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THE CRISIS

FACING

FRESHWATER

RESOURCES

SCREENING

SYSTEM STOPS

CLOGS

EXTEND

YOUR PUMP'S

OPERATING LIFE

FEBRUARY 2015PROVIDING SOLUTIONS FOR THE WORLDWIDE PUMP INDUSTRY

MODERNMODERN

TODAYTODAY®

ELIMINATING A WASTEWATER PLANT’S

PIPE FAILURES

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CONTENTS FEBRUARY 2015

4 INDUSTRY NEWS

10 TRADE SHOW PROFILE

C ASE STUDIES 12 Remotely Managing Pumps on the Farm

W ATER & W ASTEWATER SOLUTIONS 16 The Pursuit of a Green Carbon Steel Corrosion Inhibitor Part 2 in a 4-part series

22 How to Select the Most Effective Blower Technologyfor Wastewater ApplicationsPart 2 in a 2-part series

M AINTENANCE SOLUTIONS 26 Eliminating Pipe Failures from Pneumatic Conveying Line

The Smart Elbow® stops lime spills and prevents dust cloud exposure for wastewater treatment plant

PUMP SOLUTIONS 30 Small and Simple Watson-Marlow's 120 peristaltic pump answers customers' needs

32 So Fresh, So CleanHidrostal's pump cleans carrots for consumption

DEWATERING SOLUTIONS 34 Screening System Eliminates Clogging from Membrane Bioreactor Retrofit cuts upgrade costs by one million dollars

MOTOR SOLUTIONS 36 New Bearing Designs Meet Demands for Extended Pump

Operating Life

POWER GENERATION SOLUTIONS 38 The Wind Is Blowing East In South Korea and China, Alstom is providing power generation solutions

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8 | FEBRUARY 2015 www.modernpumpingtoday.com

of QuantumFlo’s products to the Daytona InternationalSpeedway. “Water requirements for large-scale events, likethe Daytona 500, demand tremendous power and reliability.QuantumFlo goes beyond that demand with greater energyefficiency and performance through our intelligent softwareand design.”

QuantumFlo has applied its cutting-edge pump technology

on past NASCAR facility projects with great success. Becauseof their superior technology and experience on these pastprojects, NASCAR, the general contractor, Barton Malow,and the plumbing contractor, Nash Plumbing Inc., selectedQuantumFlo to contribute to this great improvement to theDaytona International Speedway.

NASCAR recognized QuantumFlo’s drive for innovationand their successful pursuits towards being the worldwideleader in variable speed pumping technology. The DaytonaInternational Speedway will now benefit from QuantumFlo’stop-quality pre-packaged pump systems equipped withadvanced software to minimize the facility’s energy and waterconsumption.

As a sponsor for a dragster racecar, QuantumFlo is no

stranger to the racing world and is proud to be able to makesuch a great benefit and contribution to both their VolusiaCounty community and to what makes Daytona InternationalSpeedway a world-class facility. Recognized as an industryand business leader, QuantumFlo provides pre-packagedpump systems for plumbing, HVAC, turf and irrigation andmore both locally, as a 2014 Florida Companies to Watchaward winner, and globally, as the VMA, Inc 2014 Exporter ofthe Year.

ASHRAE, IAQA APPROVE CONSOLIDATIONA consolidation between ASHRAE and the IndoorAir Quality Association has been finalized by bothorganizations. The consolidation was approved by theBoards of Directors for ASHRAE and IAQA at ASHRAE’srecent 2015 Winter Conference in Chicago.

“We are excited about the opportunities presented by

this consolidation,” ASHRAE President Tom Phoenix says.“It opens the door to alignment of ASHRAE and IAQAprograms to create high-impact resources for buildingprofessionals around the globe.”

“This is an historic event for both associations andhas great promise for growth and development for bothorganizations,” IAQA President Kent Rawhouser says.“The opportunities and possibilities for members are onlylimited by our own imaginations. IAQA and ASHRAE arecommitted to growing and developing the IAQA brand.The consolidation will open new avenues for programsand benefits for our members.”

In July, ASHRAE announced it had agreed in principleto join forces with the IAQA, combining resources to

improve indoor air quality in the built environment.Since August, the two groups have been undergoing aperiod of due diligence. That diligence was completedearlier in January.

Under the consolidation, IAQA will become a partof the ASHRAE organization while maintaining itsown brand and Board of Directors. IAQA will operateindependently within ASHRAE’s organizationalstructure. ■

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Attended by over 4000 septic, sewer, anddrain businesses each year, the Water andWastewater Equipment Treatment and

Transport (WWETT) Show—formerly the Pumperand Cleaner Environmental Expo International—consists of the latest products and technologiesin the environmental service industry as well asproviding educational seminars taught by highlyskilled professionals.

VARIETY OF EXHIBITORS

For thirty-five years WWETT exhibitors have beenshowcasing the newest and brightest technology in

the wastewater industry. The WWETT Show flooris an ever-evolving marketplace where industryprofessionals can secure the equipment andknowledge they need to grow their businesses andin turn create a better world in the environmentalservice industry.

Attendees have access to over500 exhibits, spanning morethan 500,000 square feet of theconvention center, displayingeverything from septic systemcomponents and trailers to portablesanitation units and industrial sewerequipment. The WWETT Show hasgrown significantlyover the last severalyears, attractingsome 12,000environmentalserviceprofessionalsfrom forty-fivecountries to discussonsite installation,portable sanitation,sewer cleaning,utility location, and

much more.Exhibitor and

show sponsor, Southland Tool is a featured brandon the official WWETT pickup truck, which will begiven away as a Grand Prize during the convention.

EDUCATION SESSIONS

The WWETT Show places a premium on continuingeducation, with opportunities for professionals toearn CEUs in a variety of tracks. Available tracksfor the 2015 show include the National OnsiteWastewater Recycling Association (NOWRA),National Association of Wastewater Technicians(NAWT), Water Jet Technology Association andIndustrial Municipal Cleaning Association (WJTA-

IMCA), Southern Section Collection SystemsCommittee (SSCSC), National Association ofSewer Service Companies (NASSCO), NationalEnvironmental Health Association (NEHA), andmany more.

WORLD HEALTH

ORGANIZATION TALK

Given the recent news of a WestAfrican Ebola virus outbreak,wastewater industry professionalsare rightly concerned over thepossibility of other communicablediseases to spread through the

pumping,transport andhandling ofseptage andsludges containinghuman waste.WWETT attendeeswill hear the latestinformation onthis issue fromDr. AdrianusVlugman,World Health

Organizationsenior adviser

on water, sanitation and environmental health,who will provide a general overview covering thesurvival and life expectancy of communicablediseases in water and wastewater.

Dr. Vlugman will also address safety precautionsto consider when handling water and wastewaterin developing nations, the likelihood ofcommunicable diseases to be spread or passedthrough both centralized wastewater plants anddecentralized onsite wastewater systems, andwhether there is a concern for the spread ofcommunicable diseases through land applicationof properly treated sewage, biosolids or septage. ■

WWETT SHOW 2015New Name, Same Opportunity


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Cade Qualls has been farming in LakeCity, Arkansas, for nearly sixteenyears. He’s a third generation farmer

who produces grain, cotton, corn andsoybeans on his farm of 4000 acres. Withcrops that cover about 30 to 40 miles (48.3to 64.4 kilometers) of land, Qualls does asubstantial amount of watering. The process

can take place for up to twelve hours a day,sometimes more, depending on the time ofyear and environmental conditions. Rightnow Qualls has several irrigation pumpsand center pivots on his property andeach of them are used quite heavily in thisprominent farming community.

THE PROBLEM

During watering season, irrigation happensseveral days in a row. This has alwaysmeant that Qualls must be present at thefarm at nearly all times to ensure thatnothing goes wrong (such as power loss orequipment malfunction) with the pumps orthe pivots. If something happens while he isaway from the farm, it can lead to hundredsof gallons of wasted water, crops beingover-watered, or crops not being watered atall if a piece of equipment malfunctions. It’sa risk he can’t take, so as a result, Quallswould spend much of his time drivingacross his 30 to 40 miles (48.3 to 64.4kilometers) of land, checking on the pumpsand pivots throughout each day of watering.

While this is how the Qualls family hasrun their farm for decades—checking on

pumps and pivots throughout growingseason—Qualls hoped to find a moreconvenient way to manage the equipment.

THE SOLUTION

One day in late spring of 2014, Qualls wasat his local John Deere dealership when

Eddie DeSalle is the CEO and founder of Net Irrigate, a manufacturer of wireless irrigation monitoring technology for the agricultureindustry. The company’s hardware and software solutions are designed to notify irrigators of costly events, and its product s includeWireRat®, PivotProxy® and PumpProxy®. DeSalle is an alumnus of the Kelley School of Business at Indiana University where he

received his MBA with a focus in new product marketing and management. For more info, visit www.netirrigate.com .

About The Author

By Eddie DeSalle, Net Irrigate

REMOTELY MANAGING

PUMPS ON THE FARM

PumpProxy’s remote start and stop function will control the pump with a phone call or with the mobile app.

Qualls Farms produces grain, cotton, corn and soybeans on 4000 acres.

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FEBRUARY 2015 | 13www.modernpumpingtoday.com

his dealer introduced him to the NetIrrigate PumpProxy and PivotProxy.These products allow irrigators tomanage pumps and pivots from theconvenience of their phone, through amobile app.

Net Irrigate estimates the use of

PumpProxy has the potential toconserve approximately 5 percent ofgravity flow irrigation water per year,or about 800 billion gallons (overthree trillion liters) of water per yearin the United States, as well as reducetotal energy pumping expenditures by$96 million annually and automotivefuel expenditures for field travel by$22 million.

PumpProxyPumpProxy allows irrigators toremotely monitor, start and shut down

irrigation pumps. When used withcenter pivots, it eliminates the needfor kill wires to associated irrigationwells. Functionality includes a virtualtimer to set the pump to turn off ata given time online or through themobile app. Its remote start and stopfunction will control the pump witha phone call or with the mobile app.Also, the thermal overload/ powerfailure notifications can alert up toten recipients of thermal overload orother power failure via call, text, oremail, and its safety stop alerts providenotifications when your pump starts orstops.

PivotProxyPivotProxy provides comprehensivepivot monitoring and security. ThePivotProxy works seamlessly with allbrands of pivots. When a pivot stops,the safety stop alerts function sendstext, voice or email notifications,and the remote shut down functioncan stop the pivot with a phone call,online, or through the mobile app.

GPS allows operators to check theheading of the pivot via web or phone,and the virtual stop-in-slot can setmultiple check points and automaticstops.

WireRatIn addition, both the PumpProxy andPivotProxy were outfitted with NetIrrigate’s WireRat technology, whichoffers farmers the ability to betterprotect the valuable copper wire ontheir pivot and pump irrigation systemsby immediately sending alerts viaphone, email or text when a copper

wire is cut. The technology has led tomore than 60 thieves being arrested,and more than 200 being caught in theact and scared away.

While Qualls has never had anattempted copper wire theft on hisfarms, he knows other farmers who

have. He says he was happy to havethe copper wire theft protection, but

was most attracted to the ability toturn his pumps and pivots on and offremotely.

“What I liked about these productsis that I can be anywhere and usethem,” says Qualls. “I didn’t have toget up in the middle of the night, or

miss out on weekends with family inorder to stay back at the farm. I just

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have to pull outmy iPhone andcontrol them fromanywhere—thelake, St. Louis, itdoesn’t matter.”

Since purchasing

one PumpProxyand one PivotProxy,Qualls has beenaccessing themobile apps 3-4times a day duringwatering season.One instance inwhich this has beenespecially helpfulis when the powergoes out in thearea. It happeneda few times in the

summer of 2014.Whether the powergoes out entirely,or just flickers,doesn’t matter—thepivots and pumps will turn off andwon’t automatically re-start when thepower comes back on. In the past,Qualls had to go out and check all

the pivots that were in use when thishappens and re-start them manually.This was especially inconvenientbecause sometimes outages would

only affect certain areas in his acreage,but he wouldn’t know which pump orpivots had turned off. Qualls wouldwaste valuable watering time driving,

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Building on last month’s installment in this series,this article will detail the simulated cooling towerwater experiment’s test procedure for both a scaling

and corrosive environment. Also, we will provide visualreference and figures illustrating general corrosion rates.Later installments will build on these observations todetermine acceptable green corrosion inhibitors for usein open system cooling waters by examining the ef fect of

oxidizing biocide on their performance and, f inally, to selectthe most appropriate and costeffective product for use as agreen corrosion inhibitor.

EXPERIMENTALPROCEDUREThe test apparatus consistedof a circulation loop withthe return water line aeratedbefore entering the sump. Thisprovided the necessary oxygento simulate cooling towerwater. The flow rate was 7.0gallon (26.5 liter) per minute in1 inch (25.4 millimeter) clearPVC piping for ease of visualinspection. This corresponds toa linear velocity of 3.2 feet (1meter) per second. This is in therange of accepted flow rates for corrosion coupon racks (seereference 12). The temperature for each run was maintainedat 95 degrees Fahrenheit (35 degrees Celsius); the heat wasprovided by the main circulation pump and booster pump.Synthetic water was used to simulate both a scaling andcorrosive environment. The synthetic water quality is shownin Table 2. Scale was controlled during each run by the

addition of active 1-hydroxyethane-1,1-diphosphonic acid(HEDP) and a phosphate/iron dispersant copolymer (AA/ AMPS). The active amounts of scale inhibitors are shown inTable 2. The equilibrium pH for each run was 8.7 to 8.9. Thiswas the natural result of the amount of synthetic bicarbonatealkalinity added, the temperature, aeration, and test runduration.

New carbon steel coupons and corrator tips were used foreach run. All coupons and tips were not passivated prior toan experimental run. Each test consisted of a five day run atwhich time pictures were taken of the carbon steel couponand corrator data was graphed. A copper coupon was alsoinstalled in the loop for each run to provide a source ofpotential free copper to more closely simulate a mixedmetallurgy cooling water system. Tolyltriazole was added to

the system to minimize corrosion of the copper coupon. Thiswas done to further mimic fieldconditions. No other metallurgywas present in the system;all fittings were schedule 80PVC. The system was cleanedbetween runs with citric acidand rinsed thoroughly. Therating of an inhibitor wasdetermined by the appearanceof the coupon, the corratorgraphs, the green status, andthe use cost.

RESULTS AND DISCUSSIONCoupon AnalysisDue to the shortened five dayexposure time of each trial,coupon analysis was limitedto qualitative observations.

The results, shown in Table 3, provide a visual comparisonbetween corrosion inhibitors. Under the test conditionsoutlined in the experimental procedure, the carbon steelinorganic inhibitor performance can be ranked as follows:

Sn ≈ PO4/Zn >> PO4/TKPP > MoO4.

The relatively poor performance of the molybdateand phosphate/polyphosphate could be attributed to anineffective low dosage. It is also possible that the inhibitordid not provide both anodic and cathodic protection underthe test conditions. The molybdate coupon appeared worsethan the control coupon that had no adjunct corrosioninhibitor added beyond what may have been provided by

Matthew LaBrosse, PhD, is an engineer in research and development at U.S. Water Services, Inc. in St. Michael, Minnesota, andcan be reached at [email protected]. Donovan Erickson is a certified water technologist for U.S. Water Services,Inc. The authors wish to thank the Association of Water Technologies for allowing this series to be presented and to U.S. Water

Services for the resources necessary to conduct the research. For more information, visit www.uswaterservices.com .

About The Authors

By Matthew LaBrosse and Donovan Erickson, U.S. Water Services, Inc.

The Pursuit of a Green

Carbon Steel Corrosion Inhibitor

Part 2 of 4

Item Concentration Unit (ppm)

Ca 543 CaCO3

Mg 140 CaCO3

HCO3 328 CaCO3

Cl 114 Cl

SO4 505 SO4

HEDP 3 Active

Copolymer 8 Active

Tolyltriazole 3 Active

Table 2: Synthetic water quality used in all trials.

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the HEDP and copolymer shown in Table 2. The tolyltriazolepresent in each trial may have also provided some minor

protection for carbon steel either by limiting free copper inthe system or as a complimentary carbon steel corrosioninhibitor.

Table 4 shows corrosion coupons for the organic carbonsteel corrosion inhibitors. The qualitative performance underthe conditions tested can be ranked as follows:

HPA > PCA >> AAP ≈ PAP > Coffee.

The HPA provides excellent carbon steel corrosionprotection under the conditions tested. There is no evidenceof general corrosion or pitting on the corrosion coupon.The PCA run also provided excellent corrosion inhibitionof carbon steel. Another inhibitor tested was asparticacid polymer. AAP is not typically touted as carbon steelcorrosion inhibitor, but is known for its scale inhibitionproperties. AAP provided some carbon steel protection inthe testing. The dosage for this inhibitor was intentionally

Treatment Dosage

(ppm) Carbon Steel Coupons

Control –

PAP 15.0

HPA 15.0

AAP 30.0

PCA 15.0

Coffee 50.0

Treatment Dosage

(ppm) Carbon Steel Coupons

Control –

Mo 15.0

PO4/TKPP 3.0/1.0

PO4/ZN 5.0/1.0

Sn 3.0

Table 3: Inorganic inhibitor corrosion coupon results.

Table 4: Organic inhibitor corrosion coupon results.

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tested at twice the manufacturer recommended rate due tothe lack of documentation of using AAP as a carbon steelcorrosion inhibitor. Further testing is needed to observeAAP performance at recommended dosage. The carbonsteel corrosion coupon from the coffee extract trial showsa significant amount of surface corrosion. This inhibitor hasthe poorest qualitative results of the organic inhibitors.

The appearance of the corrosion on the coupon run usingPAP was different than the appearance of the coupon testedwith AAP. The PAP coupon appeared to have more of pittingtype corrosion, although it was not severe. PAP results arediscussed more in depth with the evaluation of the corratorresults.

If the inorganic and organic inhibitor results arecombined, the carbon steel inhibitor performance under theconditions tested based on corrosion coupon analysis was:

HPA > PCA > Sn ≈ PO4/Zn > AAP ≈ PAP > Coffee

> PO4/TKPP > MoO4.

Corrator Analysis

This type of corrosion analysis yields graphical resultsthat provided a quantitative representation for the full fiveday test run. The two-channel corrator output providedcontinuous results on general corrosion and the pittingpotential, which is called the imbalance.12 As with thecoupons, the molybdate and phosphate/polyphosphateinhibitors provided the least mild steel corrosion protectionunder the conditions of the test and the inhibitor dosagesused, as can be seen in Figure 1. Tin exhibited similar

corrosion results to the phosphate/zinc inhibitor. They bothstarted with low carbon steel corrosion rates around 1.0mpy, but the corrosion rates gradually increased over thefive day trial.

Figure 2 shows the corrosion imbalance for theinorganic carbon steel corrosion inhibitors. The phosphate/ polyphosphate saw a large increase in the pitting corrosionduring the end of the test run. This trend was also observed

0 24 48 72 96 120 144

15

10

5

0

Exposure Time (hrs)

C o r r o s i o n R a t e

( m p y )

Control Mo PO4 /Zn Sn PO4 /TKPP

Figure 1: Inorganic inhibitor corrosion rate.

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for phosphate/polyphosphate in Figure 1, indicating a pooroverall performance. The molybdate imbalance was highduring the initial part of the run but decreased toward theend, indicating high pitting potential for the first twenty-four hours. The general corrosion was relatively high forthe duration of the run. This is consistent with the severegeneral corrosion observed on the corrosion couponsurface. Both the tin and phosphate/zinc trials produced

similar corrosion and imbalance results, but the phosphate/ zinc appeared to provide less pitting potential.

Figure 3 shows the general corrosion rate for the organiccarbon steel corrosion inhibitors. AAP provided corrosionprotection for carbon steel as compared to the control, butthe corrosion rate steadily increased over the five day trial.PAP exhibited excellent general corrosion protection withthe rate staying at or below 2.0 mpy for the duration of the

15

10

5

0

0 24 48 72 96 120 144

Exposure Time (hrs)

C o r r o s i o n R a t e

( m p y )

Control PAP HPA AAP PCA Coffee

20

15

10

5

0

0 24 48 72 96 120 144

Exposure Time (hrs)

C o r r o s i o n I m b a l a n c e ( m p y )

Control Mo PO4 /Zn Sn PO4 /TKPP

Figure 2: Inorganic inhibitor imbalance rate. Figure 3: Organic inhibitor corrosion rate.

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trial. The HPA shows superior general corrosion inhibitionas compared to all other inhibitors.

Figure 4 shows the imbalance for the organic corrosioninhibitors. There is some pitting potential observed for theAAP. As was the case with the general corrosion graph,the HPA exhibits superior pitting inhibition over all theinhibitors tested. The PAP corrator results provided an

interesting and definite contrast between the generalcorrosion and imbalance rates. The PAP general corrosionin Figure 3 was good, second only to the HPA, but thepitting potential in Figure 4 appeared to be the worst ofall the inhibitors tested. The imbalance output steadilyincreased until it exceeded the maximum measuringlimit of 20 mpy. This is consistent with the PAP carbonsteel corrosion coupon, which shows evidence of severalpitting corrosion sites on the surface. Additional testing isrequired to determine the repeatability of that observation.PAP may also require a co-inhibitor to provide betteroverall anodic and cathodic protection for carbon steel.The combined results of the inorganic and organicinhibitors tested under the conditions tested based on

corrator analysis are listed below. The PAP was not rankedin the corrator performance due to the unexplainedimbalance results and pending further testing.

HPA > PCA > PO4/Zn ≈ Sn > AAP > PO4/

TKPP > MoO4 >> Coffee.

Based on the Green Chemistry criteria defined in thisresearch, aspartic acid polymer and coffee extract rankedthe most green, as can be seen in Table 1 and Table 3.They are followed by tin, phosphonocarboxylic acid,hydroxyphosphonic acid, and polyaminophosphonate.Finally, orthophosphates, polyphosphates, molybdate, and

zinc were considered the least green. If phosphate-freestatus is mandatory then polyaspartic acid and tin wouldbe the green inhibitors of choice.

CONCLUSIONS

All inhibitors tested provided some level of carbon steelcorrosion protection. Under the experimental conditions,HPA was the best carbon steel inhibitor tested as shownby both the qualitative coupon results and quantitativecorrator analysis. The corrator results compare nicely withthe coupon results based on the ranking for each corrosionanalysis method. Comparison of the normalized use

0 24 48 72 96 120 144

Exposure Time (hrs)

C o r r o s i o n I m b a l a n

c e ( m p y )

20

15

10

5

0

Control PAP HPA AAP PCA Coffee

Figure 4: Organic inhibitor imbalance rate.

Inhibitor Control Unit Typical Dosage (ppm) Normalized UseCost Green Status

Molybdate Mo 10 100 Fair

Zinc Zn 2 4 Fair

Tin Sn 2 24 Good

Orthophosphate PO4 5 14 Good

Polyphosphate TKPP 3 4 Good

Polyaminophosphate PAP 15 30 Good

Hydroxyphosphate Acid HPA 15 33 Good

Phosphonocarboxylic Acid PCM 15 50 Good

Aspartic Acid Polymer AAP 15 23 Excellent

Coffee Extract Product - - Excellent

Phosphate/Zinc PO4 / Zn 5 / 2 17 Fair

Phosphate/Polyphosphate PO4 / TKPP 5 / 3 18 Good

Table 5: Comparison of corrosion inhibitor green status (from Table 1) to its use cost. The use cost has been normalized to an arbitrary value of 100.

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cost of the inhibitors clearly showsthat molybdate is not an effectiveinhibitor for mild steel at reasonablecost when used alone in a coolingtower. The inhibitors consideredmost green and phosphate-free areaspartic acid polymer and tin. Their

use cost is approximately 30 percenthigher than a normal phosphate/ zinc program. This makes them apotentially acceptable choice inthe pursuit of a green carbon steelcorrosion inhibitor. Further testingis required including field testingto expand the scope of corrosioninhibitors investigated and verifypilot results in field trials. Furthertesting is also necessary to examinethe effect of oxidation on thecorrosion inhibitors and explorepotential synergistic effects of

combining carbon steel corrosioninhibitors. ■

REFERENCES

1. Report on Carcinogens, TwelfthEdition, National Toxicology Program,Department of Health and HumanServices, 2011. Web. May 17, 2012.

2. Qishlaqi and F. Moore, “Statistica l Analysis of Accumulation and Sources ofHeavy Metals Occurrence in AgriculturalSoils of Khoshk River Banks, Shiraz,Iran,” American-Eurasian J. Agriculture

and Environmental Science, 2, 565-573(2007).

3. J.T. Huber, N.O. Price, and R.W. Engel,“Response of Lactating Dairy Cows toHigh Levels of Dietary Molybdenum,”

Journal of Animal Science, 32, (1971).

4. B. Oram, Water Research Center, B. F.Environmental Consultants Inc., 2012.Web. May 17, 2012. “Phosphates in theEnvironment.”

5. Association of Water TechnologiesTechnical Reference and TrainingManual, 2nd edition, chapter 5.10,(2009).

6. P. Puckorius et al., “Phosphonates-PartII-Corrosion Control- Cooling Water,”

A Practical Guide to Water TreatmentChemicals Newsletter, Volume 2, Issue 1,1st quarter (1998).

7. P. Howe, M. Wood, and P. Watts,“Tin and Inorganic Tin Compounds,”Concise International Chemical

Assessment Document, 65, World HealthOrganization Geneva, (2005).

8. J. Fawell and R. Mascarenhas , “InorganicTin in Drinking-water,” Backgrounddocument for development of WHOGuidelines for Drinking-water Quality,World Health Organization, (2004).

9. W.E. Stapp and G. Westlund, “CorrosionInhibition Compositions and Methods forUsing the Same,” U.S. Patent 7,910,024,issued March 22, 2011.

10. V.V. Torres et al., “Inhibitory Act ion of Aqueous Coffee Ground Extracts onthe Corrosion of Carbon Steel in HClSolution,” Corrosion Science, 53, 2385-

2392 (2011).

11. B.P. Boffardi, “Corrosion and FoulingMonitoring of Water Systems,” The

Analyst Technology Supplement, spring(2010).

12. Rohrback Cosasco Systems, Inc., “Model9020 &9020-OEM Corrater TransmitterUser Manual,” November (2004).

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In the first part of this series, weexamined turbo, hybrid, andcombination blower technologies

and addressed the most effectivetechnology for particular applications.

In this article, we will take a closerlook at case studies il lustrating thesethree technologies and the results thatcan be achieved by implementingthem in wastewater treatment plants.After seeing the results in action, mostwastewater professionals feel moreconfident in making their next blowerselection the right one to fit theirneeds.

WASTEWATER TREATMENT PLANT

APPLICATION EXAMPLES

The following case studies il lustrateresults that can be achieved byimplementing turbo, hybrid, andcombination blower technologies inwastewater treatment plants.

Turbo Blower: Blue River WastewaterTreatment Plant Overview: Built in 1974, theBlue River Wastewater TreatmentPlant in Silverthorne, Colorado,provides wastewater services to thecommunities of Silverthorne, Dillon,Dillon Valley, Buffalo Mountain,

and Mesa Cortina. A conventionalactivated sludge plant with extendedaeration capabilities and a designcapacity of 4 million gallons (15.1million liters) per day, the Blue RiverWastewater Treatment Plant servesresort communities with high variationin usage, both seasonally and between

midweek and weekends during thepeak season.

Average demand ranges fromapproximately 1.5 to 2 million gallons(5.6 to 7.5 million liters) per day.Given the variation in basin levelsand the limitations on turndown inthe multistage centrifugal blowers,the plant operators were frequentlyoveraerating, resulting in energyloss and lowered overall blowerefficiencies. Engineers experimentedwith adding VFDs to the old blowersto reduce energy consumption, butit proved difficult to protect thecentrifugal blowers from surge.

Objective: Reduce rising energy

costs and replace the aging multistagecentrifugal blowers with newtechnology that would reduce energyconsumption and provide steady andreliable operation.

Results: The Silverthorne-Dillon Joint Sewer Authority (JSA) selectedthe Aerzen TB100, a 100-horsepower

turbo blower for its ability to meetthe plant's maximum design aerationrequirements of 1400 cubic feet(39.6 cubic meters) per minuteat a pressure of 7.5 psi. The TB

100 runs on a permanent magnetmotor specifically designed forthe high frequency and high speedrequirements of a direct drive turboapplication.

An immediately apparent benefitwas the drastic reduction in noise,eliminating the need for hearingprotection. The plant has averaged20 percent greater energy efficiencythan with its predecessor blowers,which translates to annual savingsof approximately $6500. Anotherenergy benefit is the heat recoveryfrom the blower's cooling system. Thewarm air is used to heat the facilityduring the cold winter months, and aseparate cooling air connection ventsthe heat outdoors during the summermonths. Since the blowers use airfoilbearings that are lubricated by airinstead of oil, the plant has alsoreduced its maintenance costs.

Hybrid Blower: City of AnacortesWastewater Treatment Plant Overview: The City of Anacortes

WWTP is located in the state ofWashington off the coast of PugetSound, which is home to a variety ofwildlife and aquatic life. Its WWTPprocesses 2 million gallons (7.5million liters) per day and was usingthree 150 horsepower multistagecentrifugal blowers with a minimal

Aerzen USA offers a wide array of positive displacement blowers, high-speed turbo blowers, screw compressors, rotary lobe

compressors, and vacuum pumps for various industries. For more information, visitwww.aerzenusa.com

.

For More Information

How to Select theMost Effective Blower Technology

for Wastewater ApplicationsBy Aerzen USA PART 2 OF 2

Aerzen TB100 turbo blowers at the B lue River

Wastewater Treatment Plant (Silverthorne, Colorado)

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52,972 cubic feet (1500cubic meters) per day usingtwo existing Aerzen Delta PDblowers. Approximately 75percent of the plant's energyconsumption goes towardgenerating process air, which

represented a significantoperating cost reductionopportunity.

Objective: Optimize energyuse by implementing a fullyautomated blower systemthat would meet processair requirements within theoperating range of 50 to 100percent.

Results: The plant selectedthe Aerzen AT 100 turboblower. The new turboblower serves as a base load

generator for process air, operating ata capacity range from 1200 to 2800standard cubic feet (35 to 80 cubicmeters) per minute. The two existingPD blowers are connected to the newsystem and automatically start whenneeded to handle peak loads or serveas redundant blowers. Adding the new

turbo blower resulted in cost savingson the order of 20 to 25 percent.

SUMMARY AND CONCLUSION

Wastewater treatment plant managershave more opportunities to optimizeenergy efficiency and reduceoperating costs thanks to a variety of

aeration blower technologiesand application concepts.A thorough understandingof the overall process,operating conditions, andinterplay of aeration andprocess controls is key to a

successful implementation.Often, technologies aremisapplied due the promiseof high energy efficiency,failing to consider operationalvariables that will ultimatelycause the machine to runoutside its intended range.New concepts of applyingestablished and more recenttechnological advanceswithin the context of theentire wastewater treatmentplant system have proven

effective in maximizing the benefitof each technology. The result isan improvement in the overalloperating efficiency of the wastewatertreatment plants in terms of overallequipment effectiveness (OEE), energyefficiency, and reduced operating andmaintenance costs. ■

Aerzen AT turbo blower and two PD blowers processing air at a Bremervörde,Germany sewage treatment plant.

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Robert Forgione, P.E. and his team at the UpperOccoquan Water Reclamation Plant in Centreville,Virginia were wading through yet another dust cloud to

cleanup yet another pile of dry pebble lime and dust that hadleaked from a failed elbow in the conveying line. While thehole measured a mere ½-inch (12.7 millimeter) across, it waslarge enough to spew the abrasive powder billowing all overthe building until the high pressure conveying system couldbe shut down. The elbow failure created a hazardous slip andfall situation, threatened acceptable air quality levels, andput sensitive electronic controls at risk. Although it would befeasible to recover from a single leak like this one, Forgionewas responsible for elbows that failed and leaked every sixmonths. “We had to fix this situation,” says Forgione, thedirector of the operations and maintenance division for theUpper Occoquan Sewage Authority (UOSA).

HITTING A BRICK WALLThe wastewater treatment plant handles upwards of 30million gallons (11.3 million liters) per day and providespotable water to more than 300,000 people in portions ofFairfax and Prince William Counties. Its chemical treatmentsystem relies on a non-stop supply of pebble lime forraising the pH to levels where bacteria and phosphorous

can be efficiently removed. After off-loading, the lime waspneumatically conveyed up to six silos but transporting thishuge volume of abrasive material with three to four percentgrit at high velocities proved far too demanding for everytype of elbow Forgione and his mechanics and engineerscould find. Schedule 80 steel sweep elbows had wornthrough in a few months. So did the short radius welded steelelbows. And, so did similar long radius steel elbows. Ductileiron piping and elbows lasted nearly a year. Then longer 10-foot (3.05 meter) radius steel sweep elbows were installed.They lasted for a year and a half. None worked.

Every time there was a failure, the line had to be shutdown and its silo taken offline. Inspecting elbows becamea daily ritual while maintenance personnel became expertat welding temporary patches to keep the seventeen elbowsintact. Eventually, these would also wear beyond repair andeach time an elbow had to be replaced, it consumed hours,

along with the expense. “It’s very difficult for us to replacean elbow,” says Forgione. “Not technically, but the elbows atground level are not easily accessed and the ones on top ofthe silos are four stories up. It’s a safety concern as well as acost concern.”

Meanwhile, operations personnel were being diverted fromtheir more formal responsibilities to help with the cleanups.

Miaja Marek is the advertising and marketing director for HammerTek Corporation. HammerTek is the inventor andmanufacturer of the Smart Elbow®. Having recognized a need for extremely wear resistant and space efficient elbows,the designers created a revolutionary elbow that operates by deflection. For more information, call 800.505.9665, email

[email protected], or visit www.hammertek.com.

About The Author

By Miaja Marek, HammerTek

Eliminating

Pipe Failuresfrom Pneumatic

Conveying Line

The SmartElbow® stops

lime spillsand preventsdust cloud

exposure for wastewater

treatmentplant

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“We needed to make the elbowslast longer and we needed it donefast,” says Forgione. “As far as thetype of elbow or material, we’dhit a brick wall.”

A DIFFERENT APPROACH

Then Forgione came across theSmart Elbow® from HammerTekCorp., Landisville, Pennsylvania.A completely different approach,the Smart Elbow has beeninstalled in some of the world’slargest facilities that handlehighly abrasive materials suchas ceramics, plastics, grains, andminerals—all without fail. TheSmart Elbow had been installedat a wastewater treatment plantin Alexandria, Va. to solve anidentical lime handling problem.

Under Forgione’s direction,UOSA Process Control EngineerIvan Romero and MechanicalManager Larry Brown touredthe facility. “They were veryhappy and hadn’t had a singleblowout since installing the SmartElbow,” Romero said, also notingthe cleanliness of their facility.

This 90-degree Smart Elbow from HammerTek diverts the pebble limein the pneumatic conveying line into a silo for storage. The sharp turn thathad tormented many different types of elbows has not been a concern forthe Smart Elbow, nor for facility management.

The HammerLoy Series Smart Elbow from HammerTekis one of fourteensuch elbows installed at the Upper Occoquan Water Reclamation Plant in

Centreville, Virginia, to eliminate pipe failures in the conveying line. Aftermore than four years in operation, all of the Smart Elbows continue toperform as specified without a single pipe failure.

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“You could see they weren’t havingany of the problems with leaks that wewere having.”

GOING WITH THE FLOW

The Smart Elbow is based on thenatural flow patterns of fluids. It

combines a rounded chamber ona tight radius elbow in a single,

rugged unit. The conveyed particlesgather and swirl inside the chamberin a slowly-rotating, selfrenewingball, absorbing new material whilegradually releasing it in a first-in, first-out progression. Incomingparticles deflect off of this rotating

ball of air and material and continueto the silo. Rather than inviting the

material to collide with the elbowwall, this elbow virtually eliminatessuch wearing impact, instead causinggentle deflections that promotedirectional change without affectingsystem pressure.

Forgione tested Smart Elbows

and after more than a year withoutany signs of wear, let alone a leakor blowout, he replaced all of theelbows at his second installation.With assistance in specifying theelbows from Joe Cathey of CatheyProsolutions, Sykesville, Maryland—who had originally specified theSmart Elbows in the Alexandriafacility—five 45-degree, four-inch(101.6 millimeter) elbows wereinstalled where the trucks offload theirlime and nine 90-degree, four-inchelbows were installed at the tops of

the silos. With careful considerationof the characteristics of the lime, thelength and velocity of the pneumaticconveying system and other factors,Cathey recommended the HammerLoySeries Smart Elbows, which feature acustom alloy with impressive hardnessproven in handling abrasives. “This iswhat we specified in Alexandria and ithas performed as anticipated,” Catheysays. Six years have gone by sinceinstallation there and none of themhas needed to be replaced.

A LONG-TERM SOLUTION

Similarly, four years have elapsedsince their installation at Forgione’sUOSA facilities and there hasn’t beena single blowout. “With the SmartElbow, we’ve eliminated the primarysource of lime dust along with thehazardous conditions it creates,”Forgione says. Maintenance andlabor costs have been reduced, safetyand air quality have been upgraded,the building is visibly cleaner andaccording to Romero, management

is enjoying some well-earned peaceof mind. “As an engineer, it doesn’tmatter what I think, what matters areresults,” Romero says. “The fact is, theSmart Elbow is working, we’re happywith it and I would recommend it toanyone involved in handling lime.”

Forgione adds, “Our experiencewith HammerTek has been excellent,the delivery was fast and ourmechanics were able to install it prettyquickly without any complaints. If weever get wear in an elbow anywherein the plant, we’ll replace it with theSmart Elbow.” ■

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Designing andmanufacturingequipment for the

biopharm sector requires anumber of talented people with awealth of training and expertise.However, it also means listeningto what customers ask for. Inresponse to customers seekinga small and simple casedperistaltic pump, Watson Marlowhas launched their 120 pumps,which are perfectly suited tosingle-use systems where nocontamination can be accepted.Ultimately the 120 pumps have been developed to increasethe low-flow capabilities of the company's product range forapplications in the biopharm sector. The market need for the120 range is well understood, with customers voicing their ownmantra, "keep it small, keep it simple.” Accordingly, the new120 pump is focused on size, performance, and ease-of-use.

EXTENSIVE FEEDBACK

With development based on extensive feedback fromcustomers, Watson-Marlow Pumps Group has launched its 120cased peristaltic pump range. The 120 pumps are perfectlysuited to single-use systems where no contamination can beaccepted.

Eric W. Johnson at Novozymes Inc, who was one of the firstpeople to use the 120 pump comments: "I love simple and

this has a small footprint without a lot of bells and whistles.Easy menu, short learning curve, improved performance,and hopefully zero maintenance, have generally left me veryimpressed and satisfied with this unit."

The biopharm sector embraces applications such asfermenter feed, an upstream process important in bothproduction and research, where the growth of cell culturesdemands an accurate and repeatable process with nocontamination. Ultra-compact and stackable for multiple feeds

like pH control, antifoam, nutrient and buffer addition, the120 offers the ideal combination of size and technology tooptimize the process. The pump will also be effective wherethe validation of drug research experiments demands accurateflow rate, easy monitoring of parameters and process control.

Biopharm processes require accurate and repeatablepumping that is easy to validate. With an exceptional 2,000:1


Russell Merritt is the marketing manager for Watson-Marlow Fluid Technology Group and can be reached at 978.988.5307 [email protected]. Watson-Marlow Fluid Technology group is the world’s largest manufacturer of peristaltic pumps,Biopharmaceutical grade tubing, Flexicon liquid filling systems, and BioPure single-use flow path components. For more

information, visit www.watson-marlow.com.

About The Author

By Russell Merritt,

Watson-Marlow FluidTechnology Group

Watson-Marlow’s120 peristaltic pumpanswers customers’needs

Small and SimpleSmall and Simple

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speed range (speed accuracy ±1percent) and a selection of USPClass VI tubes, the 120 deliversthe flexibility and purity so vital todrug trials.

SIZE IS A PRIORITY

Pump size was a priority on the120 enclosure design becausebenchtop space is a premiumfor biopharm companies. Pumpsmeasure just 4.3 inches (110millimeters) in width which issignificantly smaller than mostpumps offering similar flow rates.The 120 pumps also benefit froman intuitive interface which makesthem quick and simple to set-upand reduces the number of keypresses and potential errors.

Simplicity is also captured by

the new 114 pumphead, wherethe spring-loaded flip-top tracksecures repetitive flow andpressure performance. The 114pumphead provides error-free tubechanging in only seconds, withtubing clamped and tensionedautomatically to ensure repeatableperformance.

INSTALLATION AND

PERFORMANCE

The unit also has a hygienic enclosureideally suited to ethanol wipe-down, while the smooth lines of theenclosure eliminate bug traps and helpprevent the tearing of gloves.

The illuminated numeric speeddisplay provides easy recording ofoperating parameters, giving customersgreater flexibility and repeatabilityin their processes. A keypad lockprevents accidental key presses,offering process security. All 120pumps are IP31 rated and carry a threeyear warranty. Processes are boostedfurther through the use of Watson-Marlow's high tolerance tubing,which is designed specifically to giveoptimum performance in its pumps.

Further benefiting the bottom line,

operating costs can be predictedfor the customer over the lifetimeof the pump because tubing is theonly consumable. The ultra-quiet120 cased pump range is availablewith three different models for fixedspeed, manual or remote auto control,and five single and multi-channelpumpheads. ■

Ultimately the 120 pumps have

been developed to increase

the low-fow capabilities

of the company's product

range for applications in the

biopharm sector. The market

need for the 120 range is well

understood, with customers

voicing their own mantra,

"keep it small, keep it simple."

As a result, Watson-Marlow

has produced a pump that is

focused on size, performance

and ease-of-use.

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Hidrostal Ltd.,renownedmanufacturers

of pumping productsto the water industryhave provideda leading freshvegetable grower andsupplier, ProduceWorld Group, with anenhanced solution forthe cleaning of carrotsin the vegetableprocessing operation.

BOOM WASH

SYSTEM

Produce World isthe largest growerand supplier ofhigh quality freshvegetables in theUnited Kingdom andone of the largestin Europe. It provides a wide range of conventional and

organic vegetables to the major supermarket chains. Allits produce is picked fresh from the fields and processedwithout the addition of any chemical additives.

Hidrostal have supplied Produce World with animmersible pump to aid it in the pre-wash process at itsYaxley site which deals exclusively in organic vegetablesincluding carrots. Upon arrival at the plant the carrots areoff loaded from a truck and pre-washed using recycled

wash water.Produce Worldhad previouslyused an enclosedweb, open beltconveyor methodin this processbut the pump thatHidrostal havesupplied is partof a new opencatchment designwith a slopingbench arrangementto the sump area.

The boom washsystem aids themovement andflushing of newlyarrived field carrotsoff the truck at thevery start of theprocess into thesump. The wash

water is pumped using Hidrostal’s immersible pump to a

rotary screened drum where most of the solids are filteredout before re-entering the boom wash system once more.This process occurs each time a truck arrives with freshfield carrots.

THE COST OF CLEANLINESS

The carrots from the field, when mixed with the water,leave a very abrasive media consisting of flint, stones,

Gennaro Poli is a key account manager at Hidrostal Ltd. With over thirty years of experience and having deployed thousandsof pumping systems, Hidrostal fully understands the needs and technical requirements of today’s pump users. For more

information, email [email protected] or visitwww.hidrostal.co.uk

.

About The Author

By Gennaro Poli, Hidrostal Ltd.

Hidrostal’s pump cleans carrots for consumption

The pre-wash process at Yaxley

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sand, soil, weed, and the occasionalcarrot! The common approach topump selection in this type of arduousapplication has always been to err onthe side of caution and to compromiseby sacrificing pump efficiency for thesake of a pump which can handlesolids and fibrous material; the resultbeing a forgiving impeller design butgreater power absorption and energyusage.

In all cases the largest cost is therunning cost, the cost of electricitywhich is affected directly by pumpefficiency. Produce World Yaxley tookthe decision to change from the normand choose Hidrostal.

SCREW CENTRIFUGAL

IMPELLER AT WORK

The Hidrostal Screw Centrifugalimpeller is a unique design, wherebythe single spiral vane impeller isaxially extended creating a large freepassage for solids but at the same timemaintaining an optimum hydraulicdesign leading to high efficiencies, low

shear pumping, and low velocity at thepump inlet.

The Hidrostal pump retained thedesired solids handling capabilitiesand has provided longevity in itsoperation. The Hidrostal pumphas also ensured a reduction inmaintenance costs, down-time andoperational spend associated withthe cleaning and maintenance of theprevious open belt conveyor method.

SAVING ENERGY

MEANS SAVING MONEY

In addition, in this case the Hidrostal

immersible pump with its 5.5kW 4pole 3 phase motor has resulted inreducing power consumption by 50percent, a huge power saving from theprevious end suction style pump thatrequired an 11 kilowatt motor.

Kevin Lander, the lead engineer

for Produce World, has enthused:“I have been very pleased with the

performance of this pump over the lasteighteen months. It has gone beyondour expectations outlasting previousdesigns three times over.”

Hidrostal Ltd. are delighted thatthe pump is functioning so well forProduce World and look forward

to further opportunities within thissector. ■

A Hidrostal immersib le pump, simil ar to the oneinstalled at Yaxley.

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In order to keep up with the rising population, increaseddemands and tougher regulatory requirements, the U.S.Army Schofield Barracks, Hawaii’s largest Army post,

recently upgraded its wastewater treatment facility. The resultwas improved efficiency and water quality, and decreasedenvironmental impact on the region.

The project was spearheaded by Aqua Engineers of Kauaifollowing a contract with the Army to privatize the facility.Key to the project’s ultimate success was technology from

JWC Environmental, Costa Mesa, California, and GE Waterand Process Technologies, a unit of General Electric Company.

PROJECT GOALSThe goals for the facility upgrade were both specific andchallenging. The plant needed to go from R2 quality effluentto R1 quality effluent suitable for reuse in agriculture andirrigation applications, and the crew also needed to increaseplant capacity by roughly 30 percent — from 3.2 to 4.2million gallons (12.1 to 15.9 million liters) per day. Anotherrequirement was providing a surge capacity of 15 milliongallons (56.7 million liters) per day to handle Oahu’s frequentrainstorms, which further increased the design challenge. On

top of that, the total project needed to be completed withoutmajor capital expenditure.

SOLUTION AND RESULTSAqua Engineers recommended General Electric’s ZeeWeed® Membrane Bioreactor (MBR) technology to achieve the R1quality effluent des ired. This advanced wastewater treatment

system uses rugged hollow-fiber, ultrafiltration membranes inorder to protect the system from clogging and damage.

JWC Environmenta l recognized that protecting themembrane is critical in these types of MBR systems. TheBandscreen Monster was used because it provides excellentmembrane protection, since the entire screening operationis done on the inside of the screen. This prevents any debrisfrom passing through and getting to the membrane itself. Ifthat were to happen, the debris could go all the way throughthe process and wrap itself around a membrane, causing it toeither plug or break.

Originally, the project design called for building acompletely new separate screening facility downstream fromthe existing installation to accommodate the new screens.However, in working with JWC, the need for a separatescreening structure was eliminated, enabling the facility crewto replace the old 0.23 inch (2 millimeter) screens with thenew 0.07 inch (2 millimeter) ones in the same channel. Thissignificant design change saved about one million dollars ininfrastructure and screen costs.

MONSTER SCREENS AT WORK

While a number of screens were considered, Aqua Engineersselected the Bandscreen Monster and Screenings WashingMonster from JWC Environmental as the most suitable forthe project. The screens are well-equipped to handle the15 million gallons (56.7 million liters) per day per screenrequirement for storm surge capacity and were priced lessthan competitive screens. The stainless steel construction is

Kevin Bates is the global marketing director for JWC Environmental based in Costa Mesa, California. JWC Environmentalis a world leader in solids reduction and removal for the wastewater industry with its Muffin Monster grinders and Monsterscreening, compaction and washing systems. Bates has more than twenty year of experience working with global industrialleaders to solve challenging technical problems spanning a wide range of markets including wastewater, construction and

mining. For more information, visit www.jwce.com .

About The Author

SCREENING SYSTEM ELIMINATES CLOGGING

FROM MEMBRANEBIOREACTOR

By Kevin Bates,

JWC Environmental

SCREENING SYSTEM ELIMINATES CLOGGING

FROM MEMBRANEBIOREACTORRetrofit cuts upgrade costsby one million dollars

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also more desirable for the humid environment. However,one of the largest benefits is the fact that the Monster screenscould fit the existing channel without modification, somethingother competitors were not able to offer.

This retrofit aspect of the screen systems was key to theinstallations success, as it was absolutely critical that thescreen fit into the existing envelope without making any

changes to the concrete or other structures. The equipmentarrived at the scheduled time, and the crew was able to putit directly into the channel without any modifications. Thissmooth transition also was a large time-saving benefit.

The Bandscreen Monster offers high capture rates and isable to remove a wider variety of waste solids, particularlysmall solids, like trash and hair, better than traditionalscreens. The product is particularly specified to protecthigh-tech Membrane Bioreactors so they can run moreefficiently and with less maintenance. Unwanted solids arecaptured on the UHMW plastic panels with 0.07, 0.11, or0.23 inch (2, 3 or 6 millimeter) openings and lifted to thedischarge level where a spray system washes solids into theScreenings Washer Monster, used for washing, dewatering and

compacting.Used in conjunction with the Bandscreen Monster, the

Screenings Washer Monster was also employed at theSchofield Barracks wastewater treatment facility. This self-contained, hopper-fed system grinds, washes, compactsand dewaters screenings. The removed solids contain up to50 percent dry solids, are 80 percent compacted and aresignificantly lighter and cleaner than typically screenedsolids. This unique process of grinding prior to solids

separation removes virtually all of the soft organics from thedischarged product, which reduces odors and landfill costs.

A THOROUGH UPGRADE

In comparison to the previous screens used prior to theupgrade, which only dewatered the material, the combinedMonster systems collects, washes and grinds the screenings

to produce a product that is relatively dry and free of organicproducts. Not only did the screens reduce the size of thematerials passing through from 0.23 to 0.07 inch (6 to 2millimeter), they also eliminated the odor, resulting in a muchbetter quality of waste going to the landfill.

Using the latest water treatment technologies available fromGE and JWC Environmental, Aqua Engineers improved thelocal water quality and made more than 1 billion gallons (3.7billion liters) of high-quality, recycled water a year availablefor non-potable uses.

The Schofield Barracks wastewater treatment plant upgradeenabled the plant to provide premium quality recycled waterto irrigate lawns, golf courses, parks and other s ites on base,positively affecting the nearly 28,000 military personnel, their

families, and civilians who work on base and nearby.The upgrade has turned the plant into the largest privately

owned R-1 facility in Hawaii, and enables the military toconserve water, decrease pollution and contribute to thesustainability goals of the facility. After the upgrade wascompleted, the treatment facility was awarded a GlobalEcomagination Leadership award for employing the latesttechnology to achieve significant environmental and operatingimprovements to meet community needs. ■

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The pump industry, like many others in today’seconomic landscape, is striving to extendequipment operating life while putting greater

demands on that equipment. Developments toward

longer life and increased productivity are creatinga chain reaction of demands, innovations andimprovements.

The technological advances in steam assistedgravity drainage (SAGD) that are facilitating theextraction of oil shale deposits also demand thatelectric submersible pumps (ESPs) operate in highertemperatures, and sometimes at higher speeds. Giventhe high cost of a well’s downtime, equipment is expectedto continue to perform even in upset conditions such ascontamination.

Barry J. Blair is chief engineer at Waukesha Bearings, headquartered in Pewaukee, Wisconsin. Blair has responsibilities forfluid film bearing research and development activities, including new products and the refinement of bearing design tools

and methods.

About The Author

By Barry J. Blair, Waukesha Bearings®

New Bearing Designs Meet

Demands for Extended

Pump Operating Life

New Bearing Designs Meet

Demands for Extended

Pump Operating Life

In the subsea pump industry, multiphase pumps are ingreater demand to shift the separation of oil and water or gasand water to central processing facilities and eliminate theneed for auxiliary equipment. This introduces a wide rangeof fluids and fluid viscosities, as well as abrasives, to theequipment operating conditions, adding to the continueddrive to increase durability, load capacity and operating life.

BEARING REQUIREMENTS AND DESIGNSAs the industry continues to push the limits for greaterefficiency, the pumps require higher quality bearings with

a greater operating range. High temperatures in ESPs placeincreased demands on the thrust bearings in the motor andseal/protector sections of the string, and there is some pushfor bearings that can operate with abrasives, when sealing iscompromised. The subsea pump industry not only requiresprocess-lubricated bearings for multiphase pumps; it needs alow-stress leveling system that can operate with abrasives andprevent wear over time.

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To meet these demands, investmentin research and testing are necessary toevaluate the limits on durability and theperformance margins of existing andnew bearing designs.

Bearing engineers are alsomaking a significant investment in

testing a plethora of materials. Eachmaterial is evaluated for its ability toaccommodate higher temperatures,higher loads, higher speeds, abrasivesand a variety of fluids (e.g., lightoils, high temperature oils, water,multiphase).

THE LATEST BEARING SOLUTIONS

Recent bearing developments fortraditional oil-lubricated pumps includenew bearing designs and materialsthat provide higher load capacity.The benefit is twofold: the ability to

handle higher loads also allows for areduction in bearing size, resulting inlower power loss. If size reduction isnot required, the higher load capacityprovides a more durable bearing withhigher safety margins for a given sizeand load.

A new solution within the ESPmarket, specific to SAGD, is theHidrax™ HT thrust bearing fromWaukesha Bearings, which addressesthe demand for temperature capabilitiesbeyond the limits of traditional ESPbearing materials. The Hidrax HTceramic/cermet bearing surfacesretain their strength, hardness andload capacity in oil bath temperaturesin excess of 572 degrees Fahrenheit(300 degrees Celsius). In addition tohandling high temperatures, the HidraxHT bearing has the potential to handleabrasives.

For the subsea market, ceramic/ cermet bearings are handling higherloads and higher temperatures, as

well as low viscosity fluids andabrasives. These bearing designs alsooffer pivot mechanisms that eliminatethe possibility of pivot wear whileproviding load-equalizing capabilities.

CONCLUSION

When seeking a bearing solution, pumpmanufacturers and operators need to

look to advanced materials and designsthat can keep pace with the othertechnological advances in the industryto extend pump operating life. The idealbearing supplier is a partner that canserve as a reliable, consistent resourcefor product and technical information,

ensuring the quality of the bearings forthe individual operating conditions. ■

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Cleaner energyand pumpedstorage

technology are inincreased demandthroughout theglobe, and nowhereis that demandgreater than inthe expandingeconomies ofSouth Korea andChina. Alstom haspositioned itself toaid these marketsin meeting theirpower generationneeds. Alstom’sECO 110 WindTurbines are helpingoptimize wind farmperformance, andAlstom’s pumpedstorage electromechanical equipment is helping China shareresources across many power stations to reach ideal capacity.

BUILDING A BETTER WIND FARMDaeMyoung Energy Corporation, subsidiary company ofDaeMyoung GEC, a large engineering and constructionservices company in South Korea has asked Alstom to providewind turbines for Gowon wind farm. The wind farm islocated in Gangwon province approximately 105 miles (170kilometers) east of Seoul. Alstom will supply and supervise

the installation andcommissioning ofsix units of the ECO110 Wind Turbineswith 295 foot (90meter) towers, eachwith an output of 3megawatts. Whenoperational, thewind farm will havea capacity of 18megawatts.

The ECO 110is equipped withAlstom PureTorque technology,which protectsthe transmissionchain by divertingunwanted stressesfrom the wind to theturbine’s tower andthereby optimizing

performance. Exclusively developed by Alstom and deployedthroughout its entire range of wind turbines, this technologyincreases the reliability and durability of each turbine. In

addition, the nacelle’s specific design made up of threeindependent elements and of large dimensions, facilitatesmaintenance operations and safety inside of the machine.

The Gowon wind farm, the second secured by Alstom inKorea this year, will be fully operational by the end of 2015and is set to support Korea’s aim to have renewable energyaccount for 20 percent of total electricity generated by

Cécile Dodat is the media relations and content senior manager for Alstom Renewable Power. She can be contactedat [email protected]. Alstom is a global leader in the world of power generation, power transmission and railinfrastructure and sets the benchmark for innovative and environmentally friendly technologies. For more information, visit

www.alstom.com.

About The Author

By Cécile Dodat, Alstom Renewable Power

Alstom’s ECO 110 Wind Turbines reside in 295 foot (90 me ter) towers, each with an output of 3 megawatts .

THE WIND ISBLOWING EAST

In South Korea and China, Alstom isproviding power generation solutions

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2020. With a population exceeding 50million and limited domestic energysources, coupled with huge demand,South Korea relies on imported sourcesfor 96 percent of its energy supply.

The Gowon wind farm will beoperated by joint owners Eurus Energy

Holdings Corporation (Eurus Energy)and DaeMyoung Energy Corporation.Eurus Energy is a leading IndependentPower Producer in Japan with over2000 megawatts in operating assets.Alstom has supplied wind turbinesfor Eurus Energy’s Satomi Wind Farmand is currently supplying turbines toKawazu Wind Farm in Japan.

“We are pleased to be a part ofKorea’s dedication to increasing itsrenewable energy footprint. Thisopportunity is significant as it willrepresent our continued presence for

wind power in Korea and also workingwith our important customer EurusEnergy,” saya Yves Rannou, senior vicepresident, wind.

Alstom has been present in SouthKorea for over forty-five years havingsupplied to over 34 percent of hydroplants as well as the first TGV exportsystems solution in the KTX Project andthe first High Voltage Direct Currentlink between Haenam and Jeju, amongothers. Alstom is currently supplyingwind turbines to Gimnyeong windfarm.

ADVANCED PUMPED STORAGEPOWER EQUIPMENT IN CHINAInvested by China Southern PowerGrid (CSG), Hainan Qiongzhongpumped storage power station is animportant supporting facility for theHainan Changjiang nuclear station interms of peak load regulation. Alstom’slargest hydro power manufacturingsite in Tianjin, China, will providea comprehensive range of pumpedstorage electromechanical equipment

including Alstom’s pump turbine,motor generator and balance-of-plant,as well as handling the design, deliveryand installation supervision of theproject. Alstom will provide three200 megawatt units—including pumpturbine, motor generator with otherkey equipment—to the 600 megawattnew plant. The first unit is due to entercommercial operation on December2017.

During off-peak hours, pumpedstorage uses the energy from otherpower stations to transfer water toa high storage reservoir. The stored

water will later be reused to generateelectricity to cover temporary peaks.As another successful cooperationwith CSG, Alstom’s leading pumped

storage technology will enableHainan Qiongzhong pumped storagepower station to respond quickly tofluctuating power demand and tomanage demand peaks.

“This contract demonstrates ourcustomers’ confidence and trust for

the quality and excellent executioncapability of Alstom team, and furtherreinforces our leading position on thehydro pumped storage power market.I strongly believe that our globalexpertise and complete local valuechain will best position us to tap thebooming Chinese’s pumped storagepower market,” says Fabio Nossaes,General Manager of Alstom HydroChina.

Pumped storage is the mostwidespread energy storage system inuse on power networks, and today

there is over 127 gigawatts of pumpedstorage in operation around the world.Alstom has been providing units—thatis, pump turbines and generators—for over fifty years and has supplied140 units to date, which represents amarket share of more than 39 percentand positions Alstom as the leader inthis field. ■

Alstom was awarded a contract by the Hainan PumpedStorage Power Generation Co. Ltd. to equip HainanProvince’s first pumped storage power station.

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mass flow rate (measured in poundsper second) could be converted into agallons-per-minute flow rate. A drawingof the test setup is depicted in Diagram1, as well as a chart of the characteristicsof the flow meters tested (see figure 5).

Three basic flow rates were tested: 9,

72, and 118 gallons per minute. Datawas collected the entire time the pumpwas in operation, recording f low-meterreadings and the weight of the supplytank. About five seconds after pumpstartup, flow became very consistentuntil the supply tank was nearlyemptied. The data from the steady-stateflow intervals is shown in figures 6through 11.

The graphs show the precision ofeach test meter and the precision of theweight method of flow measurement.Precision of the flow meters is the

published calibration/ accuracyspecifications at the tested flow rates.The weight-method precision is afunction of the accuracy of each loadcell, the amount of weight that wasmoved during the measurement andthe amount of time required to movethe measured weight. The low flowrate (9 gallons per minute; or 34 liters


Fill Tank

Coriolis or PositiveDisplacement FlowMeter

Pump

Supply Tank

LoadCells

Flow

Diagram 1

Figure 5 : Characteristics of Flow Meters Used During Precision Test

1 Based on water flowrate - lower densityresults in higher flow,

higher density results inlower flow 2 Based on calibration

data for the metertested. Tighter precision

possib le based onmeter selection

3 Lower accuracyoccurs at lower flowrates and drops to0.1% of reading atapproximately 15% ofmaximum flow rate

FLOW METER

Characteristic PD Meter Coriolis Meter

Flow Range 10-150 gpm 8-800 gpm¹

Porting 2" 3"

Output Signal Frequency Frequency

Accuracy .5 to 1% of FS² 0.1 to 0.4% of actual flow reading³

ACCURACY AT TESTED FLOW RATES

9 gpm ±1.0 gpm ±0.04 gpm

72 gpm ±1.5 gpm ±0.07 gpm

118 gpm ±1.5 gpm ±0.18 gpm

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Blackmer sliding vane pumps are often applied in fuel-transfer applications. Blackmer provides pumps to majorpetroleum distributors that have switched from positivedisplacement meters to Coriolis mass flow meters insystems where Blackmer pumps were installed. Again,information from the field is positive in the installedbase where Blackmer sliding vanes pumps are used in

conjunction with the Coriolis flow meters. This furthersupported Blackmer’s decision to investigate—and,ultimately, invest in—the technology.

DISCUSSION AND CONCLUSIONS

Flow meters from two highly respected equipmentmanufacturers were purchased in an effort to eliminatepossible bias between “brands” of the same technology.

One unexpected observation that was discoveredduring testing was in noise generation. In both LPGand solvent tests, Coriolis mass flow meters (from bothmanufacturers) operated with less airborne noise thanthe positive displacement (PD) meters that Blackmer hadbeen using. The PD meter devices generated their own

pressure pulses in the discharge line. We had becomeaccustomed to the noise and had accepted it. We werevery favorably impressed with how quiet the new meterswere in operation.

We attempted to operate the sliding vane pumps atspeeds where the pressure-pulse frequencies would beat the same resonant frequencies as the Coriolis flowmeters themselves. We then varied the speeds to levels(pressure-pulse frequencies) above and below the meter’spublished natural frequency. We could not induce anyconstructive or destructive interference into the vibratingCoriolis tubes by intentionally operating them in thenatural frequency range of the tube spring/mass system.Nothing we could do within the normal operation of thepumps caused any degradation of meter accuracy.

Proper mounting of the meter was found to be criticalfor accurate and reliable meter performance at low flowrates. Mounting the meter horizontally was the onlyapplication parameter that we determined to have aneffect on the meters.

Measurement precision and repeatability weremarkedly better with the Coriolis flow meters thanBlackmer’s PD flow-measurement technology. This wasdetermined by measuring the weight (mass) of the liquidpumped with highly accurate NIST-traceable load cellsto verify the actual performance of both the PD meter(s)and the Coriolis mass flow meters.

Blackmer’s customer base has a great deal ofexperience using Blackmer pumps with Coriolis massflow-measurement technology. We have had no reportsfrom the field of any incompatibilities or other issues todate after many years of service.

The meter test results from Blackmer’s Researchand Development Laboratory have been compellingenough to convince us to install the Coriolis flowmeters on our production test stands. We have installedan Endress+Hauser mass flow meter on one of ourproduction pump test rigs. This rig tests three differentsizes of Blackmer sliding vane LPG pumps daily. Wehave experienced greatly improved measurementaccuracy and very good reliability in a productionenvironment. ■

Figure 9:

Precision Chart for Nominal 118-gpm Flow Rate

80

78

76

74

70

68

66

0 10 20 30 40 50 70 80

Time (Seconds)

F l o w R a t e ( G P M )

Meter Lower Limit

Meter Upper Limit

Weight Method w/Precision

82

60

72

Coriolis Meter

122

118

116

114

108

106

104

0 5 10 15 25 30 40 45

Time (Seconds)


Meter Lower Limit

Meter Upper Limit


124

35

110

20

112

120

Figure 10:

Positive Displacement Meter

122

118

116

114

108

106

104

0 5 10 15 25 30 40 45Time (Seconds)


124

35

110

20

112

120

Meter Lower Limit

Meter Upper Limit


Figure 11:

Coriolis Meter

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Wey knife gate valves have beenused in the municipal sewagetreatment market for nearly

fifty years. The valve incorporates uniquedesign features that overcome typical

problems found in other knife gate valvedesigns. Today, the Wey knife gate valvehas spread throughout the industry inall of Central Europe and other partsof the world where the original valveinstallations continue to performsuccessfully.

ENERGY SAVINGS AS A RESULT

OF GREATER VALVE FLOW

CAPACITY (CV)

This following case study is based on anactual sewage treatment plant expansionwhere the valves were supplied by WeyValve, Inc. (see Table 1) and presentsthese four premises:

• Increased valve flow capacity (Cv)will result in improved overall plantefficiency due to reduced pumpingmotor power consumption.

• Reduced valve envelope sizesresults in smaller building sizes.

• Reduced valve size and weightresults in reduced foundation andpipe support sizes.

• Reduced valve face-to-facedimensions results in less piping.

The basis for the cost comparison wasa listing of flow capacities (Cv) for apopular eccentric plug valve (70 to 80percent area) vs the Wey model VM knifegate valve.

The headloss (H) in feet througha valve is determined by: H = (Q/ Cv)2 X 2.31 where Q is in gallons perminute and the power consumed (P) inhorsepower, is determined by

P = QH / [3960(e)]where (e) is the overall pump/motor efciency.

The estimatedannual powercost will bebased on 75percent use, 8fps, 70 percentoverall pump/ motor systemefficiency and$0.09/KWH

power cost.The estimatedannual powercost for eachvalve underthe assumedconditions is asfollows:

Wey Valve Inc. was founded in Nettleton, Mississippi as the North American sales and manufacturing headquarters for theWey brand valve line. Since then, Wey Valve Inc. has developed various specialized models of knife gate and shear gate

valves to solve specific process problems.

For More Information

By Dick Smith

Take the Knife to High Costs in Wastewater Treatment

Specialty AWWA C520-10 knife gate valve

saves construction and operating costs

Valve Size Quantity

3 inch (76.2 millimeter) 16




10 inch (254 millimeter) 7



16 inch (406.4millimeter) 1

Table 1: Size and quantity of valves used in sewagetreatment plant expansion.

Cv Ratings Eccentric Plug Value versus Wey Model VM Knife Gate Valve

C v

R a t i n g s

Valve Size

80000

70000

60000

50000

40000

30000

20000

10000

0

6" 8" 10" 12" 14" 16"

Wey VM Model KGV

Eccentric Plug Valve

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By taking theannual cost savings

per valve size timesthe number of valvesused on the projectthe total annualcost savings whenusing Wey knifegate valves on thisproject will yielda $17,372 yearone cost savings ora cost savings of$434,300 over atwenty-five year lifeof the project.

It is noteworthythat despite thefact that the Weymodel VM valvehas a substantially larger flow capacitythan the commonly used eccentric plugvalve, the average selling price of theWey valve is less than the eccentricplug valve. Eccentric plug valves arealso available with 100% bore areas(higher Cv's) but with a substantial pricepremium that more than offsets anysavings in energy costs.

Further cost advantages associatedwith the use of the model VM valveinclude reductions in buildingspace, size and cost of footings andfoundations, piping, and size andnumbers of pipe hangers. Also, useof the model VM valve could make itpossible to use potentially smaller valvesizes and reduced pump and motorsizes. Furthermore, the Wey model VMknife gate valve fully complies with theAWWA C520-10.

RETHINKING KNIFE GATE VALVES

Knife gate valves in general have had

a bad reputation in the municipalwastewater treatment market. Majorproblems that users have found includeleakage to the exterior of the valvepast the top gland as well as leakagepast the seat of the valve. Knife gatevalves have also been known forsolids jamming in the seat and chestareas of the valve and requiring high

input torque to actuate the valve, withunreliable actuation after prolongedperiods of non-use. However, WeyValve offers time-tested provensolutions to these common problems.

Top Transverse SealWey knife gate valves do not makeuse of stuffing box and packing glandtop seal designs. Instead, a unique top"transverse" seal prevents leakage tothe exterior. If leakage does eventuallyoccur, the valve can be repacked whilein service and under full pressure. (Seelink to packing demonstration.)

Positive SeatSealThe seat inWey knifegate valves isa combinationof metal and

elastomer. Theelastomer ismechanicallyretained toprevent "pull-out". The gateis guided andsupported forthe full lengthof the strokewhich whencombinedwith the seat

seal provides bi-

directional bubble-tight shut-off from-28" Hg vacuum tofull pressure rating.

Self-CleaningDesignWey knife gatevalves have a uniquegate geometry andbody bore contoursto prevent solidsfrom clogging inthe valve. There islittle space for solidsto build up andin the event somesmall amount of

solids is present, it is flushed out duringactuation.

Reduced Operating ForceThe unique gate geometry again plays arole in reducing operating force alongwith a molecular graphed polymerinfusion on the stem reduces operatingfriction. Manually actuated valves utilize

a non-rising "jack screw" mechanism toopen and close the valves resulting insaved envelope space.

Long Life ReliabilityAn important measure of reliability inthe wastewater treatment industry ishow long a valve can remain "dormant"and then operate dependably aftermany years of inactivity. Wey Valveshave a proven reputation for reliableoperation after many years withoutoperation. Experienced engineers oftenspecify Wey knife gate valves for thisreason alone. ■

Valve Size Quantity

Annual Usage Costs

AnnualSavingsEccentricPlug Valve

Wey VM

3 inch (76.2 millimeter) 16 $336.00 $24.00 $312.00

4 inch (101.6 millimeter) 58 $2378.00 $116.00 $2262.00

6 inch (152.4 millimeter) 30 $2880.00 $30.00 $2850.00

8 inch (203.2 millimeter) 15 $3330.00 $36.00 $3294.00

10 inch (254 millimeter) 7 $2240.00 $21.00 $2219.00

12 inch (304.8 millimeter) 5 $2505.00 $20.00 $2485.00

14 inch (355.6 millimeter) 4 $3068.00 $24.00 $3044.00

16 inch (406.4millimeter) 1 $916.00 $10.00 $906.00

139 Total annual savings $17,372.00

Table 2: Projected annual cost savings.

U S D o l l a r s

Operating cost per year Eccentric Plug Value versus Wey Model VM Knife Gate Valve in US dollar*

*Based on .09/KWH & 8 FPS Flow Rate

10000

1000

100

10

1

3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24"

Wey VM Model K

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