Fluid Handling International May/June 2017

HELPING TO KEEP YOUR BUSINESS FLOWING

MAY/JUNE 2017

Issue 3 Volume 5

The ‘world’s biggest’ water gate valve How a British company helped solve Dallas’s growing water demand

Winds of change The ways the latest radar level technology can benefit the water and environmental sectors

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COMMENT & CONTENTS

Contents May/June 2017 ISSUE 3 • VOLUME 5

Woodcote Media Ltd Marshall House 124 Middleton Road, Morden, Surrey SM4 6RW, UK www.fluidhandlingmag.com MANAGING DIRECTOR Peter Patterson Tel: +44(0)20 8648 7082 peter@woodcotemedia.com

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Latest news

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Cutting-edge leak detection in an ancient city A water utility in Jerusalem deployed a revolutionary new system to search for leaks in the city’s water infrastructure

26

Designing the ‘world’s biggest’ water gate valve Blackhall Engineering designed the ‘world’s biggest’ water gate valve, to help deal with Dallas’ ever increasing water demand

Optimising flow control in the digital age How the Industrial Internet of Things is revolutionising fluid handling

16

Harnessing the energy of the sea Marseille uses the potential of the Mediterranean for heating and cooling buildings

28

Keeping the flow Repeatable, accurate non-contacting liquid open channel velocity measurement

20

Proper pump selection for wastewater treatment plant pumps Selecting the right pump for maximum efficiency and consistent reliability

30

Winds of change How the latest radar technology can benefit the water and environmental sectors

33

Chemical control in wastewater Reliable coagulant dosing is key to successful phosphorus control

35

Water leak detection from up high An interview with Yolande Louvet from the WADI project, a company developing an airborne water leak detection system for rural areas

Choose your mixers – stainless steel versus fibreglass Fibreglass or stainless steel impeller blades for your treatment plant’s mixers?

DEPUTY EDITOR Liz Gyekye Tel: +44 (0)20 8687 4183 liz@woodcotemedia.com ADVERTISING SALES MANAGER Russell Priestley Tel: +44 (0)208 6487 092 russell@fluidhandlingmag.com PRODUCTION Alison Balmer Tel: +44 (0)1673 876143 alisonbalmer@btconnect.com

Neither too much nor too little Finding the right amount of agitation for water and wastewater applications is pivotal for maximum efficiency and better reaction times.

12

22

EDITOR Daryl Worthington Tel: +44 (0)20 8687 4146 daryl@woodcotemedia.com

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HELPING TO KEEP YOUR BUSINESS FLOWING

Issue 3 Volume 5

MAY/JUNE 2017

The ‘world’s biggest’ water gate valve How a British company helped solve Dallas’s growing water demand

Winds of change The ways the latest radar level technology can benefit the water and environmental sectors

FC_FH_may/june_2017.indd 1

Front cover courtesy of Blackhall Engineering

05/05/2017 15:46

Comment Dear reader,

SUBSCRIPTION RATES A one-year, 6-issue subscription costs £150 (approximately $240/€185 depending on daily exchange rates). Individual back issues can be purchased at a cost of £30 each Contact: Lisa Lee Tel: +44 (0)20 8687 4160 Fax: +44 (0)20 8687 4130 marketing@woodcotemedia.com

Join Fluid Handling International on Linkedin to discuss important issues Follow us on Twitter: @FluidHandIntl No part of this publication may be reproduced or stored in any form by any mechanical, electronic, photocopying, recording or other means without the prior written consent of the publisher. Whilst the information and articles in Fluid Handling are published in good faith and every effort is made to check accuracy, readers should verify facts and statements direct with official sources before acting on them as the publisher can accept no responsibility in this respect. Any opinions expressed in this magazine should not be construed as those of the publisher.

The worldometers website has a real time meter counting the amount of water consumed globally each year. Increasing at a phenomenal rate, the figure stood at more than 3.7 billion litres at the time of writing. It brings home the importance of water, but also that the monitoring and management of this most basic element has become synonymous with the latest technology.

As the world’s population continues to grow, so does the demand for water. As you’ll see in this issue of Fluid Handling, this demand presents a challenge which is pushing innovation among engineers, businesses, water utilities and industry to make sure this vital resource is managed as effectively and efficiently as possible.

In the city of Dallas, a massive engineering project has culminated in the construction of what is claimed to be the world’s biggest water gate valve. In Marseille, France, meanwhile, seawater is being harnessed in revolutionary ways to be used for both heating and cooling buildings.

Cutting-edge technology is being developed to detect water leaks in cities and rural areas.

This issue presents two particularly unique examples, one based from up high, one from within the pipes themselves.

Other companies are taking advantage of the most modern systems, software and technologies, from radar to the Industrial Internet of Things, to meet ever more complex fluid handling needs. We present several particularly fascinating examples which have the potential to be hugely important across the industry.

If there are any topics you’d like to see covered in future issues of Fluid Handling, or any industries or innovations you feel we need to pay attention to, please feel free to contact me at daryl@woodcotemedia.com with your suggestions.

Best wishes,

Daryl ISSN 2399-5602 1

PUMP NEWS

Xylem and DC Water install North America’s ‘first’ intelligent wastewater pumping system In Washington D.C., global water technology company Xylem has presented DC Water with the first North American installation of its Flygt Concertor integrated intelligence wastewater pumping system.

Fusing software and hardware, the Flygt Concertor wastewater pumping system senses the operating conditions of its environment and adapts its performance in real time.

It increases the sustainability of the wastewater sector by consuming considerably less energy, cutting inventory needs, and ensuring reliable, clog-free wastewater pumping while reducing the overall cost of ownership.

DC Water and Xylem are working together to highlight the urgent need for investment in smart water structures to maximise operational productivity and benefit customers.

A report released in March 2017 by the American Society of Civil Engineers estimated that the US needs to invest a minimum of $123 billion (€114 billion) annually in water structure over the next decade to ensure a good state of repair.

“In the US, our water and wastewater infrastructure faces a daunting investment gap that places these critical systems at risk and leaves our communities vulnerable to the consequences of system failures,” said Patrick Decker, president and CEO of Xylem.

“We are so pleased to be able to partner with DC Water – a true industry leader – to address these challenges, leveraging technology to develop new, more sustainable solutions. Our Flygt Concertor is a great example of the type of break-through technology that we believe will fundamentally alter the way water and wastewater is managed. Working together, we will be able to bring those solutions to fruition even faster.” z

‘World’s first’ cryogenic scroll pump in development Broomfield, Colorado based oil free scroll design and manufacture specialist Air Squared has announced it is developing the world’s first cryogenic scroll pump. Named the CryoScroll, the electrically driven pump is intended for pumping multi-phase cryogenic fluids.

The Department of Energy (DOE) has awarded Air Squared ‘Phase I Small Business Innovation Research (SBIR)’ funding to support the development of the CryoScroll. The DOE is looking to further the development and reduce the costs of specialised particle and radiation detection, as part of its High Energy Detectors and Instrumentation focus.

A series of particle physics experiments the DOE has planned, such as upgrades on the Large Hadron Collider, the Deep Underground Neutrino Experiment known as DUNE and next generation searches for dark matter, require specialised detectors.

Air Squared proposed its submerged cryogenic scroll pump to address the need for large-scale cryogenic detectors.

When completed and if successful, Air Squared’s CryoScroll will be able to maintain the necessary differential pressure of 50 psig at speeds under 1000rpm while handling a range of cryostat capacities. z 2

Iwaki Air introduces new 2” TC-X500 series air operated double diaphragm pump Non-metallic magnetic drive centrifugal pumps and systems manufacturer Iwaki Air has introduced the 2” TC-X500 series air operated double diaphragm pump.

Capable of operating with variable air pressures, the powerful pumps are ideal for both start/stop and fully continuous duty pumping applications. The new pumps boast excellent flow rates and a new, heavy duty body design.

Iwaki Air operated double diaphragm pumps can safely transfer a huge variety of liquids, and can be used in many industries.

Corrosive chemicals, liquid slurries, abrasive particle slurries, viscous liquids, fuels, oils, glues, inks and flammable liquids are just some of the potential uses of the 2” TC-X500 Series Air Operated Double Diaphragm Pump.

The new air operated diaphragm pump features a maximum flow rate of 190.2 GPM (720 LPM), and a maximum discharge head of 280 ft (85m). The pumps are available in stainless steel, aluminium, polypropylene and PVDF (Kynar). They use coil spring air spool valves, and have CE, ATEX and FDA (for stainless steel models) certification.

Iwaki’s entire air operated double diaphragm pumps range can be viewed on the company’s website. z

TC-X500 series air operated double diaphragm

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

PUMP NEWS

Watson-Marlow Fluid Technology launches new peristaltic pump

Peristaltic and sinusoidal pump specialist Watson-Marlow Fluid Technology Group has launched its new Quantum peristaltic pump with patented ReNu single use technology cartridge.

The new product is a high pressure feed pump for single use tangential flow filtration, virus filtration and high performance liquid chromatography.

It offers high downstream process yields throughout the pressure range, providing virtually pulse free linear flow, minimal shear and easy validation in line with BPOG (BioPhorum Operations Group) guidelines.

Quantum’s high accuracy combined with flow linearity independent of back

pressure means it can remove the need for flow meters and load cells.

Process efficiency is maximised via the pump’s virtually pulse-free performance. It also features a 3 bar SU processing pressure range up to 20 litre/min with trace pulsation of only ±0.12 bar; integrated 4000:1 speed control ratio; a user interface located at the front of the pump for visual confirmation of operating state and easy access to pump controls; validation and extractable data in line with BPOG/BPSA/USP/ISO guidelines, a ReNu SU Technology Cartridge suitable for Gamma irradiation up to 50kGy. z

We are close to you...

Milton Roy announces new ‘intelligent’ metering pump Milton Roy has announced a new addition to the PROTEUS metering pump family, the company’s line of “intelligent” metering pumps.

According to the company, the PROTEUS Communications Model “expands the pump’s intelligence with programmable inputs and outputs”. Support for Modbus RTU and Profibus (Process Field Bus) DP protocols facilitates high speed, bi-directional communications, in turn allowing plant operators to link devices from different vendors to a central SCADA (Supervisory Control and Data Acquisition) system for control, monitoring and trouble shooting.

The PROTEUS metering pumps are a family of actuated diaphragm pumps driven by advanced variable speed technology to address the exact requirements of chemical addition in water treatment. PROTEUS pumps come in three configurations – Enhanced, Manual and Communications, and can address the process control requirements of a range of water and wastewater treatment, agricultural, chemical, oil & gas; power generation, pulp & paper, and textile industries.

“The PROTEUS metering pumps are among the most intelligent pumps in the industry, and the new communications capabilities enhance feedback and control in a way that makes the pumps even smarter,” said Eric Pittman, product manager – Water and General Industry, Milton Roy. “By expanding the PROTEUS line, we’re giving customers a wider range of choices to fit their specific needs.” z

Armstrong Fluid Technology introduces Pump Manager Fluid flow equipment manufacturer Armstrong Fluid Technology has introduced Pump Manager, a web-based service which uses embedded intelligence and connectivity available through its technologically advanced new line of Design Envelope pumps to provide sustained performance and significantly improved reliability.

Delivered as a highly secure, cloud based application, Pump Manager boasts a number of key features such as real time alerts and warnings, and online trending and analysis of multiple parameters on single pumps.

Pump Manager’s reports and summaries meanwhile, offer a simple and intuitive view of pump performance and key trends. z FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

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VALVE NEWS

Viega introduces ProPress ball valve press for copper fittings Pipe fitting technology developer Viega has introduced its line of Viega ProPress Zero Lead ball valve press x hose thread for copper fittings.

The bronze ball valves are full port and designed for potable water applications, available in ½” and ¾” press sizes and ¾” hose sizes.

Other features include a lockable metal handle, stainless steel ball, and EPDM sealing element.

The Viega ProPress for copper system is available in more than 600 fitting configurations, in sizes ranging from ½” to 4”.

The patented Smart Connect feature, available only from Viega, provides installers with added confidence in their ability to ensure the integrity of connections.

“ProPress has more approved applications than any other press

fitting system, and we look forward to developing more innovative products for the copper fittings market,” said Derek Bower, director of product management – metal systems at Viega.

Viega ProPress is the original press pipe joining system for copper tubing, connecting copper tubing in seconds without flame or heavy equipment.

The system can be customised to suit nearly any residential, commercial, industrial or marine application from potable water to natural gas.

It has been tested to the strictest standards in North America, gaining more approvals than any other press fitting system, the company reported.

Viega ProPress fittings are available with EPDM, HNBR, and FKM sealing elements. z

New industrial ball valve lines launched by Hayward Flow Control

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Hayward Flow Control has announced the introduction of a new generation of thermoplastic floating ball valves: the TBH Series True Union Industrial Ball Valve.

According to the company, the TBH Series’ new System2 Sealing Technology uses the upstream seat as a backup to the downstream seat, thereby enhancing the sealing of the downstream seat. This ensures longer life cycles and performance of the valve compared to conventional seat designs.

Hayward’s TBH family also includes the TBH-Z model with a drilled ‘Z’ ball for Sodium Hyochlorite service, as well as the CVH Series with the Profile2 ball for characterised flow.

Possible applications and uses for the TBH Series include: municipal waste and water treatment, clean water technology, chemical transfer and processing, aquatic and animal life support systems, mining and mineral processing, metal plating / surface finishing, marine, pulp and paper, landfills / environmental infrastructure, and other demanding applications. z

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

VALVE NEWS

Secure Conveying for Your Processes

IMI Precision Engineering connects its valve islands to the Industrial Ethernet IMI Precision Engineering has announced it’s upgrading the connectivity of its IMI Norgren VM and VS ranges of valve islands with PROFINET IRT and EtherNet/IP. The upgrades come in response to customer feedback about the valve islands.

The VM Series Valve Islands are available in both 10mm and 15mm valve body widths and provide flow rates of 430 l/m and 1000 l/m respectively. IMI Precision Engineering has now increased the connectivity options on the VM10 Valve Islands from individually wired, multipole and fieldbus to include Industrial Ethernet. According to the company, the valve islands can be configured from four to 16 stations, with single or double solenoids, providing a high number of manual overrides and tube fitting sizes. The VM Series Valve Island offers more than 15 million configurations.

PROFINET IRT and EtherNet/ IP has also been included in the IMI Norgren VS18/26 Modular Valve Islands. IMI says that this will let the user choose the features they need while also giving

them the modularity to easily expand and add accessories.

Ron Bennett, global product marketing manager for Valves at IMI Precision Engineering, explained: “The upgraded VS and VM Series of valve islands are our most connected ranges yet.

Incorporating the same footprint, reliability and support our customers are accustomed to, but with increased connection flexibility.

“Our support extends beyond developing products. We have implemented a number of services dedicated to helping our customers.

We’re aware that it can be a difficult task to identify the most appropriate component for the application. We are upgrading our online Valve Island configurator which helps customers select the correct valve island for their application. Intuitive, flexible and easy to use, it enables quick specification of the valve island and a live visualisation of their configuration. It also supports 60+ downloadable native CAD formats and price, availability and order-now options.” z

VS Valve Island

The right model for every application Rotating positive displacement pumps have been used for decades in the treatment of wastewater and sludge as conveying systems for all types of media.

Due to their regulatory properties, these pumps guarantee secure, dependable and efficient processing.

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Asahi/America introduces new ball valve with improved capabilities Asahi/America, a producer of thermoplastic fluid flow technologies, has revealed the next generation OmniType-27 ball valve with updated performance features and improved actuation capabilities.

A new smooth ergonomic handle with open/shut indication tops the Omni Type-27, while the rugged, injection-moulded one-piece body includes a single-threaded and sealed end carrier.

Double stem O-ring seals provide added leak protection, and a moulded ISO top flange for actuation mounting can be factory-added to the valve.

The valve is available with socket or threaded end connections in 3/8” through 2”, with PVC and CPVC, both with EPDM seals and PTFE seats, available as body materials. The Omni Type-27 is NSF-61 certified and rated 150psi at 21˚C. Ideal for water treatment, landfills, aquariums, chemical processing, power plants, swimming pools, water features, and fountains, the Omni Type-27 can be electrically actuated with Asahi/America’s Electromni Series 83 electric actuator. z FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

M-Ovas® macerator and NEMO® progressing cavity pump

NETZSCH Pumpen & Systeme GmbH Business Field Environmental & Energy Tel.: +49 8638 63-1010 info.nps@netzsch.com www.netzsch.com 5

FLOWMETER NEWS

Fluenta launches new flow calibration facility, offering uncertainties of under 1% Fluenta has launched a new calibration facility, allowing the company’s flowmeters to be calibrated prior to shipment to their final destination.

Calibration reduces set-up times whilåe also increasing the level of accuracy in flowmeters. According to Fluenta, the flow calibration facility provides a reference meter uncertainty of 0.28%.

Fluenta’s flowmeters use ultrasonic technology to deliver accurate measures of flow in a range of different temperatures and flow levels.

The company claims that the new facility is particularly relevant for customers who need better than standard accuracy without having to invest in third party certification by industry bodies. Tests at the Colorado Engineering Experiment Station showed that Fluenta’s range of meters performed with an uncertainty of less than 3% without prior calibration.

Sigurd Aase, CEO of Fluenta, says: “Accuracy can be challenging in flow measurement during periods of low flow velocity or where temperatures vary.”

“Offering our customers the ability to calibrate meters before they leave the Fluenta factory means they can be confident they will receive the most accurate and consistent readings possible.”

Fluenta is a specialist in flow sensing, measurement and management using ultrasonic technology, serving the chemical, petrochemical oil and gas markets. Originating from Norway, the company also has offices in the UK, Poland and US. z

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FS10i Flow Switch/ Monitor approved for flow detection and alarming in hazardous areas The compact FS10i Flow Switch/Monitor from Fluid Components International (FCI) has obtained hazardous area approvals from a wide range of agencies for a host of liquid or gas monitoring applications which require accurate, reliable flow assurance and alarming. The monitor was specifically designed for operation in rugged, industrial processes.

Among the agency approvals obtained are FM and FMc for nonincendive, Class I, Division 2, Groups A,B, C, D; Class II, Division 2 Groups E, F, G; Class III, T4@Ta=71°C; ATEX, IECx nonincendive for gas and dust, Zone 2; EAC (TRCU) Russia, II 3 G Ex nA IIC T4 Gc, II 3 D Ex tc IIIC T81°C Dc, IP64.

The FS10i Flow Switch/Monitor is ideal for flow detection and alarming in industries such as chemical, refining, power generation and more. Remarkably rugged, the FS10i Flow Switch/Monitor can be used in fluid temperatures ranging from -40° to 250°F (-40° to 212°C) and at pressures up to 2000 psi (138 bar).The device’s electronics are stored in stainless steel body housing with aluminium end cap/top with polycarbonate overlay. Input power is 24 Vdc (21.5 to 30 Vdc); 2.5 Watts maximum.

Versatility is a key feature of the FS10i Flow Switch/ Monitor. It is ideal for monitoring cooling water and fluids, leak detection, lubricant flow assurance, ventilation verification, chemical injection assurance, nitrogen purge verifications and compressor leak detection. z

Mass meter for extremely low flows unveiled by AW-Lake Company AW-Lake Company has revealed its latest Ultra Low Flow Coriolis mass meter.

The MicroTRICOR TCM-100 mass flowmeter is designed to accurately measure extremely low flow rates. It is suitable for use in batching, blending and dosing; for applications such as chemical injection, precision painting and coating, and batch processing associated with liquid or gas handling and dispensing.

According to AW-Lake company’s website, the MicroTRICOR TCM-100 is the only flowmeter of its kind offering a compact dual tube design, giving it greater stability and resistance to external vibration.

The MicroTRICOR TCM-100 is different to volumetric flowmeters in that it measures mass rather than volume.

The company claims this provides greater accuracy, as the mass of a fluid or gas is unaffected by pressure, temperature or viscosity. In turn, this means the flowmeter gives reading unaffected by external conditions. z FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

FLOWMETER NEWS

Krohne launches new Optimass flowmeter approved for custody transfer of liquids and gases Flow measurement specialist Krohne has introduced a new Optimass 2000 S400 16-inch Coriolis mass flowmeter.

According to the company, the large diameter mass flowmeter is ideal for bulk measurement of petroleum and oil, as well as syrup, molasses and raw chemicals. The meter has been approved for custody transfer of liquids and gases.

The Optimass 2000 S400 features the smallest installation footprint in its class and offers significant energy savings with a lower pressure drop. The meter’s small installation footprint compared to other meters on the market makes it ideal for applications where space is limited, like offshore platforms, or where alterations of existing pipework would otherwise be necessary.

According to the company, its flowmeter is able to handle flow rates as high as 4,600 tonnes per hour, the Optimass 2000 S400 features an accuracy of 0.1 percent with a turndown of 20:1, and an optional 0.05 percent “flat” accuracy with a turndown of 10:1. The high turndown ratios keep flow velocities low, preventing build up or deposits in hydrocarbon applications.

The meter is available with NACE-compliant stainless steel measuring tubes, as well as with a Super Duplex option that offers a maximum operating pressure of 180 barg; 2,610 psig. It also features an approved secondary containment option that handles up to 150 barg; 2,175 psig. z

Titan Enterprises announces new flowmeter for measuring high-pressure refrigerant flow US-based Titan Enterprises has announced a new, high pressure version of the Titan 900 Series turbine flowmeter. The new refrigerant flow sensors are adapted with steel and reinforced polymer components, giving a pressure rating of 40 bar. The new flowmeter joins the US based developer of flowmeters and flow instrumentation’s wide range of products designed for specific applications.

The new, high pressure version of the Titan 900 Series turbine flowmeter is ideal for refrigerant flow measurement. The meter’s low inertia turbines are perfect for measuring the low viscosities commonly encountered with volatile refrigerant fluids measured in a liquid form.

Titan’s refrigerant flow sensors are built with proven technology.

The new flowmeter is based on the standard 900 series turbine flow sensors, known for their balance of high performance and competitive pricing. The new 900 Series turbine flowmeter comes in a choice of body materials, making it ideal for metering a range of aggressive chemicals, such as ultra-pure water.

The standard inlet for the new Titan 900 Series turbine flowmeter is ¼“BSPF although alternatives for OEM use are available. The bearings are made of sapphire for durability and reliability, while the body is either PVDF or 316 stainless steel and the ‘O’ ring seal is Viton as standard.

Perfect for the specific application of refrigerant flow measurement, the upgraded refrigerant flow sensors are available now. Titan is currently taking enquiries about the new product on its website. z FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

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OTHER NEWS

BP sells North Sea pipeline to Ineos

BP has sold the Forties pipeline system to Ineos. Located in the North Sea, the pipeline transports around 450,000 barrels of oil per day, around 40% of the UK’s production.

Ineos, an energy company owned by British billionaire Jim Ratcliffe, has agreed to pay $250 million (€235 million) for the 235 mile long pipeline.

In operation since 1975, the Forties pipeline is one of the oldest in the North Sea. It links 85 oil and gas fields to the UK mainland, and to the Ineos refinery in Grangemouth.

Over the last few years Ineos has been growing its stakes in the North Sea oil fields, while BP has been retreating. BP sold its Forties oilfield interests to Apache in 2003, and the Grangemouth refinery and chemical plants to Ineos in 2005.

Ratcliffe told the BBC: “The North Sea continues to present new opportunities for Ineos.

“The Forties Pipeline System is a UK strategic asset and was originally designed to work together to feed the Grangemouth refinery and petrochemical facilities.

“We have a strong track record of acquiring noncore assets and improving their efficiency and reliability, securing long-term employment and investment.”

Forties Pipeline System employs about 300 staff at Kinneil, Falkirk, Dalmeny, Aberdeen and offshore locations. z

The Ultimate Pump Application Guide for Wastewater Treatment Plant Pumps Over 150 pages of content Available in hardcopy & PDF Perfect guide for those who specify treatment plant pumping systems & equipment maintenance

Trump’s pipeline memorandum causing concerns in the oil and gas industry US pipeline manufacturers and oil producers, including the company behind the Dakota Access Pipeline, have called into question President Trump’s call for US pipelines to be constructed from domestically produced steel.

One of Trump’s campaign pledges was to scrutinise US steel imports and seek a revitalisation of the American steel industry, promising “we will put new American steel into the spine of this country”.

In January 2017, Trump issued the Presidential Memorandum Regarding Construction of American Pipelines, which instructed the Secretary of Commerce to “develop a plan under which all new pipelines, as well as retrofitted, repaired, or expanded pipelines, inside the borders of the United States, including portions of pipelines, use materials and equipment produced in the United States…”

In March, the Department of Commerce called for input on the use of American-made materials in construction and maintenance of American pipelines.

This input, including responses from a number of pipeline manufacturers, has now been made public.

After welcoming the president’s support of the Keystone XL and Dakota Access Pipelines, the American Fuel and Petrochemical Manufacturers trade association wrote in its comments: “We are concerned, however, about the federal government mandating the use of domestic steel and interfering with the free market.”

Energy Transfer Partners, the major owner of the Dakota Access Pipeline set to open in May 2017, wrote: “If the US pipeline industry were constrained to only domestic steel and pipe mills, we do not believe the domestic producers have sufficient capacity. This has been evident in past years when construction activity was moderately high. The impacts of such a restriction are expected to severely delay project schedules, drive up costs, decrease availability, and lower quality. z

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

OTHER NEWS

No more pumps?

Self-propelling liquid could start a fluid handling revolution

Emerson’s acquisition of Pentair’s valve business gets conditional federal approval

Researchers from the Brandeis University claim to have taken the first steps towards creating a liquid which can move on its own without the aid of gravity or human intervention.

In their article published in the journal Science, the scientists explain how this self-propelling liquid could be the first step in creating a whole new class of fluids which can flow without human or mechanical intervention.

One possible application of this would be oil flowing through pipes without the need for pumps.

Key to the breakthrough was reproducing in the lab the incredibly complex series of processes that allow cells to change shape and adapt to their environment. Cells are built from hollow cylindrical tubes called microtubules which are capable of growing, shrinking, bending and stretching in response to their environment.

The US Federal Trade Commission (FTC) has approved Emerson Electric Company’s acquisition of the Switzerland based valves and controls arm of British industrial valve manufacturer Pentair. Conditions have been placed on the deal however, to avoid violations of federal antitrust laws.

Both Emerson and Pentair manufacture industrial valves and control products, including switchboxes, which are commonly used in the chemical, oil and gas, petrochemical and power industries.

The FTC charges that the proposed $3.15 billion (€2.9 billion) acquisition would merge the leading switchbox manufacturers in the US, which combined control around 60% of the market.

Therefore, as a key condition of the deal, Emerson has to sell Pentair’s switchbox business to Stamford, Connecticut’s Crane Company. The terms of the consent agreement state that ten days after securing the acquisition of Pentair, Emerson must divest Westlock Controls Corp, the subsidiary of Pentair which designs, manufactures and sells switchboxes to Crane. z

The scientists extracted some of these microtubules from a cow’s brain, and placed them in a watery solution with two other types of molecules found in cells: kinesin and adenosine triphosphate (ATP). Fuelled by the ATP, the kinesin started moving, binding itself to the microtubules. As the microtubules started to connect and then separate, they made swirling patterns in the fluid, patterns which the team soon realised they could control, creating a “coherent flow”.

As the university press release explains: “This microtubulekinesin-ATP reaction is the same one that goes on in cells, except in cells it is much more complicated. Yet the much more simplified model created by the Brandeis scientists achieved a similar effect. Essentially they harnessed the power of nature to create a microscopic machine capable of pumping fluid.” z

Pipelines still safest for liquid energy transport The American Petroleum Institute (API), along with the Association of Oil Pipelines (AOPL), have published the Pipeline Safety Excellence performance Report and Strategic Plan 2017-2019, which summarises the pipeline industry’s record on safety and outlines the steps being taken by operators to further safety procedures throughout the pipeline supply chain.

“Pipelines are one of the safest and most efficient ways to transport liquid energy,” said API Pipeline manager David Murk in a press release. “While nearly 100 percent of crude and petroleum products reach their destination safely, the industry remains committed to zero incidents. Strategic planning and the establishment of long-term goals will be critical for continuous, industry-wide pipeline safety improvements.”

2016 saw a 10% drop in pipeline incidents when compared to 2015, according to the new report. Although acknowledging there are some areas still in need of improvement, the report highlights the public benefits of pipelines and details the systems put in place by pipeline operators to protect people and the environment. z FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

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9

TECHNOLOGY

Cutting-edge leak detection in an ancient city A water utility in Jerusalem deployed a revolutionary new system to search for leaks in the city’s water infrastructure

10

Jerusalem is one of the oldest cities in the world, its origins dating back to the fourth millennium BC. It is a city covered with history – monuments and buildings reflecting its colourful past. At the same time, it is dynamic, modern and growing rapidly, placing huge strain on an infrastructure which relies on components that are up to 85 years old.

Since 1996 the Hagihon Company has been the city of Jerusalem’s water and wastewater utility, supplying water, sewage and drainage services in the approximately 32,500 acres of the Greater Jerusalem area, and servicing about 1,000,000 residents of the City of Jerusalem and its environs. The company is responsible for development, expansion, operation and maintenance of the water, sewage and drainage networks, in accordance with the city’s and towns’ growth and development plans.

Faced with the challenge of increasing customer satisfaction, and increasing efficiency while reducing costs and non-revenue water (NRW), Hagihon approached Aquarius Spectrum to work on a fixed water monitoring and leak detection system. Aquarius Spectrum is a start-up company based just north of Tel

Aviv, Israel. The company was started in 2009 by David Solomon, and specialises in creating sensors and software which can work together for leak detection and pipe condition assessment.

A monumental challenge

Hagihon’s water distribution network is spread across the hilly terrain of Jerusalem, meaning the company has had to create multiple pressure zones using water tanks and Pressure Reducing Valves (PRVs).

Aquarius Spectrum successfully overcame these challenging conditions during the implementation of the project.

In September 2013, the utility, together with Aquarius Spectrum, started implementing a fixed water monitoring and leak detection system. More than 1600 acoustic sensors were installed during 18 months to cover most of the utility’s water distribution network.

Aquarius Spectrum’s solutions feature fixed and mobile acoustic sensors that upload gathered data to the Aquarius servers via cellular communication.

The sensors incorporate built-in GPS capabilities, allowing for full-synchronization of readings across multiple sensors.

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

TECHNOLOGY

Aquarius Spectrum user dashboard

The rising trend in the annual number of pipe bursts was halted and a drop in number is evident since the deployment of the system

Each night, at an exact predefined time, all sensors record a noise sample and send the information to the Aquarius Spectrum cloud based servers. The signals are processed, correlation algorithms are executed and alerts are issued to Hagihon regarding leaks or malfunctioning appurtenances, such as throttled valves.

Analysed findings are displayed via a user-friendly browser-based display. From the very first reading, the system started learning the behaviour of the Jerusalem area water distribution network by following its daily trends through every sensor.

Positive results Results from a recent study by Hagihon indicate a substantial improvement in NRW (Non-Revenue-Water) in the DMAs in which Aquarius Spectrum’s system was installed and continuously operated during a period of two years (2014-2015). NRW was reduced in those neighbourhoods by 18%, mainly due to locating and fixing hidden leaks and repairing malfunctioning equipment located by Aquarius. In addition, there is a clear trend of a yearly decline in the number of water pipe bursts.

During the two years prior to the implementation of the Aquarius

system in Hagihon, there had been an increasing trend in the number of bursts per year, which was clearly reversed to a declining trend apparent during the two years in which the Aquarius leak detection system was in place.

As of August 2016, the AquariusSpectrum system had found more than 226 hidden leaks in the Jerusalem area, 171 of which were in the public distribution network and 55 in private properties. Fixing those leaks resulted in potential savings of over a million cubic meters of water for the utility. NRW was lowered by 18% and the number of visible (reported) leaks and bursts has declined significantly.

In addition, the AquariusSpectrum system has discovered more than 250 non-leak faults, including partially closed valves, faulty water meters, malfunctioning non-return valves and other items of equipment under the responsibility of the water utility.

The Aquarius-Spectrum system is helping Hagihon revolutionise the way it manages leak repairs, allowing it to switch from a reactive mode to a

As of August 2016, the AquariusSpectrum system had found more than 226 hidden leaks in the Jerusalem area.

planned approach. The utility is now able to plan its repair schedule to fix hidden leaks before they become visible bursts, thus reducing the cost of contractors, avoiding collateral damage to infrastructure, informing consumers well in advance of shutting off of water supply for maintenance, reducing shutoff times and improving customer service by notifying consumers of hidden leaks on their premises. All this saves money and improves the level of service.

Hagihon’s CTO, Mr. Aharon Rosenberg, said: “We are excited and proud to be at the forefront of municipal water system technology. The Aquarius Spectrum innovative leak detection system has proven its effectiveness in improving the maintenance of our water pipes network and is changing the way we manage our assets”.

Aquarius’ fixed system is currently monitoring over 2,000 kilometres of water pipes daily, using more than 3,000 fixed acoustic correlating sensors in major cities in Israel, US and Europe. Each month the company detects hundreds of invisible underground leaks and interferences affecting water networks.

Recently, the company has managed to reduce NRW in some municipal areas by between 20% and 90% through detecting unseen leaks and other problems. z

For more information:

This article was written by Aquarius Spectrum, Hagihon and Fluid Handling.

Visit: www.aquarius-spectrum.com

Sensor on yellow hydrant

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TECHNOLOGY

How the Industrial Internet of Things is revolutionising fluid handling

Optimising flow control in the digital age The Industrial Internet of Things (IIOT) has been heralded as a great enabler that will revolutionise manufacturing and processing. Although asset-heavy industries were slow on the initial uptake, as the cost of sensor and network development declines it is becoming more feasible to outfit industrial equipment with devices to capture and communicate data. An emerging era of smart industrial equipment will unlock new opportunities to enhance process efficiency, sustainability and safety in flow control applications.

and management capabilities and to achieve integration with wider business process management systems.

Legacy equipment can be upgraded with the addition of sensors that monitor key performance parameters and convey this data to a central network.

However, the design and integration of such sensors brings many technical challenges. Overcoming these requires a greater depth and breadth of skills and knowledge than is typically associated with the design, manufacture,

and more cost-effective solutions.

For instance, Sagentia worked with one client to devise a monitoring and diagnostic system for a complex water boiler application. In-house engineers had fitted a standard suite of sensors to monitor pressure and flow, temperature, motor torque, valve position and fan revs. This was effective but expensive.

Sagentia demonstrated that using a single microphone and sound analysis on a local embedded microcontroller enabled 95% of boiler faults to be monitored and diagnosed at less than 1% of the cost.

Bringing legacy assets online

There are indications that the next decade could bring a largescale shift towards a service-led approach

Design considerations

Developing a robust strategy to meet the increasing demand for smart equipment can be complex. Careful consideration and planning is required to ensure the upgrade or replacement of existing assets is effective and has longevity.

Much of the time, legacy assets associated with flow control and fluidics – such as valves, pumps and metering devices – are performing their original intended function perfectly well. Nevertheless, they are increasingly disadvantaged through a lack of integration with other equipment. They need to be brought online to unlock remote monitoring 12

installation and maintenance of the underlying equipment.

Many internal product development teams are reaching out to externally resource with cross-industry expertise in the physics of flow and sensor/ algorithm design. This can facilitate the development of better, simpler

The design of smart fluid control systems requires a broad spectrum of skills.

Manufacturers that acknowledge and harness this are best placed to improve new and legacy equipment, prolonging lifespan and relevance in the rapidly evolving digital age.

Defining which parameters to monitor is the first step. It’s not desirable for equipment to be covered in a forest of sensors, so understanding what information will be most useful in managing a specific application is essential.

The key is to prioritise data that can be used to leverage actionable insights. This FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

TECHNOLOGY requires a deep understanding of the core processes and equipment features.

Wider factors unique to the application also need to be considered, especially if the equipment performs a critical role or operates in a harsh environment. For instance, sensors can be programmed to monitor external factors which have a bearing on equipment performance and lifespan, such as contamination of the process medium or exposure to extreme temperatures and vibrations.

Every action performed by a piece of equipment can be summarised with a parametric model. Sensors are configured to monitor these parameters over time, and a diagnostic algorithm can be incorporated to trigger an alert if there is any significant deviation from the norm. Data fusion can bring additional benefits here. Using two or more sensors in combination gives richer insight than using each of them in a standalone configuration.

Well-designed smart equipment can help end users work proactively to mitigate against known risks of failure and overcome unwanted effects such as high noise levels. Empowering engineers with real-time insights into equipment performance can help them identify the best moment to intervene. This results in better control of the process, and facilitates informed decisions based on multiple factors, such as wider safety or environmental implications. Performance data can also provide insights that may be of value downstream, for instance by indicating whether the process medium may be contaminated.

A modern meter

Strategic deployment of smart machines can improve the next generation of equipment. By collecting data on the current model, it’s possible to learn how it fails and any precursor warning signals. Insights can be embraced to either improve future devices, or create better alerting systems. This approach can facilitate a move from classic product sales to a service based business model, as pioneered by Rolls-Royce in its sale of ‘thrust’ as opposed to aircraft engines.

Integration considerations The underlying ecosystem of connectivity spawned by the communications revolution continues to evolve rapidly.

This is a double-edged sword, bringing challenges as well as opportunities.

A major consideration is interoperability between machines and devices that use different protocols and architectures.

A detailed understanding of the compatibility of components, sub-systems and common communication protocols is required. Designing the sensor platform to integrate with a variety of communication protocols allows a single smart device such as a meter or an instrumented pump to be fitted with the requisite communications module, or to have that functionality built-in.

Smart equipment offers many prospects for better efficiency and cost savings. But this is irrelevant if expensive assets have their life shortened because they can’t adapt to emerging business process management systems or communications frameworks. One way to combat this is to embed devices with functionality and compatibility options that may not be needed now, but can be brought online later.

A detailed understanding of global technology platforms should underpin the roll out of smart products. Effective delivery of pertinent, meaningful data to relevant stakeholders is one concern. But ensuring sensors can keep pace with inevitable changes in the wider communications ecosystem is also vital. The migration of data to cloudhosted platforms provides an effective route to overcome compatibility and accessibility issues. However, cybersecurity is a major

concern, and significant effort needs to be expended to mitigate risks in this arena.

Industry spotlight: a smart fluid control system Last year, Sagentia was approached by a major player in the water industry regarding the development of a 24/7 smart fluid control system. A core requirement was the capture and conveyance of real-time data from a cloud service delivery platform to facilitate customer analytics. In addition, the user experience of various stakeholders, including calibration, commissioning and maintenance professionals, had to be considered.

Sagentia devised an iOS application incorporating near field communication (NFC) and Bluetooth technologies. To ensure its longevity and adaptability, 4G cellular support was embedded, as well as Low Power Wide Area Network technologies LoRa and SigFox. These come from a new family of communications technologies allowing devices to convey small volumes of data over a long distance with low power.

This is an important IIOT capability, offering significant advantages over current cellular network technology for machine-to-machine communications.

This progressive solution enabled the client to take a major step forward in its capability and market offering.

It created a rapid, future-proof route to out-perform competitors.

What does the future hold?

As smart devices achieve greater penetration across the fluid control industry, we are likely to see a change in the roles, responsibilities and interfaces between equipment manufacturers and end users.

There are indications that the next decade could bring a large-scale shift towards a service-led approach.

For end users, this will redefine the balance between capital expenditure and operational expenditure whereas for manufacturers it will help secure retained income.

Reliable real-time monitoring could also counter the trend for ‘over-design’ that has affected many industrial processes in recent years. Stringent environmental and safety regulations coupled with ambitious performance targets have sometimes resulted in the unnecessary

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 13

TECHNOLOGY use of exotic materials or overlapping functions. Empowering end users with better situational awareness enables them to manage flow control more proactively. This makes it easier to ensure equipment always operates within safe boundaries, reducing the need for redundancy in some applications.

A further advantage of smart, connected systems is an enhanced ability to intercept emerging problems before they escalate. The 2005 Buncefield fuel storage depot conflagration is a prime example of an occasion where early interception could have prevented a major incident. Two level control devices on a tank that was filling with petrol failed: a gauge used by employees to monitor the process stuck and an independent high-level switch intended to close down operations if the tank overfilled was inoperable. Consequently, control room staff were not alerted that the tank was filling to dangerous levels. Large quantities overflowed and a vapour cloud formed which ignited, causing a series of explosions and a fire that lasted five days. If an intelligent sensor system had been installed, staff would have

Monitoring flow with the Industrial Internet of Things

been alerted as soon as the fuel gauge stuck, enabling action to be taken long before the first explosion occurred.

Intelligent sensor design is the cornerstone of informed and purposeful fluidics decision making in the digital age. It represents an effective route to boost safe, environmentally sound and

profitable industrial practices. The stage is set for fundamental changes to the fluid handling industry as we know it. z For more information:

This article was written by Alun James, chief technology officer at Sagentia and Chris Covey, vice president – Industrial at Sagentia. Visit: www.sagentia.com

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

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Don’t miss your chance to appear in the July/August 2017 issue of Fluid Handling International For editorial suggestions contact: Daryl Worthington, daryl@woodcotemedia.com, +44 (0) 208 687 4146

For advertising information and prices contact: Russell Priestley, russell@fluidhandlingmag.com, +44 (0) 208 648 7092

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PAGE HEADER PUMPS

Harnessing the energy of the sea Marseille uses the potential of the Mediterranean for heating and cooling buildings

Courtesy of Engie Group Seawater circuit Priority pump: KSB Mega CPK 250-400 Noridur anti-corrosion steel Fluid: sea water Nominal flow: 720m3/h Nominal HMT: 48mCE Suction pressure: 3bar Rotation speed: 1500rpm Yield: 80% Power: 160kW

16

Developing new sustainable, ecologically acceptable technologies for heating and cooling domestic and commercial premises has been challenging the resources of many energy companies around the world. Harnessing the potential of the sun, sea tides and currents, the wind and the heat trapped deep beneath the earth’s surface have all proven to be successful technologies to varying degrees. To these can be added the thermal energy of the sea.

The sea provides enormous potential as an energy source for the world’s population that lives within 100km of a coastline. This has not gone unnoticed by the Engie Group, which has developed energy from tides and currents around the world. Now it has turned its attention to turning the calorific energy of the Mediterranean Sea into space heating and cooling, with the construction of a generation plant in the Port of Marseille. Called the Thassalia Marine geothermal project, the €35 million plant is the first of its type in Europe and will eventually provide a sustainable energy source for 500,000m² of buildings

in the new Eco-Cité Euroméditérranée, currently the largest urban renewal operation in Southern Europe.

Eco-Cité Euroméditérranée occupies 480 hectares in the heart of Marseille, between the commercial port, the Old Port and the TGV station, and offers housing, shops, hotels, restaurants, commercial premises, public services and cultural facilities. The development of the Thassalia plant is central to the Eco-Cité Euroméditérranée being given HQE (High Quality Environment) status.

As a referral project for renewable energy due to the recovery of about 70% of the marine thermics/frigories, Thassalia has an extremely high energy efficiency coefficient compared to an equivalent fleet equipped with standalone heating air conditioning. The result is a 70% reduction in greenhouse gas emissions for the eco-city, plus a 40% reduction in electricity consumption and 65% reduction in water consumption.

The Thassalia plant The development of the Thassalia plant by the Engie Group commenced in 2010 and brought together the expertise of its subsidiaries ENGIE Coffley and Climespace. Working with ENGIE Group right from the very start was KSB France, which supplied pumps, valves and the engineering resources of its services agency based in Aix-en-Provence.

Operationally launched in 2014, the plant was inaugurated on 17 October 2016.

The basic premise of the project concerns the creation of a hot and cold water network throughout the Euroméditérranée perimeter. It is innovative in several ways. Firstly, it delivers heating and cooling together.

While the networks in France are most often separate, Thassalia is a thermorefrigeration plant. Secondly, energy is drawn from seawater, and lastly, it is

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

PUMPS

The Thassalia plant is located in Marseille harbour adjacent to the Cité de la Méditerranée

the first European project to circulate heating and cooling throughout the whole of an eco-city of this magnitude.

How it works

special Noridur duplex steel (KSB design, Uranus equivalent B6). Noridur is used for highly corrosive and slightly loaded products, such as warm seawater, but also for concentrated acids and flue gases in desulphurisation processes.

For the same reasons, the discs of AMRI Isoria butterfly valves which perform

the isolation or regulation functions of seawater intake are protected with a Halar corrosion coating. These valves – from DN (nominal diameter) 50 to 700 – provide both manual and pneumatic actuator operation. The sea water, which ranges in temperature from about 14°C in winter to 22°C in summer, supplies heat exchangers connected to thermo-refrigeration pumps (TFP), bringing calories to heat when the water is cold and frigories to refresh when it is hot. The TFPs and refrigeration units can then produce heat or cold as required. It should be noted that supplementary gas boilers complete the installation in order to guarantee continuity of service in all circumstances.

The energy is then transported to the Euroméditerranée buildings for heating or air-conditioning, via a hot water network (60°C) and a chilled water network (5°C).

The length of the 3km network demanded powerful pumping solutions with strong HMT on both hot and chilled circuits.

TOUGHTOUGH TOUGH INNOVATOR INNOVATOR

Central to the whole operation of the plant and distribution network are pumps, which is where the know-how Courtesy of Engie Group and products of KSB were essential. The Hot water circuit thermal plant is supplied with seawater Priority pump: KSB MCPK pumped from a depth of 7m by six 150-500 Conveyed fluid: softened corrosion-resistant Norstur KSB CPKN and treated water pumps, each equipped with a 160kW Temperature: 90°C Nominal flow rate: 345m3/h variable speed motor, for a total flow HMT nominal: 110mCE of 1000l/s. The problem of corrosion by Suction pressure: 3bar Rotation speed: 1500rpm warm seawater is peculiar to this project, Yield: 74% with the pumped water reaching up Power: 160kW to 25°C in summer and its permitted discharge temperature beingThe 30°C. hose pump is the pump solution for the is a simple Thefutur. hoseItpump is the and pump solution for the futur. It is a simple and The parts of the pump in contact well with proven construction in one sense butwell alsoproven a “newthinker” in the construction in one sense but also a “newthinker” in the the fluid have therefore beenfact made thatofonly the hose is in contact with thefact fluidthat thatonly is being pumped. the hose is in contact with the fluid that is being pumped.

INNOVATOR

This minimises downtime from maintenanceThis andminimises simplifiesdowntime pump use.from maintenance and simplifies pump use.

For us at ALBIN PUMP this means lower costs and better pumps soluFor us at ALBIN PUMP this means lower andand better pumps soluThe hose pump is the pump solution for the futur.

It iscosts a simple tions. If you want to know more about well the proven technique, test and results tions.

If you want to know about the technique, construction in one sensemore but also a “newthinker” in the test and results welcome to www.albinpump.com forfact more information. that only the hose is in contact with the fluid that welcome to www.albinpump.com foris being morepumped. information.

TOUGH INNOVATOR

This minimises downtime from maintenance and simplifies pump use.

For us at ALBIN PUMP this means lower costs and better pumps solutions. If you want to know more about the technique, test and results welcome to www.albinpump.com for more information.

The hose pump is the pump solution for the future. It is a simple and well proven construction in one sense but also a “newthinker” in the fact that only the hose is in contact with the fluid that is being pumped. This minimises downtime from maintenance and simplifies pump use. For us at ALBIN PUMP this means lower costs and better pumps solu-tions. If you want to know more about the technique, test and results welcome to www.albinpump.com for more information.

since 1928 since 1928

www.albinpump.com www.albinpump.com www.albinpump.com FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 17

since

PUMPS Ice circuit courtesy of Engie Group Priority pump: KSB Mega CPK 200-500 Conveyed fluid: softened and treated water Temperature: 9°C Nominal flow: 760m3/h HMT nominal: 120mCE Suction pressure: 3bar Rotation speed: 1750rpm Yield: 84% Power: 355kW

These two circuits are each equipped with four KSB Mega-CPK pumps (8 in total), each displaying a nominal HMT of 110mCE or 120mCE depending on the motors, their power ratings ranging from 160kW to 355kW. This “secondary network” requirement was a determining factor in the choice of pumping solutions. Indeed, the requirements of the specifications were very high not only in terms of height, but also in efficiency and speed. Thus, the Mega CPK retained yields up to 84% at speeds of 1500rpm and 1750rpm.

An alternative to this arrangement would have been to consider a more “light” solution in terms of pump sizes, making them easier to install and less expensive. However in this case, there was no pump sufficiently powerful to provide the required HMT alone, so it would have been necessary to resort to pumps in series. Such a mode of operation would have been more risky in terms of reliability for the operator, so this option was finally discarded.

In addition to these pumping duties, the auxiliary circuits are equipped with Etanorm pumps operating at 650m³/h for 30mCE and with a power of 75kW and Etaline pumps for the heat exchangers and recycling duties. Furthermore, 150 AMRI Boax B valves, with manual or pneumatic control ranging from DN100 to DN600 were also installed.

The benefits of marine thermal energy Significant “collateral” benefits must also be credited to marine thermal energy. On the environmental front, the centralised production of cold favours a reduction of the heat island effect in the city, a factor that would have created a multiplication of individual units. Moreover, in a refrigeration network, the terrace surfaces are cleared due to the removal of cooling towers on the top of the buildings. Their removal also limits noise pollution and drastically reduces the risk of bacterial contamination, legionella being just one example.

At the financial level, the price of the energy produced is about 10% lower for centralised cold production compared to 18

a solution using individual units. In addition, centralisation is less sensitive to increases (if any) in electricity and gas tariffs.

Pumping energy efficiency Pumps are components of systems that consume large quantities of electricity and therefore have great savings potential. A figure to illustrate the high stakes: the annual consumption of industrial pumps in the EU is 300TeraWatt hours (= 300,000GigaWatt hours). By way of comparison, France’s total electrical consumption in 2015 was 461TeraWatt hours. It is therefore understandable that the EU has set ambitious targets for products through the Energyrelated Products (ERP) Directive.

KSB’s response, which can go far beyond these objectives, is called Fluid Future. This “global” device functions on many levels. With regard to the drive, the motor of the pumping unit can save about 10%. By working on optimising the hydraulic efficiency of the pumps, savings can reach 20%.

By analysing and optimising the entire circuit, the potential can rise up to 60%.

The search for the energy saving in a fluid transport circuit concerns both new and existing installations. For the latter, moreover, the results can be spectacular.

Indeed, not only are the technical solutions in place subject to improvement, but also it is not unusual for the needs of the installation to have evolved over time (new process, modification of the network, etc.).

The Fluid Future device consists of four phases: 1. Analysis of the hydraulic system in place and determination of the load profile.

2. Selection of the adapted solution (hydraulic, drive, automation) resulting from the collected data.

3. Control of the installation and/ or commissioning by “KSB Service” specialists.

4. Equipping the installation with technologies that will contribute to the energy efficiency of the installation.

Examples would be the SuPremE reluctance motor (IE5), PumpDrive 2 speed controller, and PumpMeter intelligent pressure sensor.

Summary The current and future residents and workers of Euroméditerranée Éco-cité will reap the benefits of a heating and air-conditioning network that is energy efficient and environmentally friendly created by a thermal plant with an installed 19 megawatts hot and 19 megawatts cold power capability.

For KSB France, the problems which they had to overcome involved providing pumps and valves that would have to resist higher than normal levels of corrosion. In addition, other key factors that had to be addressed included providing pumps with high yields for limiting power consumption, contributing to the award of the HQE label, and minimising the acoustic power of pumps to avoid “neighborhood” noise nuisance.

KSB will provide a rapid response for maintenance and repair throughout the life of the plant. z For more information:

This article was written by Bryan Orchard, a freelance journalist. bryan@bryanorchardpr.co.uk Visit: www.ksb.com

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

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PUMPS

Proper pump selection for wastewater treatment plant pumps Selecting the right pump for maximum efficiency and consistent reliability Access to clean water is essential to sustain and provide for the continued development of the world’s population and its economic growth. Even though approximately two thirds of the earth’s surface is covered by water most cannot be used for drinking without treatment.

Therefore, treatment plants are integral to solving one of the most urgent concerns today, to have sufficient supplies of clean water to meet a constantly growing demand. This need is increasing the pressure on treatment plants to increase their efficiency and production. Integral to this fact is selecting the right pump for the treatment process to ensure efficiency and the consistently reliable treatment of water. This article focuses on a wastewater treatment process, but could be applied to other processes. The guidance provided in this article is supported by the Hydraulic Institute (HI) publication Wastewater Treatment Plant Pumps: Guidelines for Selection, Application and Operation, which was developed

by a committee of volunteers, with the purpose of delivering product neutral guidance to the treatment plant industry on proper pump selection.

The treatment process The liquid streams within a wastewater treatment plant may be characterised by their typical properties, as follows: • Large solids • Grit • Corrosive materials • Sludge • Scum • Flocculated materials A conventional wastewater treatment plant contains many processes to support the removal of these materials.

Figure 2: Horizontal solids handling pump

…treatment plants are integral to solving one of the most urgent concerns today

Figure 1 shows a conventional wastewater treatment plant flow diagram sectioned by the preliminary, secondary and tertiary and effluent management portions of the plant. There are 16 different pumping processes identified, each of which requires specific pump designs to handle the various liquid streams that range from clean water to water laden with large solids, or chemicals for disinfecting.

These different liquid stream applications create different considerations that need to be addressed when selecting a pump for the intended service. The treatment plant designer must have a good understanding of the demands of each process, the characteristics

Figure 1: Conventional wastewater treatment plant with filters

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

PUMPS

Pump selection procedure

Figure 3: Vertical solids handling pump

of each process liquid and an understanding of the appropriate pump designs available for the application.

For each of the 16 pump applications listed in Figure 1, there are typically several different pump design types suitable for the application. However, the designer cannot just pick from a recommended list, they must consider and evaluate all relevant factors to ensure the selected pump can perform the service as intended. For example, if we look at application 1: Raw Sewage (influent pumps), the following pump types are recommended as suitable designs for influent pumps: • Horizontal (Figure 2) and vertical (Figure 3) solids-handling rotodynamic • Submersible solids-handling rotodynamic (vertical wet pit or dry pit mounted either horizontally or vertically) • Inclined screw • Vertical column type solids handling.

Pump selection The pump types shown in Figures 2 & 3 may be appropriate for the influent application because they are both designed to pass solids that will be in the process stream. However, more evaluation needs to occur to make a final pump selection. The pump selection procedure provided is a tool for the designer to use and coordinate with the pump manufacturer to gather the required process information, make

1. Identify treatment plant process, and the important characteristics of the process.

2. Determine the maximum and minimum flow requirements of the process and the system curve(s).

• A pump will operate at the intersection of its performance curve and the system curve so the system curve must be known to select the proper size pump(s).

Therefore, prior to selecting a pump the designer must establish the design criteria envelope and system curves.

• The system curve is a function of the static head in the system and friction losses of the flow through the piping and control devices such as a throttling valve or bypass line.

• Additionally, the net positive suction head available (NPSHA) must be determined over the operating envelop.

3. Reference Appendix A of Wastewater Treatment Plant Pumps: Guidelines for Selection, Application and Operation and choose a pump design type from the recommended list for the process application and identify the orientation of the pump to be installed.

4. Based on the NPSHA, the design flow rate and the maximum suction specific speed (S) desired the designer should calculate the maximum rotational speed for the pump. For full information on this topic, industry standards ANSI/ HI 2.3 Rotodynamic Vertical Pumps of Radial, Mixed, and Axial Flow Types for Design and Application and ANSI/HI 9.6.1 Rotodynamic Pumps Guideline for NPSH Margin should be referenced.

5. Select a pump curve that meets the maximum operating points at the speed determined in step 3. Determine if the design operating envelop for the pump falls within the preferred operating region (POR) for the pump, and if it does not, review if reliability and energy impacts will be unacceptable due to operation outside the POR. If an initial pump selection, verification, refinement and final pump selection.

Conclusion Selecting the right pump design for the application, which is sized to operate in the POR is vital to efficient and reliable operation.

The process designer must have a thorough understanding of the treatment process, its liquid composition, industry standards and

6.

7.

8.

9.

the single pump requires operation outside the POR, multiple smaller pumps could be considered to operate in parallel, variable speed pumping or a combination of both. The POR for a pump varies by design type so a general range cannot be given, for full information on the POR for a specific pump, refer to ANSI/HI 9.6.3 Rotodynamic (Centrifugal and Vertical) Pumps – Guideline for Operating Regions and for considerations on variable speed pumping and control refer to HI’s Application Guideline for Variable Speed Pumping.

Overlay the selected pump curve(s) with the system curves and verify the pump(s) will operate in an efficient and reliable manner based on the operating envelope and select a driver that will be non-overloaded throughout the operating envelope.

Consult appendix C of the Wastewater Treatment Plant Pumps: Guidelines for Selection, Application and Operation to identify the proper materials for construction for the casing, impeller, shaft, seals and hardware. Review these material selections with the pump manufacturer(s) based on your specific application requirements and make final material selections.

Determine if the pump installation will require dynamic analysis to ensure separation of the operating speed and other forcing frequencies from structural natural frequencies or rotor critical frequencies. This is of particular importance for vertical pumps and solids handling pumps that operate at variable speed or any pump design that is not proven over the operating range, which is critical to plant operation. Refer to ANSI/HI 9.6.8 Rotodynamic Pumps – Guideline for Dynamics of Pumping Machinery for recommendations.

Make final pump selection and create equipment data sheet with requirements.

best practices and work collaboratively with trusted pump manufacturers to ensure a successful outcome. No pump selection procedure can cover every detail that needs to be reviewed and considered, but what has been listed covers some of the most important aspects of pump selection. z For more information:

This article was written by Peter Gaydon, technical director of the Hydraulic Institute.

Visit: www.pumps.org

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 21

MIXERS AND AGITATORS

Choose your mixers – stainless steel versus fibreglass Fibreglass or stainless steel impeller blades for your treatment plant’s mixers?

At one of the largest research parks in the world, there is no shortage of expertise in weighing up whether one material is more suitable than another. With more than 200 companies and over 50,000 people skilled in fields such as micro-electronics, telecommunications, biotechnology, chemicals, pharmaceuticals and environmental services; Research Triangle Park in Durham County, North Carolina is a place where you’ll find no shortage of answers to all sorts of technical questions.

At the nearby Triangle Wastewater Treatment Plant though, you’ll find a pretty emphatic case for mixers with stainless steel impellers over fibreglass. Based on years of experience, this specialised plant has gradually been replacing its fibreglassbladed mixers in favour of stainless steel.

As well as 70% of its intake being industrial wastewater, Triangle WWTP also has to handle the large fluctuations in flow, from the huge 50,000 weekday workforce influx at Research Triangle Park to just 6,000 local residents on weekends when flows are appreciably slower.

Joseph R. Pearce, Deputy Director for Durham County’s Engineering and Environmental Services Department, said: “Although our percentage intake of industrial wastewater is significantly higher than the national average, we still have to deal with all the hair and rags that despite pre-screening can cause clogging problems for any treatment plant”.

Indeed, Pearce says that during his near 10-years at Triangle WWTP, he and his team have labored long and hard to keep the fibreglass-bladed mixers going.

“We’ve been doing everything that we can, but the clogging, especially during a storm event, became more and more frequent, meaning we had to pull up mixers from which heavy hair mixed with plastics and cotton swabs were hanging, taking them out of service. It became normal for this to be once per month, per mixer, in some of the treatment facility mixing zones. Eventually, the fibreglass blades’ gel-coat front edge wears off, making them split – and at up to almost 22

For this North Carolina wastewater treatment plant, it’s now stainless steel propellers all the way

$20,000 per blade to replace, this was something we had to address”.

Fibreglass to stainless steel Originally built in the early 1960s and expanded in the 1970s, Triangle Wastewater Treatment Plant was upgraded in 2005 when the 6 MGD tertiary treatment facility was replaced with a 12 MGD five stage enhanced biological nutrient removal system that provides biological nitrogen and phosphorous removal during treatment with carbon source addition and chemical phosphorus treatment using sodium aluminate. In 2005, the mixers installed had fibreglass impellers.

In 2013, a new sludge handling facility was constructed. This time around, with Pearce at the helm, the decision was

made to use mixers from Landia that have solid stainless steel impellers.

The Sludge Handling (Biosolids) Facility consists of two aerated sludge holding tanks with a capacity to hold a million gallons, three centrifuges, and an automated truck loading station.

Excess biomass flows to sludge holding tanks. The waste sludge thickens by gravity and the supernate is decanted into a side stream equalisation tank.

Landia mixers and jet aerators were installed to mix and aerate the thickened sludge (1% dry solids), to ensure a uniformed sludge/solids concentration and to minimise anaerobic conditions. Polymer is added to the thickened sludge before it is moved to the centrifuge where a cake sludge (20% dry solids) is produced and pumped to trailers before transport to a nearby commercial Class A composting facility for stabilisation and distribution to the commercial landscape market “In our sludge facility, we have no issues whatsoever with the Landia mixers”, adds Pearce. “They were very reliable, so we then retrofitted a Landia mixer into one of our problem basins to try it. After a seven-month run we had no clogging whatsoever, so one by one as the fibreglass-bladed mixers inevitably split, we’ve been replacing them with the stainless steel propeller mixers from Landia, because we fully expect fewer clogging problems and blade wear not to be an issue”.

Triangle WWTP now has a total of 15 Landia mixers, with that figure set to

Landia AirJet at Gun Barrel City

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

MIXERS AND AGITATORS

Aerated Sludge Holding Tanks at Triangle Wastewater Treatment Plant, where Landia’s stainless steel mixers are installed

almost double as the gradual switch to much longer lasting stainless steel units takes its course. In addition to anoxic and anaerobic zones, the mixers will also be installed in 18-feet deep oxidation ditches requiring propellers approximately five feet in diameter, which work at just 47rpm.

“Not surprisingly”, continued Pearce, “we’ve made a big saving on our maintenance program and I’m also pleased for our team that there is now much less use of winches and crane hoists and exposure to rags because we don’t really have to do much to the Landia mixers.

We’re extremely happy with our investment in a much higher quality product because improving Durham County’s facilities and improving safety is very much our mission”.

Waste not, want not Setting standards at Triangle WWTP is nothing new. The facility’s wastewater administration building was the first to be LEED-certified (Leadership in Energy and Environmental Design). Low-energy, recycled, and regionally manufactured materials were used in its construction.

The building’s wastewater is also treated and rerouted to the HVAC system and low-flow toilets. Using reclaimed water has reduced potable water use by 32%.

In addition, Triangle WWTP’s Recycled Water Facility consists of four turbine pumps, a hydropneumatic tank, a 500,000 gallon storage tank, instrumentation and metering, a dual disinfection system and a distribution system. Recycled water has become a valuable community asset for landscape irrigation, cooling towers, and construction activities – and in Research Triangle Park, having a redundant water supply is important for water-critical facilities, such as computer database services, pharmaceutical plants, LED manufacturing and agricultural greenhouse R&D. Triangle’s proactive recycling

certainly influenced Pearce recently when he snapped up some 12-yearold Landia mixers from another treatment plant in North Carolina.

“Even though these mixers are over a decade old”, he said, “the blades are in excellent condition. I’ll gladly have these superior quality and longer lasting stainless steel units on board as back up, rather than fibreglass, which I know will break”.

Meanwhile, in Texas Longevity was also a major factor in the installation of Landia’s pumps at a wastewater treatment plant in Texas, where sewage first enters an equalisation tank before it goes to the site’s bar screens.

Dealing with all the solids that come their way are six 30 HP chopper pumps that help break down incoming solids, as well as mixing and aerating the tank.

Situated southeast of Dallas, East Cedar Creek Fresh Water Supply District (ECCFWSD) operates two WWTPs in the Mabank area close to Cedar Creek Reservoir for a total population of 20,000 – one in its southern sector, another serving the north at Gun Barrel City.

Constructed in 1979 with a treatment capacity of .626 MGD and a surge capacity of 1.3 MGD (for a period not exceeding two hours), the WWTP at

Gun Barrel City has undergone a series of upgrades costing over $1.5 million, to bring the capacity up to .750 MGD. Operations Manager James Blodgett, who has worked with ECCFWSD for the past 11 years, commented: “During a normal day the levels in our equalisation tank here in Gun Barrel City don’t get too high, but in a rain event when we have to store the extra flow in our holding tank, we certainly don’t want the contents to go septic and cause odour problems.” Adding: “For over a decade we have used six Landia AirJets, which are 30 HP chopper pumps that help break down all the incoming solids, as well as mixing and aerating the tank. It is a very strong and reliable system that does much more than just pump.”

Renowned for its weather extremes, rain events are just one challenge in this part of Texas. The externally mounted pumps are subjected to everything from ice storms to temperatures of 110F (43°C). Despite the severe climatic challenges, all but one of the six original pumps still has its original seal.

Blodgett continued: “As well as visual and audio inspections, we carry out oil changes every 2000 hours, which does prolong seal life, but considering that the pumps have been here since 2004, that’s quite a record. We mainly take in domestic sewage with all the grit and rags you’d expect.

We also receive some non-domestic waste, including from the local hospital, but none of it troubles the Landia units.

They just keep on macerating the solids.

It’s a system that works very well for us.”

Equipped with an uncompromising external knife system, there are usually (depending on tank levels), one or two of the six Landia pumps running 24/7 at Gun Barrel City, allowing for the amount of aeration and mixing to be adjusted according to the liquid volume in the equalisation tank.

“Because the AirJet can constantly aspirate more air, we’ve not had any odour issues”, Blodgett reports. “The oxygen transfer levels are always maintained, even when we get a higher concentration of solids, so our wastewater is always aerated properly and never goes septic.

We do have to be very wary of rain events and other weather extremes. Our equalisation tanks with the Landia pumps have been hit by lightning on more than one occasion, so you could say that they’ve also been smoke-tested.” z For more information

Landia’s externally mounted chopper pump AirJet aeration system at Gun Barrel City

This article was written by Chris French, an independent PR consultant.

Visit: www.landia.co.uk

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 23

MIXERS AND AGITATORS

Neither too much nor too little Finding the right amount of agitation for water and wastewater applications is pivotal for maximum efficiency and better reaction times

Many wastewater and clean water processes require mixing and agitation to enhance the reaction time and to optimise the process. In addition, there can be several other demands that must be considered to ensure a well-functioning process. Selecting and designing agitators for water and wastewater applications is very much about finding the right balance – there should be neither too much nor too little agitation.

Sulzer has a long history of delivering dry installed agitators to the wastewater market. Typical applications in the water and wastewater industry are flash mixing (rapid inmixing of chemicals), flocculation, and denitrification. Sulzer’s Scaba branded agitators have been installed in thousands of locations worldwide, emphasising Sulzer’s solid experience and proven solutions.

The challenge to cut energy cost and reduce the environmental footprint increases the importance of power savings. Scaba agitators consume surprisingly little power. There are two main reasons for their efficiency. The first one is the propeller hydraulic. The efficient propeller design allows even flow distribution through the entire propeller diameter. The low gliding ratio provides a high pumping capacity at a low power demand, which makes the propeller ideal for all wastewater processes.

The second reason for the low power consumption of the Scaba agitator range is the selection know-how. The agitation level is described as the degree of agitation, which can predict the movement inside the tank. This powerful calculation can be applied to any tank shape and any liquid, including non-Newtonian liquids. The method has been fine-tuned by lab scale tests since the 1970s. It has been further proved by computational fluid dynamics (CFD) simulations as well as actual installations around the world.

By applying this experience, Sulzer can select exactly the most efficient agitator – neither too much nor too little.

Careful consideration

Agitator in a denitrification process

24

The flash mixers are small and light agitators where the propeller and the shaft are directly connected to the motor.

The customer process typically demands quick and efficient inmixing of chemicals before flocculation. This means that the FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

MIXERS AND AGITATORS For flash-mixing applications, the Scaba TreatX range consists of light, direct-driven agitators with three-bladed propellers for high mixing capacity. The agitators for flocculation and denitrification are gear-driven, slow-running machines with two-bladed propellers for mild agitation, yet they create enough agitation to prevent sedimentation and not to break down flocs. The agitators for flocculation and denitrification are always designed for a variablespeed drive. Each application area consists of a large variety of propellers and shafts for various rotation speeds.

Each area also provides a very dense coverage of high-efficiency agitators.

The Scaba TreatX concept is not a new product, but rather a concept that sharpens Sulzer’s offering to the water and wastewater markets. Scaba TreatX includes standardised Scaba agitators with a robust, stainless steel design.

Flocculation agitators ready to be installed

retention time, and tank shape and volume need to be considered carefully.

Both clean water and wastewater applications use flocculation as a treatment method. There are many different types of flocculation plants.

What they all have in common is that the agitation of the mixing devices used must be gentle enough to not break the flocs that are being built up, yet it must simultaneously prevent sedimentation.

Shear forces must be minimised, especially at the end of the process where the flocs are the largest. Sulzer’s design rules for agitators for flocculation ensure that the flocs grow continuously, and this is secured by several parameters.

To be able to fine-tune the process, it is recommended to install a variable-speed drive, at least during the last stages.

Nitrification and denitrification are used for the removal of nitrogen. The process can vary in different zones or even be intermittent. Agitators are often used in the denitrification process to prevent sedimentation. Since this zone is anoxic, with a low oxygen level, it is important not to let air into the tank because this would disturb the process.

Sulzer has launched the Scaba TreatX concept that offers preengineered Scaba agitators for flash mixing, flocculation, and denitrification applications. The concept combines Sulzer’s application expertise and the customers’ technical requirements with important practical issues, such as price and lead time.

The agitation level is described as the degree of agitation, which can predict the movement inside the tank

The agitators are built from Scaba modules with low energy consumption.

They are available with short delivery times and at competitive prices. z

For more information:

This article was written by Patrik Kolmodin, product line manager agitators, Sulzer Pumps Sweden.

Visit: www.sulzer.com

Scaba propellers ready to be installed in a flocculation process for drinking water

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 25

PAGE HEADER VALVES

Designing the ‘world’s biggest’ water gate valve Blackhall Engineering designed the world’s biggest water gate valve, to help deal with Dallas’ ever increasing water demand “Everything is big in Texas”, the saying goes, and that is definitely true of its water demand. Texas is the second largest state in the US both in terms of area and population. Its huge expanse includes a range of different climates, from arid to humid, yet it is always hot, making a reliable water supply vital.

In Texas lies Dallas – Fort Worth Metroplex (DFW) province, the US’s largest inland metropolitan area and the economic and cultural hub of north and central Texas. DFW’s water supply is both sourced and managed by two major Texas water authorities: Tarrant Regional Water District (TRWD) and Dallas Water Utilities (DWU). With the rapidly growing population in this area it is expected that more than 13 million residents will need water by 2060, which is more than double

Installation of lower body at the site

26

the population served by the authorities today. To meet this massive demand, the two water authorities have partnered to execute the $2 billion (€1.87 billion) Integrated Pipeline Project (IPL), which will enable them to increase the water supply by 350 million gallons per day (1.59 billion litres per day), meeting the ever increasing demand in the long term.

The project involves the construction of 150 miles (241km) of pipeline extending and integrating from multiple lakes. In addition, it includes the construction of three lake pump stations and three booster pump stations.

A trans-Atlantic project British company Blackhall Engineering are playing an essential role on this

mega project by regulating the water in the largest and longest segments of the pipeline. This has involved the design and manufacture of High Pressure DN2800/ 108 inch Parallel Faced Metal Seated Gate Valves, considered to be the world’s largest gate valves weighing in at over 100 tonnes and standing a majestic 40ft (12m) tall. The first of these valves was created and installed in March, while the second (at the time of going to press) is currently in the casting process.

The specifications for these spectacular valves were decided by some of the US’ top consulting engineering firms, such as AECOM, CDM Smith, Black & Veatch and Freese & Nichols.

Blackhall’s track record of manufacturing 100-year asset life valves was ideal for TRWD’s 100-year

Installation of top end assembly

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

VALVES

Inspection of seating faces on the body

sustainability promise on the IPL project.

As John Leithwaite, technical director for Blackhall, explained, the IPL project was one the company simply couldn’t resist getting involved with. “When the world’s most impressive pipeline scheme asks for 100-year asset life valves, you listen.”

Cutting-edge computational technology The most up-to-date computational technology was necessary to design the massive gate valves effectively, ensuring they offered the best performance and the greatest efficiency. Blackhall fused its design experience with cutting edge computational technology to ensure the valves would meet the requirements.

Along with theoretical knowledge and empirical data, Finite Element Analysis (FEA) has been comprehensively used to simulate and predict both the structural behaviour of the valve during its operation, and its capability of sealing under various flow and pressure conditions. The geometry of the components has been optimised for enhanced stress distribution. The FEA results were validated by performing strain gauge testing on the valve. The design of the valve also incorporated external loading factors, for example Computational Seismic (Modal) Analysis that was performed to ensure the sustainability and robustness of the valve during earthquakes and such events.

The success of any highly engineered product depends not only on the design, but equally on the manufacturing and assembly processes involved. Blackhall’s

Advanced Casting Simulation Programme was employed to optimise the casting process, making sure the castings manufactured were free from any residual stresses that could potentially develop during the solidification of metal. This prevents any over stressing of the components during operation and helps in ensuring the prolonged life of the valve. Extensive NDE and inspection techniques are also used to guarantee that the valves are manufactured to the highest quality standards.

world’s biggest liquid gate valve, logistics is inevitably going to be a challenge.

“Transporting such a huge valve across America was very challenging due to the size and load restrictions on many of the roads and bridges. Many of the jobsites are very remote with poor access. The engineering team had to design a valve that could be built and tested within the factory then disassembled, shipped and re-assembled on the jobsite. Manipulation and realignment of very large components being key to all of these operations.”

The project involves the construction of 150 miles (241km) of pipeline extending and integrating from multiple lakes

On schedule

Technologically advanced machining facilities were sourced for the machining of the valve components to achieve the dimensional and geometric accuracy critical for the functioning of the valve.

The complete valve was assembled with the utmost care and diligence by trained and experienced personnel to ensure the reliability of the valve build.

The first valve has been successfully installed on the pipeline, passing all tests with a Shell Strength at 375psig and seating capability tested at 250psig. Five further valves are currently in production for this impressive pipeline scheme, designed in the UK and manufactured in the US. James Blackhall the managing director of Blackhall Engineering commented “It has been a joy working with TRWD, both engineering teams worked exceptionally closely with a true sense of purpose to deliver this legacy project.” z For more information:

John Leithwaite is technical director at Blackhall Visit: www.blackhall.co.uk

Far from easy As you’d expect with a project of this size, a number of major obstacles had to be overcome. Blackhall were required to think outside the box, to develop unique solutions to unexpected problems.

Leithwate highlighted two particularly big challenges his team had to face.

“Many of the existing valve standards that we were asked to comply with did not cover valves as large as 108 inch (2800mm) bore, most stopped at 48 inch (1200mm).” he explained to Fluid Handling International. “We therefore had to develop our own design acceptance criteria and product validation methods.”

The second problem Leithwate described to Fluid Handling International is perhaps a little more inevitable on projects of this size, yet it still requires a unique solution. Components of the valves are constructed at sites around the US, but all need to eventually be transported to Dallas. When you’re constructing the

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 27

MEASUREMENT

Keeping the flow

Repeatable, accurate non-contacting liquid open channel velocity measurement Flow is very simply defined as a volume of a material travelling within a given time, so cubic metres per hour or litres per second etc. There are a variety of ways that we can directly and indirectly monitor flow and flow rate, one of which is to measure the velocity of flow and relate it to an area. In closed pipes, magnetic flow meters work on this principle, measuring changes in magnetic flux proportional to the velocity of the flow through a pipe of known diameter.

Measurement in open channels is more complicated, but new noncontacting RADAR devices such as Pulsar’s MicroFlow and the low-power version MicroFlow-i have created costeffective and easily installed options for velocity measurement that can be extended to flow calculation in a whole raft of applications that may be difficult or prohibitively expensive otherwise.

By far the most popular automatic, continuous (full measurement range) open channel flow (OCM) measurement approach worldwide remains the use of non-contacting ultrasonic technology.

The transducer can stand alone or form a system with a control unit. The instrument in these applications is designed to accurately measure the level of the

MicroFlow-i-cso-application: Pulsar’s MicroFlow-i velocity sensor monitors flow in a remote CSO application

liquid in the channel as it flows through a calibrated restriction. There is therefore another part of the equation, which is the need for a well-engineered and expertly installed primary measurement device (PMD) such as a calibrated flume or a weir. These are well understood systems, and specialist manufacturers produce standard PMD’s. The calculations required to convert level (head) into flow are built into specialist instruments such as Pulsar’s FlowCERT and in many territories subject to external standards such as the UK’s

MCERTS (monitoring certification scheme).

These calculations are generally used to measure against discharge consents.

An ultrasonic controller such as Pulsar’s Ultra or FlowCERT, along with a dB series transducer, makes it possible to derive a ‘curve’ of flow against level by measuring the flow rate using other means at various levels, and electronically recording a set point for each level within the controller.

A Pulsar ultrasonic system will typically allow around 32 points of calibration.

There are many other situations, for example in a canal or in a subterranean channel, where there is no room for a PMD to be fitted or where the system hydraulics don’t permit it, and we need to look for an alternative method to indicate the flow. In many cases it is not necessary to measure the flow rate, it is sufficient to know, reliably, that liquid is flowing within normal upper and lower boundaries, and therefore we can measure the velocity of the flow to indicate a normal condition – for example within a channel where an excessive flow velocity may indicate a process issue further upstream.

A new generation

MircroFlow-i-half-channel: A MicroFlow velocity sensor measures a discharge in a deep and difficult sump

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Pulsar’s MicroFlow and MicroFlow-i represent a new generation of low cost microwave/RADAR devices that are compact and deliver repeatable, reliable FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

MEASUREMENT

Microflow on channel 1: A velocity sensor working with Pulsar non-contacting ultrasonic system for a velocity x area flow calculation

contacting devices, typically turbines or Doppler immersion probes. These have been highly successful but occasionally problematic, obviously potentially prone to fouling and, particularly the Doppler sensor, reliant on various conditions within the flow. Pulsar’s MicroFlow and MicroFlow-i use a compact transducer, which is positioned above the flow and makes a non-contacting measurement of flow velocity. A simple bracket can be used to mount the transducer at the optimum angle, so they are easy to install, maintenance free and installation usually causes no interruption to the process.

Measuring velocity using a noncontacting technique is a very

complex challenge analytically, and has only really become realistic with the faster processors now available to instrumentation designers. Pulsar use a technique called RSSA (Refracted Spread Spectrum Analysis). In MicroFlow, a pulse is fired at the liquid surface, producing a mass of reflections from the full width of the channel, up to 1.5m width. Multiple sensors can form an array to measure across wider channels. If this were a level measurement application, we would be looking for a single strong signal. In this application, the MicroFlow applies the RSSA algorithms to analyse and integrate the received signals, then slices them for real-time analysis and

flow rate calculation. MicroFlow can be used as a stand-alone device that delivers velocity data via RS485 Modbus.

With relatively low cost per installation, this means that they can be more generally deployed within a process, so process managers can have real clarity of flow profiles within their operations.

More recently, ultra-low power versions such as Pulsar’s MicroFlow-i have come onto the market. Communicating through HART or a 4-20mA signal, they offer a valuable way of measuring such things as CSO (Combined Sewer Overflow), where flow velocity can give a volume measurement rather than the traditional time and duration from a single level device. These sites are in general physically remote and almost certainly will not be fitted with a PMD, so a low-power, zero maintenance non-contacting solution is ideal.

Going back to flow measurement, of course once a flow velocity has been determined, it can be combined with level measurement to produce a flow measurement using a velocity x area calculation.

Non-contacting velocity measurement is, then, an interesting new tool for the process and instrumentation engineer, allowing closer control and clearer process and flow measurement throughout a wide spectrum of applications. z

For more information:

This article was written by Alistair Mackinnon, director of sales and marketing at Pulsar.

Visit: www.pulsar-pm.com

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 29

Winds of change MEASUREMENT

How the latest radar level technology can benefit the water and environmental sectors

Across the world there are tens of thousands of sewage treatment plants treating billions of litres of sewage every day. Myriad measuring instruments monitor and measure water or sewage for level, flow, pressure, and water quality, as well as controlling increasingly complex biological processes at the treatment facilities themselves. Level is one of the most common measurements – for example in open channels, flumes, and weirs, controlling screening systems, emergency overflows, flood monitoring, settling ponds, sludge, solids handling and dosing systems, along with countless other tasks.

Until recently, continuous level

measurement in the water processing and monitoring industries mainly relied on non-contact ultrasonic level sensors, particularly with effluent due to the large amounts of solid material, and submersible pressure transmitters used mainly on the cleaner water supply side. Now, a still relatively new contactless level option is using radar technology. It is already wellestablished in many process industries.

Yet water utilities still have comparatively little experience with it, partly due to a perceived higher cost and complexity making them a “specialist” solution. Thanks to new developments in technology and cost, radar can these days be considered as a first choice mainly due to lesser influence from process or environment, the excellent reflectivity of water to radar signals, inherent accuracy and repeatability, and a more robust measurement technique at a price competitive to incumbent technologies.

Process challenges Jürgen Skowaisa is the product manager for both radar and ultrasonic technology at level measurement company VEGA Germany. From experience, he considers contactless radar level technology as the future for the water, environmental, and sewage sectors, primarily because of its robustness in the face of process and weather influences. He has direct experience of condensation, turbulence, vapours, wind, fog, and rain impairing ultrasonic sensors, as well as temperature influence (solar gain) from solar radiation. Velocity changes of ultrasonic signals are related to temperature changes (1.6% per 10° Kelvin).

“As long as it’s cloudy, you get reliable values,” explains Skowaisa.

“But during longer periods of direct sun, temperature on the transducer increases, and the sensor temperature can become much higher than the ambient temperature, thus causing an error.”

One solution is a solar shield or an additional temperature sensor, but it does not always mitigate errors, as temperature variations in the air between sensor and liquid surface cannot always be measured and corrected for. This was demonstrated in a test by an environment agency, who

30

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

MEASUREMENT installed a radar alongside an ultrasonic sensor (fitted with a temperature sensor and a solar shield) on a small bridge.

The data showed the ultrasonic sensor still produced noticeable errors, or drift, in certain weather conditions, while the radar device output remained accurate.

Turbulence, waves, or foam can also affect ultrasonic sensor performance.

Reflection signals can scatter, and if in the open, wind can take the signal away completely. Radar microwave signals are unaffected – with millions of pulses emitted and the output updated twice each second – which means they can even measure wave height. With surface foam, latest radar sensors also have the focusing and dynamic sensitivity to carry on working and measuring.

Radar delivers accurate, reliable level data even with sensor face condensation or vapours and gases in the vessel. The proliferation of anaerobic digestion (AD) units for energy generation and sludge handling plants typically present these environments for level controls. Also, new designs of “sealed” waste treatment plants – to reduce odour in urban areas and facilitate harvesting of gases for energy generation – provide greater potential of these issues arising in future.

Sensor capabilities A compact two-wire, 4-20mA looppowered “water” radar will typically have an accuracy in the region of 2mm or 5mm with encapsulated antennas with a 3°-10° beam angle and ranges from around eight to 15m to 120m). They can feature Bluetooth, Profibus, FF, and HART communications for setup and/ or data transmission with hazardous area approvals. Some resist submersion with flood-proof housings. Basic devices can generally handle process pressures up to 3 bar and temperatures up to 80°C, which is normally ample for most water/environmental sectors.

There are tens of thousands of radarbased devices already installed in the water industry worldwide, and the adoption looks set to accelerate. “The technology boasts higher precision in general, it is very easy to use, and can offer a great performance alternative to ultrasonic instruments,” explains Skowaisa.

“The price differential between ultrasonic and radar measurement technology used to be very high. Today, the cost of radar technology is the same, even lower depending on the application,

so it is actually turning out to be the better all-around solution,” he adds. It means customers can now choose based purely on best technology, rather than on price.

Like any industry-oriented device, application-based setup helps with both quality and speed of commissioning.

“Users in this industry require quick, easy selection for applications such as pumping stations, sludge reception and handling tanks, digesters, flow rate measurement in open channels, and other similar applications typical of this sector. Even flow curves can be programmed into the sensor itself for open channel flow measurement,” Skowaisa says.

A variety of mounting and communication options are available to make the sensors easy to integrate into existing infrastructures. Straightforward, user-friendly operation and handling, like Bluetooth apps and PC communications, delivers fast simple set up and diagnostics.

Skowaisa adds: “The measurement data can be transmitted either directly to an existing control unit or to a SCADA system, so this makes the technology a true all-rounder.” When it comes to approvals, as well as hazardous area certifications, there is a European norm for Level Probing Radar (LPR) level sensors for open air use. Devices must conform to this standard to be used outside.

Reliable data in demanding applications The following examples show the advantages the new sensors have in daily use in the water sector.

Precision open channel flow measurement: In flow rate measurement in open channels, accuracy is key due to the exponential flow calculations, which can amplify the smallest errors.

According to Skowaisa, many users do not realise that ultrasonic technology can deliver inaccurate results.

“Users simply trust that the values stated in the manual are correct, but in reality, these only apply under ideal measuring conditions,” he says. Regulators charge businesses for effluent discharge quantities on the basis of these values.

Radar technology can deliver better measurement data for all parties involved.

Recently, the first radar-based system for open channel flow measurement was approved under the MCERTS scheme, overseen by the Environment Agency in the UK. It was assessed for performance, accuracy, and quality of manufacture.

Radar technology is a perfect choice for this application, unaffected by temperature changes, reliable in all weathers, even with condensation on the sensor face, delivering precision level data for computation into flow.

There are tens of thousands of radarbased devices already installed in the water industry worldwide It is now certified for this application under the scheme and offers great advantages for versatility, capability and flow measurement accuracy.

Storm water overflows and sewer flows: SWO or CSO chambers are often situated underground and users can benefit greatly from the technology. According to Skowaisa, radar technology has no blocking distance, and thus measurement can continue even to very high water levels where ultrasonic sensors have to be mounted well above the maximum level to allow for their blocking distance to not misread or lose the reading.

Storm overflow chambers – Radar has no blocking distance, therefore its ideal in confined spaces, or mounted horizontally with a 45 reflector plate mounting to increase range of measurement

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 31

MEASUREMENT Water radar (edge of sensor at very top left of picture) at work on a on a deep shaft on a storm surge shaft, focused on the water level, ignoring the many obstructions above

He also mentions another advantage: “Even flooding is no problem, because radar sensors have IP68 protection options.”

Millimetre precision under all conditions can monitor “spill” more accurately, too.

Storage of chemicals: Some chemicals used for sewerage or water treatment and cleaning give off fumes, condensate, and vapours. They require secure, safe handling and measurement when used so close to the water courses and plants.

Radar works with fumes or vapours present and can be mounted above/outside a plastic or GRP vessel, looking down through the top to provide a reliable, accurate monitoring for inventory. They present an ideal solution for plastic mobile IBC containers, no fitting required.

Pumping stations, wet wells and shafts: Pump shafts are often narrow and filled with many pipes, fixtures, and fittings, and the pumps themselves are sometimes located directly in the shaft.

Build-up of solids is also often prevalent.

Reliability is achieved with a focused beam and the very high reflectivity of water to radar signals. On very deep shafts, seen on large-scale schemes, an alternative sensor can be used with only a 3°beam angle with ranges up to 120m.

Open waterways: Flood risk is increasing as the result of more concentrated heavy rainfall in some areas and urbanisation in others. But then, so is flood level monitoring, gauging of rivers, waterways, and estuaries. Non-contact radar sensors, with their immunity to sun, wind, rain, and fog really come in useful. They can be mounted anywhere, quickly and easily, out “in the open” without still wells or sounding tubes or under bridges. They can also be retrofitted to existing installations.

levels, supply, and sewage treatment will continue to grow in the future and will always place new challenges on technologies. Meeting these needs in different environmental markets is a challenge in itself. In Europe, the main focus is on upgrades to existing plants

and looking for the latest technology for automation, while in countries like China and Brazil new sewage plants with latest fieldbus communications are being built almost daily.

New technology level measurement devices with improved reliability and performance, application-based setup, Bluetooth setup, as well as price competitiveness, offer a real alternative to legacy sensors with a choice based on the technology, not the price. “Future market and environmental requirements can be quickly met with such a capable core technology,” concludes Skowaisa.

“I am convinced radar instruments will play a major role in achieving this.” z

For more information:

This article was written by Doug Anderson, marketing manager at VEGA UK. Visit: www.vega.com/uk

The outlook With its contradictions of scarcity and deluge, the monitoring of water and flood 32

Radar mounted off a bridge over a river, simple to install with two fixings. No effects from high winds or temperature gradients over the 15m range, powered by battery logger, both mounted in a discreet tube. Measuring every 15 minutes, working for over 3 years on same battery, zero maintenance

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

The Environment Agency takes samples from Welsh Water plants such as Rotherwas and Ross-on-Wye 12 times a year, checking for phosphorus, iron, ammonia, solids and more

WASTEWATER TREATMENT

Chemical control in wastewater Reliable coagulant dosing is key to successful phosphorous control It is well documented that the appropriate control of nutrients such as phosphorous in the world’s water courses is vital for a cleaner, sustainable future. With this in mind, the European Water Framework Directive (Directive 2000/60/EC) has set an ambitious goal, demanding that rivers, lakes, coastal waters and groundwater be in a “good ecological and chemical condition” by 2027.

So, what does achieving “good chemical condition” entail? Well, as elevated levels of phosphorous lead to excessive algal growth and eutrophication of surface waters, key measures defined by the European Commission state that taking steps to protect water from the ingress of this nutrient is advantageous.

For municipal wastewater treatment plants, this demands chemical coagulation before any discharge to water courses. Here, the addition of a coagulant such as ferric sulphate, converts the phosphate solution into insoluble phosphate compounds which can then be isolated.

a significantly stricter discharge limit of 0.9 mg/l currently applies.”

Until recently, the Schlüchtern water treatment plant used diaphragm pumps to perform coagulant dosing operations.

However, due to widely fluctuating dosage, the use of these pumps led to persistent interruption of flow. To overcome this issue, the plant turned to a 500 series cased peristaltic pump from Watson-Marlow Fluid Technology Group (WMFTG), a move that has resulted in dependable, high precision coagulant dosing. Furthermore, the Schlüchtern plant has been able to dispense with the need for a second pump as well as considerably reduce its maintenance requirements.

Intensive phosphorous removal With phosphate content in the feed water at Schlüchtern averaging 5-6 mg/l, this requires a reduction of more than 80%, thus demanding intensive P-removal.

“We have made significant investments in this area in recent years,” says Spuling.

“For instance, we have switched from manual dosing to automatic dosing using a real-time controller. This uses the current phosphate load to automatically calculate the necessary quantities of ferric sulphate coagulant required, so that we can reliably observe the necessary discharge values. The actual dosage is then performed using a pump.”

The diaphragm dosing pump technology the Schlüchtern plant had been using unfortunately caused a number of problems.

“As we do our coagulant dosing in parallel [in two pools], we also had two pumps, but this led to more and more issues,” recalls Spuling. “Above anything, the pumps had problems with variation in the feed volumes of the coagulant.”

Low feed volumes Depending on the amount of dissolved phosphate in the wastewater, the quantity of required coagulant can vary hugely – from 0.4 to 60 litres per hour.

Tight restrictions Unsurprisingly, the limit for phosphorous content (P-limit) at the discharge points of municipal water treatment plants is gradually being reduced. In Germany, the Waste Water Ordinance has published an appendix that lists P-limits on a sliding scale according to the size of the water treatment plant.

According to the appendix, the water treatment plant in Schlüchtern (population 27,500), near Frankfurt, Germany, belongs to size category four.

“The P-limit for a plant of our size is 2 mg of phosphorous per litre,” explains operations manager Eduard Spuling. “However, as the town is upstream of the Kinzigtal reservoir,

To help overcome the repeated blockage of diaphragm pumps when dosing ferric sulphate, a number of Welsh Water sites now feature Qdos peristaltic pumps

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 33

WASTEWATER TREATMENT The problems were primarily caused by feed volumes of less than 4 litres.

“With such low feed volumes, the flow of the diaphragm pumps was frequently interrupted,” says Spuling. “The result was increased P-values coming from our water treatment plant.”

As diaphragm pumps are generally designed to have only limited selfpriming capabilities, each interruption in the flow resulted in considerable workload for staff at the plant.

“With each interruption, we had to prime the lines with a hand pump, which took about 20 minutes of hard work,” reports plant operative Michael Comes. “There was also quite a lot of call-outs at night.”

If one of the pumps was damaged, it was expensive and labour intensive to replace. In addition, diaphragm pumps have many components, such as non-return valves and springs, which can clog or corrode.

“We had to stock a whole array of replacement parts” adds Comes. “We nearly always had a diaphragm pump in the workshop. What’s more, it was extremely unpleasant and at times dangerous to handle leaking coagulant.

Peristaltic solution Due to positive experiences with peristaltic pumps in a previous occupation, Spuling decided to trial a Watson-Marlow 500 series cased drive fitted with multi-channel 313 peristaltic pump heads. This model easily allows up to six pump heads to be fitted on a single drive. The advantage for the water treatment plant is that even with two independent flows, just one dosing pump is sufficient. At Schlüchtern, the WatsonMarlow peristaltic pump creates several dosing points in the respective secondary clarifying tanks. As an added benefit, the 500 series pump is completely reliable, even with flow rates as low as 0.1 l/min.

“The difference in comparison with the diaphragm pumps was noticeable from the beginning, and we’ve not had further problems with interruptions in flow,” confirms Spuling. “It is also very easy to use.

In contrast to our previous pumps, we can now easily input the dosing rate directly in litres per hour. Moreover, thanks to the accuracy and repeatability of the WatsonMarlow cased pump, frequent measuring is now no longer necessary. As a result, we are now looking to dispense with all our flow metering equipment in the near future.”

The water treatment plant at Schlüchtern also benefits from the peristaltic pump’s 34

longer maintenance intervals, as the two 313 pump heads fitted have proved to be extremely robust and durable.

“Whereas on the diaphragm pumps we had to often replace parts, the 500 series cased drives and 313 pump heads have given us trouble-free operation for three years,” states Spuling.

P-limit control By investing in the latest phosphorous coagulation technology, the water treatment plant has been able to significantly reduce the P-limits of its discharges.

“We are able to declare a reduction in levels from 1.2 to 0.9 mg/l currently,” explains Spuling. “With this in mind, we will make significant savings on wastewater charges moving forward. Moreover, we can offset the investment in the control module and new dosing pump against the wastewater charges.”

According to the Waste Water Charges Act, investments by plant operators can be offset against wastewater charges for up to three years retrospectively. This is, however, on the condition that the amounts of pollutant being discharged – in this case phosphorous – are reduced by at least 20%, a figure easily achieved in Schlüchtern. For the water treatment plant and the town’s inhabitants, the improvements can therefore be implemented on a cost-neutral basis.

“We are now planning a two point coagulation strategy, as well as the potential of implementing downstream P-coagulation,” concludes Spuling.

“If that happens, we will definitely be speaking to Watson-Marlow about more peristaltic dosing pumps.” z For more information:

This article was written by Dan Thomas, product manager at Watson-Marlow Fluid Technology Group.

Visit: www.watson-marlow.com

Dosing pumps help Welsh Water maintain strict phosphorous limits To help overcome the repeated blockage of diaphragm pumps when dosing ferric sulphate, a number of Welsh Water sites now feature Qdos peristaltic pumps from WMFTG. The investment is expected to achieve a quick return thanks to significant savings in maintenance associated with stripping down and cleaning the diaphragm pumps. Moreover, the Qdos pumps are helping Welsh Water meet increasingly strict phosphorus limits.

The continuous dosing of ferric sulphate at water treatment works requires the application of reliable, highperformance pumps. For Welsh Water, the traditional pump type of choice has been based on diaphragm technology.

However, this has had its issues.

“Our diaphragm pumps were blocking on a repetitive basis,” explains Ronnie Swain, process technician at Welsh Water.

“Almost every time I visited one of our sites there would be problems with the diaphragm pumps. We would start off by turning them up to achieve the same flow, but eventually we’d have little option but to ask our maintenance team to open up the pumps and remove the blockage. However, this obviously involves time and cost, and it was happening year-round. We had to carry a whole array of replacement parts in stock. It was clearly time to look for another solution.”

Welsh Water opted to install a Qdos 120 pump for dosing ferric sulphate at its

Rotherwas wastewater treatment plant in Hereford. Here, the pump has been set to work operating at a flow rate of 50-60 l/h. However, Qdos pumps are reliable at flows as low as 0.1 l/min.

Such was the success of the Qdos pump (no more blockages), that two more have since been duly installed at Welsh Water’s Ross-on-Wye wastewater treatment plant – one as the duty pump and one on standby. These pumps run at a much lower flow rate of 8 l/h.

“Phosphorus is already limited to 1 or 1.25 mg/l, but the expectation within industry is that it will soon become even stricter,” says Swain. “Obviously we are dosing ferric sulphate, which means we also have to be careful that we don’t fail Environment Agency (EA) tests on iron levels. This balance means we need pumps that work reliably and correctly on a 24/7 basis.”

The EA takes samples from Welsh Water plants such as Rotherwas and Ross-on-Wye 12 times a year, checking for phosphorus, iron, ammonia, solids and more.

“We have a responsibility to ensure the delivery to our watercourses is as good as it can possibly be,” concludes Swain. “We’ve calculated our averages for 2016 and I’m pleased to report that both Rotherwas and Ross-on-Wye are comfortably within the required P-limits. Our Qdos pumps have certainly played a significant part and Welsh Water is now considering adopting this technology at further plants.”

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

INTERVIEW

Water leak detection from up high The WADI project is working to prove the feasibility of airborne water leak detection for rural areas

By Daryl Worthington In some places in Europe, as much as 50% of water resources are being lost before they reach the tap. The WADI project aims to address the challenge of building a water and energy efficient society by contributing to the reduction of losses in water transmission systems for water supply, irrigation and hydropower while Yolande Louvet is the scientific coordinator of the WADI project decreasing the related energy consumption.

The project aims to prove the feasibility of an airborne water leak detection surveillance service with adequate information on leaks in water infrastructure outside urban areas, thus enabling prompt and cost-effective repairs.

WADI’s innovative concept consists of coupling and optimising off-the-shelf optical remote sensing devices (multispectral and infrared cameras) and applying them on two complementary aerial platforms (manned and unmanned) in an operational environment.

The first test took place in February 2017 in France. Equipped with hyper-spectral and infrared cameras, a Busard aircraft flew over the facilities of the Canal de Provence (SCP) in the south-east of the country. The aircraft recorded images of the facilities’ irrigation network, including buried ductile iron pipes. Three locations were captured and recorded by the aircraft’s cameras: Cabardelle (Salon de Provence), Rians (near Aix en Provence) and Valtrède (Martingues).

The three flyovers captured high quality images across the spectrum of infrared: (band III, between 8000 and 12000 nm), SWIR (between 1400 and 3000 nm) and VNIR (between 400 and 1400 nm).

Funded under the European Programme Horizon 2020, the WADI Project is coordinated by youris.com, EEIG and developed in cooperation with 11 partners in six European countries (Belgium, France, Portugal, Spain, Poland and Italy).

Fluid Handling International spoke to Yolande Louvet, the initiator of the WADI project.

What is your role in the WADI project?

I am the scientific coordinator and the initiator of the WADI project. I am the advisor on Environment and Security at ONERA’s (The Office National d’Etudes et de Recherches Aérospatiales, the French National Aerospace Research Centre.)

Department of Optics and Associated Techniques (DOTA).

DOTA has recognised expertise in the field of airborne optics instruments, and it is actively involved in all scientific and technical activities of the WADI project.

Can you tell Fluid Handling how the project started?

During an info day on “airborne remote sensing applications,” a manager of the French SME Air-Marine asked me if water leaks during water transportation in rural areas could be detected using airborne remote sensing methods. I answered “Yes, they could!” I thought this idea would be very interesting for a European project related to the challenge of sustainable water resources management.

I began looking for European partners, and Air-Marine was the first to join. In 2012, the WADI consortium was unsuccessfully submitted for a European Commission ICT (Information Communication Technology) call for proposals. In 2015, with coordination by SGI (an Italian partner on the project who are experts on ground water leak detection), the WADI project won funding under the EU Commission’s “2015-Water-bdemonstration” call, achieving the maximum possible score of 15 /15. We were ranked number one of 169 proposals submitted.

Now, the coordinator of the WADI Project is youris.com and ONERA continues to manage the scientific coordination of the project.

What stage is the project at now?

The project started in October 2016. ONERA and SCP (Société du Canal de Provence) partners are carrying out the first airborne campaign dedicated to determining the optimised detection wavelengths. The flights have been achieved successfully and the analysis of the hyperspectral/IR images collected is underway. The results are expected at the end of July and will define the WADI system used on an operational test campaign.

Where will this technology be most useful?

Sustainable water resource management will benefit both southern and northern countries. Indeed, our countries

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 35

INTERVIEW

The aim is to detect direct/indirect anomalies due to underground water leaks are faced with a scarcity of water resources and at the same time an increasing demand for water.

There is a very important point to take into account, and that is that the cost of water treatment includes an increase in electricity consumption, and this increased electricity consumption has significant environmental and economic impacts.

In some parts of Europe, especially rural areas, as much as 50% of water resources are being lost before they reach the tap.

The WADI project is dedicated to water leak detection in rural areas, and to answer your question, the WADI system will be useful on different water networks (lined and unlined channels, pressurised or gravity pipes etc) and in different environments, working through a range of soil, vegetation, and climate.

How will the system detect underground leaks?

The project will use on board multispectral and infrared cameras running at the optimised wavelength. The aim is to detect direct/ indirect anomalies due to underground water leaks, such as: • Soil moisture content • Soil surface that has been modified by water evaporation • Vegetation and lichen growth • Small-to-large erosion phenomena • Thermal soil surface and behaviour of soil thermal inertia.

All these different effects can be detected using multispectral and infrared cameras.

What are the advantages of using optical sensing on aerial platforms?

The optical sensing solution provides remote sensing detection at a long distance which permits the surveillance of all sorts of water networks (open canal, pipeline) in different environments.

The WADI system offers a fast, efficient and cheaper solution compared to the traditional terrestrial leak detection method.

WADI solution’s application will be carried out on two complementary aerial platforms. The manned aircraft is being used in long-distance and important infrastructure monitoring, whereas the unmanned platform is used for surveying branched water networks with short conduits or in particularly sensitive areas, i.e. those with a limited or difficult physical access, or located in dangerous areas.

What kinds of manned and unmanned aircraft will be used in the project?

The flights dedicated to the best wavelengths detection determination used the ONERA’s Busard aerial platform (motor glider + 2 pods for the payload), instrumented with two hyper-spectral and one IR imaging device.

The future test campaigns will use manned and unmanned aircraft provided by our Air-Marine (AM) and Galiléo Geosystems (GG) partners.

The manned platform (TECNAM P2006 T) will be provided

by AM, a surveillance service provider which has a certified platform available for oil pipeline surveillance.

GG will provide UAV, which will be chosen when the best detection wavelengths have been defined.

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ONERA Busard platform February 2017

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What is planned for the future tests?

The second campaigns, planned for 2018, will provide the validation flight tests of the WADI system over the SCP site. The validation tests will be supported by the traditional terrestrial leak detection method for assessment of the flights’ results.

The third and fourth (operational and surveillance campaigns) will be dedicated to testing in conditions close to the future WADI service and are planned for 2019 in Portugal over the site of EDIA, the second water network provider partner. z For more information:

Visit: www.waditech.eu

36 Fluid Handling.indd 1

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 13/01/2017 11:44:41

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017 37

PAGE HEADER

The ultimate for small tanks!

The future is 80 GHz: a new generation of radar level sensors

When it comes to contactless level measurement of liquids in small containers, smaller is better. With the smallest antenna of its kind, VEGAPULS 64 is simply the greatest! With its excellent focusing and insensitivity to condensation or buildup, this new radar sensor is truly exceptional. Simply world-class! www.vega.com/radar

Wireless adjustment via Bluetooth with smartphone, tablet or PC. Compatible retrofit to all plicsÂŽ sensors manufactured since 2002.

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FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

PUMPS

Intelligent wastewater pumping Xylem’s Flygt Concertor eliminates clogging at Italian wastewater pumping station As the wastewater sector continues to focus on driving energy efficiency and a reduction in the total cost of pump ownership, the demand for intelligent, sustainable pumping solutions has never been greater. Global water technology company Xylem is committed to advancing technological breakthroughs that can solve customers’ greatest needs, while reducing electricityrelated emissions. Smart, sustainable technologies such as Xylem’s Flygt Concertor – the world’s first wastewater pumping system with integrated intelligence – continue to set industry benchmarks for energy efficiency.

Field tests conducted around the world have validated significant improvements with Flygt Concertor, including energy savings of up to 70% compared to a conventional pumping

Xylem’s Flygt Concertor

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system; reduced inventory by up to 80% due to flexible performance; and clog-free pumping operation saving up to 80% in vacuum cleaning costs.

When the operators of a wastewater pumping station in Italy were seeking to address chronic clogging at the facility, a trial of Flygt Concertor yielded impressive results, eliminating clogging and significantly reducing energy consumption.

Flygt technologies installed in 40 important wastewater pumping stations across the region, Aset S.p.A. had seen first-hand the reliability and efficiency offered by these solutions. Aset was eager to try another innovative technology which could potentially solve the pumping challenges facing its wastewater network and specifically, the Squero pumping station.

Clog-free pumping for reliable, uninterrupted pumping

The challenge The Squero wastewater pumping station serves the popular seaside town and beach resort of Fano in the Marche region of Italy, bordering the Adriatic Sea. Operated by Aset S.p.A., the station consists of two 5.9 kilowatt (kW) pumps equipped with an FMC200 monitoring unit (a Xylem pump controller for pump stations with 1-2 pumps) and dedicated control panel. The station’s location, adjacent to Fano’s bustling harbour, means that overflows as a result of heavy rainfall or clogging must be avoided at all costs. Clogging had become an issue at the station however, requiring frequent maintenance call-outs to restore operation, as well as increasing energy consumption at the facility.

In order to reduce clogging and improve the efficiency of the pumping station, Aset S.p.A., a multi-utility company that runs the wastewater and drinking water networks in the Marche region, worked with Xylem to trial the new Flygt Concertor wastewater pumping system.

The Squero station presented a suitable testing site with a challenging wastewater pumping environment where a robust system was required to avoid clogging and keep the sump clean. With Xylem’s

Xylem’s Flygt Concertor was installed at the Squero pumping station in September 2015 and the system ran without interruption throughout the nine-month trial period.

Flygt Concertor is a new state-of-theart pumping system with integrated intelligence – a smart, interconnected wastewater pumping system that senses the operating conditions of its

The Squero station presented a suitable testing site with a challenging wastewater pumping environment. environment, adapts its performance in real time and provides feedback to pumping station operators.

Following the system’s installation, both the pump and sump were kept continuously clean over the ninemonth period. The pumps ran reliably and the system delivered significant

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

PUMPS The canal at Fano in the Marche region of Italy

cost-savings. Regular maintenance call-outs were no longer necessary.

Xylem’s Flygt Concertor features a built-in sump and pipe-cleaning features in a single integrated solution – an innovation for a wastewater pumping system. Furthermore, the pump cleaning function together with Adaptive N-hydraulics effectively detects and solves clogging from large debris.

Minimizer function, together with its IE4 high efficiency motor, self-cleaning Adaptive N-hydraulics and constant power functionality, automatically ensure that all the pumps in a pumping station run at their most efficient duty points.

Additionally, since there is no need for ventilation, cooling or heating of cabinets, customers benefit from substantial energy savings over the system’s total lifecycle.

Significant energy savings

User-friendly and simple to install

Flygt Concertor delivers proven reliability at a low total cost of ownership and significantly reduces energy consumption.

Regular monitoring of the Flygt Concertor system at the Squero pumping station, using data acquired via a Flygt Scada system, showed a reduction in energy consumption by 30% - a sizeable energy saving considering the challenging wastewater composition of floating debris and heavy sediment. The system also addressed a legacy issue of bad odours in the surrounding area.

Concertor’s patented Energy

The Aset maintenance team was delighted to find that installation, management and removal of the pumps was straightforward and time-efficient.

Xylem’s Flygt Concertor’s cutting-edge integrated intelligence for wastewater pumping is user-friendly, simple to install, commission and operate. All monitoring and control functions are pre-engineered, configured and tested as a total solution while installation and commissioning is swift and stress-free due to the system’s innovative set-up wizard and the straightforward cabinet design. All of this

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

reduces the need for engineering hours, both at the design stage and at the time of pump station commissioning - ultimately reducing the total investment cost.

A new era in wastewater pumping Together, demand for efficiency and intelligence is combining to advance the wastewater industry, and Xylem is responding by driving that advancement.

Building on its rich heritage of innovation, Xylem is determined to continue to push the limits of technology to create the highest quality, most reliable and sustainable wastewater pumping systems on the market. z

For more information

This article was written by Guido Di Virgilio, a product engineer with Xylem’s Monitoring and Control team.

Visit: www.xylem.com

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A fundamental breakthrough

SENSORS

Non-intrusive, ultrasonic level monitoring in tumultuous conditions There are many ultrasonic choices that are used for level monitoring in the universe of sewers, pipes and storm-water control. Although many circumstances in this environment, such as turbulence and unwanted obstructions, pose a challenge for most ultrasonics used in the fluid handling industry, they present no problem for the MassaSonic FlatPack.

The broad beamed duel transducer system is designed to have rapid signal processing and highly accurate echo return even when monitoring tumultuous fluids and irregular surfaces.

Today, MassaSonic FlatPack sensors are being used to monitor environmental challenges throughout the pipes and sewers of North America, and are being employed in Europe as well.

The problem Agitation of fluid, variance in pipe size and quick changing water levels often require multiple technologies working together, or even more expensive solutions. Pipes often allow for little or no headroom for sensor mounting. This called for a fresh new design that would provide

FlatPack V-160

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a dependable solution to the rough rise and surge of water levels and associated costs of handling them.

So how is it that an ultrasonic sensor, such as FlatPack, can perform so well in this environment?

Massa Products Corp. designed the product with the voice of the customer in mind.

Massa has extensive experience in transducer design and manufacturing, which allowed the company to approach the issues Sensor mounting in a pipe or sewer that the environment presents with a clean new approach at the transducers and electronics to the heart of the sensor – the transducer. best fit specific application challenges.

In other words, instead of applying Therefore, in uneven surface situations fancy electronics to compensate for that are commonplace when mixers transducer weaknesses, Massa designs and agitators are used, or situations

FlatPack I-95

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

SENSORS two fundamental problems in mind. The sleek and robust packaging with the dual transducers and the broader beam allows the sensor and electronics to be mounted in small spaces and still perform well. The two transducer sensor uses one transducer to send a sound pulse and the other to receive the echo. This design is capable of detecting echoes at a closer distance to the device, because the low level echo signal is not concealed by the larger signal that is still decaying from the transmit voltage, as would occur with a single transducer device.

There are two models available, one detects from one inch (25 mm.) to five feet (1.5 m.) away, and the other detects from four inches (100 mm.) to 13 feet (4 m.) away. The IP-68 rating allows it to survive being submerged. Both models are capable of calculating the distance of the targets by calculating the speed of sound in the medium.

Beam angle

MassaSonic FlatPack Sensor mounted

Agitation of fluid, variance in pipe size and quick changing water levels often require multiple technologies working together, or even more expensive solutions

in small and large pipes where there is little room for mounting and a good chance of water surges – FlatPack is used. FlatPack swiftly detects the level, and can be used together with data loggers, switches and alarm systems to alert the relevant technicians and engineers to attend to the situation

when needed. This helps keep costs down, and brings efficiency up.

One of the benefits to this sensor’s design is that beam angle was fully taken into account and paired properly with the application. Many people have a false perception that narrow beam angles deliver higher accuracy in target detection. This is not always the case and most definitely not the preferred model when using ultrasonic for turbulent or uneven surface detection.

This is because the sound pulse will more likely be deflected to alternate directions and not return to the sensor.

Results which resonate with history

The technology and design: The packaging is as it’s named, flat, and is slender enough that it can mount easily into round pipe fixtures.

Most ultrasonics work best on flat surfaces where the sound-pulse emitted bounces off the target, producing a well-defined echo that returns to the sensor. The pulse and echo travels at the speed of sound and allows the distance to be calculated by the sensor. However, when dealing with turbulence many ultrasonic sensors have trouble receiving the returned echo because often the narrow beam pulse is reflected in an alternate direction by the uneven surface, thereby causing the echo to scatter and not be detected. Furthermore, many pipes require a short detection range as well. FlatPack is designed with these

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

Massa Products Corp. was founded more than 70 years ago by Frank Massa, a pioneering figure in modern sonar and ultrasonic transducers. Located in Hingham, Massachusetts, Donald P. Massa is the current CTO and president of the corporation, and his daughter Dawn F. Massa Stancavish is in charge of new product development. The company specialises in electroacoustic design and manufacture for the military as well as for industry. z

For more information:

This article was written by Dawn F. Massa Stancavish, new products manager at Massa Products Visit: www.massa.com

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A single source for wastewater handling technology

PLANT DESIGN

The complexities of wastewater processing applications demand the simplicity of a single provider for pumps, accessories, service, and support

Applications for material handling and pumping technology in the wastewater industry tend to be complex, with a number of different people and organisations involved in installation and operation. The need to coordinate among officials from one or several municipalities, contractors and engineers means that designing, installing and operating material handling technology within these contexts is challenging. Considering this challenge along with the industry trend of buying full material handling solutions at once rather than simply integrating a stand-alone pump into an existing plant, it is clear that having a single source for pumps, accessories, design, service and support greatly simplifies material handling in wastewater applications.

Wastewater pumping applications

Custom Lube Pump Solution for a dewatered sludge application

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There are three main applications for material handling and pumping

technology within wastewater processing: polymer, sludge, and sludge cake. Polymer pumping applications tend to be fairly simple, with pumps handling polymers alone or solutions containing the polymers. Sludge pumping applications vary in their demands, from thin sludge to digested or thickened sludge. Sludge cake is the most demanding wastewater pumping application, given that it is high in solids and consequently difficult to convey.

Design, installation and service for wastewater pumping applications are unique, with a few major differences that set these applications apart from general industrial pumping and other material handling applications. The fundamental fact that wastewater processing plants are municipal entities adds layers of complexity into the design and installation process: projects are overseen by representatives from a number of different organisations, including municipalities, other government agencies, contractors, engineering companies and technology suppliers. This sizable number of people involved in the planning and installation of each project makes for a great deal of essential coordination.

In addition, wastewater processing plants tend to purchase material handling technology as a full solution, rather than a stand-alone pump or several pumps to be fitted into an existing process.

Wastewater pumping applications are generally handled during an expansion or the construction of a fully new plant, meaning that many different pieces of technology are being installed at once.

The complexity of organising and coordinating with all of the parties involved in a wastewater processing plant, combined with operators’ general desire to install full systems simultaneously,

FLUID HANDLING INTERNATIONAL l MAY/JUNE 2017

PLANT DESIGN together an answer from multiple vendors, or worry about vendors passing on responsibility when problems must be solved.

Even earlier than that, when a new project is being planned, fewer people need to be involved in designing and choosing the pump and accessories they want. A single expert or an experienced team is more able to understand the specific demands of a given application and effectively design a system to meet those demands than a collection of experts from a number of different vendors.

There is a reduction in cross-company A filter cake pump system transfers the cake by rotation of a communication metal rotor within a compressible stator and is accompanied by a Friction Loss Reduction (FLR) pump unit resulting in a lower potential for error. creates a need for simplification in Once a project is up and running, the design and installation process, as startup and training is more easily well as in servicing the equipment. The managed by a single vendor. This startup most effective way to simplify design, service and training support can be installation and service is to choose a performed by a local representative, single source provider for the full material who then becomes the wastewater handling system. With a single provider processing plant’s one point of contact who can offer design, installation and for the service and support described service, wastewater pumping applications above. That person can effectively experience reduced complexity leading provide troubleshooting and spare to greater efficacy and uptime. parts, without downtime associated

with coordinating among a number of different vendors’ representatives.

Sludge cake processing All wastewater material handling applications can reap the benefits of choosing a single vendor for sourcing pumps, accessories and service, though none so much as sludge cake handling.

Sludge cake is the most complex application within wastewater processing due to its increased solids content, thereby making the simplification offered by singlesource technology all the more significant.

With sludge cake handling, a number of accessories are important to managing operations and ensuring uptime: systems to turn the pump on and off when the hopper is full of sludge cake, control panels, load cells, pressure reduction systems, safety systems, and more. If all of these products and systems are designed, manufactured, installed, and supported by a single vendor, the ease of integration and maintenance is dramatically increased.

In all wastewater processing applications, the inherent complexity of material handling systems, as well as the impact of that complexity on ease of design and maintenance, is reduced by sourcing material handling technology from a single vendor. In doing so, wastewater processing plants can positively impact performance and uptime and simplify plant management. z For more information

This article was written by John Dean, project manager, Netzsch Pumps North America Visit: www.netzsch.com/en

Benefits of coordinating pumps, accessories, and services Acquiring the full material handling system from a single vendor such as Netzsch Pumps & Systems, including pumps, accessories, and services such as design, start-up assistance and support, helps wastewater customers to reduce complications. The need to coordinate with a number of different vendors is eliminated, which is especially critical for servicing. When wastewater processing plants purchase material handling systems from Netzsch everything is sourced through a single manufacturer, and so there is just one person, a local representative, who is knowledgeable about the whole system and can coordinate with the company. Customers need not piece

Tornado Rotary Lobe Pump seen in operation in sludge transfer line

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