boston, Mass.

314-993-2220 / www.easa.com

SEPTEMBERPUMPTEC-USASeptember 10 11, 2014

Georgia World Congress Center

Atlanta, Ga.

770-310-0866 / www.pumpconference.com

PUMP USERS SYMPOSIUM /

TURBOMACHINERYSept. 23 25, 2014

George R. Brown Convention Center

Houston, Texas

979-845-7417 / www.pumpturbo.tamu.edu

WEFTECSept. 27 Oct. 1, 2014

New Orleans, La.

New Orleans Morial Convention Center

www.weftec.org

NOVEMBERPOWER-GEN INTERNATIONALNov. 12 14, 2014

Orange County Convention Center

Orlando, Fla.

918-831-9161 / www.power-gen.com

PUMP-TEC ISRAELNov. 18 19, 2014

Haifa, Israel

770-310-0866 / www.pumpingmachinery.com

To have an event considered, please send the

information to Savanna Lauderdale,

[email protected].

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PUMP ED 101


By Joe Evans, Ph.D.

PumpTech Inc.

P&S Editorial Advisory Board

Test Submersible Wastewater Pumps & Motors Frequently to Accommodate for Changing ConditionsFirst of Two Parts

A ll pumps should be tested regularly, but wastewater pumps are at the top of the list because they are especially susceptible to changing system conditions. Even if a pump operates at its best e ciency point (BEP) at startup, many conditions will change during its lifetime of operation, including: Malfunctioning gate and check valves Partial blockages in the pipeline Air accumulation at a high point New branches entering a force main

Clear water systems can experience similar challenges, but the content of the pumpage makes wastewater systems more vulnerable. ese changes can have a major e ect on the pumps operating point on its H/Q curve. Submersible wastewater pumps can be more challenging because they are out of sight and o en out of mind.Wastewater pumps can be problematic when operated at

o -BEP conditions because of the size of their impellers. e large width that is required for solids passage increases the radial forces on higher-head pumps. is leads to increased sha de ection, which will reduce seal, wear ring and bear-ing life. In addition to radial loading, operation to the le of BEP can lead to damaging suction and discharge recirculation cavitation. To encourage frequent testing, I devel-

oped two simple submersible pump eld test spreadsheets. One uses a ow meter for ow measurement and allows for the plotting of multiple test points. e spreadsheet that will be reviewed in this column uses a drawdown test to measure pump ow. Drawdown is still the most-used procedure for measuring ow in smaller and remote li stations. Figure 1 shows the pump test portion

of the spreadsheet. e bottom right sec-tion is the drawdown test, and the bottom le section tests for total dynamic head (TDH). e gray cells are the entered

data, and the yellow ones are the calculated data. e equa-tions used for the calculations are shown to the right of the cells. e submersible motor testing portion of the spread-sheet will be featured in next months column.

DRAWDOWN ANALYSIS

We will begin with the drawdown analysis. Usually, a draw-down test measures the time required to remove one foot of water starting at the pump on level. e reason one foot is a preferred distance is that it provides for an ample time measurement, and ow changes little over a single foot. e distance can be measured with a laser device, a plumb bob, or a rod with starting and ending marks. It is best to shut o the invert once the pump start level is reached to obtain the greatest accuracy. If this cannot be accomplished, choose a time during the day when in ow is minimal. As seen in Figure 1, entering the wet well diameter, drawdown distance and drawdown time is the only data needed if the system has no in ow. e spreadsheet calculations measure the wet volume per

foot, the drawdown volume and the ow rate based on that information. In the example shown in Figure 1, the ow rate is 1,585 gallons per minute (gpm). If in ow occurred

Figure 1. The pump test portion of the spreadsheet

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during the drawdown test, an in ow test can be performed immediately following drawdown. If the in ow is small, a 2- to 3-inch rise is all that is needed to calculate the in ow. If an in ow test is performed, the in ow volume is used for the nal gallon-per-minute calculation. It is always best to perform two or three drawdown tests to obtain the most accurate results.

TOTAL DYNAMIC HEAD CALCULATION

Pump head is measured with a high-quality pressure gauge at the pump start water level, immediately a er pressure has stabilized. e TDH is calculated by taking into account the gauge to water level elevation, the pipe friction from the pump discharge to gauge location and the velocity head. Friction head loss is determined using a friction table. I considered calculating it but decided that a friction table for the proper piping material and ttings would provide a more accurate value. Discharge velocity head is calculated using the piping inside diameter at the gauge location, and the ow rate that is calculated during the drawdown test. As with the drawdown calculation, the equations used to calculate TDH are shown to the right of the calculator. Notice that a cell for pump suction diameter and a calcu-

lation for suction velocity head are included. Some people

believe that when a submersible pump incorporates an exter-nal suction bell, suction velocity head must be subtracted from the TDH calculation. If a user belongs to that group, he or she should enter the suction diameter in that cell. If the user does not believe this, he or she should enter a diameter large enough to reduce suction velocity head to zero. In Figure 1, a 19-inch suction diameter provides for a zero

velocity head at the suction. e discharge gauge reading was 51 feet, but when the calculator includes the gauge to water level elevation, friction in the piping and the discharge velocity head, the TDH is calculated at 71 feet. is pump tested at 1,585 gpm at 71 feet, which is approximately 97 percent of BEP ow. Wouldnt it be nice if all pumps ran this close to their BEP? In Part Two in the June issue, I will review the submers-

ible motor testing portion of the spreadsheet. ese tests will provide more pump hydraulic test results based on motor performance and will also provide phase voltage and current unbalance calculations. P&S

Joe Evans is responsible for customer and employee education at PumpTech

Inc., a pump and packaged system manufacturer and distributor with branches

throughout the Paci c Northwest. He can be reached via his website www.

PumpEd101.com. If there are topics that you would like to see discussed in

future columns, drop him an email.



PUMPING PRESCRIPTIONS By Lev Nelik, Ph.D., P.E.Pumping Machinery, LLC

P&S Editorial Advisory Board

Suction Valve Throttle Versus Vacuum

Last of Two Parts

In my April 2014 column in Pumps & Systems, I quizzed readers, asking if the pump suction behavior depended

on the discharge (system) side of a pump. is quiz also referenced a video that can be viewed at www.pump-magazine.com and go to Q&A, Question 120.Two tests were conducted during the video. One dropped

the suction pressure in front of a pump by throttling the suc-tion valve. e second introduced a vacuum at the supply tank with the suction valve open. In the examples, water was recirculated to the supply tank (see the dashed line in Figure 1) instead of the more common situation in which it is pumped from one tank to another. e readers were asked to explain the di erences in the two testswhy the tank vacuum had such a di erent e ect on cavitation when compared to the suction valve throttle.

THE BEST READER ANSWER

e best answer received was from Jim Gagnon, P.E., senior engineer, from CH2M HILL in Cincinnati, Ohio.

Gagnons Response

I watched the YouTube video that you posted, and I think I have the solution. In the rst experiment, the pumped ow rate decreased when you throttled the suction-side valve because closing the valve added dynamic head to the system. e result is that the operating point moved to the le on the pump curve, and the ow rate decreased.In the second experiment, the pump ow rate did not change

when you pulled a vacuum on the tank headspace because the pump system is a closed system. e change of pressure in the tank a ected the suction-side and the discharge-side equally, so no dynamic head or static head change occurred. e system curve did not move, and as a result, the operat-ing point did not move. However, cavitation became evident (air bubbles in the ow meter) because reducing the pressure in the tank decreased the net positive suction head available (NPSHA) in the system to the point that the pump started to cavitate. Im looking forward to nding out if I am correct.

Neliks Response

You are correct, Jim! Normal ow control of the pump/system is accomplished by closing or opening the discharge side valvealmost never by its suction side. Closure of the valve increases the losses across the discharge valve, and its opening decreases the losses. New system curves are created that intersect the pump curve at new operating points (see Figure 2). Once the discharge valve moves the pump to a new

operating point, its suction characteristics begin to change. It requires less net positive suction head required (NPSHR) at a lower ow and more at a higher ow (see Figure 3).Keep in mind that a di erential pump head is the

Figure 2. Connection between the discharge

performance (H-Q) and cavitationNPSHR

VacuumVvac

Vs Vd

P

Pd

Ps

Figure 1. System sketch illustrating the example in the video

Image 1. Dr. Lev Nelik conducts the experiment shown in the video.


di erence between the discharge head and the suction head. If the same pressure reduction is applied to the supply tank and delivery tank (as in the second example in the video, the tank was the same), the head (pressure) does not change. e added vacuum cancels out on both sides. e suction and discharge gauge readings change but by the same amount.However, if only the suction side is a ected (as in the rst

example with the suction valve closure) but the discharge side remains the same (the pump discharge side sees the same pres-sure because of the same tank level), a di erence exists between the suction and discharge pressures. For example, the pump head (di erential pressure) increases, and according to the H-Q curve, the pump hydraulically moves to a lower ow and at a lower NPSHR. is moves the ow farther away from cavitation.Another tweak can still be made to the example system from

the video. At my next Pump School, I will discuss how the NPSHR curve also changes at low ow (compared to the ow in Figure 2) and which pump design features are modi ed. For more information about the Pump Schools, visit www.pumping-machinery.com/pump_school/pump_school.htm. P&S

Dr. Nelik (aka Dr. Pump) is president of Pumping Machinery, LLC, an Atlanta-based

rm specializing in pump consulting, training, equipment troubleshooting and pump

repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He

can be contacted at www.pump-magazine.com.

Figure 4. Development of cavitation, starting from the incipient

bubble formation and eventually developing to highly unstable

bubble activity, their collapse, and damage of the impeller blades

Head, ft

NPSHR3

3%

NPSHA, ft

A lot of bubbles

More bubbles

Incipient

Figure 3. Point at which cavitation develops


PUMP SYSTEM IMPROVEMENT


By Ray HardeeEngineered Software, Inc.

How a Piping System Works

My last column (Pumps & Systems, April 2014) explained why resistance in implementing pump system improvement programs o en occurs. Because pump systems touch many disciplines and departments within an operating plant, it is di cult for everyone involved to clearly understand how a piping system operates.In this months column, a piping system will be discussed,

including the individual items and how they work together as a total system. It will explain the systems operation so that everyone in the plant can visualize its function.Figure 1 shows a demineralized water supply system con-

sisting of a pump, two tanks, a water treatment unit, pipe-lines and a control valve. e elements can be grouped into three general categories based on how the energy is used in the piping system. e pump element is the only component that adds

hydraulic energy to the uid in the system. e process ele-ments consist of the equipment required to create the prod-uct or provide the service. Hydraulic energy is consumed when the uid passes through the process element to make demineralized water. e control valve regulates the ow rate through the system to improve the product quality and system e ciency. e system is designed to produce 600 gallons per minute

(gpm) of demineralized water for use throughout the plant.

Figure 1 shows the elevations, levels and pressures in the raw water and demineralized water tanks. e distribution piping to provide demineralized water to plant loads is not shown because tanks and vessels make excellent locations to divide complex systems into more easily understandable subsys-tems. e distribution system can be assessed separately. To understand how the system operates, each element needs to be evaluated, starting with the pump.

PUMP ELEMENT

e pump adds hydraulic energy to the piping system. e pump curve for the raw water pump (see Figure 2) shows the pump head, e -ciency and power consump-tion for its range of opera-tion. A pump must always operate on its curve. Looking at the pump curve at a ow rate of 600 gpm, the pump produces 209 feet of head. For this pump to achieve the ow rate of 600 gpm, the 209 feet of head produced by the raw water pump must be accounted for in the process and control elements in the system.

Figure 1. Demineralized water system

Figure 2. Pump performance curve for the raw water pump


PROCESS ELEMENTS

e tanks provide a recognized system boundary and an easily determined value for the hydraulic energy that remains fairly constant during opera-tion. e locations, elevations and pressure of the tanks are determined by the needs of the process along with the space constraints of the plant. In Figure 1, a 102-foot elevation

di erence between the liquid level in the raw water and demineralized water tanks exists. is di erence in elevation must be overcome by the pump and is referred to as the eleva-tion head. In addition, a 10 psi di erence

in pressure between the raw water and demineralized water tanks must be overcome. Converting the pres-sure value for feet of uid results in an additional 23 feet required by the pump. is pressure di erence between the tanks is referred to as pressure head. e di erence in elevation and

pressure must be overcome regardless of the ow rate through the system. As a result, the elevation head and pressure head values are combined and referenced as static head. e resulting static head for this system is 102 feet + 23 feet or 125 feet of uid. e losses in the pipelines are

caused by the friction between the moving uid and the stationary pipe-lines. e pipeline head loss can be calculated using the Darcy equation, with examples found in any uid text-book. In this system, the head loss because of pipe friction is 2.6 feet of uid when 600 gpm of water ows through the system. e nal process element in this

example is the water treatment unit. According to the manufacturer, a pressure drop of 5.6 psi, or a head loss of 12.9 feet, occurs with a ow rate of 600 gpm. cir

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Adding the static head, the dynamic losses of the pipe-line with a 600 gpm ow rate and water treatment unit, the energy consumed by the system is:

h = 125 + 2.6 + 12.9 = 140.5

CONTROL ELEMENT

e control element regulates the ow into the demineral-ized water tank to maintain a constant tank level. Because 600 gpm is the plants demineralized water demand, it is also the average ow rate through the control. A ow rate of less than 600 gpm causes the tank level to decrease, result-ing in insu cient ow to the other plant loads. A ow rate greater than 600 gpm causes the tank to over ow, resulting in a waste of demineralized water.

ENERGY BALANCE

As previously mentioned, the pumps provide all the uid energy to the system. e process elements consume energy as uid passes through the system to make the product or provide the service. e control elements consume energy to regulate the ow of uid through the system required to optimize the process. Based on the energy usage, the following expression can

be assumed: hpump = hProcessElements + hControlElements

Rearranging the formula above, the head loss associated with the control element required to limit the ow rate through the system to 600 gpm is: hControlElements = hpump hProcessElements

= 209 140.5 = 68.5

The pump element is the only component that adds hydraulic energy to

the uid in the system. The process elements consist of the equipment

required to create the product or provide the service.


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Converting the head loss to di erential pressure, a 29.7-psi pressure drop across the control valve is required to regu-late the system ow at 600 gpm.

GAINING A CLEAR PICTURE

As mentioned in last months column, pushback while

implementing system improvements happens because of a lack of understanding about how the system operates by those involved in the process. e results determined that many detailed calculations were needed to understand this relatively simple process. An electric motor is driving the pump, and the plant electrical engineer is familiar with the

volts, amps, power factor and motor e ciency needed to determine the motor power required to drive the pump. e plant mechanical engineer is familiar with the pressure, head, ow and pump e ciency required to calculate the power required by the pump. e process engineer under-stands the water puri cation process along with the necessary pressure and ows required to make a quality product. e plant engineer knows how much pressure and ow rate is needed by each load to meet the plants pure water needs. However, a clear understanding of how the total system operates, how much this system costs to operate and how e -ciently it is operating is missing.Using the system information cal-

culations, Table 1 shows the hydraulic

Element Item Head (ft) Cost

Pump

Process

pump

209.0 $284,400

Process

Elevation

head

-105.0 $142,880

Pressure

head

-23.0 $31,300

Pipeline -2.6 $3,540

Water

treatment

-12.9 $17,550

Sub total -140.5 $191,190

Control

Control

valve

-68.5 $93,210

Table 1. The energy balance for the system

hydrauilc energy usage in the demineralized

water system including all associated costs

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energy usage and associated costs. Note the energy sup-plied by the pump is consumed by the process and control elements.Notice that the di erential pressure across the control

valve represents approximately 33 percent of the total energy developed by the pump. at appears to be a high percentage, but it is less than the 66 percent consumed by the pro-cess. ose are interesting gures, but demineralized water is required for the plant to make its products. Speaking in abstracts (feet of head), it is di cult to get a handle on what is occurring. Look what happens when the asso-

ciated costs are considered. Using data from the pump curve, the head, ow and e ciency of the raw water pump at 600 gpm can be determined. en the horsepower supplied to the pump sha can be calculated. Using the e ciency of the electric motor, the amount of electrical power con-sumed can be determined. With the pump running 8,000 hours per year (hrs/year) and a power cost of $0.10 per kilowatt hour (kWh), the oper-ating cost of the raw water pump is $284,400 per year. Now the energy usage for each item in the system and its associated cost can be seen. e information in Table 1 looks

more like a balance sheet for the energy costs of the process. With this information, everyone in the plant has a much better idea of how the system operates and the true costs involved. With accurate cost data, management can evaluate this system like any other plant expense. Questions can be asked and discus-sions started about ways to reduce operation costs and improve system e ciency. In next months column, an exist-

ing system will be evaluated, consid-ering di erent improvements, and the results will be explained. P&S

Ray Hardee is a principal founder of Engineered Software, creators of PIPE-FLO

and PUMP-FLO software. At Engineered Software, he helped develop two train-

ing courses and teaches these courses in the U.S. and internationally. He is a

member of the ASME ES-2 Energy Assessment for Pumping Systems standards

committee and the ISO Technical Committee 115/Working Group 07 Pumping

System Energy Assessment. Hardee was a contributing member of the HI/

Europump Pump Life Cycle Cost and HI/PSM Optimizing Piping System publi-

cations. He may be reached at [email protected].

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A single Cambodian mother of three spent the majority of each day

begging for rice and walking many miles to gather water. e work was back-breaking, and she had little hope. e 40-pound buckets were heavy, and the water was lthy. Her children were sick. ree years later, one small well with

a hand water pump has changed their lives. e mother now has time to work

and can earn an income to support her family. Her children can play and go to school. e well provides enough clean

water to meet the familys basic needs. ere is enough extra water to main-tain a garden, grow food for her chil-dren and to share with neighbors.

Her children are healthy. And she will never again have to beg for food. is is one of hundreds of success

stories Doc Hendley can tell from rst-hand experience. He is the founder of Wine To Water,

the nonpro t organization that built the well for the Cambodian mother, one of 600 wells drilled in underde-veloped regions by the humanitarian group. Since 2004, Wine To Water has

provided clean water to more than 250,000 people in 17 countries. Impacting one life at a time hasnt

always been easy, Hendley says, but it is worth it. I get to see lives change forever just

by giving these people clean water, he says. In the end, this changes me.

IT COULD HAVE BEEN A SONG

Ten years ago, Hendley was 30 years old and working as a bartender and part-time musician in Raleigh, N.C. One night, he couldnt sleep. e phrase Wine To Water was spinning in his head, but he couldnt understand why. e songwriter and ministers son

felt that maybe it had something to do with the biblical story of Water to

By Michelle Segrest

W I N E TO

W AT E R

T H E G I F T O F

C L E A N W A T E R


Wine his father had told him. Maybe it was inspiration for a song. I wrote down the words to begin

writing the song, but when I saw the words on the page, I just had a feeling in my gut, Hendley recalls. I was a bartender and knew a lot about wine, but I knew nothing about water. I began to research water on the Internet and was shocked at what I found. I had no clue.

He was inspired by the sobering information about the global water crisis. Instead of writing a song, he cre-ated the concept for an organization that would help provide clean water for people who didnt have it. e original concept was simple.

Hendley would use his connections in the food and wine industry to orga-nize wine-tasting fundraisers and then donate the money to global water

projects. Wine symbolizes fortune in our society, he explains. e goal of Wine To Water is to give the fortunate population the opportunity to ght for those who cannot ght for them-selvesand to give them the gi of clean water.

THE DREAM BECOMES REALITY

ree hundred people attended Wine To Waters rst event in February

Women and children in the developing world spend about 152 hours each day collecting water from distant, often polluted sources.

They carry it in 40-pound jerry cans on their backs. Wine to Waters wells free them from this burden.


2004. More successful fundraising events followed. It was important to Hendley that

the money be donated to a charity that would ensure him the funds were being

used to support his new passionthe worlds water crisis.He connected with Samaritans

Purse, an international organization dedicated to helping victims of war, poverty, natural disasters, disease and famine. Kenny Isaacs and Franklin Graham

(son of the legendary evangelist Billy Graham) were leaders of Samaritans Purse and took an interest in Hendleys passion. ey suggested that he visit one of

the worlds most dangerous and war-torn hot spotsDarfur, Sudan.

Hendley spent the next year living there. At the height of the government

genocide in Darfur, Janajaweed ter-rorists used water as a weapon. ey

destroyed water bladders and dumped rotting corpses into primary water sources. Hendley witnessed rst-

hand the impact of poor san-itation and the human su er-

ing that results when people have no access to clean water. He watched people die. He escaped

death many times. Some members of his team were killed. rough this experience, he developed the mission for his own organization.Hendley discovered that more than

half the wells in Darfur were broken. He didnt have the funds to build new ones at about $10,000 each, but he had a solution. We didnt have expensive machines

to replace the wells, but we began to x the wells using local people and

local materials. Hendleys team could restore a well for about $50 each.

CREATIVE SOLUTIONS

Within four years, Wine To Water helped provide clean water solutions to four more countries. In 2009, CNN named Hendley one of its Top 10 Heroes of the Year. is gave Wine To Water exposure, which helped the organization grow.Wine To Water still uses local people

and local materials, but now it has raised enough money for machines to drill new wells. ey have developed water ltration systems, ceramic lters, bio-sand lters and micro ber mem-brane lters. ey have formed partnerships with

companies like Sawyer, which makes lters for hikers and campers. Each Sawyer lter can create enough clean water for 100 people for 10 years. In Haiti and Cambodia, more than

18,000 ceramic lters have been pro-duced by local workers. In some areas,

used to support his new passion the

ddp

hit

ing that r

people lack access to clean water.

That is more than 2.5 times the

U.S. population.780M I L L I O N

Wine To Water founder, Doc Hendley, uses local people and local materials to provide clean water solutions to the worlds developing communities.


rainwater harvesting systems have been created.Each new area produces a new set

of challenges. A solution that works for one area may not work for another area, Hendley explains. Hendleys team is currently drilling

in a remote spot in the Amazon jungle at the Brazil, Colombia and Peru bor-ders. ey found the water, but cant extract it. ey need specially engi-neered pumps to produce the water to the surface, but they must be cost e -cient. e remote area is not accessible to larger drilling rigs. We are constantly searching for

solutions to problems like these, Hendley says.

AN EXCEPTIONAL LIFE

Before his inspiration for Wine To Water, Hendley recalls feeling like a failure.

I came from a family of exceptional people, Hendley says. ey all were exceptional in athletics and academics, and they were exceptional spiritually. I never really did anything successfully.Still, the desire for success was not

what inspired him.I didnt set out to build

a successful nonpro t, he says. I just wanted to see if I could maybe give clean water to one family or one village. I walked through that rst door, and there was another open door on the other side that led to the next thing. I met the right people along the way who helped me and joined my mission.It hasnt always been easy.I have been in some of the worst

places in the world and experienced a lot of ups and downs, he says. It has been a long process.

We are still very small and still very grass roots, but we are doing a lot with a little. We are doing extraordinary work and changing a lot of lives.And to see the smile on the face of an

independent Cambodian mother who

can now give her children food and the gi of clean water Well, this is what keeps me going. P&S

Michelle Segrest is editor of Pumps & Systems.

For more photography and statistics, visit www.pump-zone.com/giftofcleanwater.

Learn more about Wine To Water at www.winetowater.org. For more information about the global water crisis, visit www.unwater.org and www.water.org.

h th t t n n i h hild n f d nd th

people die each year from a water

related disease. That is almost the

entire population of Los Angeles.3.4M I L L I O N

Each location provides new challenges for

creative solutions. Wine To Water has provided

clean water to more than 250,000 people in 17

countries since 2004.


For many years, the people of Dei, Uganda, a small shing village o

the shore of Lake Albert, depended on a contaminated lake for their drinking water. For these villagers, water was not a source of wellbeing. It was a birthing ground for sickness and disease and caused frequent cholera outbreaks. e lack of access to safe water

stripped them of opportunities for education and work and contributed to a devastating cycle of poverty.When basic needs are not met,

we know that water is the di erence between life and death, says George C. Greene, III, co-founder and CEO of Water Missions International, a non-pro t engineering organization. Fatal waterborne diseases spread rampantly in untreated drinking water. Since it was founded in 2001 by

Greene and his wife, Molly, Water Missions International has provided

relief to more than 2.4 million people in developing countries and disaster areas.

A TECHNOLOGY SOLUTION

e people at Water Missions International had the heart and the determination but needed the appro-priate pumping technology. Five years ago, Water Missions

president and chief operating o cer George Greene IV made a simple call to Grundfos, a global pump manu-facturer, but this was not an average inquiry about pumping equipment. e conversation aligned a crucial need with the technology required to develop a holistic solution that now provides life-sustaining freshwater resources to thousands.In 2008, Water Missions International

began using Grundfos SQFlex, a versatile pumping system, to draw

groundwater in remote areas in which water is scarce and the power supply is either unreliable or non-existent. SQFlex pumps are tted with a per-

manent magnet motor that allows for the e cient use of energy from several alternative supply options, including solar or wind.Building o this innovative technol-

ogy, Grundfos created LIFELINK, a water management solution that combines modern pumping tech-nology with a sustainable model for ongoing nancial management. A

By Helen Mubarak

W AT E R TO

P E O P L E

T H E G I F T O F

C L E A N W A T E R


solar-powered SQFlex pumps ground-water into an elevated water tower for storage. e water is then gravity-fed into an automatic water-tapping unit. Using a mobile banking system, vil-

lagers pay a nominal fee to draw water from the system. e funds nance the ongoing service and maintenance of the system, ensuring sustainable oper-ation for many years. LIFELINK also provides real-time monitoring capa-bilities for analyzing project perfor-mance. Water Missions International began using LIFELINK in 2011.

We are so grateful for everything Grundfos does to support our e orts to reach out to people in desperate conditions, says George Greene IV. anks to their innovative technol-ogy, support from the foundation, employee-organized Walks for Water and employee giving through the Water2Life campaign, we have been able to provide safe water for thou-sands of people in need.A er learning more about the non-

pro t organization and its mission, Grundfos executives discovered that

their corporate values aligned perfectly with Water Missions Internationals goal to provide communities in the developing world with safe water. Our relationship with Water

Missions makes sense in so many ways, says Terry Teach, director of business development for Grundfos North America. ey seek to deliver clean water to people in need. We are in the business of moving water. ey focus on remote areas around the world. We build products that use solar or wind power to pump that water. ey

Children and teachers at a local school now have access to clean water thanks to the eff orts of Grundfos and Water Missions International.

Photos courtesy Grundfos


believe in the importance of making water treatment systems viable for many years. Our LIFELINK technology fea-

tures an innovative payment model that prevents the mismanagement of funds and nances system maintenance.

EMPLOYEES GET INVOLVED

Many Water Missions International projects use SQFlex or LIFELINK

technology, but a couple locations are especially important to Grundfos employees because of their role in rais-ing funds for the installations.Since 2012, Grundfos North

America employees have hosted Walk for Water events in their communi-ties to raise money for Water Missions International. e Walk for Water is a non-compet-

itive, educational event that represents the trek of those who walk almost four miles per day to provide their families with what is o en contaminated water. Halfway through the 3.5-mile walk,

participants ll three-gallon buckets

with water, simulating the true burden of life in a developing nation.Grundfos partnership with Water

Missions International has allowed us to connect incredible technology with incredible need, Teach says. Our expertise in the water indus-

try gives us a unique opportunity to help those who go through so much to obtain their daily water.Last year, Grundfos hosted events in

Chicago, Toronto and Kansas City, Mo. Employees, partners and spon-sors raised more than $55,000 to help fund three

safe water systems to the Dei, Uganda community. Today, the 10,000 residents of Dei

have access to safe water daily and no longer fear waterborne illnesses. Grundfos support of Water

Missions International shows that its values are more than words on a page, says Lauren Jernigan, regional coordi-nator for Water Missions International. ousands of Ugandans wake

up each day with access to safe water thanks to the 2013 Walk for Water events hosted by Grundfos facilities in North America.

COMMUNITY EFFORTS

e inaugural Walk for Water was in Kansas City, Mo., in 2012. It raised $50,000 for two LIFELINK systems in Dauphine and Rossignol, Haiti. Teach visited Haiti shortly a er the systems were installed.As we drove through Haiti, we saw

quite a few water systems that had been installed and then abandoned, Terry says. e people need long-term, sus-tainable solutions to li themselves out of poverty. e women and children of the two

villages no longer spend hours each day walking to a contaminated water source to gather water in ve-gallon buckets. Access to clean water close to home has given them time for educa-tion and work and prevented sickness from waterborne diseases.What Water Missions International

is doing with Grundfos help is truly transforming peoples lives, Teach says. anks to the installation of sustain-able safe water systems, Haitians are not only able to signi cantly improve their health, but they are also able to better their overall well being and qual-ity of life.Teach and the team from Water

Missions International were greeted in Dauphine by the cheers of hundreds of villagers.

Right: Children enjoy safe

water at a local school.

Left: Villagers fi ll their

buckets with clean water

at the local market.

t h l b t l l ti

CaMpsthh

f t t t

On average, every $1 invested in

water and sanitation provides an

economic return of $8. (United

Nations Development Programme)$1

Lack of community

involvement causes

50 percent of other

projects to fail.


A village leader explained Grundfos contribution to the crowd, pointing toward a company ag ying in the heart of the village, indicating the loca-tion of the new water station. It was very moving to see this area

of hope and progress, Teach says. Grundfos employees can take great pride in being a part of that. anks to those who participated in the Kansas City Walk for Water, the entire village of Dauphine has access to safe, sustain-able water. e team also visited Gorman,

a village in which Water Missions had installed a water system to draw groundwater into a water tower. Since the pump and tower were

installed, the villagers were able to build a school that supports about 200 children whose water-fetching duties previously prevented them from receiving an education. Because vil-lagers pay a small fee for their water, Water Missions International can

sustain the system and invest the proceeds into its maintenance. e 4,900 villagers of Dauphine and Rossignol now have safe water every day.Elsewhere in Haiti, the main source

of water is typically a heavily contami-nated, garbage- lled river that is used for bathing and washing clothes. In a country where houses are made of plas-tic tarps and metal scraps and where electricity and paved roads are scarce, clean water is a step toward growth.Our trip to Haiti was both

heart-wrenching and heartwarming, Teach says. It was so sad to witness the extreme

poverty and bleak living conditions of people across the island. I will never forget the moment when the children of Dauphine presented me with a Grundfos ag in gratitude of the life-changing gi they had just received.

SUSTAINABLE SOLUTIONS

Part of the money raised for both Uganda and Haiti was used toward the training needed to sustain the technol-ogy and the hygiene lessons needed to prevent contamination. From the genesis of a project to implementation, the two companies have sustainability in mind. Education is as important as technology. is summer, Grundfos will once

again host Walk for Water events at its facilities throughout North America. To learn more about Water Missions International, visit www.watermis-sions.org. P&S

Helen Mubarak is public aff airs coordinator for Grundfos North America. She may be reached at [email protected].

Top Left: Participants of the 2013 Kansas City Walk for Water pause halfway through

the walk to fi ll their buckets with water. Top Right: Participants of the 2013 Chicago-

land Walk for Water fi ll their buckets at a local pond, simulating the true burden of life

in the developing world. Bottom Right: Participants of the 2013 Kansas City Walk for

Water begin a four-mile journey to and from the water source.

5M I N U T E S

A 5-minute shower in America

uses more water than the average

person in a developing country

slum uses for an entire day.


The ongoing Syrian con ict has forced more than one million refugees

into Jordan, already one of the worlds 10 most water-deprived countries. e Mafraq City Zaatari refugee camp is experiencing a particularly signi cant water shortage. It opened in July 2012 with 100 refugee families and is now home to more than 120,000 Syrians. It is the worlds second largest refugee camp behind Dadaab in eastern Kenya.For more than ve years, Xylem

Watermark has partnered with Mercy Corps, an international humanitarian organization, to solve challenges of epidemic water scarcity. With fund-ing from the United Nations and a $150,000 grant from the Xylem Emergency Response Fund, Mercy Corps worked to create water infra-structure improvements for Zaatari. e e ort began with the construc-

tion of two new deep wells close to the Zaatari camp. e wells are tted with a submersible pump, backup generator

in case of power grid interruptions, a chlorination facility, adequate onsite water storage, booster pumps, site secu-rity and amenities to increase access to fresh water. At full working capacity, the two

wells can provide enough water to meet the daily needs of approximately 88,000 Syrian refugeesabout 73 percent of the total population of the camp. Providing the Zaatari camp with its own water supply has alleviated the pressure on other water resources used by local communities. rough the new infrastructure, local residents now have access to the same volume of water per person as they did before the Syrian refugees began arriving. is is one example of how Xylem

Watermark has addressed the complex development challenges of the worlds water crisis since 2008. rough partnerships with ve primary inter-national nonpro t organizationsMercy Corps, Water For People,

Planet Water Foundation, China Womens Development Foundation and Fundacin Avinathe company delivers sustainable water solutions through school- and community-based projects, disaster response e orts, and disaster risk reduction projects that secure water in vulnerable areas.From 2011 to 2013, the partnership

with Mercy Corps supported disas-ter risk reduction projects in China, Colombia, Ethiopia, Indonesia, Nepal and Tajikistan. Activities in these projects included the construction of ood walls and analysis of dewatering systems. e focus has been on water, sanitation and hygiene education for

By Michael C. Fields

P E O P L E TO

L I F E

T H E G I F T O F

C L E A N W A T E R


students, teachers and families. rough these e orts, Xylem

Watermark and Mercy Corps reached more than 950,000 people. e part-ners responded to 22 water-related disasters in 18 countries, providing clean water to more than 720,000 people. Jordan and other communities have received advanced ltration sys-tems, water-saving network improve-ments and improved sanitation tools. An active employee engagement pro-

gram is critical to the projects success. Xylem employees are educated about the global water crisis, take a leadership role and rally their colleagues. ey are given the opportunity to experience

these water challenges through Global Volunteer Trips. Employees receive paid leave to participate, allowing them to see rst-hand how their e orts to solve water issues make a di erence for real people around the world.

LONGTERM SUCCESS WITH

REALTIME MONITORING

Nearly half of all water projects eventu-ally fail without proper ownership and accountability. Xylem Watermark pri-oritizes the monitoring and evaluation of its projects with Water For People. rough Field Level Operations Watch (FLOW) technology, an open-source Android application, volunteers

in the eld are empowered to analyze water source functionality and report ndings in real time to a public, online database. is technology allows for the long-term tracking success of completed projects, and it quickly addresses non-functional water points. Company employees teach local lead-ers how to repair and maintain these water points, ensuring that any break-down can be addressed immediately.

CASCAS DISTRICT OF PERU

e innovative, sustainable and exi-ble approach to problems has allowed the partnership with Water For People to thrive and support other local

As part of every tower build with Planet Water Foundation, Xylem volunteers provide WASH education.

In this image, volunteers use a game of tag to teach students about germs.


programs. One example is the Cascas district in Peru. While Peru has a rapidly growing

economy, approximately 30 percent of Peruvians live in poverty, and only 85 percent have access to improved water sources. Only 72 percent have access to adequate sanitation.An agricultural economy, Cascas

is the capital of the province of Gran Chim. e total population is 14,191, and 68 percent of them live in rural areas with no access to sanitation and fresh water solutions. e project involved the construc-

tion of a water system for the commu-nity of Jolluco. e rst water system completed in the district now provides water to more than 1,000 people daily.

e project also implemented water, sanitation and hygiene (WASH) edu-cation programming in four schools and created a plan for building the capacity of water and sanitation com-mittees. Improving the communitys water system was the rst step toward a sustainable solution to the sanitation crisis and ultimately transfers owner-ship of local water systems to commu-nity members.Since 2008, the partnership

between Xylem Watermark and Water

For People has provided more than 230,000 people with clean water solu-

tions. More than 60 employee volunteers have participated in global trips with Water For Peoples World Water Corps.

TUMKUR, INDIA, AQUA TOWER

rough a partnership with Planet Water Foundation, a U.S.-based non-pro t development organization, Xylem Watermark focuses on schools, children and rural communities in China, India, the Philippines and Cambodia that lack access to clean, safe water. For the August 2012 project in the Mount View and Dodderi Schools of Tumkur, India, the mission was to build one Aqua Tower serving 1,000 people and o er WASH curriculum to

provide clean water and sanitation and hygiene education. Before the project, the Tumkur area

su ered severe drought. Many wells dried and were unable to provide consistent water to the community. e Dodderi Government School drilled deeper bores to alleviate the situation. In both schools, the need to purchase bottled water has lessened since the completion of the project. e instances of sickness and diarrhea have decreased following the success-ful installation of the Aqua Towers and deployment of the WASH program.More than 150 employee volunteers

have joined Planet Water Foundation in the eld to build water towers and provide sanitation and hygiene educa-tion to local school children. To date, 48 water tower installations have been completed throughout China, India,

Students and Xylem employees

celebrate the completion of a

water tower at a project

in China with nonprofi t

partners Planet Water Foundation

and China Womens

Development Foundation.

j l i l d TUMKUR IN

a child

dies from a

water-related

illness.

The majority of illness is

caused by fecal matter.

More people have a mobile

phone than a toilet.

E V E R Y

21SECONDS


the Philippines and Cambodia. More than 48,000 people now have clean water, proper sanitation and hygiene education.

STEPPING PUMPS AID

RURAL FARMERS

Farmers comprise almost one-third of the global population. A third of those are subsistence farmers who produce a minimal amount of food annually. In India, more than 140 million farm-ers work each day to cultivate enough crops to feed their families. ey haul water to their elds and face a daily battle to keep their crops watered. Dozens of worldwide philanthropic

organizations are working to help sub-sistence farmers by providing seeds, rudimentary equipment or donating the time of volunteers. Products such as Xylems Saajhi Stepping Pump, a manual advanced stepping pump that was engineered, designed and vetted within rural agricultural markets, has helped increase production. ough the product design is simple,

the research behind it embodies what the rural farmer needs in a water man-agement system. e technology is designed for the smallholder farmer. During development, extensive in- eld customer pro ling and research

identi ed the irrigation needs of the rural farmer and the key elements for product longevity.Saajhi Stepping Pumps have been

placed in more than 10 countriesincluding Asia, Africa and South America. Impact studies are being exe-cuted to measure the economic, social and environmental e ects of this pump within rural communities.

ESSENCE OF LIFE STRATEGY

e Stepping Pump is part of Xylems Essence of Life (EOL) business strat-egy, a planned portfolio and channel construct. EOL lever-ages an exclusive hybrid value chain that brings together the citizen sector (private and non-governmental organiza-tions), business and government partnerships. is collaboration provides a sus-

tainable engagement strategy, driving rural customer shared value that is sup-ported by technology and synergistic rural community market and channel leadership. rough Xylems small form factor,

direct-current and human-powered pumping solutions have been created to di erentiate water management systems that contribute to sustainable,

secure smallholder irrigation prosper-ity. EOL addresses the aspirational nature inherent in many rural commu-nities and unlocks rural enterprise.

THE IMPACT

In 2010, Xylem Watermark achieved its rst milestone by reaching more than 500,000 people with clean water and sanitation solutions. In 2011, it committed to reaching one million more by 2014. rough partnerships, Watermark has reached more than 2.3 million people since 2008.

Each partner provides crucial on-the-ground expertise and o ers a geographic breadth of social impact. e full spectrum of water challenges are addressed by providing nancial support, water technology, sanitation equipment and hygiene education. P&S

Michael C. Fields is the director of Corporate Citizenship for Xylem Inc. For more informa-tion, visit www.xyleminc.com and www.xylemwatermark.com.

Xylem employee volunteers

with Water For People test

the fl ow of a stream while

in the fi eld in a remote,

mountainous region of Peru.

h d l

O N L Y

10 PERCENT

of the worlds wastewater is treated.

The rest goes into lakes, rivers

and oceans.

SPECIAL SECTION


A service provider operates a sludge drying facility that is located within the Stickney Water Reclamation Plant for the Metropolitan Water Reclamation District of Greater Chicago (MWRDGC) in Cicero, Ill. e facility, which processes wet sludge into dried pellets for use as an agricultural and commercial fertilizer product, represents one process of the overall plant. e drying and pelletizing occurs in a pelletizer that indirectly heats the sludge using hot oil pumped through a series of trays at more than 570 F.

HOT OIL PUMP

e hot oil pump operates at an oil temperature of 570 F, while the motor is at ambient temperature. e coupling alignment is di cult to set and must be completed when the pump and motor are cold and again when hot because of the e ects of thermal expansion. e pumps had an ini-tial running vibration of more than 0.25 inch per second (in/sec). A 0.1 in/sec measurement would be the maximum acceptable vibration and it is recommended that vibration

Smart Couplings Enhance a Failing Hot Oil Pump at a Wastewater Treatment PlantVibration and maintenance were reduced with the installation of carefully selected equipment.

By Marc W. Yarlott, P.E., & M. Azeem, C.Eng., Veolia Environnement North America

Above: Image 2. The installed magnetic coupling

SPECIAL

SECTION


SPECIAL SECTION


Ultimately, a new type magnetic coupling based on induc-tion rotor technology was selected. is technology has the following characteristics: A minimum misalignment tolerance of 0.1 inch in any direction because of the air gap between the motor and load

Fits within American National Standards Institute and National Electrical Manufacturers Association standard dimensions so no modi cation to the motor, pump or base required

Transfers 125 horsepower at 1,800 rpm Provides transfer of 140 percent of full load torque in a

locked rotor condition, leading to a 140-percent to 150-percent increase in motor current, which can be detected using a current sensing relay set to trip a er a user-adjustable dura-tion (typically 20 to 40 seconds)

e selected design is a second-generation magnetic coupling that increases torque transfer as the per-centage of slip increases. Figure 1 shows the comparison between this design and eddy-current magnetic coupling designs. Initially, the standard air gap within

the selected coupling was thought to provide adequate space to accommo-date thermal growth. However, the coupling also had additional air gap spacer shims that allow the air gap to be increased for even more misalign-ment correction. Adding shims usu-ally reduces the overall e ective trans-fer of torque, leading to a decrease in pump speed. e amount of pump speed reduc-

tion depends on the couplings horsepower rating, the actual load horsepower and the number of shims inserted, but it is normally less than 2 percent with the selected coupling when properly sized. For systems in which full ow is not needed or throt-tling valves or recirculation loops are used to reduce ow, the selected cou-pling o ers signi cant energy savings. In this case, however, more than a nominal amount of pump speed/ ow reduction was not desired.

INSTALLATION

Prior to the installation, a new/rebuilt




is less than 0.05 in/sec for a signi cant improvement in reliability. Typical failures included mechanical pump seals, valves,

drain plugs and angeswhich were all leaking oil. Because of the oils temperature, many of these failures resulted in smoke because the oil started to burn upon leaking. e high vibration and load stress resulting from the thermal-expansion-driven misalignment was causing particularly high failure rates for the No. 4 pump, the primary ther-mal oil supply pump. is pump had a signi cant number of failures and had to be rebuilt three times in 18 months according to records in the computerized maintenance management system.

COUPLING ALTERNATIVES

Because of the ongoing misalignment-related issues, facility management researched the latest in exible coupling tech-nology. Each coupling type reviewed for the hot oil pump had distinct pros and cons. Fixed, direct and rigid style couplings su ered from the

transfer of vibration and axial loading when thermal growth of the pump sha occurred, causing perpendicular stress loading on the motor and pump axial bearings. Traditional exible couplings (for example, elastomeric, grid or gear) provided some axial load relief but did not resolve the par-allel misalignment created as the pump base and structure experienced vertical growth with increased temperature. e vertical misalignment caused torsional loads on the motor and pump bearings, in addition to loads on the cou-pling that caused vibration of the motor and pump. Finally, magnetic couplings were con-

sidered. Magnetic couplings are ideal for a hot oil pump application because no phys-ical contact between the motor and load is allowed. e magnetic air gap provides enough clearance to allow for vertical and axial changes in d

May 2014

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