Industrial Water World 2008-1101

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Industrial

WaterWorld SERVING THE PROCESS WATER AND WASTEWATER INDUSTRY

NOVEMBER/DECEMBER 2008/VOLUME 8/NO. 6

SCADA & PROCESS CONTROL PIPE INSTALLATION & MAINTENANCE WASTEWATER BIOGAS RECOVERY COOLING WATER BONUS DISTRIBUTION: POWER-GEN INTERNATIONAL

Electric Power Industry

www.industrialww.com

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2 heads are not always better than one. New Technology from KMS

Old Technology PURON™ MBR Single Header

Double Header MBR Heads clog due to non-central air flow

• Reduced Energy Demand Centrally located air nozzles improve aeration efficiency by up to 50%.

High system stress Costly maintenance

• Reduced Capital Costs Simple pre-screening due to low risk of module clogging

More cleaning required Less effective filtration

• Higher Reliability Minimal maintenance

Head into the future of wastewater treatment with KMS. Choose PURON™ MBR.

850 Main Street, Wilmington, MA 01887

978.694.7000

Toll Free: 888.677.5624

www.kochmembrane.com / iw3 _____________________

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®

WaterWorld MANAGING EDITOR Carlos David Mogollón (520) 326-2346 E-mail: [email protected]

PRESENTATION EDITOR Heather Skeith (918) 831-9176 E-mail: [email protected]

PUBLISHER Timm Dower 918-832-9237 E-mail: [email protected]

ASSOCIATE PUBLISHER James Laughlin (918) 832-9320 E-mail: [email protected]

DIGITAL MEDIA EDITOR Angela D. Godwin (603) 891-9449 E-mail: [email protected]

MARKETING Jessica Grier MANAGER (918) 832-9272 E-mail: [email protected]

𰀯𰀎𰁠𰁓𰁡𰁞𰁝𰁜𰁡𰁗𰁐𰁚𰁓𰀎𰁥𰁏𰁧𰀎𰁢𰁝𰀎 𰁐𰁓𰁢𰁢𰁓𰁠𰀎𰁥𰁏𰁢𰁓𰁠

PRODUCTION MANAGER Rae Lynn Cooper (918) 831-9143 E-mail: [email protected]

AUDIENCE DEVELOPMENT Emily Martha Martin MANAGER (918) 832-9311 E-mail: [email protected]

SR. VP AUDIENCE DEVELOPMENT Gloria S. Adams & BOOK PUBLISHING E-mail: [email protected] PRESIDENT, PETROLEUM AND Michael Silber N. AMERICAN ENERGY GROUP CHAIRMAN Frank T. Lauinger

𰁁𰁗𰁜𰁑𰁓𰀎𰀟𰀧𰀥𰀞𰀚𰀎𰀹𰁗𰁜𰁓𰁢𰁗𰁑𰁝𰀎𰁖𰁏𰁡𰀎𰁐𰁓𰁓𰁜𰀎𰁓𰁜𰁕𰁗𰁜𰁓𰁓𰁠𰁗𰁜𰁕𰀎𰁥𰁏𰁢𰁓𰁠𰀎 𰁡𰁧𰁡𰁢𰁓𰁛𰁡𰀎𰁢𰁖𰁏𰁢𰀎𰁒𰁝𰀎𰁛𰁝𰁠𰁓𰀎𰁥𰁗𰁢𰁖𰀎𰁚𰁓𰁡𰁡𰀜𰀎𰀺𰁓𰁡𰁡𰀎𰁓𰁜𰁓𰁠𰁕𰁧𰀜𰀎𰀺𰁓𰁡𰁡𰀎 𰁥𰁏𰁢𰁓𰁠𰀜𰀎𰀺𰁓𰁡𰁡𰀎𰁡𰁏𰁚𰁢𰀜𰀎𰀺𰁓𰁡𰁡𰀎𰁓𰁦𰁞𰁓𰁜𰁡𰁓𰀜𰀎𰀺𰁓𰁡𰁡𰀎𰁛𰁏𰁗𰁜𰁢𰁓𰁜𰁏𰁜𰁑𰁓𰀜𰀎 𰀺𰁓𰁡𰁡𰀎𰁓𰁜𰁤𰁗𰁠𰁝𰁜𰁛𰁓𰁜𰁢𰁏𰁚𰀎𰁥𰁏𰁡𰁢𰁓𰀜𰀎 𰁂𰁝𰁒𰁏𰁧𰀎𰁥𰁓𰀎𰁑𰁝𰁜𰁢𰁗𰁜𰁣𰁓𰀎𰁢𰁖𰁗𰁡𰀎𰁢𰁠𰁏𰁒𰁗𰁢𰁗𰁝𰁜𰀎𰁐𰁧𰀎𰁐𰁠𰁗𰁜𰁕𰁗𰁜𰁕𰀎𰁔𰁝𰁠𰁢𰁖𰀎 𰁜𰁓𰁥𰀎𰁢𰁓𰁑𰁖𰁜𰁝𰁚𰁝𰁕𰁗𰁓𰁡𰀎𰁔𰁝𰁠𰀎𰁥𰁏𰁢𰁓𰁠𰀎𰁢𰁠𰁓𰁏𰁢𰁛𰁓𰁜𰁢𰀎𰁏𰁞𰁞𰁚𰁗𰁑𰁏𰁢𰁗𰁝𰁜𰁡𰀎 𰁝𰁔𰀎𰁏𰁚𰁚𰀎𰁡𰁗𰁨𰁓𰁡𰀎𰁏𰁜𰁒𰀎𰁡𰁑𰁝𰁞𰁓𰁡𰀎𰁢𰁖𰁏𰁢𰀎𰁒𰁝𰀎𰁛𰁝𰁠𰁓𰀎𰁥𰁗𰁢𰁖𰀎𰁚𰁓𰁡𰁡𰀜

PRESIDENT & CEO Robert F. Biolchini 1421 South Sheridan Road, Tulsa, Oklahoma 74112 Tel: (918) 831-9862 Fax: (918) 831-9776 http://www.industrialww.com

FOR ADDRESS CHANGES

𰀰𰁓𰁢𰁢𰁓𰁠𰀎𰁥𰁏𰁢𰁓𰁠𰀎𰃀𰁝𰁥𰁡𰀎 𰁔𰁠𰁝𰁛𰀎𰁐𰁓𰁢𰁢𰁓𰁠𰀎𰁢𰁖𰁗𰁜𰁙𰁗𰁜𰁕𰀜

INDUSTRIAL WATERWORLD P.O. Box 3474 Northbrook, IL 60065-3474 Phone: (847) 559-7520 Fax: (847) 291-4816 E-mail: [email protected]

Industrial WaterWorld (ISSN: 1934-3922) serves management, operations, engineering and consulting professionals in the industrial process water and wastewater industry. Industrial WaterWorld reports the news and product/ service information necessary to succeed in planning, designing, operating and maintaining of industrial water systems.

𰀦𰀞𰀞𰀜𰀡𰀠𰀟𰀜𰀣𰀞𰀠𰀠𰀎 𰁥𰁥𰁥𰀜𰁙𰁗𰁜𰁓𰁢𰁗𰁑𰁝𰀜𰁑𰁝𰁛 _________________

SUBSCRIPTIONS: All subscription correspondence should be addressed to: Subscriber Service Industrial WaterWorld, P.O. Box 2847, Tulsa, OK 74101-9796. For address changes, please include both old and new addresses, and if possible, enclose an address label from a recent issue. Subscription rates for U.S. and possessions: 1 yr. $43, 2 yrs. $68, 3 yrs. $102, Digital $31; Canada/Mexico: 1 yr. $55, 2 yrs. $87, 3 yrs. $131; International: 1 yr. $61, 2 yrs. $97, 3 yrs. $145. Single copy: U.S. $12; other countries: $19; Digital $14. Periodicals Postage Paid at Tulsa, OK and Additional mailing offices. Industrial WaterWorld is published 6 times per year (Jan./Feb., March/April, May/June, July/Aug., Sept./Oct., Nov./Dec.) by PennWell Corporation, 1421 S. Sheridan Road, Tulsa, OK 74112. Editorial and advertising offices at 1421 S. Sheridan Road, Tulsa, OK 74112. Copyright 2008 by PennWell Corporation. All rights reserved. Material may not be reproduced in any form without written permission of the publisher. POSTMASTER: Send address changes to Subscriber Service, Industrial WaterWorld, P.O. Box 3474, Northbrook IL 60065-3474. Return Undeliverable Canadian Addresses to: P.O. Box 122, Niagara Falls, ON L2E 6S4

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CONTENTS

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NOVEMBER/DECEMBER 2008/VOLUME 8/NO. 6

w ww.industrialww.com __________________________

FEATURE EDITORIAL 20

Trends & Technologies: A Hot & Cool Relationship – Despite Cooling Market, Water & Wastewater Treatment Sales in Power Generation Still to Grow by Near Double-Digits By Shilpa Tiku

22 26

Water Straining: Filtration Devices Offer First Line of Defense for Power Industry Raw Water Intake Piping Installation & Maintenance: Monitoring System Saves Oil Pipeline from Severely Corrosive Environment

22 Choosing the correct strainer technology crucial at raw water intake to protect equipment for power generation industry.

By Elfriede Lynch-Willson

27

Cooling Water: UV Disinfection of Cooling Tower Water By Marc C. Scanlon

29

Stormwater & Watershed Issues: Kansas City to Host Urban Water Management II By Angela Godwin

30

Pump Efficiency: Enhancing Pumping Systems’ Energy and Life Cycle Cost Savings By Joe Melton

COLUMNS 6

Viewpoint: Speculation on New Administration Soars By Carlos David Mogollón

16

Regulatory Reports: Mining Firms Ordered to Continue Cleanup

27 UV disinfection, with secondary dosing using a suitable biocide, is one of the most cost-effective, efficient methods to reduce biofilms in cooling tower water.

By Patrick Crow

15

Investor Index: Market Turmoil and Investing in the Water Industry By Neil Berlant

18

36

Pump Issues: Failure Analysis Asks ‘Why?’ By Robert L. Matthews

33

Product Focus: Unknown SCADA Connections Could Mean Disaster for Process Control in Utilities & Other Critical Industries By Michael Markulec

45

Executive Corner: Flowserve’s Powers Focuses on the Future By Carlos David Mogollón

46

Case Study: Biogas Recovery from California Dairy Wastewater Eases Energy Needs By John Franceschina

Programmable Vibration Switches provide 24/7 monitoring of vibration levels on equipment such as large motors, pumps, compressors, fans, centrifuges, blower and cooling towers.

DEPARTMENTS 8 Showcase

44 New Literature

10 Water Events

48 Advertising Index

12 Water Briefs

45 Product Index

38 New Products

49 Classifieds/Bulletin Boards

Products & Services: 36 SCADA & Process Control

45

Cover Photo courtesy of Lumeta Corp. See article p. 33.

Product Index ®

Industrial

WaterWorld I

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Viewpoint CARLOS DAVID MOGOLLÓN, MANAGING EDITOR

Speculation on New Administration Soars

“Many are suggesting that an infrastructure investment plan as a cornerstone of any stimulus program could be just the ticket to get the economy rolling again... One issue is to make sure that infrastructure includes water and wastewater.”

What will a new Obama Administration in the White House come Jan. 20, 2009, do for the water and wastewater industry? That seems to be the question on everyone’s mind. And mind you, there’s a lot of speculation to go around. Many are suggesting that an infrastructure investment plan as a cornerstone of any stimulus program could be just the ticket to get the economy rolling again. It’s such a good idea that China proposed a similar plan. Still, opinions were mixed at the 100th Annual Conference of the Water & Wastewater Equipment Manufacturers Association’s (WWEMA), held Nov. 13-15 in Tucson, AZ, about whether such a program would be effective. One issue is to make sure that infrastructure includes water and wastewater. Concerns centered on the 120-day window for projects to be up and running mentioned by Michigan Gov. Jennifer Granholm, tagged to explain it on NPR earlier in the week, as well as how it might be rolled out, i.e., possibly through state revolving funds for water and wastewater loans. On the first, it was concluded only projects already approved and in the pipeline would likely be involved, meaning “ditch-digging” jobs for sewer and water projects. On the second, it was doubted whether SRF programs could get anything rolling in 120 days, as the application process could take longer than that. Unfortunately, on the 15th, Congress scaled back its economic stimulus plan until after Obama took of-

fice due to opposition to inclusion of a “rescue plan” for the Big Three automakers. Still, most were encouraged the talk was about providing increased funding for water and wastewater projects that have gotten such short shrift in recent years. Later in this issue, you can read our interview with Flowserve’s Chuck Powers, a member of the WWEMA Presidents Council since 2004 and now serving his second WWEMA board term, in the “Executive Corner” column. At WEFTEC.08 in Chicago, Oct. 19-22, the PennWell water publication editors – James Laughlin, Angela Godwin and me – did a series of video interviews with over 30 different water and wastewater equipment manufacturers (all of which can be found at our website: http://ww.pennnet. com/videogallery/). With the recent financial meltdown fresh on everyone’s minds, we asked for an outlook from most of the interviewees. Again, the responses were mixed. Some WEFTEC interviewees felt municipalities smarting from bond market volatility would be less likely to spend and, because of tax revenue shortfalls, would stall major capital intensive projects such as infrastructure spending. Some felt the critical nature of water quality (not to mention regulatory burdens and an already poor report card regarding related infrastructure) meant that the industry was better insulated than others to recessionary pressure. While there would be some impact, it would be less than other industries

might experience, they said. Considering that this year’s WEFTEC broke records for attendees (21,950), exhibitors (1,111) and exhibitor floorspace (290,000 net sq. ft.) – surpassing Aquatech Amsterdam on Sept. 30-Oct. 3 – that’s a bit of a testimonial as to this industry’s strength in the United States. All previous WEFTEC records were set only a year earlier in San Diego. Lastly, since this issue will be at the Power-Gen International in Orlando, Dec. 2-4, I thought I’d mention a recent report: “Lights Out In 2009?” – released Oct. 1 by the NextGen Energy Council from Denver which warns that the U.S. “faces potentially crippling electricity brownouts and blackouts beginning in the summer of 2009.” It estimates the U.S. will require about 120 gigawatts of new generation just to maintain a 15% baseload generation capacity reserve margin, down from 30-40% in the early 1990s. This will require at least $300 billion in generation and transmission facility investments by 2016, NextGen says. Given that, opportunities in the power industry may be more positive than recent economic turmoil may indicate. While I can’t agree with lessening environmental requirements for upgrades and new construction, that’s something that shouldn’t be ignored in terms of public investment in infrastructure.

EDITORIAL ADVISORY COMMITTEE

6

Wayne Bernhal W. Bernhal Enterprises

Donald A. Treslar Jr. Eaton Filtration

Tony Kobilnyk GE Infrastructure, Water & Process Technologies

Imran M. Jaferey Koch Membrane Systems Inc.

Peter Cartwright Cartwright Consulting Company

Tim Schilz Thermo Fischer- AquaSensors

Kurt Tyler Hach, A Danaher Company

Gaspar Lesznik Ozonia North America, SUEZ

Jeri Longtin-Kloss Dow Water Solutions, Dow Chemical

Charles J. Powers Flowserve Pump Div., Flowserve Corp.

John Manna ITT Industrial & BioPharm Group

William Willersdorf Siemens Water Technologies Corp.

INDUSTRIAL WATERWORLD

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NOVEMBER/DECEMBER 2008

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PRODUCT

Showcase

Industrial process control Moore Industries’ new service – SNAP, or Special Needs and Products – provides customized solutions to meet unusual signal interface needs in industrial process control, systems integration and factory automation applications. It’s meant to solve problems customers sometimes face when they need something specific to their operation. Typical modifications include special instrument functions, such as non-standard signal inputs and outputs, non-standard power ranges, computing and math functions, alarm trip modifications, and more. SNAP engineers also will work with customers to develop special and OEM instrument housings and enclosures and custom mounts, connectors, temperature sensors and thermowells. Moore Industries-International Inc., North Hills, CA, 818-830-5501, www.miinet.com/snap Circle No. 102 on Reader Service Card Pipeline corrosion monitoring With corrosion costing the pipeline industry $5.4-to-8.6 billion a year, a new service from Space Data Corp. – the Cathodic Protection Rectifier Monitoring Service, which takes advantage of its high altitude, balloon-borne SkySite® mobile communications platform – provides 24/7 M2M communications for the energy industry to assess pipeline conditions in remote and inaccessible areas. The low-cost alternative to erecting towers or using satellites has flown over 15,000 successful flights for the oil and gas industry. Space Data Corp., Chandler, AZ, 877-773-4155, www.spacedata.net Circle No. 103 on Reader Service Card Low temperature, fast-cure coatings Enviroline Group has introduced four new products to its existing line of low temperature, fast-cure coatings and linings. Each is ultra high solids, VOC compliant and cures without heat in temperatures as low as 20-30°F (-7°C to 0°C). Total cure time is typically half the time of other low temperature coatings, saving tank and pipe owners in downtime and/or heating costs. Enviroline Group, Pompano Beach, FL, 954-978-9355, www.envirolinegroup.com Circle No. 104 on Reader Service Card 8

INDUSTRIAL WATERWORLD

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Optical DO sensors The RDO Pro DO Sensor from Thermo ScientificAquaSensors represents the latest in rugged luminescent dissolved oxygen technology for wastewater monitoring. RDO Pro employs ‘smart sensor’ technology and complements the company’s full range of online liquid analytical sensors. The unique ‘direct-to-SCADA’ product design reduces equipment and installation costs while improving reliability in a wide variety of municipal and industrial water treatment applications. Thermo Scientific-AquaSensors, Menomonee Falls, WI, 262-255-4459, www.thermo.com/water Circle No. 105 on Reader Service Card Oil, grease measurement To ensure compliance with regulations and avoid fines for exceeding permit discharge levels, more frequent wastewater measurements are necessary to determine total oil/grease concentrations. Portable infrared analyzers from Wilks Enterprise are designed for easy, on-site measurement of oil/ grease concentrations. The InfraCal TOG/TPH Analyzer, Model HATR-T2 or the Model CVH – depending on the solvent selected for the extraction process – provides on-site measurement of total oil/grease concentration in wastewater in 10-15 minutes. Wilks Enterprise Inc., South Norwalk, CT, 203-855-9136, www.wilksir.com Circle No. 106 on Reader Service Card Submersible motors ITT has expanded its line of CentriPro® 4” Submersible Motors to include models from 1/2-HP to 3-HP in single- and three-phase models. The motors feature all stainless construction and builtin lightning and surge protection. Both the two- and three-wire models feature on-winding thermal overloads; precision machined, one-piece, stainless steel castings used for upper and lower end bells; improved welds; and water-filled design with non-toxic propylene glycol solution to protect the motor during shipping and storage. ITT Residential & Commercial Water, Morton Grove, IL, 847-966-3700, ____ http:// ittfluidbusiness.com Circle No. 107 on Reader Service Card

NOVEMBER/DECEMBER 2008

Desalination membrane elements Dow Water Solutions offers two new FILMTEC™ 8-inch SWRO membrane elements for improved performance and energy efficiency in desalination applications. At 99.80%, the SW30XHR-400i has the highest salt rejection consistently demonstrated in the industry. It also effectively removes boron and other dissolved solids. The SW30ULE-400i elements have a flow rate of 11,000 gpd with 99.70% salt rejection, offering flow twice that of the original sea water element introduced in 1985, without having to sacrifice salt rejection. They’re especially suited for seawater desalination at low temperatures, in addition to high TDS brackish water systems. Dow Water Solutions, Edina, MN, www.dowwatersolutions.com Circle No. 110 on Reader Service Card Sludge blanket level probe The Hach SONATAX sc Sludge Blanket Level Probe is an ideal tool to optimize sludge extraction, manage recirculation, warn of potential solids washouts, or process upset by continuously measuring the depth from the surface or height from the tank floor. The probe’s wiper design reduces maintenance, and automatic frequency adjustment provides superior accuracy. Hach Company, Loveland, CO, www.hach.com Circle No. 109 on Reader Service Card Turbine agitator Chemineer’s HT Turbine Agitator is capable of handling almost any process from aeration and sludge conditioning to chemical make-up and disinfection. With a compact, rightangle gear drive, it has output speeds of 5-350 rpm and 13 standard drive sizes from 1-1,000+ hp. It’s ideal in harsh, demanding water and wastewater treatment operating environments, having logged years of dependable, field performance in blending, agitation, solids suspension and gas dispersion applications, among others. With a variety of mountings, shaft seals and impellers, the design results in high strength, low wear, quiet operation and minimal maintenance. Tapered roller bearings are service rated to over 100,000 hours (L-10) life. Chemineer Inc., Dayton, OH, 800-643-0641, www.chemineer.com Circle No. 108 on Reader Service Card www.industrialww.com

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EVENTS December 2008 ▲ Dec. 2-4 – Power-Gen Int'l, Orlando. Contact: http://pgi08.events.pennnet.com ▲ Dec. 2-5 – NGWA Ground Water Expo, Las Vegas. Contact: www.ngwa.org/2008expo/ ▲ Dec. 4 – Industrial Water Quality Workshop, Houston: www.weat.org ▲ Dec. 10-12 – CG/LA's Global Infrastructure Leadership Forum 2, Washington, DC: http:// ___ www.cg-la.com/global2 ▲ Dec. 11 – LIMS Seminar Tour, Reston, VA. Contact: [email protected] 2009 January 2009 ▲ Jan. 16-19 – American Boiler Manufacturers Assoc. Annual Meeting, Fort Lauderdale: www. ___ abma.com ▲ Jan. 26-28 – External Corrosion Direct Assessment, Houston: www.nace.org ▲ Jan. 28-30 – Int'l Poultry Expo, Atlanta: www. ___ internationalpoultryexposition.org ▲ Jan. 29 – 20th Annual Industrial Wastes Seminar, Covington, KY: www.swowea.org February 2009 ▲ Feb. 3-5 – Paperweek Int'l/EXFOR, Montreal, Canada: www.paptac.ca ▲ Feb. 8-12 – Cooling Technology Institute Annual Conference, San Antonio: www.cti.org ▲ Feb. 15-18 – PACE 2009 - SSPC/PDCA Paint &

Coatings Expo, New Orleans: www.pace2009.com ▲ Feb. 17-20 – AWWA/WEF Utility Management Conference, New Orleans: www.awwa.org/ Conferences/ _______ ▲ Feb. 23-25 – Water Investment World North America, Bridgewaters, NY: www.terrapinn. com/2009/waterworld/ ▲ Feb. 24 – Water Treatment & Monitoring for Dialysis, Atlanta: www.ameriwater.com/semi_______________ nars.html _____ ▲ Feb. 25-March 1 – AWT Sales Training Seminar & Wastewater Seminar, Salt Lake City: www.awt.org ▲ Feb. 28-March 3 – WEF Disinfection 2009, Atlanta: www.wef.org March 2009 ▲ March 2-5 – 25th Int'l Pump Users Symposium at Texas A&M, Houston: ________ turbolab.tamu. edu/pumpshow/pump.html _______________ ▲ March 3-5 – REMTEC - Remediation Technology Summit, Atlanta: www.remtec09.com ▲ March 4-6 – Design-Build for Water/Wastewater Conference, Denver: www.designbuildwaterww.com ▲ March 8-13 – Pittcon Conference & Expo, Chicago: www.pittcon.org ▲ March 15-18 – AWWA Membrane Technology Conference & Exposition, Memphis: www.awwa.org ▲ March 17-20 – WQA Aquatech, ChicagoRosemount: www.wqa.org

▲ March 17-19 – Americana Int'l Environmental Trade Show & Conference, Montreal: www. ___ americana.org ▲ March 22-25 – CORROSION/NACExpo, Atlanta: www.nace.org ▲ March 23-26 – Urban Water Management: Overland Park, KS: www.urbanwatermgt.com April 2009 ▲ April 1-2 – AEE's Globalcon, Atlantic City: www.globalconevent.com ▲ April 1-5 – AWT Sales Training Seminar & Wastewater Seminar, Cleveland: www.awt.org ▲ April 4-7 – Offshore Technology Conference, Houston: www.otcnet.org/2009/ ▲ April 8-10 – Water Security Congress, Washington, DC: www.awwa.org/conferences/ ▲ April 13-17 – SPIE Defense, Security & Sensing 2009 Exhibition, Orlando: spie.org/defense_________ security-sensing.xml ___________ ▲ April 19-23 – NGWA 2009 Ground Water Summit, Tucson, AZ: www.ngwa. org/2009summit/ ▲ April 20-21 – CANECT 2009, Toronto: www. ___ canect.net/compliance.ht ▲ April 22-24 – United Fresh Tech, Las Vegas: www.unitedfreshshows.com/2009/

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HEADLINES AMONG OTHER RECENT HEADLINES AT WWW.INDUSTRIALWW.COM, _________________ SEE:

VRTX EXPANDS INTO PACIFIC ISLANDS

Schertz, TX-based VRTX Technologies, a chemicalfree water treatment company specializing in cooling towers and evaporative condensers, is now providing water treatment to some familiar locations in Hawaii and Guam. Hawaii’s state capitol building in Honolulu needed a non-chemical device to treat its system due to close proximity of the Vietnam and Korean War Memorial on the capitol grounds’ west end. Within months, the system increased its cycles of concentration from 2.1 to four, saving an estimated 2.5 million gallons of water a year. The Pacific Islands Club, the largest resort in Guam, is switching from an air-cooled system to a water-cooled system from VRTX. The new locations add to over 500 worldwide customers saving over a billion gallons of water annually with environmentallyfriendly water treatment. K-TEK ABSORBS ASI INSTRUMENTS

The Rialto Regional Biosolids Processing Facility in Rialto, CA, finished the first phase of testing for start-up by accepting its initial truckload of biosolids for conversion by EnerTech’s SlurryCarb™ technology into renewable ‘E-Fuel’ – about 170 tons per day. Also in Rialto, Siemens Water Technologies and Chevron Energy Solutions are installing two Dystor gas holder systems to store methane (to be used by Chevron) at the city’s wastewater treatment plant as part of a comprehensive upgrade to recover, store and convert biogas to hydrogen and generate power electrochemically without combustion. Its 900-kW fuel cell system will run on 75% biogas by the end of the year, giving the city a significant rebate from California’s Self-Generation Incentive Program.

ASI Instruments and its line of dry bulk solids level detection and measurement instruments have been integrated into K-TEK Corp., a manufacturer of level measurement instrumentation. It will become the KTEK Solids Level group and will focus on dry bulk solids level detection and measurement devices. K-TEK’s traditional liquid level products will be part of the K-TEK Liquid Level group. N.H. HONORS FIRMS FOR ENVIRONMENTAL ACHIEVEMENT

The New Hampshire Department of Environmental Services announced winners of the 2008 Governor’s Award for Pollution Prevention: Anheuser-Busch Inc. and Southeastern Container. Gov. John Lynch visited both facilities Oct. 30 to recognize their outstanding pollution prevention practices. The brewery installed an anaerobic Bio-Energy Recovery Systems to pre-treat brewery wastewater and produce biogas for use as a renewable fuel. In addition to odor control, this process also reduced costs associated with its onsite wastewater pretreatment processes and off-site treatment by the Town of Merrimack Waste Water Treatment Facility. The net air emissions reduction was 178 metric tons; energy reduction was 1,024,000 kWh; and net fuel savings were 91,000 MMBtu – saving Anheuser-Busch over $2.3 million per year... PARKER BUYS WATER RO FILTRATION EQUIPMENT MAKER

Parker Hannifin Corp. has acquired Aqua Pro Inc., a manufacturer of reverse osmosis filtration systems for military, commercial and pleasure marine applications. With FY2008 sales of $33.0 million, its results will be reported as a part of Parker’s Industrial North America segment. Doing business as Village Marine Tec and Offshore Marine Laboratories, Aqua Pro has manufacturing centers in Gardena and San Fernando, CA. Sales and service locations are located in California, Florida, Hawaii, Virginia, and Washington. The company sells to OEMs including boat and ship builders, independent distributors, U.S. military branches and end-users. Its product line includes RO systems for military on-board submarines, and land applications as well as offshore oil rigs, work boats, fishing vessels, and pleasure boats. Correction: The cover image for the September/October 2008 issue was incorrectly credited. It was actually from the Enviroline Group, of Pompano Beach, FL, which specializes in monitoring systems, coatings, linings and related services to reduce corrosion risks. 12

INDUSTRIAL WATERWORLD

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NOVEMBER/DECEMBER 2008

• Dow Chemical donates performance fluids to Midland Curling Center • California approves APT’s HiPOx for disinfection for unrestricted water reuse • AkzoNobel strengthens protective coatings portfolio with Enviroline purchase • Aqua-Chem acquires product lines, other assets of Matrix Utilities • Insituform wins $10.3M CIPP project in Connecticut • IDEX acquires Integrated Environmental Technology Group • Veolia’s John Meunier hits headworks equipment milestone • Global growth opportunities fueled by demand for energy efficiency - Frost reports • Alfa Laval Group acquires U.S. energy market specialist Hutchison Hayes Separation • GE recognized for helping Saudi Arabia address water, power challenges • Met-Pro business unit to supply odor control systems in Midwest • Black & Veatch to add ozone technology at Texas water treatment plant complex • MWH to upgrade, expand Utah wastewater treatment plant • Malcolm Pirnie j.v. starts work on world’s largest UV disinfection facility • Finland’s Lamor buys U.S. ballast water treatment manufacturer Hyde Marine • Storage tank specialist CST Industries buys Conservatek Industries Inc. • CleanTech Biofuels engages Hazen Research on solid waste to ethanol project • Pa. DEP recognizes wellhead protection efforts in Honey Brook, Chester County • EPA releases document on TMDLs for mercury-impaired waters • Johnson Controls acquires software company Gridlogix • JMAR’s BioSentry recognized as ‘Biological Detection Product of the Year’ • RESI installs ‘green’ stormwater management system at UMinn stadium

www.industrialww.com

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EnvironmentalCompliance

Concentrated Animal Feeding Operations Rules Expanded BY JAY COLLERT, CHMM, CET

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s part of a final rule issued in 2003 by the EPA, Concentrated Animal Feeding Operations (CAFO) were required to apply for NDPES permits and establish effluent guidelines. Legal challenges were answered by the Second Circuit Court of Appeals with its decision in Waterkeeper Alliance, et al., v. EPA. The agency was directed to remove the requirement for all

Oct. 31, address this legal decision. The final rule includes two key changes. First, it revises the requirement for all CAFOs to apply for NPDES permits and instead requires only those CAFOs that discharge or propose to discharge to apply for permits. In the discussion accompanying the revised rule, EPA provides added clarification on how operators should evaluate whether they discharge or propose to dis-

CAFO regulations will prevent 56 million lbs of phosphorus, 110 million lbs of nitrogen, and 2 billion lbs of sediment from entering streams, lakes, and other waters annually, says EPA .

CAFOs to apply for NPDES permits, and add those for Nutrient Management Plans (NMPs) to be submitted by CAFOs with permit applications, reviewed by permitting authorities and the public, and the NMP terms incorporated into permits. The revised regulations for CAFO, signed

charge. As explained in the final rule, this evaluation calls for a case-by-case determination by the CAFO owner or operator as to whether it does or will discharge from its production area or land application area based on an objective assessment of the CAFO’s design, construction, oper-

ation and maintenance. Second, the rule adds new requirements relating to NMPs for permitted CAFOs. CAFO operators were already required to develop and implement NMPs under the 2003 rule; the new rule requires CAFOs to submit the NMPs along with their NPDES permit applications. Permitting authorities are then required to review the NMPs and provide the public with an opportunity for meaningful review and comment on the plans. They’re also required to include terms of the NMP as enforceable elements of the permit. More information can be found at the CAFO final rule page. The rule deadline for newly defined facilities to apply for permits is Feb. 27, 2009. IWW About the Author: A nationally recognized environmental consultant, Jay Collert is training director at the Aarcher Institute of Environmental Training LLC, based in Houston, TX. Contact: 281-256-9044, jcollert@ aarcherinstitute.com or www.aarcherinstitute.com

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InvestorIndex

Market Turmoil and Investing in the Water Industry BY NEIL BERLANT

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he heart of the argument is the stock market is clearly driven by either fear or greed, and history shows fortunes are made during times of economic distress or financial corrections. Every time we’ve experienced major market declines, e.g., 2001 and 1987, people said this time it’s different and we’ll never return to the prior highs. As we now know, not only did we return

only exacerbates the problem. Along with forced margin calls and you have the makings of this massive sell-off. In other words, very little of recent market action has to do with the operations and successes of the companies represented by the shares of stock changing hands on the stock markets. Much of it can be attributed to the combination of fear and margin calls. A better quote to use to address the

four decades of experience in the securities markets as an analyst, portfolio manager, researcher, and money manager, all reaffirm the merit of investing in this particular time of turmoil. Be assured, I’m not cavalierly dismissing the pain connected to investment positions that are declining. Nor am I ignoring news of the time – it would be hard to do that. On the other hand, I am paying close attention to continuing suc-

“The time to buy is when blood is running in the streets,” is a quote variously attributed to Baron Rothschild, Bernard Baruch, and John D. Rockefeller Sr. Regardless, dating back as far as the early 19th century, it’s as timely today as it was then. to robust markets, but we sharply surpassed prior highs. Certainly while we were experiencing those periods – and I lived through both and several others before them – it truly looked like the doomsayers were right. Most pundits cautioned then that those who hesitated to sell would be punished unmercifully. I suggest it isn’t too terribly different today, although it probably feels like it’s worse now. It always feels like today is different than before. Indeed, some things are different today in that stock markets, or rather investors, have disconnected the value of the businesses with prices of the stocks. What we’ve seen in the stock market over the past several weeks has very little to do with the enterprise values of the businesses, or even their prospects, but instead reflects the excesses of leverage (margin), margin calls, and preponderance of speculation present in the market for a very long time. Among the biggest culprits in this massive global sell-off are the hundreds of hedge funds using leverage, of as much as 10-20 times, and which cannot tolerate a sell-off. As prices decline, they’re forced to sell, which www.industrialww.com

I

current state of the markets is, “It was the best of times, it was the worst of times.” While Dickens was certainly not referring to the stock market, it does feel like the worst of times. Our nation is at war, the economy is slowing, we were just weeks away from a national election, and the stock market was plunging. You might ask, what about that makes it the “best of times?” Well, from my perspective as an investor focused on owning businesses not stocks and investing for the long-term, the opportunity to purchase shares of outstanding companies at significant discounts from recent levels is simply too enticing to resist. The dynamics of the water industry, which is of course the focus of all of my attention, haven’t changed or even deteriorated during this market meltdown. In fact, nearly every day, the prospects seem to improve. So, what this all means is we’re being presented with an unusually attractive opportunity to purchase shares of outstanding companies when they’re on sale. I’m not denying it takes much courage to proceed when all others are fleeing, but more than two decades of specializing in the water industry and

cess and prospects of the businesses we own and this industry we specialize in. Their prospects, in my view, are the best they’ve been since I began my focus here in the mid-1980s. I have no doubt before long we’ll look back at this period and see what a unique time and opportunity this was. While we’re in it, though, it does take a great deal of confidence to stick with what we have and add more. Again, it takes confidence, not courage. I’m quite certain about our prospects, market conditions notwithstanding, and continue to add to positions and stay the course. As always, I welcome your questions, comments, and occasional smiles. IWW

About the Author: Neil D. Berlant, a Los Angelesbased securities analyst with a lengthy history covering investment strategies in the water industry, is portfolio manager for the PFW Water Mutual Fund. Contact: 800-227-0319, [email protected] or www.profitingfromwater.com

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NOVEMBER/DECEMBER 2008 INDUSTRIAL WATERWORLD 15

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RegulatoryReport

Mining Firms Ordered to Continue Cleanup

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he U.S. Environmental Protection Agency issued a unilateral administrative order to international mining company Newmont USA Ltd. and its subsidiary Dawn Mining Co. LLC to continue treating contaminated water at the Midnite Mine Superfund Site in eastern Washington State. Failure to operate the system that captures and treats water at the site to remove uranium and other metals would contaminate Blue Creek, which flows to the Spokane River, and would delay overall cleanup of the site. Since starting water treatment in 1992, the mining companies disposed of sludge at the mill in Ford, WA, where they processed ore from this open-pit uranium mine on the Spokane Indian Reservation from the mid-’50s until 1981. The mill is now being closed

BY PATRICK CROW

under state authority, and they must dispose of the sludge at an alternative site. As low-level radioactive waste, it will have to be taken to a licensed facility, such as American Ecology in Richland, WA, until treatment can be altered to remove the uranium separately. In a ruling this summer, the Spokane federal district court found the mining companies liable for $15 million in EPA investigative costs and future site cleanup costs. The 2006 approved cleanup plan calls for moving and covering over 33 million tons of waste rock to prevent formation of acid drainage. Future cleanup costs are estimated at $150 million. Perchlorate Period Extended

By request, EPA extended time for public comment on its pre-

RECENT EPA HEADLINES • Agency settles with Memphis Light, Gas & Water for alleged PCB violations • EPA combats improper pesticide manufacturing, labeling and use in Pacific Northwest • Plantation Pipe Line to pay penalty for fuel spills in VA, NC, GA • On-line video underscores importance of urban wetlands • Bacardi to purchase, protect sensitive land

and pay fine to settle water pollution case

waterways

• EPA finalizes plan to address contamination at mercury refining superfund site

• PCB cleanup to begin at O’Sullivan’s Island Site in Derby, CT

• EPA, Indiana announce $33 million cleanup of Grand Calumet River

• Arizona developer settles Clean Water Act violations along Santa Cruz River

• Puerto Rico Electric Power Authority to build new pipe at South Coast plant

• Greka Oil violates enforcement order, EPA takes over Gato Ponds

• Metalast International Inc. ordered to comply with wastewater laws, protect

• MYD Samoa Inc. may face fines if shipyard pollutants enter Pago Pago harbor

liminary regulatory determination not to regulate perchlorate in drinking water at a national level to Nov. 28. The initial comment period on the decision was to expire Nov. 3. The agency announced Oct. 3 that the move was based on the fact its survey “found that in more than 99 percent of public drinking water systems, perchlorate was not at levels of public health concern.” With fewer than 1% of drinking water sources at perchlorate levels above the health reference level, EPA set an action level of 15 ppb and was encouraging states to make their own determinations based on local measurements. With so many detection sites nationally DOD related, expect lawsuits to fly on this one. Indians, Oil & Wells

EPA began delegating key groundwater protection responsibilities to Indian tribes. It approved the Fort Peck Assiniboine and Sioux Tribes’ underground injection control (UIC) program, making the Montana tribes first in the nation to assume the program to protect underground drinking water sources. They’ll administer and enforce their own Class II injection well program under the Safe Drinking Water Act, regulating all such existing and future wells on the reservation. The 24 Class II injection wells now on there are used to dispose of brines produced at oil wells. EPA also authorized the Navajo Nation to administer a similar program that will apply to 400 existing oil and gas Class II injection wells on its tribal lands. IWW About the Author: Patrick Crow covered the U.S. Congress and federal agencies for 21 years as a reporter for industry magazines. He has reported on water issues for

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NOVEMBER/DECEMBER 2008

more than 10 years. Crow is now a Houston, TX-based freelance writer.

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Uniquely Vanton

SGK cantilevered pump designed to run dry • No bearings in contact with the fluid • Zero corrosion… all fluid contact parts are of inert thermoplastics • Better abrasion resistance than stainless steel or FRP

Vanton Sump-Gard SGK cantilevered thermoplastic vertical pumps are designed to handle corrosive, abrasive and hazardous process fluids, as well as wastewater liquids and slurries over the full pH range, in those applications where there is danger of the pump running dry for short or extended periods of time. There are no submerged bearings in these rugged sump pumps and the large diameter steel shaft is completely isolated from the fluid by a thick sectioned thermoplastic sleeve. Models are available in PVC, CPVC, PP AND PVDF for flows to 1000 gpm, heads to 240 feet and temperatures to 275˚ F. Closed and semi-open impellers are available for handling fluids with stringy materials or solids to 3 inches in diameter.

To find out more about what makes us “Uniquely Vanton,” visit our website. SGK cantilevered bearingless pump has dry-run capability

VANTON PUMP & EQUIPMENT CORP. 201 Sweetland Avenue, Hillside, NJ 07205-1793 Tel. 908-688-4216 • Fax 908-686-9314 • E-mail: [email protected] Europe: Vanton Pumps, Ltd., Congleton, Cheshire, England E-mail: [email protected]

www.vanton.com

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World's Leading Manufacturer of Thermoplastic Pumps

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PUMP ISSUES

Failure Analysis

I

t’s a must to have a Root Cause Analysis (RCA) program. This is one part of the pump reliability puzzle required to be effective in our businesses. The easiest way to start an RCA is to simply ask “why?” until you can’t ask it again. What happened? Seal failure? Why? What else could it be? Why?

a S

BY ROBERT L. MATTHEWS

spection, operator interviews, and any added scrutiny – then you try to determine what caused the failure and why. This involves two steps. The first is determining exactly what happened, and the second is determining why it happened. The second step is key to preventing the failure in the future, and is the whole reason for doing the analysis.

bearings, but inspection of the pump sight shows that oil was in the housing and had leaked out. The front or wet end bearing cap is pulled and there’s a crack in the gasket. The crack wasn’t noticed at installation because it was on the back side. The gasket was cracked because store room workers had folded the gasket – the last “why?”. You get the picture.

“Failure analysis is using all the information from the change-out tag, disassembly checks, visual component inspection, operator interviews, and any added scrutiny – then you try to determine what caused the failure and why.” In the case of seal failure, for example, statements such as “seal”, “seal leak”, or “seal blow out” don’t constitute a failure analysis. Not only does this not give any clue as to why the failure happened, it doesn’t even give enough information to track down the cause. Too often operations will shutdown equipment with a seal failure and it was a gasket leak at the seal or an o-ring under a sleeve and not the seal at all. Since this costs plants so much unnecessary repair cost, it’s where operator awareness to rotating equipment is so important. Failure analysis is using all the information from the change-out tag, disassembly checks, visual component in-

Let’s walk through a quick example of Root Cause Analysis. A pump has sprayed caustic from a mechanical seal and the operations night crew shuts it down and starts the standby pump. Shift maintenance is called to pull the pump. The pump has a failed mechanical seal and, as the rotating assembly is pulled, obvious visual signs point to the impeller clashing and rubbing the casing. This would have caused the seal to fail. Next the radial bearing labyrinth is damaged and oil has leaked out, causing the bearings to fail – and that would cause impeller clashing. The bearing housing is opened and the oil gone which we know will knock out the

With training in the store room and inspections in the pump shop this never happens again. Root cause analysis works and the payback is worth the effort. IWW About the Author: Reliability manager for Houstonbased Royal Purple Ltd., Bob Matthews has 35+ years of pump industry experience – from hands-on to supervision, in-plant maintenance management, consulting and training. He has taught advanced pump classes for Fortune 500 companies, universities, the Vibration Institute, ASME and FSA. Contact: www. ___ royal-purple.net

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TRENDS & TECHNOLOGY

F

A Hot & Cool Relationship

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BY SHILPA TIKU

• Water and wastewater treatment in the power industry expected to cool, but market still projected to grow at near double-digit rate through 2013, Frost & Sullivan reports.

P

ower generation facilities are usually characterized as either utilities or non-utilities. Utilities are defined as public or privately owned companies that supply electricity, whereas non-utilities are privately owned companies that generate power for their own use. Non-utilities also have the option to sell power to utilities and others. The power generation industry produces and consumes large volumes of water, and it has one of the largest wastewater streams as compared to any other industry. There are three main areas of water application in a power plant – boiler feed, cooling tower, and wastewater treatment. Typically, the treatment technologies vary depending on the type of application. While boiler feed water requires high purity water, cooling towers don’t. Cooling tower water accounts for the majority of water consumption in a power plant. Treatment Technologies

A wide range of water treatment technologies and solutions are required by the power industry. Some of these are as follows: • Ion exchange systems • Electro-deionization systems (EDI) • Membrane systems • Wastewater treatment systems Strategic Market Analysis

Industry Challenges – According to the most recent report by IHS CERA Power Capital Costs Index (PCCI), the cost of new power plant construction in North America has risen 130% in the last eight years. And recent results of the IHS CERA PCCI show that the cost for power plants, such as those powered by coal, gas and wind, continued to rise. In addition, steel and metal costs have been escalating dramatically. Following 20

INDUSTRIAL WATERWORLD

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are some estimates provided by the IHS CERA PCCI. 1. Rising costs a challenge in construction of new power plants: Wind has shown the largest increase at 6% since the third quarter of 2007, and 108% since 2000. This is in response to an increased demand for wind turbines that has elevated equipment costs and delivery time, and is compounded with increasing labor and construction costs. Gas has increased by 3% since 3Q 2007, and 92% since 2000. Coal has increased in cost by 2.3% since 3Q 2007, and 78% since 2000. [Source IHS CERA PCCI.] 2. Economic fluctuation thwart manufacturers’ development & expansion schemes: The effects of the current global economic downturn can also be seen in the U.S. water and wastewater treatment market in the power industry. There’s a decrease of investment in new systems because end-users aren’t holding a high priority in wastewater treatment equipment as spending is limited. Manufacturers face difficulties in planning company expansions because of the uncertain forecasts regarding future profits. The effect of the economic downturn is a challenge for small as well as large manufactures within the water treatment industry. 3. Major market participants dominate through industry consolidation: The trend of industry consolidation has resulted in the domination of the water treatment industry by several large conglomerates. These companies have strong financial advantage over smaller competitors in major business areas such as R&D, as well as marketing. In the long run, smaller market players will be eliminated. The lack of competitive forces could reduce consumers’ price elasticity, which could limit market growth due to higher prices set by dominant manufacturers. 4. Population growth and expansion generates ongoing need for more facilities and water treatment: The nation’s

NOVEMBER/DECEMBER 2008

growing population is generating a need for increased power generation, transmission, and distribution facilities. Ultrapure water is used extensively in powergen boilers. As the number of power generation plants increases in the United States, the need for water treatment will continue to grow nationwide and globally. Market Size & Revenue Forecasts

Figure 1 shows the revenue forecasts for the water and wastewater treatment equipment market in the power industry. Figure 1. Water and Wastewater Treating Market in the Power Industry: Revenue Forecasts (North America), 2003-2013 Year

Revenues ($ Million)

Revenues Growth Rate (%)

2003

437.3

---

2004

479.8

9.7

2005

527.3

9.9

2006

580.0

10.0

2007

638.4

10.1

2008

703.9

10.3

2009

777.2

10.4

2010

859.5

10.6

2011

951.5

10.7

2012

1,054.5

10.8

2013

1,170.5

11.0

Compound Annual Growth Rate (2006-2013): 9.0% Note: All figures are rounded; the base year is 2006. Source: Frost & Sullivan

The total North American market for water and wastewater treatment in the power industry generated $638.4 million in revenues in 2007, at an annual growth rate of 10.1%. This market is witnessing a steady growth primarily due to the rise in population, and the resulting demand for energy. An increase in the U.S. and Canadian GDP is also contributing to the overall power consumption, leading to a growth in the market. This trend is expected to continue throughout the forecast period, as more power plants are likely to be commissioned to www.industrialww.com

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TRENDS & TECHNOLOGY EVENTS-Continued FROM page 10 cater to the increasing energy demand over the next few years. This market is projected to grow at a compound annual growth rate (CAGR) of 9% from 2006 to 2013. Competition

There are essentially three tiers in the total water and wastewater treatment market in the power industry. Tier 1 is composed of large companies with the capability to offer nearly any type of solution. Siemens Water Technlogies and GE Water & Process Technologies are examples of Tier 1 companies. There are several mediumsized to small participants in this market active in one or more of the market segments. Examples of these Tier 2 companies are Tenergy Christ Water LLC, Aquatech, Degremont Technologies. Tier 3 companies comprise participants that are fairly large but specialize in a niche market or a specific product.

May 2009 ▲ May 4-7 – American Filtration & Separations Society Spring Conference, Minneapolis: www. ___ afssociety.org ▲ May 6-8 – 82nd AWPCA Annual Conference & Exhibition, Glendale, AZ: www.awpca.org June 2009 ▲ June 9-11 – Gas & Oil Exposition, Calgary: www.petroleumshow.com/goexpo/ ▲ June 14-18 - AWWA ACE.09, San Diego: www.awwa.org

▲ June 20-24 – North American Membrane Society’s NAMS 2009, Charleston, SC: www.mem______ branes.org ______ July 2009 ▲ July 13-16 – AMTA Annual Conference &

Exposition, Austin, TX: www.amtaorg.com — For a comprehensive list of the events for the Water and Wastewater treatment industry click on the “Events” tab at the top of our website.

Conclusion

The degree of competition within this market is high and forces manufacturers to differentiate themselves. The one-stop shopping trend, in which potential clients often look for a manufacturer that can provide them with the whole package, is a product of this differentiation. There are several mergers and acquisitions taking place within the industry. Added support, competitive pricing, and superior technological credibility are likely to realize improved success and yield maximized sales returns in the market. IWW About the Author: Shilpa Tiku is a research analyst with Palo Alto, CA-based global growth consulting company Frost & Sullivan’s North American Environmental & Building Technologies practice. Joining the company in August 2003, she focuses

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on monitoring and analyzing emerging trends, technologies and market behavior in U.S. markets for water

w e ’ v e

s e e n

i t

a l l .

and wastewater treatment, waste management, and air pollution control. Contact: [email protected] or www.frost.com

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12800 York Road • Cleveland, OH 44133 USA www.oilskim.com • USA Toll Free: 800-200-4603 Wo r l d C l a s s Q u a l i t y i n O i l S k i m m i n g Phone: 440-237-4600 • Fax: 440-582-2759 ©2008 Oil Skimmers, Inc.

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NOVEMBER/DECEMBER 2008 INDUSTRIAL WATERWORLD 21

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ELECTRIC POWER INDUSTRY

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Water Straining

First Line of Defense • Choosing the correct strainer

sign doesn’t allow for sufficient straining surface area. In applications using raw water from rivers, for example, single basket strainers sometimes become overwhelmed and clogged during periods when there were high volumes of debris in water due to seasonal conditions such as rainfall carrying dirt, leaves and other loose particles into the water supply. “You never really know what you’re going to experience with river water,” says Sang Partington, a senior engineer with PPL’s Generation Technical Group. “It changes from season to season. During autumn and high water flow in the river you may have a lot of debris such as tree branches, leaves and other solids in the water. Therefore, your water strainer has to be able to handle the solids and still maintain a continuous volume of water flow.”

technology crucial at raw water intake and more for industries such as power generation.

B

ulk raw water users, such as PPL Electric Utilities of Allentown, PA, protect process and downstream equipment by selecting multi-element water strainer technology Whether used for cooling, or the process itself, raw water drawn from lakes, rivers and reservoirs must first be strained to create acceptable water for use. In many industries, this means continuously straining tens of thousands of gallons of water per minute to remove dirt and debris that can wreak havoc on critical process systems and equipment. In essence, raw water strainers that accomplish this task are the first lines of defense for the entire plant’s system.

Bulk raw water users, such as PPL Electric Utilities, protect process and downstream equipment by selecting multi-element water strainer technology.

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Which Design?

Whether used for cooling, or the process itself, the raw water drawn from lakes, rivers and reservoirs must first be strained to create acceptable water for use. In many industries this means continuously straining tens of thousands of gallons of water per minute to remove dirt and debris that can wreak havoc on critical process systems and equipment.

Choosing an inadequate strainer can lead to high maintenance and operating costs, periods of insufficient water supply, damage to process equipment, and expensive downtime. Worse, straining media of an overwhelmed water strainer can rupture or collapse, permitting debris to compromise critical plant operating components. In the power industry, for example, clean water is crucial for a variety of tasks including extending the service life of turbine seals and for protection of spray nozzles and heat transfer equipment. Unfortunately, such failures aren’t unusual, particularly when the strainer de-

NOVEMBER/DECEMBER 2008

Water strainers for mass raw water filtration have been around for decades, and today manufacturers offer a variety of designs, including those that operate automatically. One of the more significant advances in strainer design occurred in the 1960s when the first multi-element, automatic self-cleaning strainer design was developed. This strainer design was particularly significant because it provided a durable and reliable alternative to the classic basket-type strainer that – although it sometimes carries a lower price tag – is also limited by its strainer surface area, which can quickly become clogged and force excessive cleaning cycles (backwashing) and reduced water for process requirements. By replacing the basket with multiple tubular elements, the design provides 3-4 times the straining surface area of a typical basket strainer. As a result, debris and solids – including from seasonal peaks – are efficiently removed without downtime. The increased surface area of the multi-element design allows for fewwww.industrialww.com

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Quick-Ship Blower Packages • Fully packaged blowers • From 5 to 200 hp • Low noise - 75 dB(A) or less • Available for immediate delivery, most units can be shipped in one working day www.kaeser.com/omega or (866) 516-6888 Circle No. 23 on Reader Service Card

Tri-Lobe Blower Package • Rotary tri-lobe blower in a compact, sound dampening enclosure

a S

Rotary Screw Air Compressors

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Consulting Services • Blower Products • Clean Air Treatment Products • Compressor Products

Tri-Lobe Blower • Our unique pressure equalization channels reduce pulsations, lowering noise levels • Rotor profiles with closer machining tolerances that minimize losses and improve energy efficiency www.kaeser.com/omega or (866) 516-6888 Circle No. 22 on Reader Service Card

Wastewater Treatment Made Easy

New BB52C Com-paK Plus • The smallest, most quiet process quality blower on the market today • Unique molded polymer shell • Comes completely assembled with blower, motor, and silencers

Rotary-lobe blowers have replaced expensive liquid oxygen injection systems and inefficient mechanical surface splashers to become the most efficient method to introduce oxygen to aerobic digesters. Kaeser's Com-paK and Omega-paK blower packages are ideal for the job. Designed and built from the ground up for reliability and energy efficiency, they come complete with motors, drives, silencers, and controls. Omega packages save you both system design time and installation costs. Of course, the whole "factory package" concept is a Kaeser innovation. We take all the guesswork and headaches out of selecting and configuring components into a superior-quality blower package. Whether your a system designer or owner/operator, Kaeser blower packages save you time and money. For details, call or visit us online today.

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W AT E R

S T R A I N I N G

er backwashes, equating to lower operational costs, less maintenance and greater overall efficiency. Optimizing Water Flow

tween the straining media and the backwash arm. The result is straining media damage and/or rupture that can compromise plant operations. The multi-element design utilizes a tube sheet to separate the straining me-

About five years ago, PPL’s Partington noticed that the old, basket-type water strainers at its Brunner Island plant required high maintenance and continuously shifted to backwash mode. “The old system was constantly backwashing,” he says. At PPL’s electric power generation utilities the priority is maintaining sufficient volume and pressure, although there’s certainly concern about the debris and other solids that can be in the rivers that feed water to the coal-fired plants. PPL began to upgrade the raw water strainers at its Brunner Island and Montour plants, both feeding off the Susquehanna River in central Pennsylvania. Both are large generating facilities with about 1,500-megawatt capacity, and it’s critical to ensure sufficient clean water to keep the plants on line continuously. According to Partington, the outflow of clean, filtered water through the strainers was also at lower-than-optimal volume when backwashing was taking place, so he began to look for a more advanced and efficient strainer technology. After reviewing several more advanced designs, he A multi-element design selected a multi-element R.P. Adams provides three to four times strainer from SFC-Adams Inc. the surface area of a basket strainer. Although initially designed for raw This translates directly into less frequent backwater applications, this multi-element washing so less water goes to waste, less power is strainer can actually remove solids as consumed, and there is less maintenance required. small as 25 microns (μm), so it can be utilized as the “first line of defense” in water filtration or installed at a point of dia from the backwash mechanism. This use (POU) for critical plant operations re- prevents the backwash mechanism from quiring fine levels of separation. coming into contact with the media and damaging the elements caused by large Backwash Mode solids becoming lodged between the meAnother significant feature is in the en- dia and the backwash arm. Furthermore, gineering of the backwash mechanism. the design provides three to four times With basket strainers, this mechanism the surface area of a basket strainer. This comes into direct contact with the strain- translates directly into less frequent backing media. This can be problematic, as washing so less water goes to waste, less large, suspended solids often encountered power is consumed, and there’s less mainwith raw water can become lodged be- tenance required. 24

INDUSTRIAL WATERWORLD

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NOVEMBER/DECEMBER 2008

Partington’s decision was also due to the fact that these strainers could provide the necessary plant water requirements even while in backwash mode. “The new units will not backwash unless the differential pressure of the strainer is high enough to activate backwashing automatically or by the timer, thereby saving us money on the power consumption,” he explains. “We should also save significant money on maintenance too, but we don’t know how much yet because the units are so new.” Other Advantages

Partington also appreciated the fact that the strainer manufacturer was willing to customize them to meet PPL’s design specifications, and also offered an exchange program whereby he could replace the strainer elements to a different micron size if he needed to do so. “The element exchange program allowed us to go for greater straining efficiency, which helped us optimize the raw water system,” Partington says, “We elected to exchange the original elements for a smaller micron size. It has worked very well, so we’re going to stay with that size for that particular installation. But as we continue to upgrade our water strainers at various locations, we can do the same thing – in effect, finetune the solid removal and water flow as the situation warrants.” Conclusion

To date, PPL has upgraded to eight R.P. Adams strainers at the Brunner Island plant and installed the first unit at its Montour County, PA, site. It intends to standardize on the multi-element design, and will phase-in new strainers as opportunities arise. IWW Based in Buffalo, NY, SFC-Adams Inc. is a subsidiary of Service Filtration Corp. (SFC), which is commonly known as Serfilco Ltd. and is headquartered in Northbrook, IL. In business for over 60 years, R.P. Adams was bought by SFC in 2004. Contact: 800-896-8869 or www.rpadams.com

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Wastewater treatment drives productivity. Think about ITT. It takes 39,000 gallons of water to manufacture one car. And automotive is just one of the many industries that rely on plentiful, clean water. ITT is the world’s largest provider of water and wastewater treatment solutions serving virtually every industrial segment in every corner of the globe. With Goulds pumps, Flygt submersible pumps, mixers and control systems, WEDECO disinfection systems, and more than a dozen more leading global brands, ITT is all you need for wastewater solutions in any environment. Come see for yourself. Visit www.ittwastewater.com today and download our wastewater brochure.

ITT Fluid Technology

FPO Lifeline

The “ITT Engineered Blocks” symbol and “Engineered for life” are registered trademarks of ITT Corporation. © 2008

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PIPELINE INSTALLATION & MAINTENANCE

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Monitoring System Saves Pipe

from Severely Corrosive Environment BY ELFRIEDE LYNCH-WILLSON • Corrosion monitoring system from Enviroline alerts a Canadian oil & gas pipeline operator of a problem, allowing it ample time to fix it before destructive wall loss could occur.

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fter pigging one of its gathering lines as part of its regular maintenance, a majoroil & gas pipeline company in Western Canada became concerned about wall loss in one section due to corrosion. Though not immediately in jeopardy of rupturing, the company understood it needed to replace the section of pipe. To keep the pipeline operational until the section could be replaced, the company installed two Field Signature Method (FSM) units and an Enviroline Hydrogen Monitoring System to the section of pipe, to monitor for additional corrosion and wall loss. Initially, the pipeline remained stable, each unit reported no additional corrosion or wall loss. The company was confident its inhibitor process was protecting the pipe from further deterioration. In August of 2007, however, the Enviroline monitor readings began to fluctuate, though the two FSM units reported no changes. The company hadn’t made any changes to its inhibitor process and didn’t feel the corrosive environment inside the pipe had worsened, so it contacted Enviroline believing the Enviroline monitor was malfunctioning. Enviroline visited the site to check the system but found nothing wrong with its unit. After several weeks, the readings from its monitor indicated a gradual increase in corrosive activity, yet the two FSM units still showed no change. To understand what was happening inside the pipe, the pipeline operator performed additional testing and reviewed previous process data. The company discovered a highly corrosive environment may have resulted from acidization (chemical flooding) of an upstream well in June that releases 18 times the 26

INDUSTRIAL WATERWORLD

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normal amount of water into the pipeline. This water produced a highly corrosive environment, yet several unusual circumstances prevented the pipeline company from realizing the change until two months later, when the Enviroline system first alerted them. As a result of its findings, the pipeline operator pigged the line and increased the inhibitor rate to stabilize the environment. After testing for additional wall loss, it was pleased to report no significant deterioration in the pipe, thanks to the early notification. The monitoring system is based on the principle of hydrogen flux – as corrosion occurs and metal dissolves on the inside of a tank or pipe, atomic hydrogen is formed and, because of its small size, permeates through the metal wall. Such movement of hydrogen atoms through a tank or pipe is often the first sign a corrosive environment exists. Additionally, hydrogen in the metal wall can cause hydrogen embritlement, hydrogen induced cranking (HIC), hydrogen blistering, and stress corrosion cracking (SCC), all potentially devastating conditions for a tank or pipe. The Enviroline system utilizes this natural process of hydrogen flux to monitor for corrosion. A vacuum is placed outside the tank or pipe that collects escaping hydrogen molecules. This data is sent continuously via satellite to the company’s website where it’s charted to provide a vi-

NOVEMBER/DECEMBER 2008

sual representation of the migration and corrosion activity. Pipe and tank operators have instant, accurate access via web reporting and email alerts of corrosive conditions inside their tank or pipe. This major oil & gas pipeline company expects to add many more Hydrogen Corrosion Monitors to its pipeline network as a result of the fast and accurate performance of the Enviroline system. IWW About the Author: Elfriede Lynch-Willson is Enviroline Monitoring Systems marketing manager at Enviroline Group. The Pompano Beach, FL-based industrial environmental linings and coatings specialist is the manufacturer of the Hydrogen Corrosion Monitor, the only continuous system used for both corrosion and process monitoring. Contact: 800-449-6525, [email protected] and www.enviroline_________ group.com/ems/ ________

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UV Disinfection

of Cooling Tower Water

BY MARC C. SCANLON S

C

ooling towers are used to dissipate heat produced by industrial processes such as power generation, oil refining and chemical processing. They generally work in two ways, either through evaporation of water to remove heat and cool process fluid, or relying solely on air to cool the fluid. Towers utilizing water evaporation are an ideal breeding ground for microorganisms – many of them pathogenic – which thrive in the warm, wet conditions, forming “biofilms.” Various species of Legionella bacteria, the cause of Legionnaires’ disease in humans, are commonly associated with cooling towers and must be controlled by law. As well as health risks for surrounding populations, biofilms also cause many mechanical problems with the cooling process, such as a reduction in heat transfer, microbial corrosion, interference with corrosion inhibitor effectiveness, and water flow disruption. There are several ways of controlling microbial infection, including biocides such as chlorine, chlorine dioxide, hypobromite and ozone. In addition, a nonchemical method that’s gaining increasing acceptance is ultraviolet (UV) disinfection. Whatever treatment method is used faces many demands and needs to meet the following criteria: • It should be effective against all microorganisms. • It should work fast. • It should have a residual effect. • It should be cost effective. • It should be easy to use. • It should have minimal environmental impact. It’s often recommended two treatment methods be used simultaneously to control biofilms and Legionella. UV, in combination with another biocide, meets all of the above criteria, with much reduced reliance on the secondary biocide. UV Disinfection Advantages

UV disinfection, with secondary doswww.industrialww.com

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Ultraviolet lamp

ing using a suitable biocide, is in fact one of the most cost-effective and efficient methods of reducing biofilms in cooling tower water. It works instantaneously against all waterborne microorganisms, including bacteria, viruses, molds, spores and protozoa – not excluding those resistant to chlorine. UV systems also are easy to use and can be effectively monitored and integrated with online process control systems. The only other requirement is residual disinfection. Because UV has no residual effect it cannot reduce levels of bacteria colonizing pipework walls. To achieve this, dosing with a secondary biocide is required. Even though residual disinfection is always needed, UV dramatically reduces the frequency and level of secondary dosing and therefore reduces costs and safety issues associated with purchasing, handling and transporting chemicals. UV disinfection systems are very compact, modular and easy to install into existing water treatment systems. In addition, secondary dosing doesn’t require complex monitoring equipment necessary if biocides are used as a primary disinfectant. UV also doesn’t cause formation of chemical disinfection by-products,

many of which can have undesired effects of their own. How UV Works

UV is the part of the electromagnetic spectrum between visible light and Xrays. The specific portion of the UV spectrum between 185-400nm (also known as UV-C) has a strong germicidal effect, with peak effectiveness at 265nm (although some put it at 254nm). At these wavelengths, UV kills microorganisms by penetrating their cell membranes and damaging the DNA, making them unable to reproduce and effectively killing them. A typical UV disinfection system consists of a UV lamp housed in a protective quartz sleeve which is mounted within a cylindrical stainless steel chamber. The water to be treated enters at one end and passes along the entire length of the chamber before exiting at the other end. UV System Design

UV systems for cooling water treatment should be installed post-filtration. The UV dose received by a microorganism is dependent on the energy output of the UV lamp, water flow rate, ability of the water to transmit UV (its transmit-

NOVEMBER/DECEMBER 2008 INDUSTRIAL WATERWORLD 27

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C O O L I N G

W AT E R

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Cooling tower at UK’s Slough Heat + Power.

tance value), and also the geometry of the treatment chamber. Proper design of the treatment chamber must take all of these factors into account. Transmittance is especially important and is a measure of the amount of UV light absorbed or scattered by suspended material in the water. This can vary considerably depending on the source of the water and its level of purity, so a transmittance test should always be carried out to determine correct UV system design. As flow rates increase, chamber size and lamp power output can be increased as required. For larger flows, multiple chambers are used, in series or in parallel, until the required degree of disinfection is reached. The use of high intensity, medium pressure UV lamps is recommended to treat large flow rates, as these produce a high UV output without taking up valuable space. Reliable disinfection requires that a constant UV dose is applied to the water. Power transformers are available to absorb fluctuations in power supply while

maintaining constant power to the UV lamp(s). Power switching options are also available, adjusting the lamp power on-line as the water flow or the quality of the water changes. The power switching option maintains a constant, pre-determined UV dose level whilst ensuring maximum energy efficiency. In most disinfection systems, an instantaneous means of monitoring UV effectiveness is desirable. With chemical dosing techniques, disinfection is presumed to have been effective after a certain dose ELIMINATE COSTLY MAINTENANCE has been applied. WITH OUR SIMPLE, SEALLESS Similarly with UV, PERISTALTIC HOSE PUMP. if a minimum dose • Ideal for abrasive sludge or of UV energy, caltreatment chemicals culated from the • No costly rotors, stators or maximum flow universal joints to repair or rate and taking replace into account wa• Low maintenance - the hose ter transmittance, is the only wearing part can be shown • Can run dry in complete safety & self-priming to have reached • Rugged 24/7 continuous the outer surface duty dependability of the treatment chamber (where 1-800-282-8823 the UV monitor is www.watson-marlow.com situated) then the necessary disin-

ABRASIVE SLURRIES EATING YOUR PUMPS ALIVE?

fection has taken place. The UV monitor can detect variations in the transmittance value of the water and helps to adjust the UV output accordingly, ensuring consistent UV disinfection at all times. Conclusion

If used in conjunction with a secondary chemical biocide, UV disinfection is one of the most cost-effective methods of controlling biofilms in cooling tower water. It’s especially effective against the Legionella bacterium, a microorganism which thrives in the warm, wet, sheltered environment of a cooling tower. UV works instantly and is effective against all waterborne microorganisms, including those resistant to chlorine. Treatment systems are very compact and can usually be retrofitted easily to existing water treatment systems. In addition, secondary dosing doesn’t require the complex monitoring equipment necessary if biocides are used as a primary disinfectant. All these factors add up to a simple, effective treatment process that saves the operator time and money while providing reliable protection against the spread of dangerous diseases. IWW About the Author: Marc C. Scanlon is national industrial sales manager for Aquionics Inc., a Halma company based in Erlanger, KY, that’s a specialist in nonchemical disinfection via ultraviolet light of water, air and surfaces in a diverse range of applications. Contact: 800-925-0440 or www.aquionics.com

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Stormwater & Watersheds

Kansas City Hosting Urban Water Management II BY ANGELA GODWIN • Registration now open for second annual integrated water quality event.

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egistration is now open for Urban Water Management 2009, an integrated water quality conference and exhibition March 24-26, 2009, in Overland Park, KS, a suburb of Kansas City. Now in its second year, Urban Water Management, a PennWell event sponsored by the National Association of Clean Water Agencies (NACWA) and city of Independence, MO, Water Pollution Control (WPC) Department, will provide a venue for discussion of the latest technologies and techniques for controlling urban water runoff, protect- G. Tracy Mehan III, former ing urban EPA assistant administrastreams and tor for water, will deliver the watersheds, keynote address at Urban controlling Water Management 2009 in and prevent- Overland Park, KS. [SOURCE: ing sewer www.seagrant.umn.edu] ov e r f l ow s , and complying with environmental regulations. Additional sponsors include CI Agent Solutions, Environment 21, Myron L Co. and StormTrap. Keynote speaker G. Tracy Mehan III is a former EPA assistant administrator for water during President Bush’s first term. Prior to that, he served as director of the Missouri Department of Natural Resources and Michigan Office of the Great Lakes. Widely respected as an expert in environmental policy, Mehan is now a consultant with Cadmus Group in Arlington, VA, and an adjunct professor at George Mason University School of Law. In 2007, he was appointed to the Water Science and Technology Board www.industrialww.com

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(WSTB) of The National Academies’ National Research Council (NRC) in Washington, DC. Designed with engineers, consultants, regulatory groups, municipal employees, watershed/stormwater program managers, and contractors in mind, Urban Water Management features a full conference program covering many of the issues faced by today’s urban water managers. The three-day event’s agenda includes 45 technical sessions covering topics such as: BMPs, GIS/mapping, stormwater treatment and management, CSO control, low impact development, watershed management and water quality monitoring. It includes two complimentary networking receptions. In addition, a pre-conference inte-

grated flood-modeling workshop will be available to attendees, instructed by Colby Manwaring, XP Software. A pre-conference Certified Inspector of Sediment and Erosion Control (CISEC) review course also will be offered for inspectors who have demonstrated proficiency in observing, inspecting and reporting on implementation of Stormwater Pollution Prevention Plans (SWPPPs), along with the accompanying examination. Both will be held on Monday, March 23, with the CISEC exam taking place Tuesday, March 24. IWW For more information on Urban Water Management 2009 or to register, visit: www.urbanwatermgt.com

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CT PROGRAMMABLE CONTROLLERS with BAS Comm Capability (Modbus, Lonworks, N2Bus, BacNet, others) — — — — — — — — — —

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NOVEMBER/DECEMBER 2008 INDUSTRIAL WATERWORLD 29

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Enhancing Pumping Systems’ Energy and Life Cycle Cost Savings BY JOE MELTON

Figure 1. Pump system curve uncertainty.

560

Application range

Head

520

1

480 440 400 360 Feet

tional life cycle cost savings through reduced maintenance needs, improved system reliability, enhanced process control and extended product quality. This is why management, operations and engineering professionals working in industries that use pumps need to fully understand both the energy and economic potential of pumping systems optimization and their facility’s pumping system network. In most cases, this includes: • Realizing that pump and motor efficiencies play key roles in minimizing energy consumption.

280

160 120 80 40 0 Effidency

80 72 64

3480 rpm (142)

56 48 40 32 24 16 8 0 –8

0

40

80 120 160 200 240 280 320 360 400 440 480 520 560 600 640 680 720 760 800 840 880 US gpm

• Using life cycle cost (LCC) analyses and efficiency testing to benefit all parties involved with pump system activities at water treatment plants.

Efficiency Example

Assuming the elevation lift might be 25 feet and allowing for piping losses, the system curve might look like:

• 0 gpm @ 25 ft plus 85 psi = 221 ft • 250 gpm @ 226 ft • 500 gpm @ 236 ft • 750 gpm @ 250 ft

From the pump curve, the significant points are: • 250 gpm at 476 ft and 61% hydraulic efficiency • 500 gpm at 416 ft and 78% hydraulic efficiency • 750 gpm at 250 ft and 62% hydraulic efficiency Obviously, the pump is adding more pressure than required at lower flows and might require pressure reducing valves for the lower flow conditions. Using the operating schedule listed above and a motor efficiency of 80%, the pump will draw an average of 64.1 kW or 512.7 kWhr per 8 hour shift. Now, let’s look at the same pump on a variable speed control system.

SEE FIGURE 2 30

INDUSTRIAL WATERWORLD

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NOVEMBER/DECEMBER 2008

78.2% 3 3480 rpm(142)

200

• Properly applying speed controls to significantly reduce peak operating costs and improve overall system response.

An industry uses a centrifugal pump to pump 750 gpm of process water from a reservoir to three applications in its process. The 3 applications aren’t in constant use: 70% of the time, two of these applications are in use; 5% of the time, only one is in use; and 25% of the time, all three are in use. The application is wash down and they must guarantee 85 psi water available at all times.

2

320 240

Percent

A

ccording cording to the U.S. U S Department of Energy (DOE), pumping systems account for about 25% of annual motor systems electrical energy consumption at most industrial plants and up to 50% in other pump-intensive industries. As such, the optimization of pumping systems can reduce a typical facility’s pumping system energy costs by over 20% a year – a significant savings for any company operating in today’s economic climate. In addition, given the varied and extreme uses of water in industrial applications, heightened pump system efficiencies can also significantly impact facility operating costs as well as produce addi-

Figure 2.

SEE FIGURE 3

Pump System Life Cycle Costs

LCC analysis takes into consideration the costs to purchase, install, operate (including energy costs), maintain, and dispose of all components of the system. Used as a comparison tool of possible design and overhaul alternatives, this analysis offers a way to predict the most cost-

Putting that same pump on a variable frequency drive (VFD), the same duty points are: • 250 gpm at 226 ft and 71% hydraulic efficiency • 500 gpm at 236 ft and 76% hydraulic efficiency • 750 gpm at 250 ft and 62% hydraulic efficiency By matching requirements of the conditions and using the same assumptions as above plus a 97% efficiency for the VFD, the same pump would draw an average of 45.7 kW or 365.3 kW-hr per 8-hour shift. This represents a direct energy savings of 28.7% to accomplish the same job with the same pumps. An alternate solution would be to use multiple constant speed pumps. www.industrialww.com

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P U M P effective solution. While LCC doesn’t guarantee a particular result, it also permits plant personnel pe to make a reasonable comparison between alternate solutions within the limits li of available data. Most wate water facility pumping systems will have life lif cycle costs dominated by energy and maintenance costs. It’s thus important to t accurately determine the current cost of energy, expected annual energy price escalation for the estimated life, and expected maintenance labor and material costs. Other elements, such as lifetime costs of downtime, decommissioning and environmental protection, can often be estimated based on historical data for the facility. Mechanical pump failures for industrial users often result in a production shutdown costing hundreds of times more than the cost of the repair of the pump. Many mechanical failures are caused by shaft deflection, which causes premature failure of bearings, seals and other components. Shaft deflection can be lessened by reducing the distance between the bearings and impeller (shaft overhang) and by using the slowest practical motor speed. A well-designed distribution system can affect pumping requirements, potentially allowing for selection of a smaller pump and motor, thereby reducing both initial purchase costs and life cycle costs. Once in operation the system should be operated as close to its “Best Efficiency Point” (B.E.P.) as possible (see Figure 1). Maximizing efficiency also maximizes system reliability. As pump operation moves away from the B.E.P., the energy and maintenance costs will increase and the expected life of the pump will be reduced. One measure of pump motor efficiency is Brake Horespower (BHP), also known as Water Horsepower (WHP). A simple calculation can be made to determine BHP: GPM X TDH BHP = _____________________________ 3960 X PUMP EFFICIENCY where: GPM = gallons per minute at B.E.P. TDH = total discharge head (measured in feet) 3960 = conversion factor

percentage points (e.g., 74% vs. 80%) can have a big impact on pumping power requirements and energy use. It’s critical then to not only install the most efficient pump, but also to match the pump performance accurately to the pump system curve. Pump Efficiency Testing

In addition to LCC measures, another way to positively impact pump system performances is through the use of effi-

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ciency tests that can help engineers and operations personnel to identify inefficient systems, determine energy efficiency improvement measures, and estimate potential energy savings. In most cases, these tests are usually conducted on larger pumps and on those that operate for long periods of time. For instance, flow rates can be obtained with reliable instruments installed in the system or preferably with stand-alone tools

_________________

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P U M P

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E F F I C I E N C Y Figure 3.

• Pumps with operating points below the manufacturer’s pump curve (if available) • Systems with flow rates of 30% or more from the BEP flow rates, or with system

Clean Water. Clean Technology.

Cooling Water for Power Generation

The Automatic Self-Cleaning Filters for Today’s Clean Water Needs

560

Application range

Head

520 480

1

440 400

78.2%

2

Feet

360 320 280 240

1

200 160

378.2% 78.2%

80 40 0 80

2

3

3478 rpm (142)

49 Hz 42.5 Hz

120

Efficiency

72 64

42.5 Hz 49 Hz

56 48 Percent

such as a sonic (Doppler-type) or “transit time” flow meter or a Pitot tube and manometer. Turbulence can be avoided by measuring the flow rate on a pipe section without fittings at a point where there is still a straight run of pipe ahead. In addition, internal leaks caused by excessive impeller clearances or by worn or misadjusted parts can reduce the efficiency of pumps. Corrective actions include restoring internal clearances and replacing or refurbishing worn or damaged throat bushings, wear rings, impellers, or pump bowls. Changes in process requirements and control strategies, deteriorating piping, and valve losses all affect pumping system efficiency. Over time, a pump’s efficiency can degrade as much as 10-25% before it’s replaced, according to a study of industrial facilities commissioned by the DOE, and efficiencies of 50-60% or lower are quite common. Because these inefficiencies aren’t readily apparent, though, opportunities to save energy by repairing or replacing components and optimizing systems are often overlooked. Several suggested actions for increasing pump system efficiencies include identification of: • Misapplied, oversized, or throttled pumps, or those that have bypass lines

40

3478 rpm (142)

32 24 16 8 0 –8

0

40

80 120 160 200 240 280 320 360 400 440 480 520 560 600 640 680 720 760 800 840 880 US gpm

Conclusion

The industrial water industry must not only realize the value of optimized pumping systems, but also that there are numerous resources available to them which can help lower pump system energy use and improve bottom-line profitability. In fact, there are also many savings programs and attractive paybacks for companies seeking to improve motor-driven system efficiencies, especially with pumps. For example, many energy efficiency organizations and state and federal government agencies are currently offering industrial pump users incentives and/or rebates to optimize pump systems for energy saving purposes. This includes free energy assessments, rebates on energy efficient equipment, and use of renewable energy resources, business tax credits and exemptions, project grants, equipment loans and financing programs. As an ongoing resource to these efforts, industrial water companies are urged to visit www.PumpSystemsMatter.org and review the valuable resources available on the website. Pump Systems Matter™ (PSM) was launched in 2006 by the Hydraulic Institute to help North American pump users gain competitive business advantages through strategic, broad-based energy management and pump system performance optimization. IWW About the Author: With over 20 years experience in the design and application of pumps, controls and various water and wastewater treatment equipment, Joe Melton is products/marketing manager at Wilo-EMU USA, of Thomasville, GA. He has worked as an estimator for a mechanical contractor, as a piping systems design engineer, as a sales engineer and sales manager for manufacturers’ representative firms, and now for a pump manufacturer. As a charter sponsor of Pump Systems

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Matter, he and his company have worked actively with PSM to develop and market tools and information that integrate pump system performance optimization and efficient energy management practices into normal business operations. Contact: 973-267-9700 x22 or [email protected]

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PRODUCT FOCUS

Unknown SCADA Connections Could Mean Disaster BY MICHAEL MARKULEC

• Analyzing TCP/IP connectivity in assets and networks, uncovering risk patterns and pinpointing policy weaknesses is crucial to power utilities and other critical industries where water level and pump control vulnerabilities could risk lives.

T

he ease with which TCP/IP (Transmission Control Protocol/Internet Protocol) enables one to connect networks has been a huge boon for the power generation industry. Far-flung operations can be hooked up to the network and controlled remotely, and devices that once required manual adjustment can now be tweaked with the click of a mouse button. The easy flow of information throughout the organization has made

nearly every aspect of business more efficient and effective. But easy connectivity isn’t always desirable, especially with supervisory control & data acquisition (SCADA) systems that control the vital infrastructure of industrial operations in water management and power systems, traffic signals, mass transit systems and others. One thing is certain: SCADA security incidents will occur and, given how much of the world’s infrastructure they con-

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Silhoette of nuclear power plant.

trol, could potentially have serious repercussions. In fact, some serious accidents and safety breaches have resulted from linking SCADA systems to the main TCP/ IP network. In March, for instance, the 883-megawatt unit 2 at the Hatch Nuclear Power Plant in Georgia had an emergency shutdown as a result of a software update made on the plant’s business net-

Providing systems, equipment and industrial gases to the water and wastewater industry: • • • •

Biosolids reduction with ozone Oxygenated aeration Carbon dioxide for pH control Odor control [email protected] 1-800-PRAXAIR www.praxair.com/wastewater

© Copyright 2008, Praxair Technology, Inc. All Rights Reserved. Praxair and the Flowing Airstream design are trademarks or registered trademarks of Praxair Technology, Inc. in the United States and/or other countries.

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PRODUCT FOCUS -

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SCADA & PROCESS CONTROL

work. The update synchronized information on both systems, wiping out much of the data on the SCADA side. After everything was reset following a reboot, the SCADA safety system detected a lack of data, which it interpreted to mean the water level in the cooling systems for the nuclear fuel rods had dropped – a dangerous situation indeed, if in fact it actually occurred. Unfortunately, the safety system instigated an automatic shutdown due to a software update. Engineers were aware of the two-way communication link, but didn’t know the update would synchronize data between the two systems. Luckily, in this case, no one was hurt, but as with any unplanned shutdown, it was expensive, as the plant was completely offline for three days. Still, it was only the latest in a string of accidents and unnecessary shutdowns caused by some problem on the network. The Browns Ferry nuclear plant in Alabama, for example, shut down in 2006 when a network traffic overload locked up pump controls. And in 1999, a steel gas pipe-

line ruptured near Bellingham, WA, with tragic results: two children and an 18-year-old were killed and eight others injured. A subsequent investigation found that a computer failure just prior to the accident locked out the central control room operating the pipeline, preventing Power plant control room. technicians from relieving pressure, which caused the explo- tee all connections conform to security sion. policy, critical infrastructure should not Some engineers believe the best protec- fall prey to unforeseen security risks. tion is to sever all ties between the business Understanding the network risk proand SCADA networks, but they would file of today’s SCADA systems requires be mistaken in thinking that the SCADA new insights into the nature of security network is safe without a regular assess- threats. Following are examples of comment of connectivity to ensure no connec- mon network vulnerabilities today’s utiltions between the SCADA network and ity companies face when implementing corporate network appear. TCP/IP net- next generation networks: works are designed • Remote access vulnerabilities – SCAto make connec- DA and other process control system nettivity easy, and the works often consist of a primary network ubiquity of today’s linking SCADA-related facilities, with adcorporate networks ditional connections to the corporate netopen up the possi- work of the utility company. Since netbility of someone work connectivity is often permitted to inadvertently con- the Internet, business partners, regulanecting SCADA to tors and outsourcer networks, there’s inthe larger network, creased potential for unauthorized acwith potentially cess to supposedly “separate” SCADA disastrous conse- networks as well. Use of remote access quences. services also increases likelihood of seIn truth, indus- curity breaches. try need not nec• Network leak vulnerabilities – Imessarily give up on proper network configuration often leads the cost and man- to inbound and outbound network leaks agement advantag- – between SCADA networks, corporate es of connecting its networks, business partners, regulators SCADA networks and outsourcers, and even the Internet to the larger net- – which pose a significant threat to network. As long as work reliability. Network leaks can allow strong safety sys- worms, viruses or hackers direct visibility tems are in place to vulnerable SCADA systems. and frequent and • Network security design – The net__________________ regularly scheduled work infrastructure layer that supports network scans are SCADA and other process control sysconducted to un- tems is often developed and modified derstand the full based on business and operational rescope of connec- quirements, with little consideration for Circle No. 32 on Reader Service Card tivity and guaran- the potential security impact of network

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SCADA & PROCESS CONTROL -

changes. Over time, security gaps may be inadvertently introduced within the network infrastructure. These gaps may represent a back door, or even a front door, into networks. • Lack of formal and documented SCADA network policies, processes and procedures – Due to highly proprietary and legacy nature of these systems, owners, administrators and vendors often don’t follow strict configuration change management procedures. This may lead to security oversights that may again lead to serious network exposures and risks. • Improperly configured and/or unauthorized network services – Use of improperly configured or unauthorized network services running on systems, such as SendMail, Finger, Telnet, FTP and NFS can create network exposures that can leave systems vulnerable to attackers. To protect their SCADA networks, utilityies and other industrial companies need to develop comprehensive security risk management programs that adopt a proactive approach to isolating and closing network exposures that are often the “first point of attack” for intruders and are weaknesses vulnerable to internal errors like the incident at the Hatch Nuclear Power Plant. Solutions now exist to identify network vulnerabilities while also conveying a deep understanding of how network defenses are deployed in relation to SCADA systems. Via sophisticated data analysis techniques, these solutions can show how an IP-based SCADA network is “wired together” including all the sub-networks, systems, devices, and routes that IP traffic can traverse. Through use of regular scans, organizations can understand how their network is changing over time – even identifying devices previously unknown to administrators – so as to ensure their SCADA networks remain separate and secure. Conclusion

Unknown network connections aren’t just security risks. When you’re talking about the controls systems for nuclear power plants, hydroelectric dams, chemical factories and other vital infrastructure, stakes could quite literally involve hundreds or thousands of lives. The complex designs, interconnected nature and extreme sensitivity of SCADA & process control SCADA and other process control systems help protect process, systems mandates utility and other cooling and waste water syscritical industrial organizations im- tem integrity at power plants plement comprehensive plans for as- and other industrial facilities. sessing and mitigating potential network vulnerabilities and threats. To do this successfully requires development of security risk management programs that start with gaining control over network risk. IWW About the Author: Michael Markulec is chief operating officer of Lumeta Corp., of Somerset, NJ. Lumeta’s flagship product, IPSonar, creates a foundation for network assurance by providing global network visibility and measuring risk from a network perspective by mapping every asset on a network. Contact: 866-586-3827 or www.lumeta.com

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PRODUCT FOCUS

Industry-Leading HAYWARD Plastic Diaphragm Valves

...An Open and Closed Case for Cost-Effective Handling of Corrosive Fluids, Abrasives, and Slurries Hayward’s Newly Expanded Line of All-Plastic Diaphragm Valves feature a multi-turn design for precise control of difficult to handle media and can be used for on/off, throttling, high purity, and sanitary service in a wide range of applications. ➧ Manual or Actuated models in 1/2˝ - 10˝ ANSI Flanged, 1/2˝ - 2˝ ASTM True Union Sizes, and Threaded Bodies in 1/2˝ - 1˝ Sizes ➧ Choice of PVC, CPVC, PVDF OR PPL Valve Bodies and EPDM, FPM or PTFE Diaphragms ➧ PVDF Vapor Barrier Available for Use with PTFE Diaphragms ➧ Unique Diaphragm Stroke Adjustment Feature for Very Precise Flow Control ➧ Self-Draining Design so Little or No Volume Remains in Valve ➧ Large Sure-Grip Handwheel and Beacon-Type Position Indicator

To learn more about new Hayward All-Plastic Diaphragm Valves or locate a factory-trained distributor who can help you, visit us at

www.haywardflowcontrol.com

One Hayward Industrial Drive Clemmons, NC 27012 Tel: 1-888-429-4635 (1-888-HAYINDL) Fax: 1-888-778-8410 E-mail: [email protected] www.haywardflowcontrol.com

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PRODUCTS & SERVICES

SCADA & PROCESS CONTROL Multi-pump load control The Schneider Electric Relay Competency Center (SE Relays LLC) announces the release of the Square D® brand 8501KA series alternating relay, a superior and cost-competitive alternative to existing alternating plug-in relays utilized in the pump industry to control multiple loads. The relay offers 12-amp contact ratings while utilizing less space on the DIN rail. It also works well as a dropin replacement in the MRO industry and offers features that appeal to OEM panel builders. Schneider Electric, Palatine, IL, 847-397-2600, www.us.schneider-electric.com Circle No. 159 on Reader Service Card Alarm audit software The LogMate® AlarmKB™ (Knowledge Base) provides a straightforward way to audit alarm settings. It compares two alarm profiles, highlighting differences in a summary of contrasting settings. The AlarmKB Import Utility (AKBIU™) simplifies the audit process by importing control system settings from native configuration files into the AlarmKB. It takes just a few keystrokes to import and compare a configuration file. Imports can be performed on demand or set to run on a predefined schedule. Updated regularly, AKBIU is compatible with: ABB/Bailey Infi-90, Emerson DeltaV, Emerson DeltaV Operate for PROVOX and Fisher PROVOX, Foxboro I/A, Honeywell Experion and TDC, Rockwell Automation RSView, Yokogawa Centum and Kongsberg. TiPS Inc., Georgetown, TX, 512-863-3653, www.tipsweb.com/alarmkb/ Circle No. 127 on Reader Service Card Manufacturing solutions Wonderware, a business unit of Invensys, announced new software solutions designed to enable customers to better address critical issues in manufacturing operations. These enhanced software solutions include Wonderware Operations Software 3.4 and Wonderware Performance Software 3.4 and are evolutions of the Factelligence offerings from the acquisition of Cimnet, an MES software company integrated into Wonderware in 2007. Wonderware, Lake Forest, CA, http://us.wonderware.com/ Circle No. 128 on Reader Service Card 36

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Programmable vibration switches Balmac Model 550 Programmable Vibration Switches provide 24/7 monitoring of vibration levels on equipment such as large motors, pumps, compressors, fans, centrifuges, blower and cooling towers. The Model 550 features two user-programmable vibration limits (alarm and shutdown) and time delays. Additionally, the Model 550 features: a 4-20mA output for connecting to PLC’s, DCS, SCADA systems and panel meters for additional network compatible monitoring, a selfdiagnostic system test button to confirm proper operation with LED limit trip indicators, and field configurable automatic limit and control relay with remote reset. Balmac Inc., Plain City, OH, 614-873-8222, www.balmacinc.com Circle No. 131 on Reader Service Card

High power Ethernet radios Phoenix Contact’s new high-power industrial radios provide secure wireless communication over a long-distance, wireless mesh network of up to 40 radios. The RAD-80211-XD/HP and RAD-80211XD/HPBUS feature 400 mW (26 dBm) transmit power and 128-bit AES encryption. A unique auto-bridge mesh mode allows the network to self-form and heal if a radio drops out of the network. This results in an uninterrupted flow of data even if other bridge devices or network segments in the data’s path fail. Like the other radios in the RAD-80211-XD series, the high power radios also support access point, client and bridge/repeater modes. Phoenix Contact, Middletown, PA, 800-322-3225, www.phoenixcontact.com Circle No. 132 on Reader Service Card

Water crisis management solution Whitewater Security, a subsidiary of the Whitewater Technology Group, has introduced a comprehensive security solution for water utilities and municipalities that covers all areas of water crisis management – including protection, monitoring, and contamination detection. Designed and implemented by some of the world’s leading security specialists, the Whitewater Security solution protects against both deliberate and accidental contamination, minimizes infrastructure vulnerability, and ensures a continuous supply of safe, high quality water. Whitewater Security, a subsidiary of the Whitewater Technology Group, Tel Aviv, Israel, 972-3-6099011, www.w-water.com Circle No. 130 on Reader Service Card

Fieldbus temperature transmitter The TFZ Programmable FOUNDATION Fieldbus Temperature Transmitter can be installed on the same segment with all standard FOUNDATION fieldbus devices. The TFZ converts a temperature sensor input to a FOUNDATION fieldbus H1, two-way digital communication protocol that is ready for interface to a DCS, computer-based SCADA system, or asset management software. The TFZ saves wire and installation costs by allowing up to 32 field devices (126 with repeaters) to be networked onto one, low cost FOUNDATION fieldbus H1 segment. Moore Industries-International Inc., North Hills, CA, 818-894-7111, www.miinet.com Circle No.133 on Reader Service Card

Data radios products Control Microsystems has announced the release of SCADAWave, a line of data radio products that includes remotes, base stations and hot standby/redundant station variants in both licensed and unlicensed frequency formats. The license-free format is represented by the SCADAWave Ultra-Series radios, which are designed to provide reliable and secure serial data communication in the 900MHz ISM band. Control Microsystems, Ottawa, ON, Canada, 888-267-2232, www.controlmicrosystems.com Circle No. 129 on Reader Service Card

NOVEMBER/DECEMBER 2008

Supervisory control solution GE Fanuc Intelligent Platforms, a unit of GE Enterprise Solutions, offers the latest version of its supervisory control solution, Proficy® HMI/SCADA - CIMPLICITY® 7.5, offering more diagnostic tools, security, development tools, connectivity and flexibility than ever before. Notable enhancements include Digital Graphical Replay (DGR), enhanced screen navigation, and easy-to-use application deployment. GE Fanuc Intelligent Platforms, Charlottesville, VA, www.gefanuc.com Circle No. 134 on Reader Service Card www.industrialww.com

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SCADA & PROCESS CONTROL SCADA interface Semaphore has introduced a 1-Wire® interface for its T-BOX line of SCADA system products. This interface is compatible with a T-BOX MS Modular System, when equipped with a 32-bit CPU. 1-Wire is a half duplex communications network that uses a single wire to provide data transmission and power. 1-Wire provides access to a wide range of small, inexpensive sensor devices, which are used in energy management, infrastructure management, and environmental monitoring applications. Semaphore SCADA solutions, Nashua, NH, 603-577-3803, www.cse-semaphore.com Circle No. 137 on Reader Service Card

USB device servers Quatech’s USB Wired and Wireless Device Servers help maximize productivity by connecting to and sharing a wide range of USB peripherals to members on a network. Quatech USB Device Servers offer added features such as streaming video and audio with the USB Wireless Device Server or the Network Attached Storage option with the USB Wired Device Server for added storage. Access and share files saved on USB storage devices, send and receive data from remote USB devices or pictures taken on a digital camera, and print and scan to any device on your network. Quatech, Hudson, OH, 800-553-1170, www.quatech.com Circle No. 136 on Reader Service Card Frequency-hopping serial radios ProSoft Technology’s new Industrial Frequency Hopping serial radios are license-free and are available in both the 900 MHz (RLX-IFH9S) and 2.4 GHz (RLX-IFH24S) bands. Frequency hopping radios use a proprietary signal that hops from channel to channel, which provides the wireless network with an extra layer of security allowing it to avoid interference or existing wireless networks. ProSoft Technology, Bakersfield, CA, 661-716-5257, www.prosoft-technology.com Circle No. 135 on Reader Service Card www.industrialww.com

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Multi-service access platform TC Communications Inc. has announced availability of its new flagship Gigabit Ethernet Multi-Service Access Platform (MSAP), the JumboSwitch™ product family. The center piece of the JumboSwitch family is an industrial hardened (-40°C to 80°C), fully-managed and easily scalable Gigabit Ethernet switch that is ideal for Utility & SCADA environments. It integrates up to seven hot-swappable Ethernet, Voice & Data interface cards onto a Gigabit backbone Ethernet fiber optic network. Currently available Interface cards include 10/100/1000M Ethernet (SFP copper or fiber optic); T1/E1 (TDMoIP); Serial Data (RS-232/422/485); and, VoIP (FXO & FXS). Future interfaces will include T3/E3 & DI/DO. TC Communications Inc., Irvine, CA, 949-852-1972, www.tccomm.com Circle No. 138 on Reader Service Card Enhanced fleet tracking SkyWave Mobile Communications has introduced the SureLinx 8100c Satellite/GPRS terminal. With an on-board computer (OBC), Controlled Area Network (CAN), RS485 and RS232 interfaces, this new product offers transportation and logistics managers a flexible and low-cost option for communicating with vehicles in both urban and remote locations. The SureLinx 8100c combines SkyWave’s Isat M2M satellite technology with worldwide cellular capabilities and intelligent message routing in a single integrated package. Designed to minimize networking costs as well as increase communication reliability and coverage, SureLinx 8100c allows customers to take advantage of low cost, high-data rate GPRS networks in cellular regions and seamlessly switch to reliable satellite communication in other areas. SkyWave Mobile Communications, Ottawa, Canada, 613-836-4844, www.SkyWave.com Circle No. 139 on Reader Service Card

LOWER ELECTRICAL CONSUMPTION LOWER MAINTENANCE COSTS INCREASED AERATION EFFICIENCY

Our totally new design uses low 10-50 hp motors to achieve higher aeration levels than most conventional aerators inefficiently using high hp motors. Let us prove it: Call or email us to learn more.

Phone: 888-813-3680 www.airmasteraerator.com

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NEW PRODUCTS

Gas/liquid separators A new full-color Guide to Gas/Liquid Separators, from Eaton Filtration, details how this product removes potential damage-causing moisture and particulate matter from steam, compressed air and compressed gas lines to protect turbines, heat exchangers and other expensive equipment. Application examples in the guide, downloadable from Eaton’s website, clearly show how they pay for themselves over time via removal of over 99% liquid and particulate matter that can cause damage to expensive components. The guide also features a full color, cut-away illustration that shows how Eaton’s exclusive Vortex Containment Plate works to improve separator efficiency by shielding removed liquid from turbulence of the swirling gas passing through the separator to prevent it from being re-entrained. Eaton Filtration, 800-859-9212, www.filtration. eaton.com Circle No. 140 on Reader Service Card

Cooling water treatment VRTX Technologies is now offering the VRTX Full Service Agreement (FSA) at a fixed price for a minimum of five years for customers in North America and Europe. The FSA provides all necessary equipment and filtration, installation, monthly service, periodic mechanical service and a continuing mechanical warranty. With a fixed cost, chemicalfree service facilities with cooling towers and evaporative condensers can eliminate surcharges and container fees added to already doubled chemical prices. Facilities also can eliminate need for environmental safeguarding, employee training programs and special permits, while also improving the employee work environment. VRTX Technologies, Schertz, TX, 800-722-0476, www.vrtxtech.com Circle No. 141 on Reader Service Card

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Acrylic polyurethane coating Sherwin-Williams’ Hazardous Air Pollutant (HAPS) free Waterbased Acrolon 100, an environmentally friendly acrylic polyurethane coating, is well within Ozone Transport Commission (OTC) guidelines with a VOC level