Gorman-Rupp Co. - Experts & Thought Leaders

Founded in 1925, the Western Carolina Regional Sewer Authority (WCRSA) is a special purpose district of South Carolina, located in northwestern South Carolina. The organization serves over 400,000 customers in Greenville County and parts of Anderson, Spartanburg and Laurens Counties, covering a total of 296 square miles. WCRSA maintains 300 miles of major sewer trunk lines and conducts operations through nine major wastewater treatment facilities located on three river basins; the Enoree, Reedy and Saluda rivers. For more than eight decades, WCRSA has been committed to protecting the public health and providing the necessary infrastructure to support economic growth in the state, despite the tightening of state and federal environmental regulations. Wastewater treatment services Celebrating 80 years of environmental stewardship, WCRSA’s goals are to be a world-class organization and to have zero violations all while being dedicated to enhancing the quality of life in its service area by providing high quality wastewater treatment services. But due to a population surge over the last 15-20 years – and to the age of one of the area’s oldest pump stations, WCRSA was challenged with the task of rebuilding the Tubbs Mountain Road #1 pump station. WCRSA was challenged with the task of rebuilding the Tubbs Mountain Road #1 pump station Originally installed in the 1960s, this particular pump station was operating at its maximum duty cycle and exhibiting telltale signs of aging. However, just prior to launching an overhaul for the pump station, WCRSA completed its participation in the EPA’s CMOM Program, whereby the Tubbs Mountain Road #1 site was identified as one of WCRSA’s top five repeat SSO (Sewer System Overflow) sites. Very small footprint As a result, WCRSA made a commitment to correct the problems associated with this SSO site within a two year period – while maintaining operation of the site during the construction and rebuilding process, so as to minimize the community’s discomfort. “This process is very difficult – and can be very expensive,” attests Tony Walton, Collection System Manager for Western Carolina Regional Sewer Authority. “The one thing that makes this project specifically difficult is space,” shares Trent Bowles, Pump Station Supervisor with the Western Carolina Regional Sewer Authority. “We’re in a developed area, so we have a very small footprint that we have to work within. Currently, the site is very compact, but the redesign is putting even tighter restrictions on space. It’s a challenge.” Uncovering new solutions As a new and smaller footprint was mandated, creativity was required to uncover new solutions Rogers & Callcott, the planning firm charged with addressing the WCRSA challenge, originally drafted the new pump station design to incorporate two 7’ x 10’ Gorman-Rupp pump stations working within a larger footprint. However, as a new and smaller footprint was mandated, creativity was required to uncover new solutions. According to Rogers & Callcott, the Tubbs Mountain Road #1 pump station is also capacity limited by the facilities that receive its discharge. Therefore, the decision was made to reroute the force main to a remote destination, approximately two miles away – whereby WCRSA could discharge into a large gravity trunk sewer that would have no pumping facilities on it, rather than building a force main to its original discharge point. Regional pump station “The day that decision was made was a big day in western South Carolina. This new pump station, with the new design, has removed a load from a regional pump station – and that is an additional benefit to the sewer authority,” shares Steve Bowen, a Consultant with Rogers & Callcott. Proceeding with the plan, the team determined the yield and the delivery conditions that would be needed to achieve their desired result. The station took into account a yield of 800 gallons per minute to achieve a total dynamic head of 160’ Because of the area served by the pumps, the station took into account a yield of 800 gallons per minute to achieve a total dynamic head of 160’. A conventional, single pump was incapable of delivering this type of volume and pressure. The plan was drafted to incorporate two Super T Series® pumps, operating in a series, one right behind the other, in order to obtain the required head. New pumping technology However, midstream, Rogers & Callcott became aware of new pumping technology that could further maximize the new station’s efficiency and performance overall – up to 30% more capacity in fact than what the team was previously hoping to experience. “Regarding efficiency, by using the new Gorman-Rupp Ultra V Series® with UltraMate® pump technology, we’re now able to use a lot more of the horsepower for future capacity too – versus the previous design, which was really at the top of the 40 HP curve,” adds Barry Harms, P.E., of the Tencarva Machinery Company, the manufacturer’s representative that serves WCRSA. Rogers & Callcott became aware of pumping technology that could maximize the station’s efficiency “That also cuts down on our size requirements for the onsite generator.” Being able to reduce the required footprint for WCRSA, while also freeing up space to allow for equipment to be better positioned for safer, more comfortable routine maintenance in the future – to clean the wet wells and things of that nature – was also key in the decision making process. Change in technology “To integrate the new technology required a quick redirect and redesign, but we went to work, modifying drawings to accommodate the change in technology,” recalls Walton. “We felt as if the benefits of the site, the savings of this compact configuration – and the fact that these pumps are really more suitable for what we were trying to do – made it all worthwhile.” The first pump of its kind in South Carolina, WCRSA concurs with the decision to use the new Ultra V Series with UltraMate. “We aren’t able to fully utilize the Ultra V Series with UltraMate initially for what it’s designed to accomplish at peak performance. However, it will give us more room, allowing us to get our equipment in and perform the work that we will have to perform to keep this station functioning for the next 20 to 30 to 40 years. That’s a lot of return of investment,” adds Walton. High-Efficiency pump The advantages that this new technology has over older technology made it well worth" “We never really had any concerns about the technology being new, because of the reputation that Gorman-Rupp has, and because of the past experiences we’ve had in working with their pumps,” shares Bowles. Rogers & Callcott concurred with the recommendation. “The advantages that this new technology has over older technology made it well worth any associated risks,” concurs Bowen. “We trust that any product put on the market by this company has been pretty well tested. If Gorman-Rupp is confident with the technology, so are we.” “As the manufacturer’s representative, when we’re introducing a new product that the industry has been needing and asking for, a high head, high-efficiency pump, there’s always a bit of anxiety because it’s revolutionary,” adds Harms. Pump station technology “But this technology has been in design for nearly two decades, and has had over 3,000 tests. We believe in it.” A custom level controller has also been adopted for this new application, integrating air release valve technology into the solution. But this technology has been in design for nearly two decades, and has had over 3,000 tests" “What we like to do with customers is attempt to custom fit the pump station technology with individual organizational needs,” shares Harms. In this case, WCRSA utilizes a level control system into the pump’s control panel. For communication requirements for the data, WCRSA relies on a RACO dialer, which is also used on all WCRSA pump stations for data monitoring. “We also have an internal polling system,” adds Walton. Sponsored training courses “We’re presently using land lines at all our facilities – and poll those stations twice per hour to ensure communications. If we don’t get a signal, then we know we’re experiencing a disruption in the system – and someone is instantly dispatched to the site to rectify the failure.” To WCRSA, the ability to monitor the pump stations is extremely important – allowing the engineering team instead to focus their time and attention on other items such as repairs and line work associated with the pump stations as well as the authority’s collection system. With the new system, the authority can now diagnose problems whenever they occur – simply by using gauge readings. To ready staff and personnel for this constant flow of information, all WCRSA personnel are exposed to ongoing, authority-sponsored training courses. Cost effective decision These teams are solely responsible for the inspection and repair of approximately 21 pump stations “In these programs, our personnel are taught the basics of centrifugal pumps, operation and maintenance, safety and trouble shooting, so that problems can be diagnosed before they become acute,” shares Harms. With maintenance a clear priority to WCRSA, the pump station crew is staffed with seven members, including a certified electrician and mechanic for each team. These teams are solely responsible for the inspection, operation and repair of approximately 21 pump stations on each of the three routes. The decision to install the new Ultra V Series with UltraMate self-priming, centrifugal pump was also a cost effective decision for the sewer authority. “Due to the inventory of parts available to us within a 24-hour period, any problem that could arise could be quickly rectified with our own staff and simple maintenance in the field,” adds Walton. Comprehensive collection systems Out of our 63 pump stations, over 50% of the stations are Gorman-Rupp stations" In all, the authority is responsible for nine different pump manufacturers throughout their comprehensive collection systems. “Out of our 63 pump stations, over 50% of the stations are Gorman-Rupp stations. By having that amount of experience with the Gorman-Rupp pumps and pump stations, we benefit from our familiarity with the technology and the company, and trouble-shooting and service are easier.” To further ensure that repairs are streamlined, WCRSA maintains an inventory of critical spare parts – in the event that a pump does have difficulty, and to support their internal ability to rebuild all of their pumps. Universal rotating assembly The authority also values the ability to use one universal rotating assembly and other spare parts for all like series pumps being used within the system. “We do have spare parts for the other manufacturers in the system, but by having a large number of Gorman-Rupp lift stations within our system, it’s just more cost-effective to be able to maintain a streamlined spare parts inventory,” offers Walton. “I’ve had downtimes upwards of 13-14 weeks waiting on parts for other pump brands. If it’s the wrong time of year...you start sweating bullets.”

Located in the southeastern corner of Pennsylvania serving a population of less than 20,000, the Newtown Township Municipal Authority’s sewer system needed three new pumping stations and rehabilitation for two existing stations. Two and a half years into the project, four stations are up and running, with the remaining station set to be live in summer 2021. The stations are Newtown Hunt, Goshen Road, Old Masters, Camelot and Springton Pointe. There was a significant community need for the pumping stations, according to Dave Porter, Project Manager and Project Engineer for Herbert E. MacCombie, the local engineering firm tasked with designing the stations. Substantial growth opportunities The eastern half of the municipality’s sewerage system was in working order, but the western half needed an upgrade in order to provide reliable and efficient wastewater management. “It was a pretty large project [considering] the eastern half of the municipality had already been sewered,” Porter said. In addition, 1,300 EDU’s are scheduled to come online as a result of the project “[In] the western half of the township, there were a lot of systems failing in a couple of neighborhoods, and we had folks that were pumping on a bi-weekly basis. So there were certain areas that were in dire need of public sewer.” Overall, the service area would provide for approximately 961,000 gallons per day (GPD) of capacity to that half of the municipality, Porter said. In addition, 1,300 EDU’s are scheduled to come online as a result of the project, marking substantial growth opportunities for the impacted community. Pumping station project The pumping station project was funded by a $35 million bond issue for sewer revenue bonds sold in October 2018. Gorman-Rupp was a vital partner to the success of the project, according to Porter. Dan Weaver, Sales Representative for Gayle Corp., a Gorman-Rupp distributor, assisted with the design early on in the project to help meet both the firm and authority’s goals of reliability and minimal service. The team came up with some unique solutions to better fit these needs. “In particular, some of the unique things that were [needed for] the job [included] the head required,” Weaver said. “Very high pressure [and] very high head pumping systems were required. Fortunately for us, that fell right into some unique products that Gorman-Rupp has.” The team designed five pumping systems, all of which use multistage pumps. Wastewater treatment plant Weaver’s team also recommended using bypass pumps instead of utilizing a generator Weaver’s team also recommended using bypass pumps instead of utilizing a generator, which he cited as an increasing trend. Using an engine-driven bypass pump instead of a generator allows for backup pumping when the power is out or when some part of the pump station is down. This was utilized at four of the five stations, as one station was large enough that a generator remained a viable option. To Porter, working with Gorman-Rupp on the pump design and execution brought peace of mind to the project, as their products are ‘the gold standard,’ he said. While three of the pumping stations were new, two were existing and rehabilitated. One of the rehabilitated sites involved essentially replacing the wastewater treatment plant, as that station has its own headworks, wet well and pumping lift station to get into the wastewater treatment plant. Regional pump station This involved coordinating around site development work. The other station that required rehabilitation was a larger regional pump station that needed to be upgraded from approximately just under 400,000 GPD to just under 600,000 GPD. The station also needed to be relocated farther away from residential dwellings. The other station that required rehabilitation was a larger regional pump station In fact, working in partnership with the communities to ensure that the pumping stations met their needs was a vital part of the overall project design, Porter explained. The team even worked to coordinate the aesthetics of the buildings with the surrounding neighborhoods, with pumping station exteriors ranging from brick to fieldstone and even cedar shingles. As mentioned, reliability was one of the key goals for all project stakeholders. Main pump stations For the main pump stations, Gorman-Rupp built a PLC-based panel with VFDs where each VFD had its own bypass reduced voltage starter, so if the VFD were to fault then the bypass would run. Furthermore, if the PLC were to fail, there is a backup float system that would run the pumps. If that failed, there is a backup engine-driven pump system that has its own level control system to further run. These three levels of backup support ensure station reliability. Gorman-Rupp also tested the completed unit at the factory test pit prior to delivery. The manufacturer even invited Porter, Weaver and several other stakeholders to witness the testing of the largest station at Gorman-Rupp. Porter describes this opportunity to see the design in action as ‘awe-inspiring.’ Multistage bypass pumps “We were fascinated to be able to see hands-on how our design, calculations and our coordination with Dan [Weaver] was able to bring this to fruition,” Porter said of the Gorman-Rupp factory trip. “It was valuable to see, first-hand, the operation they have going on there.” Beyond reliability, other elements of the overall design ensure long service life and minimal service, including the multistage bypass pumps, stainless steel impellers and stainless steel self-cleaning wearplates. A RACO alarm alert for cellular communication provides online data access and recording to ensure any issues are addressed in a timely manner.

Increasingly, end users in the construction, industrial and wastewater markets are realizing the need for higher heads or to pump liquids greater distances, over challenging topography. Professional Engineers and municipal designers have previously had little choice but to overextend pump performance limits of conventional self-priming centrifugal trash pumps, potentially shortening the life of the pump and risking safety issues in the process. Thousands of hours of research and development and years of experience have resulted in the introduction of Gorman-Rupp’s new Ultra V Series®: self-priming centrifugal trash pump. New pump technology The pump offers increased pressure/flow range, up to 170 feet of head in the allowable operating region, designed to meet the new challenges presented by end users. For pressures that go beyond the improved capability of this new pump technology, an innovative straight centrifugal, the UltraMate®, has been developed to become an integral part of the Ultra V pumping system. The combination of the Ultra V and the UltraMate produces up to 325 feet of head This patent pending staged design allows the UltraMate to be mounted directly on top of the Ultra V pump. This is accomplished by using a unique transition chamber which reduces pressure loss, increases efficiencies, and minimizes the required footprint. The combination of the Ultra V and the UltraMate produces up to 325 feet of head, again within the allowable operating region. The new Ultra V and the UltraMate from Gorman-Rupp are designed from the ground up with increased performance and serviceability in mind. Improved impeller design By featuring revolutionary new volute geometry, higher efficiency is achieved. An increased suction port size reduces friction losses, decreasing net positive suction head (NPSH) requirements. The pump also features improved impeller design geometry and nominally increased shaft speed. All of these design features contribute to the pump’s increased performance. At the same time, the pump has reduced the noise level over previous pumps while maintaining municipal solids handling requirements. The results of thousands of test have shown unparalleled performance, achieving up to 60 percent increased pressure while offering up to 40 percent increased flow over any self-priming centrifugal solids handling pumps of the same size. Peak unit efficiency is also an improvement over current self-priming, centrifugal, solids handling pumps. Improved efficiency means lower horsepower that equates to reduced operating costs. Replaceable wear plate The large back cover plate offers easy access for inspection and maintenance Available in 3”, 4” and 6” models, the pump housing is made of cast iron. The impeller is ductile iron. The pumps can be fitted with Gorman-Rupp Hard Iron or stainless steel. The pump is designed for solids handling – dirty water, trash laden – applications. By incorporating a self-cleaning feature, total operating costs are reduced since the pump is kept at peak performance. The combination of specifically developed notches on the replaceable wear plate and matching grooves in the back cover plate ensures debris is cleared away and does not hang up on the impeller vanes, causing a clog. The large back cover plate offers easy access for inspection and maintenance. The cover plate has external shimless adjustments, which also helps maintain the clearance between the impeller and wearplate, keeping the pump at peak efficiency. Self-Priming centrifugal pumps To meet demands for ease of operation, an easily removable rotating assembly is also part of the pump’s innovative design. This feature makes replacement easy - without disturbing the pump casing or piping, resulting in less downtime. Pusher bolt holes are provided to assist with removal. The rotating assemblies are interchangeable between the upper and lower pump assemblies Additionally, the rotating assemblies are interchangeable between the upper and lower pump assemblies. A positive sealing suction check valve is standard on the pump to reduce constant re-priming associated with some self-priming centrifugal pumps. An externally removable stainless steel cap can easily be removed and the check valve replaced without taking the pump out of service, or disconnecting any piping. A blowout center is provided to protect the pump should an internal pressure spike occur. Atmospheric isolation barrier The suction check valve on Ultra V Series pumps is externally removable eliminating the need to disconnect from piping for inspection or replacement. Each rotating assembly is supplied with Gorman-Rupp’s patented cartridge seal, making installation easy. There is also extra large seal oil capacity that provides superior seal face longevity. Within the seal chamber, anti-vortexing ribs to reduce internal wear are also featured. Additionally, the pump has a patented atmospheric isolation barrier to protect the bearings from contamination should pumpage move past the primary containment. Dual sight gauges allow for easy observation of oil condition and levels for both the seal and bearing chambers. The Ultra V, with up to 168 feet of usable head, will satisfy approximately 80 percent of the application requirements that currently exist. Space-Saving footprint The rotating and coverplate assemblies are interchangeable with the first stage When extreme head requirements are encountered, the UltraMate may be added to the configuration to reach up to 325 feet of usable head. There are just two components the Ultra V and UltraMate do not share, which means parts inventories are kept to a minimum. The rotating and coverplate assemblies are interchangeable with the first stage. The UltraMate is staged directly on top of the Ultra V, offering end users a space-saving footprint, which can be a significant point of savings. Further, optimizing floor space allows for several innovative motor arrangements powering the pump. It is, in essence, two pumps in one. Minimizing friction loss The transition chamber between the Ultra V and UltraMate pump is direct, minimizing friction loss and maximizing the unit efficiency. The second stage also has the patented SmartScroll® discharge feature that allows it to be rotated in 90-degree increments to a variety of orientations, offering installation flexibility while easing plumbing restrictions. New pump technology is designed to meet – and exceed – the new challenges in the construction, industrial and wastewater markets. Professional engineers and municipal designers now have more choices in pump applications.