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MPT
New Lift Station Saves
JULY 2021
Florida Paradise
Pump Industry Prepares
for the Brain Drain
Learn the Economics
Modern Pumping Today ®
of Reliability
Providing Solutions for the Worldwide Pump Industry
www.mptmag.com
JULY 2021
22
MPT
Modern Pumping Today ®
www.mptmag.com
P.O. Box 660197 | Birmingham, Alabama 35266
@modpumpmag
J. CAMPBELL Editor
jay@mptmag.com
26 35
TONYA BROWNING Vice President
tonya@mptmag.com
JEFF FLETCHER National Sales Manager
jeff@mptmag.com
LISA AVERY Art Director
CAMILLE BLACK Graphic Designer
SETH SAUNDERS Digital Media Specialist
INGRID BERKY Office Manager
A NOTE ON THIS ISSUE:
Welcome to the July issue of MPT! Sewage spills
can detract from the appeal of any community, and SUBSCRIPTIONS
frequent MPT contributor Thomas Renner provides For all changes, go to:
a look at the particularly problematic issues that MPTMAG.COM
faced Sarasota, Florida, in this month’s Case Click the SUBSCRIPTIONS button
Studies section (pg. 12). Find out how a creative lift in the main menu
station plan provided the solution.
As more baby boomers continue to retire in
J. Campbell, Editor
2021, 62 percent of companies struggle to fill
Modern Pumping Today
critical, skilled technical trade positions. Plus, the
Department of Labor estimates 31 million skilled technical trade positions
will be vacant by the end of year. In this month’s Pump Solutions section
(pg. 22), Sulzer’s David Fasnacht offers ideas on how the pump industry www.highlandspublications.com
can prepare for the brain drain. 312 Lorna Square | Birmingham, Alabama 35216
866.251.1777
Lastly, reliability analytics company Pinnacle recently released its
second Global Economics of Reliability Report, which analyzes the impact
TIM GARMON RUSSELL HADDOCK
reliability has on the water and wastewater treatment industry. Jeff Krimmel, CEO President
Pinnacle’s director of data and market analysis, shares the details in this
month’s episode of The Efficiency Point (pg. 36). Enjoy! CHRIS GARMON DONNA CAMPBELL
CFO Vice President, Editorial
EDITORIAL ADVISORY BOARD: TONYA BROWNING
Vice President
Terry Bell Product Manager, ABB
Heinz P. Bloch, P.E. Consulting Engineer, Process Machinery Consulting No part of this publication may be reproduced or transmitted in any form or
by any means, electronic or mechanical, including photocopy, recording,
Robert G. Havrin Director of Technology, Centrisys Corporation or any information storage-and-retrieval system without permission in
writing from the publisher. The views expressed by those not on the
Michael Mancini Consultant and Trainer, Mancini Consulting Services staff of Modern Pumping Today, or who are not specifically employed
by Highlands Publications, Inc., are purely their own. All Industry News
John M. Roach Engineering Manager for New Product Development, Trebor International, material has either been submitted by the subject company or pulled
Inc.: A Unit of IDEX directly from their corporate website, which is assumed to be cleared
for release. Comments and submissions are welcome, and can be
Lisa Riles Business Development Manager, Wastewater Pumps, Xylem Inc.: Flygt submitted to jay@mptmag.com.
Frank Knowles Smith III Executive Vice President, Blacoh Surge Control
Greg Towsley Director of Regulatory and Technical Affairs, Grundfos
Trey Walters, P.E. President, Applied Flow Technology
CONTENTS
I N DU S T RY NE W S
What's happening in the industry.......................................... 6
12
CASE STUDIES
Sarasota Banking on New Lift Station To Stop
Messy Sewage Spills.........................................................12 16
When environmental damage threatens paradise, a creative plan
provides the solution
WAT E R & WA S T E WAT E R FO C US
Seattle Takes FOG Program Online.................................16
Improving remote access and customer compliance
M A I N T E N A N C E & RE L I A B I L I TY
Scanning Accurate Models of Harsh Environments.......20
New 3D reality capture technology proves a cost-effective, reliable, and safe solution
PUMP SOLUTIONS 20
Pump Industry Prepares for the Brain Drain..................22
Retirees cause massive shortage in trades jobs, so what’s the best solution?
MOTOR SOLUTIONS
22
Taking It to the Edge.........................................................26
Numerical simulation of the propagation of a gearbox crack
SEALING SOLUTIONS
Proactive Design with Hydraulic Modeling....................30
When technology takes root in the industry, everyone benefits
M O D E R N PU M P I N G P RO D UC T S
Blacoh Surge Control
SurgeWave™ Transient Monitoring System..........................34
EFFICIENCY POINT
Learning the Economics of Reliability............................36
Pinnacle’s Jeff Krimmel on the water industry’s need for expansive capital investment
34
INDUSTRY NEWS SEEQ AND AMAZON WEB SERVICES PARTNER cloud,” says Mona Chadha, director, AWS Marketplace TO LAUNCH OF SaaS MIGRATION PROGRAM Category Management. Seeq Corporation announces the launch of a new program, the Seeq SaaS Workshop. In collaboration GWS TOOL GROUP ACQUIRES INDEXABLE with Amazon Web Services (AWS), the Seeq SaaS CUTTING TOOLS OF CANADA Workshop simplifies the migration path to the cloud GWS Tool Group has acquired Indexable Cutting Tools, for Seeq’s on premise customers. Seeq SaaS on AWS Inc., the third acquisition in 2021 for GWS Tool Group benefits for manufacturing organizations include ease and the first international acquisition by the U.S.-based of deployment, added support, and faster access to new manufacturer. Located in Welland, Ontario, and Edmonton, Seeq capabilities. Alberta, Canada, Indexable is a technology leader in Eligible customers participating in the Seeq SaaS the manufacturing and distribution of ceramic, PCD, Workshop will benefit from a no-cost SaaS migration and CBN inserts. For more than fifty years, mastery of service, along with additional pricing options for Seeq insert production and precision cutting technology has subscriptions. In addition, Seeq's dedicated support provided manufacturers around the world with an edge in team will assist in efficiently migrating on premise Seeq operational efficiency. implementations, data connections, and workloads to the The company supports an array of manufacturing AWS cloud. companies with its products. From automotive and Seeq’s rapid growth is being fueled in part by its powertrain customers to commercial and defense commitment to cloud-based computing. Seeq is available aerospace manufacturers, Indexable has used its model of on AWS Marketplace, has AWS Industrial Competency quality and flexibility to deliver what few others can. With status, and supports many data storage services, including six global patents surrounding their microwave sintering Amazon Redshift, Amazon S3, plus machine learning in processes, Indexable can output ceramic inserts with ultra- Amazon SageMaker, and other services. fine-grained microstructures that yield increased hardness, “Customers go to AWS Marketplace to find toughness, and thermal stability versus traditional ceramic solutions that provide advanced analytics and real- grades in the same categories. Their emphasis on quality, time collaboration to support their journey to the which is supported by their ISO9001:2015 certification, 6 | July 2021 | Modern Pumping Today www.mptmag.com
INDUSTRY NEWS
aligns perfectly with what GWS demands and solidifies demand for this real-time worker alert technology, Triax
its position as a multi-disciplinary manufacturer of high- launched Spot-r Radius in May 2021. This next-generation
performance cutting tools in the marketplace today. solution leverages preventative alerts with added safety
and efficiency data insights.
TRIAX TECHNOLOGIES RAISES $12.5 MILLION
SERIES A FUNDING AMERICARES, XYLEM PARTNERSHIP DELIVERS
Triax Technologies has raised a Series A funding round CLEAN WATER AND SANITATION TO 3.5
of $12.5 million. The round, led by McRock Capital, an MILLION PEOPLE
institutional investor focused on industrial IoT, along Xylem Watermark, the corporate social responsibility
with Connecticut Innovations and support from existing program of Xylem Inc., and health-focused relief and
shareholders, will be used to grow the Triax team and development organization, Americares, aim to reach
scale its solutions globally. As part of the financing, Scott one million people in 2021, through their collaboration
MacDonald, cofounder and managing partner of McRock to improve access to clean water and sanitation. The
Capital, has joined the Triax board. program builds on the first year of the partnership, which
The funding comes amid growing demand for, and delivered clean water and sanitation services to over 3.5
investment in, IoT technology, and increased adoption of million people, helping to slow the spread of COVID-19.
the company’s wearable solutions to improve worksite In 2021, the partners will provide water, sanitation, and
safety and efficiency. hygiene (WASH) infrastructure repairs and education
“Our mission is to provide IoT technology and data to frontline healthcare workers and communities across
insights that help companies change the way they work six countries including India and Bangladesh, currently
to keep workers safer and worksites more efficient,” says experiencing COVID-19 spikes. In Mumbai, where
Robert Costantini, CEO of Triax. “By working closely with informal, urban settlement communities are particularly
innovative customers, we have demonstrated the ability to impacted by the second wave of the pandemic,
service large-scale operations with robust and scalable interventions will include rehabilitating WASH facilities
technology, and to serve as a trusted partner in their at healthcare facilities, serving 70,000 people from the
digital transformation initiatives.” Building on the market city’s most low-income areas. The partners will also
8 | July 2021 | Modern Pumping Today www.mptmag.comINDUSTRY NEWS
provide WASH assistance to disaster-prone coastal
communities in Bangladesh.
“Through our partnership with Americares we aim to
bring this message to life for communities around the
world and to empower them through improved access to
clean water and sanitation,” says Austin Alexander, vice
president of sustainability and social impact at Xylem.
ATLAS COPCO POWER TECHNIQUE
ANNOUNCES NEW POSITIONS
Atlas Copco Power Technique names Jim O’Brien as the
vice president of strategic accounts, effective immediately.
O’Brien has been a part of the Atlas Copco group since
2000. Originally joined the Atlas Copco group twenty-one
years ago, O’Brien started his journey with Atlas Copco
as a key account manager for General Motors. In 2007,
O’Brien was promoted to global key customer manager
for portable energy, working in Belgium and stationed in
Shanghai. In 2013, O’Brien returned to the United States to
serve as the integration manager for American Pneumatic
Tools. With O’Brien’s background and experience, he is a
strong fit for this newly created position.
Along with O’Brien, Atlas Copco Power Technique names
Meadow McClure as the strategic accounts specialist,
assisting designated strategic accounts to help maintain
and grow customer share within current accounts. McClure
has been with the Atlas Copco group for eight years.
She started her journey as a service coordinator for
BeaconMedaes, then later moved to the role of equipment
coordinator for Power Technique North America. Now,
McClure’s main responsibility is assisting with customer
service on major accounts and supporting any urgencies.
SOFTINWAY WINS NASA SBIR CONTRACT,
CHANGING TURBOMACHINERY DESIGN
METHODOLOGY
SoftInWay has been awarded a NASA SBIR contract to
leverage artificial intelligence to improve turbomachinery
designs for use in high power-density engines. Thanks to the
team’s efforts, SoftInWay was awarded the Phase II contract
to expand upon its work developing an axial compressor
map generation program that leverages an autonomous
self-training AI. This project will redefine turbomachinery
research and development, enabling companies to develop
reliable and efficient technology faster.
After being awarded the Phase I contract back
in September, the SoftInWay engineering team has
partnered with engineers from Raytheon Technologies,
a leading defense contractor in the United States, and
researchers from Purdue University, a leading institution
in turbomachinery research and education. SoftInWay will
work with these two partners to further refine the developed
AI-based program by making it applicable to a wide variety
of axial compressors, a key component in making powerful
yet efficient gas turbine engines for airbreathing propulsion,
without the need to retrain the AI. ◆
10 | July 2021 | Modern Pumping Today www.mptmag.comgame
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1-800-891-2941 | sales.us@lselectricamerica.comCASE STUDIES
Sarasota Banking
on New Lift Station
To Stop Messy
Sewage Spills
When environmental damage threatens paradise, a
creative plan provides the solution
By Thomas Renner
P
eople have discovered there is a lot to like in same name, the city on the state’s western side has seen a
Sarasota, Florida. Fewer than 1,000 people called significant rise in citizenship.
the city home in the early 1900s. Its population now The motives are many: weather, culture, recreational
approaches 60,000, with an increase of more than 12 activities, and affordable housing are among the reasons
percent since 2010. Like the rest of the county with the people have flocked to the community. Sarasota Bay’s
12 | July 2021 | Modern Pumping Today www.mptmag.comCASE STUDIES
Photo: Charlie Fernandes Photography).
abundant marine life, plentiful variety that contributed to city’s sewage
of plants and exotic birds add to the control problems. After the spill in
appeal, along with opportunities for 2004, another 500,000-gallon spill
fishing, kayaking, and water sports just seven months later sparked
activities. Sarasota County attracts community outrage.
more than 2.2 million annual visitors, The problems, it turns out,
accounting for $2.24 billion in total were just beginning. The road to Lift Station 87 in Florida will have a capacity of 9.5 million
gallons per day, treating about 33 percent of the city’s
economic impact. By any measure, completing the new lift station—at a wastewater. (photo credit: Charlie Fernandes Photography)
Sarasota has got the goods. reported final cost of $67 million—
Sewage spills can detract from the was complicated, lengthy, and costly. were demoted, reprimanded, or
appeal of any community, and they forced to retire. McNees left his
seem particularly problematic in ROCKY START position as the city’s chief executive
Sarasota. “The overall health of the Neighbors complained to the city’s in 2007.
bay has regressed in many ways over public works department about foul The state’s Department of
the past decade,’’ Orion Morton, a odors emanating from Lift Station 7 Environmental Protection established
kayak tour guide and advocate for almost from the beginning after it was a 2011 deadline to move the city’s
Sarasota Bay wrote in the Herald- constructed in the 1980s. Other city Lift Station from Pomelo Avenue. Luke
Tribune newspaper in April. “We officials, however, had been unaware Wood Park was determined to be the
have become accustomed to of resident complaints. best site in terms of efficiency and
sewage leaks.” Tensions reached a boiling point cost. The city estimated the project
A 500,000-gallon sewage link in in February 2005. Residents learned would cost $8.5 million.
February 2004 in the city provided about the 2004 spill only after the The city awarded Westra
the impetus for a new lift station to incident one year later. Michael Construction Corporation a $9.6
handle approximately one-third of McNees, Sarasota’s city manager at million contract in February 2011.
the city’s wastewater flow. Lift Station the time, defended city employees, AECOM served as the initial project
87, which opened late in 2020, will further angering residents. In August engineer, and teams estimated to
replace Lift Station 7, an aging facility 2005, six public works employees have the station completed in 2012.
www.mptmag.com Modern Pumping Today | July 2021| 13CASE STUDIES
A BIG LIFT
FOR FLORIDA
COMMUNITY
WHAT: Lift Station 87 in
Sarasota, Florida, is a new
above-ground station with a 9.5
million gallon per-day capacity.
WHY: The project is Thirteen floor doors manufactured by BILCO were included in a new lift station in Sarasota, Florida.
necessary to improve the
wastewater system and Construction began in June 2011, but THE BIG DIG
mitigate overflows due to more problems quickly surfaced. Microtunneling was one of the most
aging infrastructure and significant decisions made by McKim
equipment. It will replace ANOTHER SPILL & Creed for the project. A trenchless
Lift Station 7, which will be Just two months after work began, method of sewer construction, the
decommissioned and the
another spill—this one not caused process is effective in soft, unstable
site will be restored and
by aging Lift Station 7—pushed soils. The tunneling process is
landscaped to its park-like
the project in a new direction. A remotely controlled and involves
setting. The new station will
contractor inadvertently broke a digging a sending and receiving
handle about 33 percent of
force main, causing an estimated spill pit, placing a microtunnel boring
the city’s wastewater flow.
of 200 gallons into the Hudson Bayou, machine into the sending pit, cutting
HURRICANE-PROOF: a Sarasota Bay tributary. AECOM and a hole through the ground and
The two-story building was Westra were terminated, stopping pushing the new sewer pipe in place.
designed to withstand the work on the project. An article in the Workers then have to remove the
impact of a Category 3 Sarasota News Leader magazine microtunnel boring machine.
hurricane. The design will said contractors were on the verge A jacking rig, functioning similar
allow Sarasota Memorial of drilling into a support slab of the to a jack hammer, pushes the new
Hospital and other critical Osprey Avenue bridge. “We’re very sewer pipe in place. The process
designated storm shelters lucky we didn’t have a catastrophe is slow, progressing about 20-40
to remain operational after a with our utility department,’’ then- feet per day. “You’re underground,
storm. City officials directed Mayor Shannon Snyder says. chewing through rock, under
the project engineer, McKim McKim & Creed took over as the a historic bridge, and in an
& Creed, to bring critical project engineer in 2013 and after an environmentally sensitive area,’’
equipment above ground to evaluation phase, made two significant McKim & Creed’s Robert Garland,
a height above Category 3 changes to the project. The new team P.E., said in a radio interview. “We
storm surge elevation. wanted to build a new, above-ground went about this in a methodical way.”
“hurricane-proof ” lift station, designed While slow, the advantage is that
CUSTOM FLOOR DOORS: the process does not disturb the
to withstand Category 3 hurricanes.
Thirteen floor doors from
The new model also required surface above. The bridge, and the
BILCO were installed in the
digging eight-feet further down to sensitive environment in Hudson
project, and include factory-
construct microtunnels to convey Bay, concerned Sarasota officials
installed fall protection
waste. Engineers believed the bridge and McKim & Creed. Wastewater is
grating. The doors were
customized to meet unique might have collapsed in the soft silt carried through a 36-inch PVC pipe
size requirements. base around the bridge without the in the microtunnel, and it is encased
deeper microtunnels. in a 60-inch casing.
DID YOU KNOW? Sarasota While necessary, the new design “We put the steel casing in first,
has been impacted, directly or was more time-consuming and costly. which is the wall of the tunnel,’’
indirectly, thirty-six times in the Previous work also needed to be Garland said. “Inside that casing
last 146 years by hurricanes. done over. Work on microtunnels will be the pipe that carries the
The city is brushed or hit by started in January 2017, and wastewater. It helps us in the
hurricanes every 2.16 years. estimates increased from $27.1 construction, but if there is any failure
million in 2014 to $32 million in 2015 of the pipe, it is contained within
and finally, $54.1 million in 2017. that casing.”
14 | July 2021 | Modern Pumping Today www.mptmag.comCASE STUDIES
Work on the 670-foot microtunnel
under the bridge began in January
of 2017. The Osprey Avenue Bridge,
which was closed in 2016, opened in
June of 2017. The project also included
a 560-foot long microtunnel under
Luke Wood Park that connects to Lift
Station 87 and with the microtunnel
installed under the Hudson Bayou.
TWO-STORY LIFT STATION
The other critical change designed The BILCO doors will allow access to pumps and vaults for workers at the lift station.
by McKim & Creed included the
construction of a two-story lift “The doors are durable, and they gravity wastewater pipeline by
station designed to withstand strong are a good product for this application open cut to connect homes and
hurricanes. Sarasota Memorial because they are aluminum and won’t businesses to the new lines. Crews
Hospital and storm shelters will be as impacted by corrosive gases also replaced aging ductile iron and
be served by the new station. and water,’’ says Cory Westphal, an asbestos cement pipe, installed new
Maintaining operations during assistant project manager for PCL. reclaimed water mains and replaced
hurricanes was an important concern “It was a fairly standard installation storm sewers. New curbs, sidewalks,
for city officials and residents as a except that they were installed and drainage improvements were
hurricane or tropical storm brushes before the building was finished. The included. Osprey Avenue, which had
the city, on average, every other year. building was built around the doors.” been closed earlier in the process for
The building includes HVAC and PCL ordered the doors through the digging of the microtunnels, was
equipment exhausts in the towers, Building Specialties of Bradenton, closed again from June 2020 through
and the two-story building was built which worked with them to March 2021.
over a new, 50-foot deep wet well. manufacture special sizes. “BILCO Wastewater flow was diverted
It has a maximum capacity of 9.5 was selected because they had the to Lift Station 87, and Lift Station
million gallons per day. capability to make very large hatches,’’ 7, seventeen years after its failing
PCL Construction installed thirteen Westphal says. “Competitors had systems surfaced, will eventually
doors from BILCO in the lift station. difficulty building the sizes we needed be demolished and restored to a
The doors were manufactured in and meeting the loading requirements. park-like setting. The final price will
a wide range of sizes and allow The ability to make them that large and amount to about $67 million, and
access to vaults, pipes, and pumps meet those requirements was essential. that figure includes $48.6 million for
in the wet well. The floor doors are They were prepared because they planning and construction, according
constructed from aluminum with build doors like this frequently and to reports.
stainless steel hardware for corrosion they knew how to do it.” For city officials and residents, the
resistance and are reinforced for project’s completion is noteworthy,
H-20 loading to withstand the force FINAL LEG but hardly celebratory. “I think we
of heavy equipment vehicles used at The final phase included the need to own up to it and explain to
the facility. installation of a 24-inch diameter the community what happened so
that we and future commissioners
The BILCO doors are designed to withstand the force of heavy equipment. don’t have the same problem or learn
from those mistakes,’’ Commissioner
Hagen Brody told the Herald-Tribune
last September. ◆
Thomas Renner writes on building,
construction, engineering, and other
trade industry topics for publications
throughout the United States.
www.mptmag.com Modern Pumping Today | July 2021| 15WATER & WASTEWATER FOCUS
Seattle Takes
FOG Program Online
Improving remote access and customer compliance
By Chris Weinandt, Aquatic Informatics
W
ith more than 5,000
restaurants and food
service establishments
(FSEs) in Seattle, the city’s fats, oils,
and grease (FOG) program is vital
to protecting community health
and keeping sewers flowing by
preventing unlawful discharges from
entering the system. With a team
of five inspectors and one program
supervisor responsible for a large
program, Gary Christiansen, program
supervisor for the Wastewater Source
Control Program (WSCP) at Seattle
Public Utilities, needs to optimize on Seattle Wastewater Source Control team.
efficiencies wherever possible.
“The reality is our small team is not “We realized if we connected these uploaded into GIS. To bring the GIS
able to inspect every Food Service two software solutions, we would data into the Linko platform, WSCP
Establishment (FSE) immediately; be able to better manage our FOG staff contracted Linko to design and
our success depends on identifying program, automate tasks that were build an import feature to allow for
problem areas and prioritizing time-consuming, and reduce human the integration of data between GIS
establishments that require the greatest error in the process,” says Christiansen. and the FOG software. After a few
attention. Our overarching goal is to months, the integration between the
create a data-driven vs. an effort-driven INTEGRATION OF FOG software and GIS was complete.
program in order to serve the City of SOFTWARE PROGRAMS When the city receives the
Seattle in a cost effective and efficient Wastewater Source Control Program automated reports, data is entered
manner,” says Christiansen. staff worked closely with the County and categorized by the GIS system.
Health Department, Food Safety The team is then able—at the click
OPTIMIZING EXISTING PROGRAMS Division to maintain an accurate of a button—to send information
For a little over fifteen years, the city listing of restaurants. By working from ArcGIS directly to the Linko
has used Linko, a software program with the permitting agency, SPU was database. Previously, this information
that tracks data from FSEs, as well able to set up regularly scheduled, would have been entered manually
as ArcGIS that maps sewer lines, automated reports containing the and updated annually based on a list
connections, and identifies hotspots. business information about active of several hundred new facilities.
The problem was these two systems restaurants, new permits issued, and Integrating the two major software
were not integrated, but if they were, recently closed permits enabling systems allowed certain data elements
the city could use its GIS system to them to keep their database of over to be shared between the systems.
identify which FSEs were discharging 5,000 restaurants up to date. Once the Now, the FOG software can seamlessly
to which service connections and permit data is received, it is married schedule initial inspections for new
then cross-reference that data with its with the results of SSO, maintenance facilities—and ensure new businesses
FOG data. data, and CCTV findings and are not missed.
16 | July 2021 | Modern Pumping Today www.mptmag.comWATER & WASTEWATER FOCUS
“By consolidating GIS and other The smart forms introduced with categories.” From there, Hockett
data into the FOG software, we can Remote Inspector allow inspectors would manually assign inspections
get a much more accurate picture of to enter findings into their mobile for each facility using data from the
the network, connections to FSEs, and device directly from the field. asset management software and its
the condition of actual sewers, which By creating standardized digital basic information.
really helps us pinpoint problem forms, the city can now quickly and Armed with the new smart forms
areas and reduce problems overall,” easily specify what data must be in Remote Inspector, the inspector
says Christiansen. collected and build a baseline for completes a questionnaire with
better analysis. information observed during
DIGITIZING DATA ENTRY the inspection. The form then
Now that the two programs were STREAMLINING RISK ASSESSMENT calculates the results, assigning
working well together, Christiansen The second instrumental form points to determine the facility’s
had a vision to further improve data or process to be digitized was a FOG discharge risk. The smart
accessibility and streamline processes facility’s FOG risk assessment, which form combines the FOG discharge
by taking the whole program online. is a ranking based on key factors. risk with the Hotspot category and
“Cloud native applications enable Angelique Hockett, a city FOG automatically assigns an overall FOG
our inspectors to access all of our inspector who established the Risk risk value. Based on the FOG risk
facility information from the office, in Priority Assessment ranking for the value, the software automatically sets
the field, and in the current COVID- FOG program, says, “If we had a a tailored inspection schedule for
19-work environment—from their sanitary sewer overflow (SSO) on the facility, allowing SPU to schedule
homes utilizing a laptop or tablet, a main line, that line was given a resources in sync with actual need
even their smartphones. We have unique number if SSO and CCTV out in the field. Meaning, FSEs that
already experienced the efficiencies crews had identified grease. I would require more touches are scheduled
of integrating previously-siloed data then join the lines in the GIS software as such, and those needing less
between the FOG and GIS systems. and a summation of the various touch are scheduled accordingly
The first step to taking the program criteria would dictate a hotspot as well. “Digitizing this process has
online was to optimize the digitization category per facility. There are thirty- improved accuracy and enables us
of processes. Next, we intend to move seven different ranking numbers, to take preventative action before
to online maintenance reporting,” organized to fit into six hotspot hotspots occur,” concludes Hockett.
adds Christiansen.
A natural extension for the city was to
add Linko Remote Inspector, a software
tool that digitizes inspection data
and standardizes the data gathered
during inspections. “Prior to this, we
had paper forms that didn’t have a
lot of direct questions and were very
text-based,” explains Christiansen.
“The inspector would write his or her
findings and what they thought was
relevant onto these paper-based forms,
with no specific direction to ensure
basic information was captured.” Often,
this led to many more questions by
the FSE and corrective actions would
require multiple follow-ups before the
action could be resolved.
In addition, when hotspots
occurred, there were no warnings
or indications because no data
was available for analysis. Instead,
as hotspots were identified, the
city would send out inspectors—a
reactive approach that meant no
preventative steps were being taken,
resulting in a backlog of inspections. Linko Remote Inspector allows inspectors to easily collect data electronically in the field.
www.mptmag.com Modern Pumping Today | July 2021| 17WATER & WASTEWATER FOCUS
MOVING ONLINE remains consistent, making it easier FOSTERING PARTNERSHIPS
With digitized processes in place, to use and access the entire suite WITH FSE
moving the city’s FOG program of FOG software from anywhere. Once an inspection has been
online has several advantages. Being “The uniformity that comes along completed, inspectors can easily
accessible through a browser, it with a cloud application makes it email a copy of the completed
can now be used on any connected a lot more efficient and gives us inspection form to the FSE. Previously,
mobile device or computer. The look, flexibility for the future as the city the recipient of the inspection report
feel, and function of the software grows,” says Christiansen. received a copy of the paper form
along with an inspector’s business
card. The form included handwritten
comments about what corrective
actions needed to be taken, which
weren’t always clearly stated and
required subsequent follow-up visits to
ensure action was taken. Now, a report
is emailed directly to the FSE with
specific corrective action information.
From a compliance perspective,
this helps ensure all parties clearly
understand the city’s expectations.
This has helped the city dramatically
improve relationships with FSEs. The
city can now receive an email with
pictures when something is cleaned
or corrected, meaning that staff don’t
need to go back to the establishment
to verify the problem is fixed.
“Since deploying the FOG
management software we have been
able to increase the number of our
inspections by 316 percent over
four years. The new program has
improved work processes, like route
planning and reduced admin time
by bringing everything online, so
we are able to visit more sites which
is a good thing for Seattle’s sewer
system,” concludes Christiansen. ◆
Chris Weinandt is the Aquatic
Informatics product manager for
Linko and Tokay. Weinandt has been
with Aquatic Informatics for over
eighteen years where he has helped
build and deliver software solutions
for fats, oils, and grease; industrial
pre-treatment; liquid hauled waste;
and cross connection control and
backflow prevention. Weinandt focuses
on delivering software features and
functionality that drive efficiencies
and better informed and timely
decisions. For more information, visit
www.aquaticinformatics.com.
18 | July 2021 | Modern Pumping Today www.mptmag.comW E BI NA R S
LEARNING FOR TODAY’S PUMP
INDUSTRY, AT YOUR FINGERTIPS
Whether your work focuses on water and wastewater, chemical
processing, or original equipment manufacturing, you need to stay up
to date with the latest training. MPT’s hosted webinars bring industry
experts from leading companies to your computer and offer professional
certificates for completion.
FOR MORE INFORMATION:
J. Campbell (jay@mptmag.com)
visit our website mptmag.comMAINTENANCE & RELIABILITY
Scanning Accurate
Models of Harsh
Environments
New 3D reality capture technology proves
a cost-effective, reliable, and safe solution
By Dean Solberg and Steve Young, Exact Metrology
M
any industrial sites present inhospitable Geosystems and distributed by Exact Metrology, these
environments, where the health and safety of portable coordinate measuring machines are designed to
the employees and visitors are at risk due to measure large-scale objects. This laser scanner uses 3D
temperature, corrosive materials, moving machinery, and reality capture.
heavy objects. In addition, sites often have networks of Thanks to 3D reality capture, building information
pipes, tunnels, storage vessels and other structures that modeling (BIM) experts save time and money as BIM
need to be examined. 3D reality capture permits complete processes become more efficient, from the accuracy of
site visualization for safety training. Site visibility also construction documentation to design and build quality
greatly improves plant management efficiency. Accurate assurance. The latest laser scanning technological
measurements help designers create extensions without developments improve understanding and documentation
needing to visit the site and enhanced planning of of the build environment through the use of millimeter-
workflow avoids disruptions. accurate laser scanning and high-dynamic range (HDR)
3D reality capture is a process of scanning and imagery. By using 3D reality capture, previews of data
capturing any site, for example, factories, buildings, and imagery are viewable onsite directly from a tablet,
crashes, and crime scenes, in a 3D digital model, enabling scans to be checked and verified before going
combining measurements and imagery. The model can to the office.
be used for design and comparison purposes
in various situations, capturing ACCURATE AND RELIABLE
every detail with to-the-millimeter The RTC360 3D Reality capture
accuracy. This technology scanner is ideal for professionals
combines one-touch operation managing project complexities
with portability and speed to with accurate and reliable 3D
deliver high levels of accuracy, representations. This scanner
automation, and the ability to effectively combines a high-
create 3D environments in a matter performance 3D laser scanner with
of minutes. Leica Cyclone Field 360, a mobile
device app for edge computing
3D REALITY CAPTURE that automatically registers scans
UP CLOSE in real time and Leica Cyclone
Exact Metrology, a comprehensive Register 360, an office software that
metrology service provider and integrates the 3D model into the
an architectural scanning company, workflow. Additional features include
is proud to announce the immediate capturing scans, including enriching
availability of the Leica RTC360 3D HDR imagery in less than two minutes,
laser scanner. Manufactured by Leica automatically recording moves from
20 | July 2021 | Modern Pumping Today www.mptmag.comMAINTENANCE & RELIABILITY
station to station, and augmenting
data capture with information tags.
Using 3D technology is useful
when a crash or crime scene
requires quick analysis of the scene.
Scanning creates a 3D environment
that can be explored and analyzed,
as well as documents the entire
scene in detail. Furthermore, fast
scanning minimizes disruption
and delays and removes scene the device and software greatly
degradation, thus providing jurors reduce time spent in the field and
with credible evidence. Security maximize productivity. Exact Metrology is ISO9001,
and site validation at public events The scanner’s portable design AS9100 certified as well as FFL and
are likewise very important and and collapsible tripod fit into most ITAR registered. With facilities in
an accurate model of the area backpacks. Low noise data allows Cincinnati, Ohio; Moline, Illinois; and
Milwaukee, Wisconsin, plus affiliated
can highlight threats and risks not for better images, resulting in crisp,
offices throughout the country,
readily evident. high-quality scans that can be used in Exact Metrology is a comprehensive
a variety of applications. metrology services provider, offering
REAL-TIME MEASUREMENTS As part of the RTC360 solution, the customers 3D and CT scanning,
AND HIGH-QUALITY SCANS Cyclone Field 360 links the 3D data reverse engineering, quality inspection,
product development, and 2D
With a measuring rate up to acquisition in the field with the laser
drawings. The company also provides
two million points per second, scanner and data registration in the turnkey metrology solutions, including
automated targetless field office with Cyclone Register 360. equipment sales and lease/rental
registration (based on VIS The user can automatically capture, arrangements. For more information,
technology) and automated register and examine scan and visit www.exactmetrology.com
transfer of data from site to office, image data. ◆
www.mptmag.com Modern Pumping Today | July 2021| 21PUMP SOLUTIONS
Pump Industry
Prepares for
the Brain Drain
Retirees cause massive shortage in trades jobs, so
what’s the best solution?
By David Fasnacht, Sulzer Pump Services Inc.
A
s more baby boomers continue to retire in 2021, manufacturing facilities, power plants, pipelines, water
it is reported that 62 percent of companies are processing plants, and chemical plants have employees
struggling to fill critical, skilled technical trade with decades of experience retiring with their intimate
positions, such as millwrights, machinists, mechanics, knowledge of the equipment and processes.
welders, operators, pipefitters, and electricians. Thirty- These plants supply us with electricity, water, gas,
one million skilled technical trade positions will be and diesel for our vehicles and heat in our houses, just
vacant by the end of 2021, per the 2020 U.S. Labor to mention a few necessary living requirements. Jobs
Department Report. that supply our everyday needs cannot be outsourced.
Skilled tradespeople are key components to the In a perfect world, the trade's person retiring would
domestic workforce and are vital to the economy. The be paired with their replacement, for six months to
need for skilled technical trade labor training is only a year, to learn all the tricks of the trades that have
becoming more evident. Today's maintenance facilities been mastered by the senior employee over their
decades of employment.
Understanding the technical aspects of pump operation can improve
operator performance.
ENTRY-LEVEL TRAINING
Due to cost constraints, companies rarely invest in
training new employees prior to the retirement of
their predecessors. The need for skilled, entry-level
employees is becoming so great that employers are
starting to look at many ways to find qualified personnel.
Some companies are starting to work with the local
trade schools in their areas. These trade schools have
substantial access to manufacturing and processing
plants in their area to develop the specific training
required for manual maintenance operations and
automated operations at these facilities.
Companies may need to revisit company-specific
apprenticeship/mentorship programs to ensure they
have a qualified employee base. In the past, companies
had training programs available to interested, new talent.
One of the challenges industries are being faced with
is the shallow talent pool from which to draw a skilled
tradesperson. Companies may receive 400 applications
but only six of those applicants are qualified for the
skilled labor trade job available.
22 | July 2021 | Modern Pumping Today www.mptmag.comPUMP SOLUTIONS REAL-WORLD SKILLS Training programs can range from a thirty-minute online seminar to two- to five-year programs / mentorships. The goal of the two- to five-year programs / mentorships is to have a skilled technical tradesperson with the company's required specific skillsets. The reality is trade schools do not offer many classes for the manual processes and the real-life skills needed in these manufacturing facilities. Most of the chemical plants, maintenance facilities, and refineries have little use for automated machining of parts. The facilities may need to machine one or two parts, not thousands, thus making manual machining processes necessary. This creates a disconnect between Regular training sessions offer a great return on investment. outside/third-party training offered and the actual needs of the facilities. knowledge—retiring employees and utmost importance. The employers New employees need exposure training classes. must invest in the new employees' to and training for all aspects of From the viewpoint of a skilled internal training, so the company the processes and the equipment technical tradesperson, already can perform efficiently and safely in the shortest time possible, working in the industries mentioned, and maintain a healthy profit margin. which can be achieved by tribal the training type and timing is of the Internal training can also supply the www.mptmag.com Modern Pumping Today | July 2021| 23
PUMP SOLUTIONS
may not understand how running
a centrifugal pump incorrectly
increases the frequency of repairs,
which could otherwise be avoided;
in addition, maintenance personnel
may not understand why they are
repairing the equipment so often.
This lack of knowledge can cost the
employers excessive, unnecessary
downtime, loss of production and the
added maintenance costs, leading to
significant revenue losses.
The rate of return for a company
investing in their employees'
training is hard to gauge, but
training is extremely beneficial to
the maintenance of the facility while
keeping downtime and unnecessary
repair costs to a minimum. Every
training session, whether it is a
thirty-minute, online seminar or
a three-day, face to face seminar
Broadening the knowledge base of the younger generation helps to retain valuable information with hands-on training, can have
within the organization. an enormous rate of return for the
facility, thus decreasing costs and
employees with critical information FILLING THE KNOWLEDGE GAP increasing efficiency as well as safety.
and hands-on experience, thus Lack of training can work in two If a company were to send a
decreasing the learning curve and ways in a manufacturing plant. For tradesperson to attend one subject-
minimizing unnecessary mistakes. example, operations personnel specific class, once a year for five
years, pertaining directly to the
Investment in training is vital for the support of new employees and their development within the company. equipment supported, tremendous
benefits and cost savings will be
achieved in production and safety.
Ongoing training programs can
ensure staff are well qualified for
their positions.
BECOMING QUALIFIED
Take for example an employee
who is personally responsible
for the successful installation,
rebuilding and maintenance of
centrifugal pumps. The most benefit
would be obtained by attending
a centrifugal pump fundamentals
course, which supplies a solid
foundation of installation, operation
and maintenance of rotating
equipment. This also satisfies the
OSHA Codes of Federal Regulations
(CFR) 1910.399 requirement. OSHA
defines a "qualified person" as
"one who has received training in
and has demonstrated skills and
knowledge in the construction
and operation of electrical,
24 | July 2021 | Modern Pumping Today www.mptmag.comPUMP SOLUTIONS
equipment and installations and
the hazards involved."
When applied to pumps and systems, David Fasnacht is customer training manger for Sulzer Pump Services. Sulzer is a global leader
a qualified person can demonstrate in fluid engineering. The company specializes in pumping, agitation, mixing, separation, and
relevant skills and knowledge related application technologies for fluids of all types. Sulzer customers benefit from its commitment to
innovation, performance, and quality and from our responsive network of 180 world-class production
to the installation, operation and facilities and service centers across the globe. For more information, visit www.sulzer.com
maintenance of such equipment and
systems. In addition, the employee will
receive the safety training needed to
identify and avoid hazards, including
the proper identification and use of
personal protective equipment and
proper lockout/tagout procedures.
Instructor-led training teaches
the basics along with the safety
knowledge needed to meet OSHA's
"qualified person" definition.
The learning curve can be
exceptionally steep when people
begin their trades careers. Mistakes
are not acceptable. Companies
must invest in their employees if
they expect them to perform at the
elevated level needed to compete in
today's business world.
EMPLOYEE INVESTMENT
Training is often the first thing to be cut
in tough economic times, making for
enormous ramifications, considering
20 to 60 percent of the skilled trades
employees in most facilities have been
hired in the last five years.
Businesses must invest in the talent
that they currently employ and plan
on hiring. Employee investment will
provide years of successful operations
with a minimal amount of growing
pains, as the baby boomers retire.
The shortage of skilled trades
workers today is unprecedented.
Therefore, training is critical for the
future success of a facility. Employers
must supply the training necessary,
as the hiring pool is young and
inexperienced, which will give the
companies the best chance for a
smooth transition from the retiring
employees to the new hires.
There has never been a better
time to be an ambitious, well-trained,
skilled technical tradesperson.
Being proactive instead of reactive
with training is necessary for
both the employer and employee
in today's times. ◆
www.mptmag.com Modern Pumping Today | July 2021| 25MOTOR SOLUTIONS Taking It to the Edge Numerical simulation of the propagation of a gearbox crack By Lin Liu and Suri Ganeriwala, SpectraQuest Inc. 26 | July 2021 | Modern Pumping Today www.mptmag.com
MOTOR SOLUTIONS
I
n this article, fracture propagation is simulated using Gearbox
a finite element model for a gearbox that is designed
for a rotor dynamic test rig. The circumferential plates
of the gearbox are welded along the side as well as the
bottom edges. Micro-cracks are usually generated at
weld toes and the welding process will introduce residual
stresses. The effect of the locations of initial fracture on
fracture propagation path is studied.
INTRODUCTION
SpectraQuest Inc. specializes in design, development,
and fabrication of gearbox system for diagnostics and
prognostics researches. Upon request from a customer,
we have performed a numerical simulation of crack
propagation in a gearbox. The gearbox is installed in the Figure 1: Gearbox in gearbox dynamic simulator.
Gearbox Dynamic Simulator, which is illustrated in figure 1.
The gearbox is made of six aluminum plate. Each one of Because of the small thickness of the plate, it can be
the four circumferential plates is welded with one another. considered as a plane stress problem and two-dimensional
Furthermore, the circumferential plates are welded to the finite element model is created using FRANC2D software.
bottom plate. The top plate is bolted to the circumferential The finite element model is displayed in figure 3. There
plates. A closer look of the gearbox is displayed in figure 2. are total of 800 Q8 quadrilateral elements. The bottom edge
is constrained both in the x and y directions. The assumed
GEARBOX MODEL load is a node load applied at the uppermost node in the
The end plate of the gearbox facing the direction of the hole in the y direction with amplitude of 200 pounds.
rotor “B” assembly is modeled in the work. The geometry An edge fracture is introduced on the left side of the plate
of the plate is a 14 by 14 inches square with a 3-inch radius with different initial locations. The three fracture initial locations
hole in the center. The thickness of the plate is 0.5 inches. studied in the work are displayed in figure 3. The lengths
www.mptmag.com Modern Pumping Today | July 2021| 27MOTOR SOLUTIONS
X Location along bottom edge(in.)
(a)σxx
Figure 2: Gearbox. (a) tensile stress
Third location
Second location
X Location along bottom edge(in.)
First location (b)σ yy
(b) compression stress
Figure 4: Stress distribution in whole plate
without fracture.
Figure 3: Finite element model of plate.
of three initial fractures are all 0.21
inches. And the initial crack direction is
horizontal for all the three cases.
For each fracture studied, automatic
fracture propagation is performed. The
crack increment length is 0.2 inches,
and fifteen steps are simulated.
X Location along bottom edge(in.)
SIMULATION RESULTS (c)σxy
The tensile and compression stress Figure 5: Stress distribution along the bottom edge.
bar distributions for a plate without
Figure 6: Remeshed area along the crack.
fracture are displayed in figure 4. The deformed mesh for the first
The three sigma distributions crack case is displayed in figure 7.
along the bottom edge are displayed The deformation is amplified to make
in figure 5. It can be noticed that the it distinguishable.
vertical external load will introduce The crack propagation paths for
normal stress in the horizontal the three crack cases are displayed in
direction as well as shear stress figure 8. The first crack, which has the
beside the normal stress in the lowest vertical initial location among
vertical direction. the three cases, will propagate in an
The software has the capability to upward direction. The third crack,
remesh the cracked area every time which has the highest vertical initial
the fracture is propagated. The mesh location among the three cases, will
scheme after the first crack simulation propagate in a downward direction.
is finished is displayed in figure 6. Note However, the second crack, which
the refined mesh along the crack. is initiated at a position between the Figure 7: Deformed mesh for first crack.
28 | July 2021 | Modern Pumping Today www.mptmag.comMOTOR SOLUTIONS
CONCLUSIONS
Under the simulation conditions for
this work, the results indicate an edge
crack initiated close to the bottom of
the plate has lower stress intensity
factor than those initiated at a higher
position along the plate side edge. An
edge crack along the gearbox plate
needs to be monitored carefully. ◆
(a) First crack (b) Second crack (c) Third crack
Figure 6: Remeshed area along the crack.
SpectraQuest, Inc. is a leading developer
and manufacturer of complete turn-
key systems for training and diagnosis
in machine vibration analysis, rotor
balancing, and shaft/coupling alignment.
System includes machinery fault
Crack Length (in.) Crack Length (in.) Crack Length (in.) simulators, interactive training program,
(a) First crack (b) Second crack (c) Third crack data acquisition hardware/software, and
Figure 6: Remeshed area along the crack.
accessories. To accelerate the learning
and design process SpectraQuest offers
a series of interactive software CDs on
first and third cracks, will develop figure 9. Figure 9 indicates vibration fundamentals and calculations,
in a horizontal direction. second and third cracks signal processing, alignment, and
The Mode I stress intensity have larger stress intensity balancing. For more information, visit
www.spectraquest.com.
factor history for the three factors which suggest faster
crack cases is displayed in fracture propagation.
www.mptmag.com Modern Pumping Today | July 2021| 29SEALING SOLUTIONS
Proactive
Design with
Hydraulic
Modeling
When technology takes
root in the industry,
everyone benefits
By Walt Prentice, Applied Flow Technology
30 | July 2021 | Modern Pumping Today www.mptmag.comSEALING SOLUTIONS
N
o longer is over-engineering, or designing from pressure surges from vapor pocket collapse. Traditional
heuristics, as necessary as it once was. Why? analyses do not predict this and can leave the engineer
Because engineers can build and test systems with incorrect expectations.
in a computer rather than in the field. Flow analysis The other problem with traditional approaches is
software has improved multiple facets of hydraulic waste. If systems are designed with unrealistically bad
system engineering. As technology improves, knowledge expectations, more money and resources are spent than
expands, and communication systems tighten, engineering necessary. This leads to higher costs, lower efficiency, and
teams can better prepare for more complicated systems. Engineers
unexpected events, design for the should always design for the simplicist,
most efficient systems, and leave most effective solution, which is best
clearer footprints behind for future determined through modeling.
engineers to follow. DO THE MATH
The math involved EFFICIENCY AND COSTS
UNEXPECTED EVENTS to analyze these Current design is driven by the best
Things rarely go exactly as planned: in and most cost-effective solution, not
pumping systems and in life. At some situations is only one that gets the job done. Fluid
point, an emergency shutdown or beyond what the modeling has improved both pump
power failure will impact the system. average engineer and system efficiency. For example,
In the past, the safe approach was to engineers can digitally build their
over-engineer the system to mitigate cares to work out. system to determine what head rises
any perceived worst-case scenarios. This can lead to are required for various flow rates
However, the introduction of modeling many simplifying and conditions. Then they can look at
software allows widespread testing capital and operating costs to see what
of these scenarios to predict system assumptions, pump configuration is best suited.
responses without having to test in the causing the analysis One example of efficient software
field, or worse, to find out during the to deviate further design was a refinery cooling loop
event itself. Yet, over-engineering is redesign. It had four pumps in parallel
still common today. While better tools and further from as standard operation. One of them
exist, it takes time for them to take reality. If only vibrated violently and eventually
root and become standardized. Two engineers knew how failed. After years of operational
main reasons software modeling is changes, no one had hydraulic models
advantageous are: accessible modeling to see the effects until consultants
accurate worst-case were called to help. Modeling
(1) The assumed worst-case scenarios was. software revealed the problematic
scenarios often do not account for pump ran far outside its preferred
everything. operating region and that two pumps
in parallel were more cost effective
(2) Over-engineering leads to than four. Not only were operating
waste. costs reduced, but the remaining pumps would be running
at their best efficiency point (BEP), as shown in figure 2.
A common worst-case scenario is a waterhammer event This is not initially obvious because spreading the load
and the resulting pressure surge. The failure of traditional across four pumps sounds less stressful than loading
methods for predicting waterhammer repercussions come two. However, pumps are built to operate in certain
from a lack of understanding the methods’ limitations. regions, and factors like these must be considered during
Engineers must identify the maximum pressure that could design. Without software, these efficiency sweet spots
arise in a piping system to ensure safety and meet code. in complicated systems are much harder to identify. The
Typically, that involves a few extreme assumptions, such as study both extended pump life and saved $200,000 a year
an instantaneous valve closure, and applying pressure-rise simply by modeling the system.
calculations. Yet there are three common situations that Similar thinking can be applied to pipe sizing, as
escape the engineer’s view: line pack, wave reflections, there are both capital and operating costs to consider.
and liquid column separation. Smaller pipes generally cost less, but they cause more
Figure 1 demonstrates how liquid column separation frictional losses. This means the pump needs to supply
causes pressure spikes downstream of a fast valve closure. more pressure than it would in larger pipes to drive
The initial pressure rise occurs on the upstream side from the same flow. Hypothetically, though a pump may be
sudden flow stoppage, but the downstream side sees sized “properly” according to the system proposal, that
low pressure, causing vapor formation, leading to other system may have been sized inappropriately, resulting
www.mptmag.com Modern Pumping Today | July 2021| 31You can also read
