Smart Solutions Category: Pumps

How Smart Pump Technology Simplifies Installation & Maintenance

The development of intelligent pumping systems with smart motors is key to meeting the growing demand for better efficiency and reduced energy consumption. Integrating smart technology in pump systems can simplify installation and maintenance, ensure reliable operation, and minimize environmental impact.

Technological advancements like electronically commutated motors (ECMs) have vastly improved overall performance and efficiency in pumps used for heating and cooling applications. ECMs use variable speed controls to react to system demand by speeding up or slowing down, resulting in the most efficient system operation. By determining the minimum energy required to obtain optimal pump flow, ECM pump systems can dramatically reduce the power consumption of a traditional circulator pump without sacrificing comfort.

High-efficiency pumps outfitted with international efficiency level 5 (IE5) motors also substantially contribute to energy savings and reduced carbon footprint. The International Electrotechnical Commission, which established the IE standard motor rating system, created the IE5 rating to designate ultra-premium efficiency. IE5 motor losses are at least 30-percent lower than IE3 motor losses, which alone reduces the energy consumption by 10 percent with a typical pump load profile.

See how countries around the world incorporate international efficiency standards into their regulations: https://www.iec.ch/government-regulators/electric-motors

Xylem’s Smart Pumps, equipped with built-in IE5 motors, are simple to install and commission in new and retrofit installations. With its embedded electronic drive, motor size is reduced, resulting in a compact footprint. Additionally, Xylem Smart Pumps can handle extreme environmental conditions and shocks, ultimately extending the life of the equipment. Bell & Gossett, a Xylem brand, recently introduced the Series e-90E Smart Pump combined with the Xylem Smart Motor. The integrated pump solution combines pump, motor, and variable speed drive in one package, which allows for easy, cost-effective installation.

As industry professionals continue to prioritize optimizing HVAC performance while reducing energy consumption and carbon footprint, integrated drives and controls, ECM technology, and motors with IE5 efficiency are proving to be game-changers in the commercial building market, giving contractors an entirely new level of control over system design and performance. With the ability to improve water usage, detect anomalies, and adapt to changing conditions, these smart pumping systems provide a dynamic approach to pump operation and efficiency.

For more information, visit www.xylem.com.

Bell & Gossett Helps NYC Add ICU Beds ASAP

When New York City was confronted with a surge in COVID-19 cases in March, Xylem brand Bell & Gossett quickly provided the design assistance and products needed to increase capacity at North Central Bronx Hospital (NCB), the smallest of 11 public hospitals in the city’s health system. The hospital went from 15 intensive care unit (ICU) beds before the COVID-19 outbreak to 135 ICU beds in just a few months.

New York City Mayor Bill de Blasio, in consultation with the Federal Emergency Management Agency, identified NCB as one of several target locations for the construction of 120 additional ICU beds in preparation for the crisis. To accommodate the additional beds and support space for the executive administration staff, two existing floors within the hospital had to be renovated and converted into specialized COVID-19 support wings—all within an expedited time frame.

As part of the emergency construction project, a new hydronic system design was needed for both floors. Bell & Gossett provided engineering design assistance, selecting high-quality, energy-efficient equipment matched to the specific application and a complete hospital hydronic system.

To meet the hospital’s accelerated construction schedule, Bell & Gossett fast-tracked the manufacturing of the hydronic system equipment through Xylem’s Quick Ship Program. Within two weeks, the hospital received the necessary hydronic equipment, including e-1510 pumps, e-80 pumps, variable frequency drives, balanced triple duty valves, 3X suction diffusers, Rolairtrol air separators, shell and tube heat exchangers, and domestic watchman units.

The project, which began in March, was finished in just a few months. Construction moved at record pace, with the first set of 20 ICU beds available in early May, and the rest completed by mid-July.

“That is a dramatic change from everyday business here,” said John Doyle, a spokesman for the hospital.

Bell & Gossett is proud to have supported NCB during this emergency building project, helping get critical building systems online quickly and safely and allowing the hospital to treat more COVID-19 patients sooner.

For more information, visit www.bellgossett.com.

Xylem Illustrates How Smart Technology Streamlines Preventive Maintenance

By Stephen Clark, Director, Product Management for Intelligent Solutions, Xylem

Preventive maintenance is crucial for ensuring the reliability and efficiency of pumps and motors, which are essential components of commercial HVAC applications. An effective maintenance program can reduce unplanned downtime, decrease maintenance costs, and extend asset life. All of these drive business value, which is especially important in today’s competitive and challenging commercial building environment, when building operation teams are being asked to do more with less.

However, traditional preventive maintenance plans can be labor- and cost-intensive, with the potential for overmaintenance and unnecessary inspections and repairs. For those reasons, many building owners and operators are turning to digital tools and intelligent technologies from companies like Xylem Inc. – Bell & Gossett to enhance their preventive maintenance plans and optimize HVAC system performance. These smart technologies have the potential to effectively streamline operations, reduce maintenance costs and energy consumption, and increase awareness about overall equipment health.

Ongoing Condition Monitoring

One of the most common and effective ways to use digital tools and technologies for preventive maintenance is to install sensors and monitoring devices on pumps and motors. These devices can track the condition and performance of HVAC equipment in real time and identify potential issues or anomalies before they escalate into failures or breakdowns.

Although condition monitoring sensors have been used in industrial applications for some time, the commercial sector has only recently started incorporating these tools in mechanical rooms, thanks in large part to declining costs and smaller device size.

Condition monitoring devices provide health guidance and predictive maintenance insights for mechanical and electrical assets, such as pumps, motors, heat exchangers and steam traps. Monitoring solutions like Xylem’s optimyze^™ sensor use magnets to mount directly to the pump or motor and periodically monitor system vibration, temperature, and pressure. These devices also collect, store, and analyze asset health information, allowing users to understand health and historical trends, create maintenance reminders, and generate detailed reports.

Affordable and easy-to-use, optimyze monitoring sensors are now being fastened directly to Bell & Gossett pumps before they ship to the customer. Integrating monitoring sensors on commercial pumps can also help lower lifecycle costs and improve the return on investment. All the customer needs to do is download the monitoring app and take action only if a reading indicates an issue.

Data-Driven Insights

Remote monitoring and control systems also boost preventive maintenance by enabling easy and convenient access to data for building owners and managers. They can improve communication, collaboration, and feedback among maintenance teams and stakeholders.

Xylem recently launched Avensor, a cloud-based monitoring system that allows customers to remotely monitor HVAC equipment from their smartphones, tablets, or laptops. Avensor collects and analyzes data to provide live data, trends, and alerts via the web or mobile app. An affordable alternative to advanced supervisory control and data acquisition (SCADA) systems, for which integrating new devices can be complex and costly, the Avensor system can connect assets by leveraging existing systems while protecting data.

Remote monitoring and control systems like Avensor help detect system issues early, sending automatic alerts to building owners and operators so they can adjust equipment settings, parameters, or operation modes as needed. Receiving remote data and actionable insights also helps reduce the need for physical inspections, site visits, or manual interventions, saving time, money, and resources.

A Smarter Future

As the commercial building sector continues to seek ways to better optimize HVAC system performance, connected digital solutions are pushing the boundaries of traditional preventive maintenance plans.

Intelligent solutions like optimyze and Avensor demonstrate the ability to bridge the gap between the industry challenges of today with adaptability for the future. Both tools feature true remote connectivity and real-time monitoring to prioritize system equipment health and enable more efficient allocation of system time and resources.

With the help of service providers like Xylem, building owners and operators are implementing advanced predictive maintenance plans that deliver key insights and a new level of connectivity through simple-to-use smart technologies.

For more information, visit www.xylem.com.

Xylem’s Bell & Gossett Little Red Schoolhouse Teams Up with the UA

Xylem’s Bell & Gossett Little Red Schoolhouse and the United Association (UA) union of plumbers, fitters, welders, service technicians, and roofers have formed a training partnership to equip trade professionals in the HVAC field with the technical expertise to service and repair pumps in an HVAC system.

“Both Bell & Gossett and UA are well respected in the United States and around the world for their comprehensive premier skills training programs,” said Larry Konopacz, manager of training and education at Xylem. “This partnership gives us the opportunity to share our industry-leading training with UA craftsmen who are just as dedicated to delivering the best outcomes for facility owners.”

The Pump Service and Maintenance class debuted during UA’s 2015 Instructor Training Program, which draws 2,000 instructors from UA locals across the United States, Canada, Australia, and Ireland to Ann Arbor, MI, for weeklong instruction in the latest teaching methods and emerging technologies in the trades. Participants then take their newfound knowledge and expertise back to their UA locals to train journeymen and apprentices.

Little Red Schoolhouse instructor Stan Kutin delivered key curricula to 30 craftsmen from HVAC, plumbing, and other fields on pump selection and performance, followed by interactive exercises on actual Bell & Gossett pumps in repairing mechanical seals and other service techniques. In addition, UA training specialist John Hopkins visited the Little Red Schoolhouse—a state-of-theart training facility at Xylem’s facility in Morton Grove, IL—for instruction prior to the class.

UA offered the 20-hour course again at its August 2016 Instructor Training Program. “Sharing our expertise in hydronic heating systems with UA’s members is a natural extension of our Little Red Schoolhouse classes and our online Little Red Schoolhouse curriculum,” Konopacz said. “We are pleased to continue this valuable training with UA in 2016.”

“UA is committed to providing its members with the best teaching tools available, and this partnership with the Bell & Gossett Little Red Schoolhouse helps achieve that goal,” said Chris Haslinger, UA director of training. “Demand for HVAC service technicians is growing, and the field is becoming ever more technical in nature, [so] making partnerships with manufacturers like Xylem is essential to enhancing our members’ knowledge of the scientific and technical aspects of the trade.”

For more information, visit www.xylem.com.

Bigger Is Not Always Better

Tips from Wayne Water Systems on Choosing the Right Sewage Pump for the Job

Contractors who spend their days visiting customers for new sewage pump installations know that they often prefer larger, higher horsepower pumps. The common misconception that bigger pumps equal better performance leads to various issues and callbacks related to pumps’ short cycling. Short cycling generally occurs when the pump starts and stops frequently, leading to premature burnout. Use the tips below to educate yourself on properly sizing your sewage pump, which will prevent constant callbacks and, more importantly, dissatisfied customers.

Before starting the sewage pump installation or replacement, consider the system capacity. System capacity, normally determined by the requirements of the dwelling (number of bathrooms, kitchen appliances, etc.), is extremely important when deciding the horsepower of the pump.
Determine the total dynamic head for the system. Total dynamic head can be defined as the total height that the fluid will be pumped and is the sum of the static head and friction head. Static head is the total change in elevation from the fluid level in the pit to the highest point of discharge in the system. Friction head is an additional loss created as water flows through pipes, check valves, elbows, and fittings. Friction is a function of the velocity of the fluid and changes with pipe size, flow rate, and surface roughness.
Consider the type of solids that the pump may encounter. No two sewage pumps are the same. One may handle solids up to 1″while another may handle solids up to 2″. Improper installations, such as effluent pumps instead of solids-passing sewage pumps, can lead to pump failure and flooding.
Select the correct basin. After you have properly determined the type (horsepower, construction, switch, etc.) of sewage pump, determine if your basin will discharge from the top or the side. The average basin depth is 24″ for standard sewage pumps.
Consider the type of impeller being used in the application as well. The vortex impeller is recessed inside the pump chamber, and the spinning action creates a swirl that pumps water through the system. The advantage of the design is that the impeller is not in the flow path, which greatly reduces the opportunity for clogging. The centrifugal sewage pump, in comparison, is more effective in moving water. However, the possibility of a clog is increased because all of the water pumped must pass between the impeller vanes.
Consider your customers’ pumping needs. Will you be installing a simplex system or a duplex system? A simplex system is a single sewage pump in a standard basin and is the standard system for a level basement of average size in a single-family home. A duplex system includes two sewage pumps in the same basin. Consider a duplex system if the customer has an above-average sized basement or encounters daily instances of high water usage. Duplex systems often require the installation of a pump controller to allow the homeowner to properly manage each sewage pump individually.
Test the new sewage installation to ensure maximum velocity is reached. Often times, improper pipe sizing, among other factors, can lead to sewage pumps failing to achieve the advertised gallons per minute. Properly calculating the total fixture units (dishwasher, bathrooms, washing machines, etc.) to find the correct pump capacity will ensure that you’ve chosen the correct sewage pump for the job.
Select your pump system based on the required flow rate and total dynamic head to meet system demands. Most pump manufacturers publish performance curves indicating the flow and head capabilities of their products.

For more information, visit www.waynewatersystems.com.

Stroh Corporation Finds Wayne Water Systems Pumps Stand Up to Harsh Weather and Hard Deadlines

Even as the Stroh Corporation crew ran into an unexpected roadblock—actually, a mud-filled pit—in the midst of an urgent installation effort, they stayed on schedule, thanks to the ease of installing Blue Angel Pumps from Wayne Water Systems. Stroh was able to clear the mud and install reliable new pumps in the few days it had to meet its customer’s expectations.

Based out of Des Moines, IA, Stroh has made a name for itself as a company businesses trust when it comes to mechanical and electrical contracting. Stroh prides itself on quick, quality work that leaves the customers satisfied. Providing their customers not only the best service but also the best products on the market has been a main priority of Stroh’s since day one.

By making the switch to installing Blue Angel Pumps, Stroh found that areas such as pre- and postplanning for jobs, installation times, and call-backs related to pump failure had dropped dramatically. “They’ve crafted a rugged, professional pump,” said Dan Whalen, mechanical project sales member at Stroh. “Often times, we’re called out to large businesses that require our immediate attention. We need products that offer us the ability to supply our customers with the most durable, job-ready products on the market, at a moment’s notice.”

“Because of prior experiences, we knew getting the basin and pump installed would be a breeze; it’s one of the reasons we choose the T50E.”

—Dan Whalen, Mechanical Project Sales Member, Stroh Corporation

Never has this been more relevant than on a recent call to a jobsite at Helena Industries. As heavy rain hammered Des Moines, Helena experienced flooding at their shipping and receiving dock. With shipping and receiving sidelined, Steve Kloewer, maintenance manager at Helena Industries, put in a call to Stroh. “We had experienced flooding at this particular loading dock location in the past, and as a direct result of the inability to ship, we’ve had to apologize to quite a few customers,” said Kloewer. “When we put the call in to Stroh, we made it very clear that we needed the job done quickly, and we needed a product that could withstand heavy rain and the harsh winters.”

With under a week to assess the jobsite, excavate, and install the new effluent pump and basin, Stroh got to work planning immediately. “Typically, we take our time during the planning phase; however, it was made abundantly clear that this loading dock needed to be drained and cleaned up as soon as possible,” said Whalen. Picking a product that would be durable enough to last 10 years, heavy-duty enough to pass solids, and easy to install would prove easy for Stroh. Whalen selected Blue Angel Pumps’ T50E ½ HP Submersible Cast Iron Effluent Pump for the job. “We’ve had great success partnering with Blue Angel Pumps in the past,” said Whalen, “When we took into account how positive feedback has been from past clients in regards to their Blue Angel Pump, including the fact that it is assembled in the U.S., it was a no-brainer for us.”

The T50E ½ HP Submersible Cast Iron Effluent Pump checked all of the categories that Helena Industries had required. It included ½ horsepower (HP) performance, with a max flow of 78 gallons per minute, a cast iron motor housing to extend the life of the pump, and the capacity to withstand below-freezing temperatures. It also included a corrosion-resistant thermoplastic impeller and the ability to pass up to ½” solids, which would keep the shipping and receiving dock at Helena free of water.

Once Stroh had picked the product they would use, it was time to get to work. Planning as efficiently as possible, work was started to drain the loading dock of the existing water. After draining the standing water, Stroh began to excavate the area and hit a roadblock. Because of the heavy rain the week before, mud had filled the existing sump pit. “We had no idea the situation was so bad. We now understand why the area flooded so often,” Kloewer explained.

With only a couple days left to complete the project, work was started to remove the current pit and mud. After clearing the area and existing pit, the new basin and Blue Angel Pump were installed. “The installation process was extremely quick,” Whalen said, “Because of prior experiences, we knew getting the basin and pump installed would be a breeze; it’s one of the reasons we choose the T50E.”

“There’s a reason we decided to approach Stroh with such a stringent deadline,” said Kloewer. “We had a unique situation that was directly affecting how we provided for our customers. Given the situation, the roadblocks that stood in the way, and how quickly Stroh was able to complete the project, we’re walking away completely satisfied with this collaboration.”

“As our industry advances and new techniques are discovered that make the job easier for contractor and customer, we’re always looking for ways to improve our processes,” said Whalen. “The collaboration between Stroh and Blue Angel to provide Helena the best service and quality, easy-to-use products in such a short amount of time makes this a win-win for us.”

For more information, visit www.waynewatersystems.com.

Geiler Plumbing Cuts Installation Times with Wayne Water Systems’ Blue Angel Pumps

Geiler Plumbing found that using Wayne Water Systems’ Blue Angel Pumps cut down their installation time, improving overall productivity. The new Blue Angel Pumps’ Pre- Assembled Back-Up and Primary System combines all the components needed for a sump pump with a high-quality backup pump and an autodialer that can notify up to five numbers.

“It’s definitely easier (the installation). You’re not playing with acid, and you don’t have to put prongs in anywhere and make sure you have everything wired up correctly,” said Jose Varos, technician for Geiler Plumbing. “With the old ones, you’d have about 15 lead wires coming over and each one has to be hooked to a certain side. It’s nice that they (Blue Angel) color-code all of them.”

The cast-iron primary pump pushes 60 gallons per minute, while the fully submersible thermoplastic backup pump pushes 47. The backup system includes connection ports for third-party security system notification, while the autodialer allows plumbers to input up to five numbers (including their own) to be alerted in the event flooding occurs. Is this beneficial to the consumer? “I think it is, for quite a few reasons,” Varos said. “People never go down and look at their sump pump. I’ve gone out on inspections, and it’s full to the drain tile, where it’s been running for who knows how long.”

A bright LCD screen displays the time, date, and various messages about the current state of the primary and backup pumps. The system is also extremely quiet while it runs. “It is super quiet. It’s very nice. The only thing I hear is the check-valve when it closes, and that’s how I know it’s actually working.” When he first installed a system, Varos said, “I expected to go downstairs and see water everywhere because of how quiet the pump was.”

Varos continued, “It’s just really nice—for ease of installation, the simplicity, and how user-friendly it is.”

For more information, visit www.waynewatersystems.com.