pump source
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2009
PUMP SOURCE a guide for pump users
Pumps Provide a Siphon Bypass Solution Siphon bypass prevents potential sewage spill and increases sewer flow
A Supplement to Water & Wastes Digest
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PUMP SOURCE contents
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20 09
Driving Efficiency
City of Lawrence, Ks., moves from across-the-line starts and constant-speed operation to ramp up/down of critical lift station pumps via motor drives
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Successful Suphon Bypass
Siphon bypass eliminates leak, prevents potential sewage spill and increases sewer flow
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Peristaltic Advancements
Using peristaltic pumps to pump sodium hypochlorite in water treatment plant applications
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Efficient Pumping
Smart Control
A California park district finds value in its new pump control system
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editorial letter
An Up-and-Coming Metering Solution
The elegantly simple operation of peristaltic pumps Scranton Gillette Communications 3030 W. Salt Creek Ln., Ste. 201, Arlington Heights, IL 60005-5025 tel: 847.298.6622 • fax: 847.390.0408 • www.wwdmag.com
E DI T OR I A L S TA F F Editorial Director Managing Editor Associate Editor Associate Editor Associate Editor Graphic Designer Production Editor Web Editor Web Production Editor
Neda Simeonova Clare Pierson Caitlin Cunningham Stephanie Harris Rebecca Wilhelm Melissa Rosenquist Jason Kenny Adam Terese Morgan Jeffrey
A DV E R T I S I N G & S A L E S 6900 E. Camelback, Suite 400 • Scottsdale, AZ 85251 tel: 480.941.0510 • fax: 480.423.1443 Regional Sales Manager David Rairigh [email protected] (phone x25) Regional Sales Manager Eric Smith [email protected] (phone x14) Regional Sales Manager Fred Ferris [email protected] (Arlington Heights office, 847.391.1003) Regional Sales Manager Brenda Yanez [email protected] (phone x12) Regional Sales Manager Lori Glenn [email protected] (phone x17) Media Sales Manager Heather Madril [email protected] (phone x24) Specialty Sales Representative Amanda McAdams [email protected] (Arlington Heights office, 847.391.1031) Internet Sales Rep. Michael Mansour [email protected] (phone x16) Classified Sales Manager Donna Aly [email protected] (phone x13) Reprint Coordinator Adrienne Miller [email protected] (Arlington Heights office, 847.391.1036) Advertising Coordinator Renee Fonferko [email protected] (Arlington Heights office, 847.391.1027)
M A N AG E M E N T Vice President/Publisher Associate Publisher VP Events VP Custom Publishing & Creative Services Director of Production Operations Circulation Director
Dennis Martyka [email protected] Greg Tres [email protected] Harry Urban [email protected] Diane Vojcanin [email protected] Judith H. Schmueser [email protected] Mike Serino [email protected]
C OR P OR AT E Chairperson President/CEO Sr. Vice President Chairman Emeritus
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K.S. Gillette E.S. Gillette A. O’Neill H.S. Gillette (1922-2003)
P
umping is a highly energy-intensive process. The California State Water Project pumps water close to 2,000 ft over the Tehachapi Mountains, making it the largest single user of energy in the state. It consumes an average of 5 billion kWh per year and accounts for 2% to 3% of California’s electricity consumption, according to the U.S. Environmental Protection Agency. While pumps can be huge energy hogs, the right technology can also offer facilities energy-saving opportunities, as well as longer equipment life and lower maintenance costs. With energy costs on the rise, water and wastewater facilities across the country are looking to lower their electricity costs. Many have upgraded pump stations by replacing existing magnetic-coupling drives with variable frequency drives (VFDs). Initial costs of VFDs can be relatively expansive depending on the system size and complexity. The payback period, however, is rapid—ranging from just a few months to less than three years—and the benefits are long term. There are various incentives available for energy-efficient equipment. Additionally, water and wastewater facilities that are looking to decrease their energy consumption by upgrading existing less-efficient systems can take advantage of different funding options. In response to the ever-increasing interest in existing and new pumping system practices, the staff of WWD is pleased to bring you its annual supplement publication, Pump Source. Now in its seventh year, Pump Source continues to offer a wide variety of articles, which offer valuable insight into relative and detailed pump applications. Beyond Pump Source, WWD is also the organizer and co-sponsor of PumpTec 2009, the 5th Annual Pump Theory and Hands on Maintenance and Reliability Conference, to be held Sept. 14 to 15, 2009, at the Holiday Inn Select in Norcross, Ga. Attendees will learn how to assemble and troubleshoot pumps to improve reliability and extend their life. Efficiency and energy savings will also be discussed. More information is available at www.pumpconference.com. PS
Neda Simeonova, editorial director [email protected] PUMP SOURCE 2009
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application drives
By Mark Kenyon
Driving Efficiency
City of Lawrence, Ks., moves from across-the-line starts and constant-speed operation to ramp up/down of critical lift station pumps via motor drives
W
ith 450 miles of sanitary sewer collection lines and 33 lift stations that feed into a central wastewater treatment plant, the city of Lawrence, Ks., has an extensive wastewater management system. The city has been recognized as one of only two in the nation that have three environmental management certifications for wastewater operations. These certifications demonstrate the city’s ability to provide customers with an efficient level of service while maintaining a high standard of environmental protection.
The Need for Retrofit Gravity is the driving force for wastewater distribution to the treatment plant, except where there are vertical elevation changes in the topography. In these circumstances, lift stations are used to move wastewater to the treatment plant. Because of ongoing increases in demand, Dave King, the city’s wastewater maintenance manager, is continually looking for ways to improve efficiency. Lift Station No. 16, built in 1958 and located close to downtown Lawrence, transports about 600 million gal of dry-weather flow per year, about 25% to 30% of the city’s wastewater usage. The combination of aging equipment and increasing flow from new residential developments led to the decision to retrofit the station completely in the spring of 2006. King turned to the city’s longtime PLC supplier, Logic, Inc., to help develop a solution. ACS800 drives were installed on each of four new 125-hp pump motors to: increase efficiency and power factor, improve electricity cost savings, extend the life of the motors, reduce repair costs and minimize or eliminate harmonics that can interfere with instrumentation.
Ensuring Constant Flow When wastewater enters a lift station, it initially goes through a course screening process, which removes solid particles that might cause damage to the pumps. The wastewater then flows into an enclosed wet well, which can
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be 30 to 40 ft deep. Sensors monitor the depth of the wastewater in the wet well. Pumps are used to displace the wastewater from the well to the treatment facility. Drives often play a key role in supporting the pump operation, ensuring that a constant flow is discharged to maintain optimum wastewater levels. “By controlling pump speed, an optimum level can be maintained that ensures constant flow between what’s coming in and what needs to be pumped out,” King said. “Installing the ABB drives has enabled us to eliminate unnecessary pump starts.” Previously, the site ran the pumps based on an on/off level and used an across-the-line starter. When the level in the wet well reached a designated point, it would trigger the starter to get the pump motors up to maximum speed as quickly as possible. This rapid acceleration created spikes and mechanical stress on both the motor and pump. It would run at full speed until it reached the off-level elevation, and then it would turn off. The continuous starting-and-stopping process caused wear and tear on the bearings and impellers, causing the motors to deteriorate.
to limit potential turbulence and reduces the need for maintenance. The drives respond to sensors in the wet well that are relayed to a PLC unit via DeviceNet. The plant communicates with the PLC unit at the lift station via Ethernet to ensure that wastewater levels are being pumped out consistently, based on established parameters. Although three pumps are needed to run the station, the city keeps an installed fourth pump on
standby at all times, running them alternately to balance wear. The station operates 24 hours per day and cannot afford downtime. “ABB drives give us the ability to handle the wide range of variations in wastewater flow entering the station due to time of day, time of year and weather conditions, as well as the capacity to accommodate future growth,” King said. “The fact that we can now pump wastewater out at
Preventing Water Hammers By maintaining a consistent level in the lift station wet well, drives also help to avoid water hammers. When a pump starts or stops suddenly, it slams the check value on the back of the pump and creates a water hammer effect (pressure surges caused by the energy of a fluid in motion when it is forced to stop suddenly). In a lift station, hydraulic water hammers often occur when trying to pump fluid vertically or at a slant. Once a pump stops, the fluid will come back to the source, jarring the piping. Over time, water hammers can lead to pipe deterioration. Because the ACS800 drives provide acceleration and de-acceleration ramp to the pumps, wear and tear on the pump mechanicals is reduced.
Drives & Bypass Drives also incorporate a soft-start function that gently ramps speed write in 8120
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the same rate it enters also helps us reduce odors.” Because wastewater is constantly running throughout the city, another important feature to the lift station is the bypass function, which allows a manual override of the pump if a drive was to go offline. “Even though modern drives are very reliable, if for any reason we were to have multiple drive failures, the bypass gives us the ability to still operate the station,” King said. “At this location, station downtime is not an option.”
ULH drives feature bypass valve, fuse disconnect, remote I-O and selector switches.
Providing Protection Because the lift station is located next to a residential district, minimizing harmonic distortion is a necessity. With the amount of dynamic load on the existing transformer, standard drives were not a viable option. “Excessive harmonics can interfere with pump instrumentation,” King said. “Plus, we didn’t want
write in 8129
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to cause any interruption to the electrical appliances of our customers.” Ultra-low harmonic (ULH) ACS800 drives do not require a multipulse transformer, external filters or other additional equipment for minimizing harmonics. The drive features an active converter with direct torque control to eliminate low-order harmonics. With an active front-end inductor/ capacitor/inductor line filter to reduce high-frequency harmonics, the city did not have to worry about overheating feeder breakers or transformers.
ABB drives in four other wastewater pump stations now under construction. “I anticipate extended pump life, electric cost savings and ultimately better service to our customers as a result of ABB drives,” King said. PS
Because the drives were shipped with all of the specifications preinstalled, installation was smooth and easy. To maintain constant uptime during the retrofit, two pumps were taken offline at a time, keeping the other two pumps running.
Mark Kenyon is manager, component AC products, for ABB, Inc., Low Voltage Drives. Kenyon can be reached at 262.785.3200 or by e-mail at mark. [email protected]. For more information, write 1101 on this issue’s Reader Service Card.
Turnkey Solutions ABB offered turnkey solutions direct from the factory. “We required certain features in the cabinet, such as a bypass, fuse disconnect, remote I/O and selector switches. ABB was able to provide all that from a factory service center,” King said. “The lift station fits in a 900-sq-ft space and the ACS800’s compact footprint fit well into the facility.”
A Continued Relationship The lift station retrofit was not the first instance where the city has benefited from using ABB drives. The wastewater treatment facility also has ABB drives equipped with bypass to increase efficiency. Because of the positive experience with the drives at Lift Station No. 16, the city is installing
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application controllers
Smart
Control
T
he East Bay Regional Park District (EBRPD) is designated a special district by the state of California.
It is the largest special district in the U.S., with more than 90% of its land protected and operated as natural parklands.
By Carl L. Meisner
A California park district finds value in its new pump control system
EBRPD is responsible for 1,745 sq miles of land, encompassing both Alameda and Contra Costa counties on the eastern side of San Francisco Bay. It manages 29 park trails, 65 parks, camping and recreation areas, lakes and lagoons, wilderness, shorelines, fishing docks and preserves as well as education centers and conference facilities. For such a large and widely spread district, effective management of water and wastewater is critical. The supply of potable water—and wastewater collection and treatment—needs constant monitoring and control across all facilities to prevent problems and avoid any possible environmental issues.
New Five-Year Plan “We used to have an amalgam of antiquated and largely incompatible equipment to control 38 pumping stations. Some wastewater pumps dated back to the 1970s,” said Richard Guest, water utilities maintenance
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supervisor for the district. “Two years ago, I developed a five-year plan to modernize all wastewater plants and pump stations. The objective was to develop a highly reliable, centralized control system that is simple to operate and can accommodate SCADA with minimal adaptation.” “However,” he continued, “I had to consider our many employees who transfer within the district on a regular basis, and a significant number of part-time and seasonal employees as well. It became crucial to standardize every panel so that employees would not have to relearn how to operate unfamiliar equipment when they moved around. We also wanted a simple, user-friendly configuration. Simplicity is key to a well-managed, smooth-running operation.” In the past, the district’s water and sewer pump stations had no communications ability at all. Visual inspection was the only way to identify a problem at a pumping station, and
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to use the equipment. All I had to do was select an answer and confirm.” With MultiSmart controllers, there are several fail-safe features built into the system. For instance, the controller has alarms and pre-alarms, where an operator is notified prior to an alarm. The system is not limited to only look at things that have failed. It is also able to pinpoint potential failures and other problems before they happen. “Suppose the sewage level has risen
far enough that a pre-alarm is tripped,” Guest said. “Once the operator is alerted, he can log onto a system computer and check the station in question. It’s not in alarm mode yet, but it’s past the point that an operator would normally be comfortable if he were standing there watching the station.” District staff controlling the pump stations are able to log into a station and take a critical look and see if a pump has failed to start, or a pump
Wouldn’t it be nice to have a hose pump that: ɶ Provides exceptional dosing accuracy ɶ With flow rates from 3.5 US GPH - 450 US GPH ɶ Can pump abrasive, any failure had to be addressed on site. After extensive review of pump control systems, MultiTrode’s MultiSmart pump controllers were selected by EBRPD for their proven reliability and modular expansion and open interface capabilities. Other positive considerations included easy installation and simple, intuitive operator controls. The controllers combined ease of use with advanced functionality for up to nine pumps.
The Installation During installation, no design modifications were required, the product was user-friendly and easy to understand and no setting or programming adjustments were needed. “The installation was the easiest thing I ever did,” Guest said. “I took the unit out of the box, wired it up, turned it on and it ran. The initial startup screen came on, asked me four or five questions and gave me a choice of options depending on how I wanted
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is starting too fast, or even if the sun is heating the inside of the control panel and causing a component to malfunction. Any of these conditions would prompt a pre-alarm signal. The controller not only sends a signal, it is capable of identifying the problem. As part of the five-year plan, EBRPD is preparing for SCADA to go online in the fall. With SCADA interfacing with MultiSmart controllers, a centralized network will be able to reset, troubleshoot and otherwise correct the majority of problems directly from a remote location computer or a centralized computer. With SCADA, the operator can see what the problem is, what caused the problem and decide to either reset it from the base computer or dispatch someone to the station for service. The dispatcher can tell that person exactly what he or she is going out there for, what to do and what to bring.
Cost Savings & Flexibility EBRPD has pump control stations
all over the 1,700 sq miles it covers, and sometimes it takes up to an hour and 20 minutes to reach a location. “The real cost saving is not in the purchase price or installation cost, but on the operational and maintenance side. The new pump controllers have greatly reduced the need for emergency responses,” Guest said. “Now the stations are checked once a week, and it takes less than 30 minutes. In fact, we are to the point where we almost never have emergency calls on our wastewater pumping stations. This results in much less overtime. In the past, when we had a problem, someone had to go quickly, regardless of the time or day.” Performing predictive maintenance used to be a manual operation. Now tracking things like bearing and field life in station pumps is accomplished systemically, without estimations or calculations from the operator. The controllers are capable of accommodating up to four different software
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EBRPD staff checks the district’s new pump controllers once a week, and the inspection takes less than 30 minutes.
WEB resources hhh Related search terms from www.waterinfolink.com: pump station, controllers, SCADA For more information related to this article, visit www.wwdmag.com/lm.cfm/ps040902
changes to the control panel by making simple software configuration changes with little more than a flash card. In a parks and recreation district, flexibility in pump station control is an important issue. Sudden population shifts at the park may require a station to perform differently or that alarm criteria change to accommodate a critical upcoming event. In the past, the pumps were either on or off, and the same applied to the alarms. The new controllers also allow stations to communicate with each other. This is a very valuable feature. In cases where there are long distances to the sewer, there are often multiple stations connected serially. If one station fails, it can communicate to the stations behind it to stop pumping and become holding tanks to eliminate the risk of overflow.
can still function when there is a power outage is cost savings waiting to happen. Sometimes extreme heat from the sun will cause a circuit breaker to trip. When that happened with the old system, there was no way to tell. Consequently, people used to check stations two and three times a day. The new system not only works without power, but it also signals when a circuit breaker is turned off; service people know immediately and can fix it before a more serious problem develops. A value-added feature of the controllers is their ability to protect pump motors from sporadic voltage sags and surges or spikes on the utility line. If a pump is running during one of these events, it can harm the motor. PS Carl L. Meisner is a contractor for MultiTrode. Meisner can be reached at 760.231.5483.
Additional Advantages The controllers also come with battery packs. The fact that the system
For more information, write 1102 on this issue’s Reader Service Card.
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application sewer flow
I
n wastewater applications, siphons work to divert sewage under large obstructions such as rivers or streams. In such applications,
a siphon structure serves as a basin that collects sewage on one side, then delivers it through underground pipes to a slightly more elevated basin on the other side using atmospheric pressure.
Siphon bypass eliminates leak, prevents potential sewage spill and increases sewer flow
A Leaky Siphon The San Antonio Water System (SAWS) makes use of a siphon capable of 92 million gal per day (mgd) in its Historic Mission Reach area. Installed in the 1940s, this 54-in. double-barrel siphon diverts roughly 21 to 40 mgd of sewage under the San Antonio River. Though it had been successfully repaired throughout its years of service, the siphon showed signs of leaking in late 2006. SAWS determined that the structure was irreparable and needed to be replaced as soon as possible. “We realized that we were continuing to make repairs to a leak at the base of this structure, and that there was the potential for creating a larger problem if we kept trying to make repairs to it,” said Ernesto Leal, superintendent for SAWS. “Obviously, we wanted to proactively avoid a catastrophic event.”
more quickly than the previous concrete structure. In addition, having the pipe buried underground presents less surface exposure to sewage overflow. The SAWS management team— including Leal, Mike Sellers and Gordon Mahan—developed a plan to dig and replace the structure. At the same time, they called on Godwin
1
A Reliable Solution
By Stephanie Maurer Morgan
SAWS elected to replace its failing high-flow siphon structure with newer technology that depends on buried fiberglass pipe. When the pipe is in place, the fiberglass makeup will deliver the flow of sewage through the line
S uccessful
siphon bypass
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The pumps were equipped with digital controllers, allowing them to stop and start automatically.
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Pumps—on contract with the organization—to provide a bypass solution that would divert the maximum peak flow of 40 mgd, with ability to handle wet peak flows of 70 to 92 mgd.
A Large Bypass “I have been working with SAWS since 1992,” said Godwin Pumps San Antonio Branch Manager Greg White. “However, this is by far the largest bypass we have designed for them, and it involved crossing the San Antonio River, which presented a challenge.” Within 20 days of receiving the call from SAWS, Godwin had designed, delivered and installed a complete system that included 12 Critically
Silenced Dri-Prime CD300M (12-by12-in.) pumps and four open-unit CD300M pumps for standby. Each pump is capable of delivering flows to 6,000 gpm and heads to 200 ft. Powered by Caterpillar C-9 engines, the pumps were equipped with PrimeGuard controllers. The PrimeGuard is a digital control system that can be programmed to vary pump and diesel-engine speed based on input from level floats, allowing the pumps to start and stop automatically without an operator. These controllers came in handy on Feb. 1, 2009, when the use of more pumps was required to keep up with the extraordinary flow that was generated during the Superbowl.
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In addition to the diesel-driven pumpsets, Godwin installed five 18-in. and two 24-in. high-density polyethylene (HDPE) pipes, each running 3,800 ft for a total of five miles of pipe. While a majority of the HDPE pipe setup was routine, the pipe did eventually have to cross the San Antonio River. The pumps were situated upstream of the leaking siphon, intercepting the flow from the two 54-in. lines through a custom-designed and -built concrete suction pit. Bypass pumping began on Nov. 5, 2008, and ended on March 6, 2009, after the new 54-in. fiberglass siphon structure installation was completed. “Our short-term goal was to bypass the leak at the old siphon structure and to prevent sewer from spilling into the San Antonio River,” Leal said. “In the long run, we are also looking to increase sewer flow with the new siphon.” Making use of a custom-built suction pit and automatic self-priming pumps with digital controllers, and installing the latest in fiberglass pipe technology, SAWS has taken this Historic Mission Reach project to test the effectiveness of “new technology” and is happy to report success. PS Stephanie Maurer Morgan is corporate communications manager for Godwin Pumps. Morgan can be reached at 856.467.3636 or by e-mail at stephanie.morgan@ godwinpumps.com.
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For more information, write 1103 on this issue’s Reader Service Card.
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Five miles of HDPE pipe were installed, and some of it had to cross the San Antonio River.
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Related search terms from www.waterinfolink.com: siphon, sewer bypass, pumps For more information related to this article, visit www.wwdmag.com/lm.cfm/ps040903
The pumps were situated upstream of the leaking siphon, intercepting the flow through a customdesigned and -built concrete suction pit.
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application dosing
T
By Gary Rose
he quality of life for Americans was greatly enhanced in the early 1900s due to the introduction of chlorinated drinking water throughout the U.S. water systems. From the stockyards of Chicago to the Boonton Reservoir of Jersey City, the case was established that filtration alone was not sufficient to guarantee clean water. By the 1920s, chlorination was well entrenched as the primary means of disinfecting drinking water. The combination of filtration and chlorination reduced typhoid fever by 91% within five years, which led to its near eradication by 1936, according to a statistical study of disease rates. Chlorine-based disinfectants have been the choice for treating drinking water since the turn of the 20th century. This is the only type of disinfectant that provides a residual in the distribution system that is vital to preventing waterborne diseases. Three forms of chlorine that are commonly used are gaseous chlorine, calcium hypochlorite tablets and sodium hypochlorite solution. However, safety concerns and costs have prompted many municipalities to switch from chlorine gas to sodium hypochlorite. The most common disinfection method is some form of chlorine or its compounds such as chloramine or chlorine dioxide. Other nonchlorine-based disinfectants are ozone and ultraviolet radiation.
peris taltic
advancements
Using peristaltic pumps to pump sodium hypochlorite in water treatment plant applications
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According to the Water Quality and Health Council, 98% of systems that treat water utilize chlorine-based disinfectants. Moreover, the World Health Organization concurs that disinfection by chlorine is still the best guarantee of microbiologically safe water.
Case Study The Orange Water and Sewer Authority (OWSA) operates the Jones Ferry Road Water Treatment Plant in Chapel Hill, N.C. The plant serves as a model for state-of-the-art improvements. The plant can treat up to 20 million gal of raw water daily—nearly double the average demand of water usage from the local population of 70,000 people. The water treatment process encompasses several phases. The first phase is the addition of powdered carbon to the water supply from the lakes to improve the taste and control odor in the water. Secondly, the solid particles are separated from the water in settling tanks. Once that process is complete, the water is pretreated with sodium hypochlorite and then filtered through layers of sand and anthracite coal. Lastly, chemicals are added for disinfection and public health. The chemicals include chlorine, ammonia and fluoride. The pretreatment stage consisted of a bank of 10 diaphragm pumps injecting sodium hypochlorite continuously and simultaneously at a rate of 1.3 gal per minute against zero back pressure. OWSA noticed numerous problems with the diaphragm pumps in this WWW.WWDMAG.COM
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particular application. The central issues were the outgassing or off-gassing of the sodium hypochlorite and the inability of the diaphragm pump to operate efficiently due to the gas buildup in the pump head. Enviably, a loss of prime would occur, costing OWSA valuable downtime. Despite the fact that auto-degassing valves were implemented, the problem was not totally eliminated. Consequently, the treatment plant’s chief operator, Dusty Martin, was compelled to make the switch to peristaltic pumps. First and foremost, the peristaltic pump eliminates the core problem with outgassing of the sodium hypochlorite by utilizing precision-engineered rollers to optimally squeeze a heavy-duty norprene tube efficiently and with unparalleled accuracy. Gas has no effect on this simplistic pumping method. Furthermore, the tube life has been greatly increased through an innovative rotor design that allows the pump to handle the same maximum pressure in
either direction. The ability to reverse the motor, in essence, doubles the tube life. Of course, the tube life will always vary depending on the chemical used, the output pressure, the size of the tube and the rpm of the motor. Other notable advancements with the peristaltic pumps include a tube failure detection system built into the pump head; increased output pressure of up to 125 psi; precision stainless steel ball bearings supporting the front and back of the rotor shaft; and highly advanced electronics to connect to SCADA systems. At the Jones Ferry Road plant, the peristaltic pumps are wired via 4-20mA into the SCADA system for monitoring and alarm responses. Martin said that he was amazed how easily the peristaltic pump hooked up into the plant’s SCADA system. Continual monitoring using powerful graphic and alarm software programs allows the SCADA system to ensure the exact amount of chemicals have
been dispersed into the water supply. In addition, Martin said that the dosing is much more precise, accurate and consistent using a peristaltic pump compared to a diaphragm pump. Overall, Martin highly recommends a peristaltic pump over a diaphragm pump for sodium hypochlorite injection. PS Gary Rose is president of Rose Industrial Marketing, Inc., and a representative of Blue-White Industries. Rose can be reached at 800.975.5469 or by e-mail at [email protected]. For more information, write 1104 on this issue’s Reader Service Card.
WEB resources hhh Related search terms from www.waterinfolink.com: peristaltic pumps, sodium hypochlorite For more information related to this article, visit www.wwdmag.com/lm.cfm/ps040904
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application metering
By Chuck Treutel
The elegantly simple operation of peristaltic pumps
P
eristaltic pumping is the fastest growing pump technology in the world, displacing more complex and higher-maintenance positive displacement (PD) pumps for chemical metering. Acids, caustics and solvents attack diaphragm and progressive cavity pumps, causing downtime and increased life-cycle costs. The peristaltic principle mitigates these costs. Peristaltic pumps are valve-less and seal-less and have no mechanical parts in the product stream. The fluid only comes into contact with the inside of a hose or tube element, which is a low-cost, low-maintenance and easily serviceable component. A peristaltic pump’s operation is elegantly simple. A hose or tube element is positioned along a stationary pump housing and is compressed from the outside by a roller (tube pump) or a shoe (hose pump). Fluid is pushed toward the discharge as the roller or shoe moves along the outside of the element while the restitution of the hose or tube element behind the shoe draws more fluid into the pump. The heart of the pump is a hose or tube that is available in different elastomers specifically formulated to balance
long mechanical pumping life with resistance against concentrated acids, bases and solvents. The “wetted end” simplicity of a peristaltic pump stands in contrast to a diaphragm pump, where one must properly select materials for the pump housing, diaphragm, ball checks and seals to prevent pump failure from corrosive attack.
Accuracy PD pumps are normally chosen to accurately meter or dose exact amounts of chemicals. In a peristaltic pump, flow is proportional to pump speed, and the complete closure of the hose or tube element at all times gives the pump its positive displacement action, preventing flow drop or erosion from backflow and eliminating the need for check valves. Without check valves, peristaltic pumps eliminate the primary source of metering inaccuracy and will not vapor-lock. The “turndown ratio” or “flow range” of a peristaltic pump is unparalleled. A high-quality peristaltic pump is capable of a more than 2,000:1 flow range by simply controlling one parameter—the rotor speed. With the added versatility of putting different tube sizes into one pump, the flow range
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expands to 1,000,000:1 range with a single pump. Diaphragm pumps are normally limited to 20:1 speed range with typical controllers.
Life-Cycle Costs While the initial capital cost of a peristaltic pump can be slightly higher than other PD pumps, an assessment of costs associated with ancillary items, installation, maintenance downtime and spare parts quickly tip the life-cycle cost calculation in favor of the peristaltic pump. With the tube or hose element being the only wetted part, peristaltic pumps are virtually maintenance-free, with no expensive seals to replace, no check valves to clog and no rotors and stators to wear out. In a peristaltic pump, the hose or tube element needs periodic replacement. Industrial-duty peristaltic pumps will provide thousands of hours of reliable and repeatable hose or tube life before the element fatigues and needs replacement. When it comes time to replace a hose or tube element, the procedure takes less than an hour and in some cases only a couple of minutes. Additionally, the change of the element is done quickly and safely where the pump sits without the need for any special tools. Process control requirements and chemical compatibility often make peristaltic pumps a lower-cost capital item than other PD pumps, delivering financial benefits even before the reduction in maintenance and ancillary costs are considered. For example, a progressive cavity pump’s price can be exponentially inflated when expensive metallurgy becomes the only corrosionproof option for its components. Additionally, many PD pumps require the additional cost of a separate control panel or variable frequency drive (VFD) for achieving variable flow metering. Peristaltic pump manufacturers build high-turndown, closedloop speed control capability and expansive I/O connections for DCS and SCADA systems into their pumps.
Chemical Applications Historically, there was a technological limitation to applying peristaltic pumps to heavy-duty chemical
applications; they lacked in-hose or tube design that could withstand highly corrosive fluids while yielding long life at continuously high pressures and flow rates. For this reason, peristaltic pumps have found their niche in low-pressure, batch pharmaceutical processes, with limited use in industrial processes. This has turned around over the past 50 years, however. Pumps and chemical duty elements have been developed that are
capable of more than 350 gal per minute (gpm), 240 psi, thousands of hours of continuous-duty hose and tube life and metering accuracy better than 0.5%. Peristaltic pumps have proven to be highly resistant to the acid and caustic chemicals that quickly eat away at the metallic components of progressive cavity and diaphragm pumps. For example, an engineered plastics manufacturing plant in the Southeast uses a SPX10 pump with a rubber hose to meter hydrochloric
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acid in the production of linear polyphenylene sulfide. Because of the hose pump’s metering capability, the plastics manufacturer does not require separate flowmeters and valves to measure and control the flow. Rather, they adjust the speed of the feed rate by simply altering the rpm of the rotor motor with a VFD. A power generation servicing company in the Mid-Atlantic region uses peristaltic pumps to meter 65 gpm of sulfuric acid when cleaning out the condensers
of a power plant, driving the pH below 4 to breakdown scale. Precise control of the flow of the acid is necessary to ensure that after the scale is dissolved, the discharge to the municipal wastewater system will have a neutral pH. On the other side of the pH scale, peristaltic pumps are used extensively with sodium hydroxide for many different applications such as bleaching pulp at paper mills and disinfecting potable water. Because the hose in a peristaltic
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pump is self-cleaning, it does not experience the crystallization that builds up in other pumps and eats away at seals. Until recently, petrochemicals, hydrocarbons and oil-based products were all beyond the reach of peristaltic pumps due to incompatibility with the rubber hose. A new thermoplastic elastomer hose called PetroProof, introduced by Watson-Marlow Bredel, is now available for toluene and other highly corrosive solvents used in the production of a number of materials. Frequently, corrosive fluids contain not only corrosive chemicals, but abrasive material as well. Peristaltic pumps, originally designed for caustic and abrasive cement applications, stand up well to the challenge. A Southeastern U.S. building products manufacturing plant also uses peristaltic pumps to make its fiber cement siding products. The cement mixture has little effect on the hose despite being highly abrasive and strongly basic. Despite all of the advantages of peristaltic pumps, they represent only a modest but growing percentage of the market in the U.S. This is primarily because peristaltic technology is relatively new, whereas diaphragm and progressive cavity pumps have a lengthy history. However, with the pressure on plant managers to reduce the life-cycle costs of their pumps, the functionality and benefits of peristaltic hose pumps are becoming more widely known, and new peristaltic technology is fast becoming the pump of choice for tough, chemically aggressive and abrasive applications. PS Chuck Treutel is marketing manager for Watson-Marlow, Pumps Group. Treutel can be reached at 608.883.6851 or by e-mail at [email protected]. For more information, write 1105 on this issue’s Reader Service Card.
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PUMP SOURCE a guide for pump users
Pumps Provide a Siphon Bypass Solution Siphon bypass prevents potential sewage spill and increases sewer flow
A Supplement to Water & Wastes Digest
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PUMP SOURCE contents
04
20 09
Driving Efficiency
City of Lawrence, Ks., moves from across-the-line starts and constant-speed operation to ramp up/down of critical lift station pumps via motor drives
08
Successful Suphon Bypass
Siphon bypass eliminates leak, prevents potential sewage spill and increases sewer flow
14
Peristaltic Advancements
Using peristaltic pumps to pump sodium hypochlorite in water treatment plant applications
16
Efficient Pumping
Smart Control
A California park district finds value in its new pump control system
12
editorial letter
An Up-and-Coming Metering Solution
The elegantly simple operation of peristaltic pumps Scranton Gillette Communications 3030 W. Salt Creek Ln., Ste. 201, Arlington Heights, IL 60005-5025 tel: 847.298.6622 • fax: 847.390.0408 • www.wwdmag.com
E DI T OR I A L S TA F F Editorial Director Managing Editor Associate Editor Associate Editor Associate Editor Graphic Designer Production Editor Web Editor Web Production Editor
Neda Simeonova Clare Pierson Caitlin Cunningham Stephanie Harris Rebecca Wilhelm Melissa Rosenquist Jason Kenny Adam Terese Morgan Jeffrey
A DV E R T I S I N G & S A L E S 6900 E. Camelback, Suite 400 • Scottsdale, AZ 85251 tel: 480.941.0510 • fax: 480.423.1443 Regional Sales Manager David Rairigh [email protected] (phone x25) Regional Sales Manager Eric Smith [email protected] (phone x14) Regional Sales Manager Fred Ferris [email protected] (Arlington Heights office, 847.391.1003) Regional Sales Manager Brenda Yanez [email protected] (phone x12) Regional Sales Manager Lori Glenn [email protected] (phone x17) Media Sales Manager Heather Madril [email protected] (phone x24) Specialty Sales Representative Amanda McAdams [email protected] (Arlington Heights office, 847.391.1031) Internet Sales Rep. Michael Mansour [email protected] (phone x16) Classified Sales Manager Donna Aly [email protected] (phone x13) Reprint Coordinator Adrienne Miller [email protected] (Arlington Heights office, 847.391.1036) Advertising Coordinator Renee Fonferko [email protected] (Arlington Heights office, 847.391.1027)
M A N AG E M E N T Vice President/Publisher Associate Publisher VP Events VP Custom Publishing & Creative Services Director of Production Operations Circulation Director
Dennis Martyka [email protected] Greg Tres [email protected] Harry Urban [email protected] Diane Vojcanin [email protected] Judith H. Schmueser [email protected] Mike Serino [email protected]
C OR P OR AT E Chairperson President/CEO Sr. Vice President Chairman Emeritus
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K.S. Gillette E.S. Gillette A. O’Neill H.S. Gillette (1922-2003)
P
umping is a highly energy-intensive process. The California State Water Project pumps water close to 2,000 ft over the Tehachapi Mountains, making it the largest single user of energy in the state. It consumes an average of 5 billion kWh per year and accounts for 2% to 3% of California’s electricity consumption, according to the U.S. Environmental Protection Agency. While pumps can be huge energy hogs, the right technology can also offer facilities energy-saving opportunities, as well as longer equipment life and lower maintenance costs. With energy costs on the rise, water and wastewater facilities across the country are looking to lower their electricity costs. Many have upgraded pump stations by replacing existing magnetic-coupling drives with variable frequency drives (VFDs). Initial costs of VFDs can be relatively expansive depending on the system size and complexity. The payback period, however, is rapid—ranging from just a few months to less than three years—and the benefits are long term. There are various incentives available for energy-efficient equipment. Additionally, water and wastewater facilities that are looking to decrease their energy consumption by upgrading existing less-efficient systems can take advantage of different funding options. In response to the ever-increasing interest in existing and new pumping system practices, the staff of WWD is pleased to bring you its annual supplement publication, Pump Source. Now in its seventh year, Pump Source continues to offer a wide variety of articles, which offer valuable insight into relative and detailed pump applications. Beyond Pump Source, WWD is also the organizer and co-sponsor of PumpTec 2009, the 5th Annual Pump Theory and Hands on Maintenance and Reliability Conference, to be held Sept. 14 to 15, 2009, at the Holiday Inn Select in Norcross, Ga. Attendees will learn how to assemble and troubleshoot pumps to improve reliability and extend their life. Efficiency and energy savings will also be discussed. More information is available at www.pumpconference.com. PS
Neda Simeonova, editorial director [email protected] PUMP SOURCE 2009
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application drives
By Mark Kenyon
Driving Efficiency
City of Lawrence, Ks., moves from across-the-line starts and constant-speed operation to ramp up/down of critical lift station pumps via motor drives
W
ith 450 miles of sanitary sewer collection lines and 33 lift stations that feed into a central wastewater treatment plant, the city of Lawrence, Ks., has an extensive wastewater management system. The city has been recognized as one of only two in the nation that have three environmental management certifications for wastewater operations. These certifications demonstrate the city’s ability to provide customers with an efficient level of service while maintaining a high standard of environmental protection.
The Need for Retrofit Gravity is the driving force for wastewater distribution to the treatment plant, except where there are vertical elevation changes in the topography. In these circumstances, lift stations are used to move wastewater to the treatment plant. Because of ongoing increases in demand, Dave King, the city’s wastewater maintenance manager, is continually looking for ways to improve efficiency. Lift Station No. 16, built in 1958 and located close to downtown Lawrence, transports about 600 million gal of dry-weather flow per year, about 25% to 30% of the city’s wastewater usage. The combination of aging equipment and increasing flow from new residential developments led to the decision to retrofit the station completely in the spring of 2006. King turned to the city’s longtime PLC supplier, Logic, Inc., to help develop a solution. ACS800 drives were installed on each of four new 125-hp pump motors to: increase efficiency and power factor, improve electricity cost savings, extend the life of the motors, reduce repair costs and minimize or eliminate harmonics that can interfere with instrumentation.
Ensuring Constant Flow When wastewater enters a lift station, it initially goes through a course screening process, which removes solid particles that might cause damage to the pumps. The wastewater then flows into an enclosed wet well, which can
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be 30 to 40 ft deep. Sensors monitor the depth of the wastewater in the wet well. Pumps are used to displace the wastewater from the well to the treatment facility. Drives often play a key role in supporting the pump operation, ensuring that a constant flow is discharged to maintain optimum wastewater levels. “By controlling pump speed, an optimum level can be maintained that ensures constant flow between what’s coming in and what needs to be pumped out,” King said. “Installing the ABB drives has enabled us to eliminate unnecessary pump starts.” Previously, the site ran the pumps based on an on/off level and used an across-the-line starter. When the level in the wet well reached a designated point, it would trigger the starter to get the pump motors up to maximum speed as quickly as possible. This rapid acceleration created spikes and mechanical stress on both the motor and pump. It would run at full speed until it reached the off-level elevation, and then it would turn off. The continuous starting-and-stopping process caused wear and tear on the bearings and impellers, causing the motors to deteriorate.
to limit potential turbulence and reduces the need for maintenance. The drives respond to sensors in the wet well that are relayed to a PLC unit via DeviceNet. The plant communicates with the PLC unit at the lift station via Ethernet to ensure that wastewater levels are being pumped out consistently, based on established parameters. Although three pumps are needed to run the station, the city keeps an installed fourth pump on
standby at all times, running them alternately to balance wear. The station operates 24 hours per day and cannot afford downtime. “ABB drives give us the ability to handle the wide range of variations in wastewater flow entering the station due to time of day, time of year and weather conditions, as well as the capacity to accommodate future growth,” King said. “The fact that we can now pump wastewater out at
Preventing Water Hammers By maintaining a consistent level in the lift station wet well, drives also help to avoid water hammers. When a pump starts or stops suddenly, it slams the check value on the back of the pump and creates a water hammer effect (pressure surges caused by the energy of a fluid in motion when it is forced to stop suddenly). In a lift station, hydraulic water hammers often occur when trying to pump fluid vertically or at a slant. Once a pump stops, the fluid will come back to the source, jarring the piping. Over time, water hammers can lead to pipe deterioration. Because the ACS800 drives provide acceleration and de-acceleration ramp to the pumps, wear and tear on the pump mechanicals is reduced.
Drives & Bypass Drives also incorporate a soft-start function that gently ramps speed write in 8120
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the same rate it enters also helps us reduce odors.” Because wastewater is constantly running throughout the city, another important feature to the lift station is the bypass function, which allows a manual override of the pump if a drive was to go offline. “Even though modern drives are very reliable, if for any reason we were to have multiple drive failures, the bypass gives us the ability to still operate the station,” King said. “At this location, station downtime is not an option.”
ULH drives feature bypass valve, fuse disconnect, remote I-O and selector switches.
Providing Protection Because the lift station is located next to a residential district, minimizing harmonic distortion is a necessity. With the amount of dynamic load on the existing transformer, standard drives were not a viable option. “Excessive harmonics can interfere with pump instrumentation,” King said. “Plus, we didn’t want
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to cause any interruption to the electrical appliances of our customers.” Ultra-low harmonic (ULH) ACS800 drives do not require a multipulse transformer, external filters or other additional equipment for minimizing harmonics. The drive features an active converter with direct torque control to eliminate low-order harmonics. With an active front-end inductor/ capacitor/inductor line filter to reduce high-frequency harmonics, the city did not have to worry about overheating feeder breakers or transformers.
ABB drives in four other wastewater pump stations now under construction. “I anticipate extended pump life, electric cost savings and ultimately better service to our customers as a result of ABB drives,” King said. PS
Because the drives were shipped with all of the specifications preinstalled, installation was smooth and easy. To maintain constant uptime during the retrofit, two pumps were taken offline at a time, keeping the other two pumps running.
Mark Kenyon is manager, component AC products, for ABB, Inc., Low Voltage Drives. Kenyon can be reached at 262.785.3200 or by e-mail at mark. [email protected]. For more information, write 1101 on this issue’s Reader Service Card.
Turnkey Solutions ABB offered turnkey solutions direct from the factory. “We required certain features in the cabinet, such as a bypass, fuse disconnect, remote I/O and selector switches. ABB was able to provide all that from a factory service center,” King said. “The lift station fits in a 900-sq-ft space and the ACS800’s compact footprint fit well into the facility.”
A Continued Relationship The lift station retrofit was not the first instance where the city has benefited from using ABB drives. The wastewater treatment facility also has ABB drives equipped with bypass to increase efficiency. Because of the positive experience with the drives at Lift Station No. 16, the city is installing
WEB resources hhh Related search terms from www.waterinfolink.com: pump station, drives, harmonics, bypass For more information related to this article, visit www.wwdmag.com/lm.cfm/ps040901
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application controllers
Smart
Control
T
he East Bay Regional Park District (EBRPD) is designated a special district by the state of California.
It is the largest special district in the U.S., with more than 90% of its land protected and operated as natural parklands.
By Carl L. Meisner
A California park district finds value in its new pump control system
EBRPD is responsible for 1,745 sq miles of land, encompassing both Alameda and Contra Costa counties on the eastern side of San Francisco Bay. It manages 29 park trails, 65 parks, camping and recreation areas, lakes and lagoons, wilderness, shorelines, fishing docks and preserves as well as education centers and conference facilities. For such a large and widely spread district, effective management of water and wastewater is critical. The supply of potable water—and wastewater collection and treatment—needs constant monitoring and control across all facilities to prevent problems and avoid any possible environmental issues.
New Five-Year Plan “We used to have an amalgam of antiquated and largely incompatible equipment to control 38 pumping stations. Some wastewater pumps dated back to the 1970s,” said Richard Guest, water utilities maintenance
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supervisor for the district. “Two years ago, I developed a five-year plan to modernize all wastewater plants and pump stations. The objective was to develop a highly reliable, centralized control system that is simple to operate and can accommodate SCADA with minimal adaptation.” “However,” he continued, “I had to consider our many employees who transfer within the district on a regular basis, and a significant number of part-time and seasonal employees as well. It became crucial to standardize every panel so that employees would not have to relearn how to operate unfamiliar equipment when they moved around. We also wanted a simple, user-friendly configuration. Simplicity is key to a well-managed, smooth-running operation.” In the past, the district’s water and sewer pump stations had no communications ability at all. Visual inspection was the only way to identify a problem at a pumping station, and
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to use the equipment. All I had to do was select an answer and confirm.” With MultiSmart controllers, there are several fail-safe features built into the system. For instance, the controller has alarms and pre-alarms, where an operator is notified prior to an alarm. The system is not limited to only look at things that have failed. It is also able to pinpoint potential failures and other problems before they happen. “Suppose the sewage level has risen
far enough that a pre-alarm is tripped,” Guest said. “Once the operator is alerted, he can log onto a system computer and check the station in question. It’s not in alarm mode yet, but it’s past the point that an operator would normally be comfortable if he were standing there watching the station.” District staff controlling the pump stations are able to log into a station and take a critical look and see if a pump has failed to start, or a pump
Wouldn’t it be nice to have a hose pump that: ɶ Provides exceptional dosing accuracy ɶ With flow rates from 3.5 US GPH - 450 US GPH ɶ Can pump abrasive, any failure had to be addressed on site. After extensive review of pump control systems, MultiTrode’s MultiSmart pump controllers were selected by EBRPD for their proven reliability and modular expansion and open interface capabilities. Other positive considerations included easy installation and simple, intuitive operator controls. The controllers combined ease of use with advanced functionality for up to nine pumps.
The Installation During installation, no design modifications were required, the product was user-friendly and easy to understand and no setting or programming adjustments were needed. “The installation was the easiest thing I ever did,” Guest said. “I took the unit out of the box, wired it up, turned it on and it ran. The initial startup screen came on, asked me four or five questions and gave me a choice of options depending on how I wanted
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is starting too fast, or even if the sun is heating the inside of the control panel and causing a component to malfunction. Any of these conditions would prompt a pre-alarm signal. The controller not only sends a signal, it is capable of identifying the problem. As part of the five-year plan, EBRPD is preparing for SCADA to go online in the fall. With SCADA interfacing with MultiSmart controllers, a centralized network will be able to reset, troubleshoot and otherwise correct the majority of problems directly from a remote location computer or a centralized computer. With SCADA, the operator can see what the problem is, what caused the problem and decide to either reset it from the base computer or dispatch someone to the station for service. The dispatcher can tell that person exactly what he or she is going out there for, what to do and what to bring.
Cost Savings & Flexibility EBRPD has pump control stations
all over the 1,700 sq miles it covers, and sometimes it takes up to an hour and 20 minutes to reach a location. “The real cost saving is not in the purchase price or installation cost, but on the operational and maintenance side. The new pump controllers have greatly reduced the need for emergency responses,” Guest said. “Now the stations are checked once a week, and it takes less than 30 minutes. In fact, we are to the point where we almost never have emergency calls on our wastewater pumping stations. This results in much less overtime. In the past, when we had a problem, someone had to go quickly, regardless of the time or day.” Performing predictive maintenance used to be a manual operation. Now tracking things like bearing and field life in station pumps is accomplished systemically, without estimations or calculations from the operator. The controllers are capable of accommodating up to four different software
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EBRPD staff checks the district’s new pump controllers once a week, and the inspection takes less than 30 minutes.
WEB resources hhh Related search terms from www.waterinfolink.com: pump station, controllers, SCADA For more information related to this article, visit www.wwdmag.com/lm.cfm/ps040902
changes to the control panel by making simple software configuration changes with little more than a flash card. In a parks and recreation district, flexibility in pump station control is an important issue. Sudden population shifts at the park may require a station to perform differently or that alarm criteria change to accommodate a critical upcoming event. In the past, the pumps were either on or off, and the same applied to the alarms. The new controllers also allow stations to communicate with each other. This is a very valuable feature. In cases where there are long distances to the sewer, there are often multiple stations connected serially. If one station fails, it can communicate to the stations behind it to stop pumping and become holding tanks to eliminate the risk of overflow.
can still function when there is a power outage is cost savings waiting to happen. Sometimes extreme heat from the sun will cause a circuit breaker to trip. When that happened with the old system, there was no way to tell. Consequently, people used to check stations two and three times a day. The new system not only works without power, but it also signals when a circuit breaker is turned off; service people know immediately and can fix it before a more serious problem develops. A value-added feature of the controllers is their ability to protect pump motors from sporadic voltage sags and surges or spikes on the utility line. If a pump is running during one of these events, it can harm the motor. PS Carl L. Meisner is a contractor for MultiTrode. Meisner can be reached at 760.231.5483.
Additional Advantages The controllers also come with battery packs. The fact that the system
For more information, write 1102 on this issue’s Reader Service Card.
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application sewer flow
I
n wastewater applications, siphons work to divert sewage under large obstructions such as rivers or streams. In such applications,
a siphon structure serves as a basin that collects sewage on one side, then delivers it through underground pipes to a slightly more elevated basin on the other side using atmospheric pressure.
Siphon bypass eliminates leak, prevents potential sewage spill and increases sewer flow
A Leaky Siphon The San Antonio Water System (SAWS) makes use of a siphon capable of 92 million gal per day (mgd) in its Historic Mission Reach area. Installed in the 1940s, this 54-in. double-barrel siphon diverts roughly 21 to 40 mgd of sewage under the San Antonio River. Though it had been successfully repaired throughout its years of service, the siphon showed signs of leaking in late 2006. SAWS determined that the structure was irreparable and needed to be replaced as soon as possible. “We realized that we were continuing to make repairs to a leak at the base of this structure, and that there was the potential for creating a larger problem if we kept trying to make repairs to it,” said Ernesto Leal, superintendent for SAWS. “Obviously, we wanted to proactively avoid a catastrophic event.”
more quickly than the previous concrete structure. In addition, having the pipe buried underground presents less surface exposure to sewage overflow. The SAWS management team— including Leal, Mike Sellers and Gordon Mahan—developed a plan to dig and replace the structure. At the same time, they called on Godwin
1
A Reliable Solution
By Stephanie Maurer Morgan
SAWS elected to replace its failing high-flow siphon structure with newer technology that depends on buried fiberglass pipe. When the pipe is in place, the fiberglass makeup will deliver the flow of sewage through the line
S uccessful
siphon bypass
1
The pumps were equipped with digital controllers, allowing them to stop and start automatically.
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Pumps—on contract with the organization—to provide a bypass solution that would divert the maximum peak flow of 40 mgd, with ability to handle wet peak flows of 70 to 92 mgd.
A Large Bypass “I have been working with SAWS since 1992,” said Godwin Pumps San Antonio Branch Manager Greg White. “However, this is by far the largest bypass we have designed for them, and it involved crossing the San Antonio River, which presented a challenge.” Within 20 days of receiving the call from SAWS, Godwin had designed, delivered and installed a complete system that included 12 Critically
Silenced Dri-Prime CD300M (12-by12-in.) pumps and four open-unit CD300M pumps for standby. Each pump is capable of delivering flows to 6,000 gpm and heads to 200 ft. Powered by Caterpillar C-9 engines, the pumps were equipped with PrimeGuard controllers. The PrimeGuard is a digital control system that can be programmed to vary pump and diesel-engine speed based on input from level floats, allowing the pumps to start and stop automatically without an operator. These controllers came in handy on Feb. 1, 2009, when the use of more pumps was required to keep up with the extraordinary flow that was generated during the Superbowl.
3
In addition to the diesel-driven pumpsets, Godwin installed five 18-in. and two 24-in. high-density polyethylene (HDPE) pipes, each running 3,800 ft for a total of five miles of pipe. While a majority of the HDPE pipe setup was routine, the pipe did eventually have to cross the San Antonio River. The pumps were situated upstream of the leaking siphon, intercepting the flow from the two 54-in. lines through a custom-designed and -built concrete suction pit. Bypass pumping began on Nov. 5, 2008, and ended on March 6, 2009, after the new 54-in. fiberglass siphon structure installation was completed. “Our short-term goal was to bypass the leak at the old siphon structure and to prevent sewer from spilling into the San Antonio River,” Leal said. “In the long run, we are also looking to increase sewer flow with the new siphon.” Making use of a custom-built suction pit and automatic self-priming pumps with digital controllers, and installing the latest in fiberglass pipe technology, SAWS has taken this Historic Mission Reach project to test the effectiveness of “new technology” and is happy to report success. PS Stephanie Maurer Morgan is corporate communications manager for Godwin Pumps. Morgan can be reached at 856.467.3636 or by e-mail at stephanie.morgan@ godwinpumps.com.
2
For more information, write 1103 on this issue’s Reader Service Card.
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2
Five miles of HDPE pipe were installed, and some of it had to cross the San Antonio River.
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3
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The pumps were situated upstream of the leaking siphon, intercepting the flow through a customdesigned and -built concrete suction pit.
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application dosing
T
By Gary Rose
he quality of life for Americans was greatly enhanced in the early 1900s due to the introduction of chlorinated drinking water throughout the U.S. water systems. From the stockyards of Chicago to the Boonton Reservoir of Jersey City, the case was established that filtration alone was not sufficient to guarantee clean water. By the 1920s, chlorination was well entrenched as the primary means of disinfecting drinking water. The combination of filtration and chlorination reduced typhoid fever by 91% within five years, which led to its near eradication by 1936, according to a statistical study of disease rates. Chlorine-based disinfectants have been the choice for treating drinking water since the turn of the 20th century. This is the only type of disinfectant that provides a residual in the distribution system that is vital to preventing waterborne diseases. Three forms of chlorine that are commonly used are gaseous chlorine, calcium hypochlorite tablets and sodium hypochlorite solution. However, safety concerns and costs have prompted many municipalities to switch from chlorine gas to sodium hypochlorite. The most common disinfection method is some form of chlorine or its compounds such as chloramine or chlorine dioxide. Other nonchlorine-based disinfectants are ozone and ultraviolet radiation.
peris taltic
advancements
Using peristaltic pumps to pump sodium hypochlorite in water treatment plant applications
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According to the Water Quality and Health Council, 98% of systems that treat water utilize chlorine-based disinfectants. Moreover, the World Health Organization concurs that disinfection by chlorine is still the best guarantee of microbiologically safe water.
Case Study The Orange Water and Sewer Authority (OWSA) operates the Jones Ferry Road Water Treatment Plant in Chapel Hill, N.C. The plant serves as a model for state-of-the-art improvements. The plant can treat up to 20 million gal of raw water daily—nearly double the average demand of water usage from the local population of 70,000 people. The water treatment process encompasses several phases. The first phase is the addition of powdered carbon to the water supply from the lakes to improve the taste and control odor in the water. Secondly, the solid particles are separated from the water in settling tanks. Once that process is complete, the water is pretreated with sodium hypochlorite and then filtered through layers of sand and anthracite coal. Lastly, chemicals are added for disinfection and public health. The chemicals include chlorine, ammonia and fluoride. The pretreatment stage consisted of a bank of 10 diaphragm pumps injecting sodium hypochlorite continuously and simultaneously at a rate of 1.3 gal per minute against zero back pressure. OWSA noticed numerous problems with the diaphragm pumps in this WWW.WWDMAG.COM
3/20/09 5:40:02 PM
particular application. The central issues were the outgassing or off-gassing of the sodium hypochlorite and the inability of the diaphragm pump to operate efficiently due to the gas buildup in the pump head. Enviably, a loss of prime would occur, costing OWSA valuable downtime. Despite the fact that auto-degassing valves were implemented, the problem was not totally eliminated. Consequently, the treatment plant’s chief operator, Dusty Martin, was compelled to make the switch to peristaltic pumps. First and foremost, the peristaltic pump eliminates the core problem with outgassing of the sodium hypochlorite by utilizing precision-engineered rollers to optimally squeeze a heavy-duty norprene tube efficiently and with unparalleled accuracy. Gas has no effect on this simplistic pumping method. Furthermore, the tube life has been greatly increased through an innovative rotor design that allows the pump to handle the same maximum pressure in
either direction. The ability to reverse the motor, in essence, doubles the tube life. Of course, the tube life will always vary depending on the chemical used, the output pressure, the size of the tube and the rpm of the motor. Other notable advancements with the peristaltic pumps include a tube failure detection system built into the pump head; increased output pressure of up to 125 psi; precision stainless steel ball bearings supporting the front and back of the rotor shaft; and highly advanced electronics to connect to SCADA systems. At the Jones Ferry Road plant, the peristaltic pumps are wired via 4-20mA into the SCADA system for monitoring and alarm responses. Martin said that he was amazed how easily the peristaltic pump hooked up into the plant’s SCADA system. Continual monitoring using powerful graphic and alarm software programs allows the SCADA system to ensure the exact amount of chemicals have
been dispersed into the water supply. In addition, Martin said that the dosing is much more precise, accurate and consistent using a peristaltic pump compared to a diaphragm pump. Overall, Martin highly recommends a peristaltic pump over a diaphragm pump for sodium hypochlorite injection. PS Gary Rose is president of Rose Industrial Marketing, Inc., and a representative of Blue-White Industries. Rose can be reached at 800.975.5469 or by e-mail at [email protected]. For more information, write 1104 on this issue’s Reader Service Card.
WEB resources hhh Related search terms from www.waterinfolink.com: peristaltic pumps, sodium hypochlorite For more information related to this article, visit www.wwdmag.com/lm.cfm/ps040904
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application metering
By Chuck Treutel
The elegantly simple operation of peristaltic pumps
P
eristaltic pumping is the fastest growing pump technology in the world, displacing more complex and higher-maintenance positive displacement (PD) pumps for chemical metering. Acids, caustics and solvents attack diaphragm and progressive cavity pumps, causing downtime and increased life-cycle costs. The peristaltic principle mitigates these costs. Peristaltic pumps are valve-less and seal-less and have no mechanical parts in the product stream. The fluid only comes into contact with the inside of a hose or tube element, which is a low-cost, low-maintenance and easily serviceable component. A peristaltic pump’s operation is elegantly simple. A hose or tube element is positioned along a stationary pump housing and is compressed from the outside by a roller (tube pump) or a shoe (hose pump). Fluid is pushed toward the discharge as the roller or shoe moves along the outside of the element while the restitution of the hose or tube element behind the shoe draws more fluid into the pump. The heart of the pump is a hose or tube that is available in different elastomers specifically formulated to balance
long mechanical pumping life with resistance against concentrated acids, bases and solvents. The “wetted end” simplicity of a peristaltic pump stands in contrast to a diaphragm pump, where one must properly select materials for the pump housing, diaphragm, ball checks and seals to prevent pump failure from corrosive attack.
Accuracy PD pumps are normally chosen to accurately meter or dose exact amounts of chemicals. In a peristaltic pump, flow is proportional to pump speed, and the complete closure of the hose or tube element at all times gives the pump its positive displacement action, preventing flow drop or erosion from backflow and eliminating the need for check valves. Without check valves, peristaltic pumps eliminate the primary source of metering inaccuracy and will not vapor-lock. The “turndown ratio” or “flow range” of a peristaltic pump is unparalleled. A high-quality peristaltic pump is capable of a more than 2,000:1 flow range by simply controlling one parameter—the rotor speed. With the added versatility of putting different tube sizes into one pump, the flow range
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expands to 1,000,000:1 range with a single pump. Diaphragm pumps are normally limited to 20:1 speed range with typical controllers.
Life-Cycle Costs While the initial capital cost of a peristaltic pump can be slightly higher than other PD pumps, an assessment of costs associated with ancillary items, installation, maintenance downtime and spare parts quickly tip the life-cycle cost calculation in favor of the peristaltic pump. With the tube or hose element being the only wetted part, peristaltic pumps are virtually maintenance-free, with no expensive seals to replace, no check valves to clog and no rotors and stators to wear out. In a peristaltic pump, the hose or tube element needs periodic replacement. Industrial-duty peristaltic pumps will provide thousands of hours of reliable and repeatable hose or tube life before the element fatigues and needs replacement. When it comes time to replace a hose or tube element, the procedure takes less than an hour and in some cases only a couple of minutes. Additionally, the change of the element is done quickly and safely where the pump sits without the need for any special tools. Process control requirements and chemical compatibility often make peristaltic pumps a lower-cost capital item than other PD pumps, delivering financial benefits even before the reduction in maintenance and ancillary costs are considered. For example, a progressive cavity pump’s price can be exponentially inflated when expensive metallurgy becomes the only corrosionproof option for its components. Additionally, many PD pumps require the additional cost of a separate control panel or variable frequency drive (VFD) for achieving variable flow metering. Peristaltic pump manufacturers build high-turndown, closedloop speed control capability and expansive I/O connections for DCS and SCADA systems into their pumps.
Chemical Applications Historically, there was a technological limitation to applying peristaltic pumps to heavy-duty chemical
applications; they lacked in-hose or tube design that could withstand highly corrosive fluids while yielding long life at continuously high pressures and flow rates. For this reason, peristaltic pumps have found their niche in low-pressure, batch pharmaceutical processes, with limited use in industrial processes. This has turned around over the past 50 years, however. Pumps and chemical duty elements have been developed that are
capable of more than 350 gal per minute (gpm), 240 psi, thousands of hours of continuous-duty hose and tube life and metering accuracy better than 0.5%. Peristaltic pumps have proven to be highly resistant to the acid and caustic chemicals that quickly eat away at the metallic components of progressive cavity and diaphragm pumps. For example, an engineered plastics manufacturing plant in the Southeast uses a SPX10 pump with a rubber hose to meter hydrochloric
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acid in the production of linear polyphenylene sulfide. Because of the hose pump’s metering capability, the plastics manufacturer does not require separate flowmeters and valves to measure and control the flow. Rather, they adjust the speed of the feed rate by simply altering the rpm of the rotor motor with a VFD. A power generation servicing company in the Mid-Atlantic region uses peristaltic pumps to meter 65 gpm of sulfuric acid when cleaning out the condensers
of a power plant, driving the pH below 4 to breakdown scale. Precise control of the flow of the acid is necessary to ensure that after the scale is dissolved, the discharge to the municipal wastewater system will have a neutral pH. On the other side of the pH scale, peristaltic pumps are used extensively with sodium hydroxide for many different applications such as bleaching pulp at paper mills and disinfecting potable water. Because the hose in a peristaltic
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pump is self-cleaning, it does not experience the crystallization that builds up in other pumps and eats away at seals. Until recently, petrochemicals, hydrocarbons and oil-based products were all beyond the reach of peristaltic pumps due to incompatibility with the rubber hose. A new thermoplastic elastomer hose called PetroProof, introduced by Watson-Marlow Bredel, is now available for toluene and other highly corrosive solvents used in the production of a number of materials. Frequently, corrosive fluids contain not only corrosive chemicals, but abrasive material as well. Peristaltic pumps, originally designed for caustic and abrasive cement applications, stand up well to the challenge. A Southeastern U.S. building products manufacturing plant also uses peristaltic pumps to make its fiber cement siding products. The cement mixture has little effect on the hose despite being highly abrasive and strongly basic. Despite all of the advantages of peristaltic pumps, they represent only a modest but growing percentage of the market in the U.S. This is primarily because peristaltic technology is relatively new, whereas diaphragm and progressive cavity pumps have a lengthy history. However, with the pressure on plant managers to reduce the life-cycle costs of their pumps, the functionality and benefits of peristaltic hose pumps are becoming more widely known, and new peristaltic technology is fast becoming the pump of choice for tough, chemically aggressive and abrasive applications. PS Chuck Treutel is marketing manager for Watson-Marlow, Pumps Group. Treutel can be reached at 608.883.6851 or by e-mail at [email protected]. For more information, write 1105 on this issue’s Reader Service Card.
WEB resources hhh
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