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Flow meters are some of the most versatile and integral components in any fluid handling system. From agriculture chemical production to water treatment facilities, meters offer a reliable means to monitor how efficient your operation is and provide a tangible reading to identify potential issues within the plumbing system. This makes choosing the right flow meter for your application even more important. Selecting the wrong meter causes inaccuracies within your flow monitoring processes and creates inefficiencies throughout the rest of the system, not to mention significant unintended costs.

Dultmeier Sales is here to ensure that doesn’t happen.

In this guide to flow meter selection, we’ll take a look at several common meter types and the various applications in which they are used. We will also highlight some key considerations to keep in mind so that you always choose the best flow meter for your application needs. So, without further ado, let’s get started.

How to Choose the Right Flow Meter

Simply put, a flow meter is a device that measures the flow of material—typically either liquids or gases—through a pipe. The flow meter then calculates the volume and flow rate of the product, referred to as the “fluid,” being measured. Flow meters are, however, more complicated in practice.

Fill-Rite mechanical flow meters & digital flow meters

For one, no two meters are exactly alike. Depending on application and metering needs, you may have several meter options or a single very specific one from which to choose. Complicating things further are the many external considerations your meter must satisfy in order to accomplish its intended purpose. As they say, the “devil is in the details,” and the same goes for choosing the best flow meter for your application.

Below are some key characteristics to keep in mind when selecting the proper flow meter:

• Accuracy & Repeatability
• Type of Fluid (liquid, gas, slurry, steam)
• Density
• Viscosity
• Conductivity
• Temperature
• Pressure
• Flammable/Oxidizer
• Corrosiveness/Toxicity
• Flow Range/Turndown
• Materials of Construction
• Environment/Location & System Configuration
• Hygiene Requirements (pharmaceutical, food processing, etc.)
• Costs
  • Initial Investment
  • Installation
  • Long-term Maintenance

While the meter you ultimately select should ideally meet every factor above, ensuring it meets the most important ones for your operation will help guarantee you receive the best results. Let’s dive into a few of the main ones on which you should focus.

Accuracy & Repeatability

Near the top of the list when evaluating flow meter specs is flow meter accuracy. Accuracy is how close a measurement is to the actual true value passing through a system. Expressed as a percentage (i.e. +/- 1%) accuracy represents how close the meter’s output is to its calibrated parameters. Generally, the lower the percentage, the more accurate a meter is.

However, accuracy is not the only side of the coin. Repeatability, or the production of like outcomes under the same conditions, is perhaps even more important when evaluating which flow meter to choose. This is because accuracy is only reliable so far in as its consistency. As you can see below, repeatability is possible without high accuracy, but high accuracy is not achievable without repeatability.

Flow meter accuracy & repeatability

If your flow readouts are unreliable—meaning you receive inconsistent results despite the same conditions—then you aren’t gaining any value. Likewise, if your flow volume falls short of or exceeds your meter’s rated flow range (also known as turndown), you won’t receive accurate readings either.

Precision readings go hand in hand with any well-tuned operation. Choosing the best flow meter accuracy and repeatability percentages that meet your application requirements ensures your system maintains the precision readings you desire.   

Liquid, Gas, or Semi-Liquid?

The type of fluid you work with is another big factor when choosing which flow meter best fits your application. Fluid type breaks into four categories: gas, liquid, slurry, and vapor—each with it's own unique characteristics.

Properties such as fluid density, temperature, viscosity, and corrosiveness/acidity all must be determined before a final selection. This ensures you avoid choosing a flow meter incompatible with the fluid type you are attempting to measure. Electromagnetic flow meters, for example, won’t work with non-conductive fluids like hydrocarbons. Likewise, few meter types are capable of measuring slurries because of their unique semi-liquid characteristics.

Illustration of how slurry particles behave between homogenous & heterogeneous mixtures

Here is a shortlist of flow meter types commonly used for the four fluid categories:

• Gas: Coriolis, Thermal Mass, Positive Displacement, Turbine, Variable Differential Pressure, Ultrasonic
• Liquid: Coriolis. Thermal Mass, Positive Displacement, Variable Flow, Paddlewheel, Turbine, Variable Differential Pressure, Ultrasonic, Electromagnetic  
• Slurry: Coriolis, Electromagnetic, some subsets of Differential Pressure
• Vapor: Vortex, Ultrasonic, Floating Element

While not comprehensive, this list should offer a good starting point. That said, not every meter listed may work for your specific setup or needs. For instance, if your operation handles multiple fluids, you’ll want to ensure that the meter you go with is compatible with all fluids—not just one. Otherwise, you likely spend valuable time calibrating your flow meter each time you handle a different product or troubleshooting why your inventories are off from your readouts.

Location & System Configuration

Meter location, as in real estate, is another major consideration. Will the flow meter be installed inside a controlled environment or outdoors in the elements? Is space a non-factor, or must size be considered? Certain flow meters even require stretches of straight pipe before and after the meter to generate accurate flow readings.

As a rule of thumb, pipe lengths of 10X (where X = pipe diameter) are needed before and after a meter for straight runs of pipe. So, if your plumbing’s diameter is 2” you would need 20” or approximately 2 feet of pipe before and after the flow meter. This goes for just about any meter type, but it is always best to check the manufacturer’s specs.

Also, keep in mind horizontal or vertical mounting. Some meters can be mounted in either orientation while others must be one orientation or the other. Variable flow meters, for example, rely primarily on gravity in order to measure flow rate. Thus, they must be installed vertically to work. Determining how and where a meter will be installed while choosing a meter saves installation time and avoids costs related to unintended system reconfiguring.

Differentiating Between Volumetric vs. Mass Flow

Before we breakdown various flow meters, it is important to say a word on flow measurement. While there are many types of flow meters, most used today fall under two primary categories according to how they calculate flow: volumetric and mass.

As their name suggests, volumetric flow meters measure flow by calculating the volume of a fluid. Flow is often directed through an intrusion metering device such as a turbine or orifice plate, which then measures fluid velocity proportionally to the volume of matter passing by. Volumetric flowmeters make up the majority of meter types today and include turbine, magnetic, positive displacement, ultrasonic, and vortex meters to name a few.

Volume flow vs. mass flow within a cylinder

Mass flow meters, meanwhile, calculate flow rate by measuring the mass of a fluid. Mass meters have become increasingly popular due to their precision performance and truer reading of product flow compared to older metering technologies. In the diagram above, for instance, the product volume significantly changes depending on the position of the piston—even as mass remains the same. Today, mass meters have more or less become synonymous with Coriolis mass meters, but other types do exist. We’ll discuss how mass meters work later in the article. 

Whether you choose volumetric meters and mass meters depends on your application and metering needs, as well as your operational preferences and cost differences. In the end, you can still calculate volume to mass or mass to volume so long as the fluid density, surrounding temperature effects, and other conversion factors are all understood. 

Comparing Flow Meter Types

There is, unfortunately, no such thing as a universal flow meter. Each flow meter type has fluids and applications for which it is well suited, and similarly, ones for which they are not. The following is a breakdown of some of the most common types of flow meters and the pros and cons of using each one.

Positive Displacement Flow Meters

Pros

• Accurate across wide flow ranges
• *Can handle very viscous fluids
• Versatile applications—simple, reliable design
• Require no power supply
• Cost effective

*Thicker viscosity fluids create larger pressure losses & reductions in flow rates

Cons

• Requires medium to high flow applications
• Experience greater pressure drops
• Larger/heavier than other meters
• Not recommended for dirty fluids or gases
• Some subsets require constant lubrication
• Many moving components need regular maintenance and replacement

Positive displacement (PD) meters consist of chambers featuring mechanical components that rotate in relation to volume flow. As fluid passes through, the reciprocating components—generally a type of gear, vane, or diaphragm—divides the fluid into fixed, metered volumetric units. The number of units rotated through within a specified time frame directly correlates to flow rate. Subtypes include screw meters, rotary vane meters, diaphragm meters, reciprocating or oscillating piston meters, and helical or oval gear meters.

TCS 700 Series Rotary Fuel Meter with Register

Since PD meters only measure flow while fluid passes through, they’re ideal for applications where metering is crucial to calculate fluid usage. The TCS 700 series rotary vane meters, for example, are widely used in oil and gas custody transfer industries, while diaphragm meters are commonly installed on residential or municipal water and gas lines. Their fluid driven design additionally makes positive displacement flow meters one of the more cost effective options since they require no outside power supply to operate. However, these meters are ill-suited for impure fluids such as wastewater or slurries, as the suspended soils can clog or slow the reciprocating elements and create inaccurate readings.

Electromagnetic Flow Meters

Pros

• Obstruction-less/No moving components
• Highly accurate—unaffected by density, viscosity, turbulence, or pipe configuration
• Can handle wide flow ranges & multiple fluid types
• Zero pressure drop
• Bi-directional
• Cost effective

Cons

• Cannot measure gases, vapors, or non-conductive liquids
• Limited fluid temperature range
• Interference possible with certain suspended fluids
• Specialized subsets can be expensive

 

Electromagnetic flow meters, also known as magnetic flow meters or magmeters, are rather unique in the technology they use to measure flow. Magmeters feature two parts, a transmitter and an inline sensor, the latter of which features coils that generate a magnetic field. When a conductive fluid passes through the field, a voltage is produced proportional to flow. This flow principle is known as Faraday’s Law.

 

Unlike other meters, magnetic flow meters can measure fluids regardless of fluid density, viscosity, or flow turbulence. This makes mag meters highly accurate and reliable across a wide range of solutions. Additionally, their design features no obstructions in the pipe, making these meters ideal for a wide spectrum of applications, from highly sanitary liquids to slurries and highly corrosive fluids. Electromagnetic meters can be found in industries such as pulp and paper, metals and mining, food and beverage, water and wastewater, chemical transfer, and many more.

Magnetic meters, however, only work with conductive fluids. This means hydrocarbons such as oils or gasolines or deionized liquids are not recommended with mag meters. Suspended solids, such as those found in various ag chemicals and fertilizers, can also sometimes pose a problem. The suspended soils, which may not be conductive, can interrupt the magnetic field and throw off the reading’s accuracy. Newer, specialized magmeters such as slurry magmeters are engineered to counteract this magnetic interference. However, these units generally feature heftier price tags compared to standard models. 

Turbine Flow Meters

Pros

• Highly accurate
• Cost effective
• Capable of measuring low flow rates
• Versatile applications—simple, reliable design

Cons

• Not recommended for dirty or suspended liquids
• Require straight pipe runs for best results
• Limited to certain pipe sizes
• High flows rates can cause damage or inaccuracies
• Moving components need regular maintenance and replacement

Like paddlewheel or propeller flow meters, turbine meters feature a multi-bladed rotor mounted inline to fluid flow. Sensors attached to one or more of the turbine blades transmit the number of revolutions the turbine makes. The speed at which these revolutions happen is proportional to volumetric flow rate. Similar to positive displacement meters, turbine and paddlewheel meters only measure flow when fluid mechanically acts upon their metering components.

 

Because turbine meters provide accurate readouts in relation to linear flow—even at low flow rates—they are widely used in the oil and natural gas, custody transfer, and petrochemical industries.  In fact, turbine meters are often used to help verify accuracy on other meter types.

Turbine meters aren’t without their limitations, though. For starters, turbine meters are not well suited to handle dirty or highly viscous fluids, as the turbines can be easily fouled by the soils. These meters also require straight runs of pipe before and after the meter to stabilize flow for the most accurate results. Additionally, larger pipe diameters are incompatible from an engineering standpoint. This limits where and for what applications turbine meters can be installed. Finally, as with any technology with moving components, regular maintenance is necessary to keep these meters in peak performing condition.

Coriolis Flow Meters

Pros

• Extremely accurate
• Low maintenance
• Can handle a wide spectrum of flow ranges
• Compatible with many dirty, corrosive & difficult to handle fluid types
• Versatile installation—no straight pipe runs required
• Serviceable without removing from pipeline
• Easy in-field calibration
• Capable of measuring gases

Cons

• Expensive initial investment
• Not suited for low pressure gases
• Limited to certain pipe sizes

Coriolis meters, more commonly known as mass meters, differ from other meter types in that they measure mass flow instead of volume flow. These meters also feature a unique means of calculating flow rate based upon the Coriolis Principle. Check out the video below for a quick look at Coriolis meter technology.

 

Advantages of Mass Meters

Mass meters generally hold an NTEP certification and are widely used in legal-for-trade (resale) applications. In the Dultmeier Sales world, this generally means fertilizers or chemicals with respect to the agricultural industry. Back in the 1990s, Dultmeier Sales partnered with Kahler Automation to offer some of the first automated solutions for fertilizer/chemical plant automation. 

The mass meter was at the heart of the system because it was new technology that allowed end-users to sell using the real-time density of the product – a truer way to meter liquids. For example, water is known to be 8.34 lbs. per gallon at 70⁰F.  However, as temperature drops, the weight of water increases. Thus, the solution of water becomes denser as the ambient temperature drops. This would mean static volumetric calculations would be off if one pumped 1000 gallons of water and converted to 834 lbs. (using 8.34lbs/gal as the constant conversion factor) if the water were only 50⁰F. 

This same principle happens with fertilizer and chemicals – as they are generally water-based solutions.  Volumetric meters of the time; however, were unable to account for this change in density in relation to volume flow. Take this scenario for example, which was quite common in the 1990s and early 2000s:

Let’s say that it’s 40⁰ F. and we’re loading a 10,000 gallon tender trailer, running 32% Nitrogen into the vessel. We’re using a paddlewheel meter as our measuring device and pumping the product into the vessel. Once we reach our hit point of 10,000 gallons – the automated equipment shuts down and we send our trucker to the scale. The scale breaks in 20 lb. increments. 

Our potential for error:

• Paddlewheel meter runs at approx. +/- 2% accuracy (mass meter is +/- .3% accuracy)
• Paddlewheel cannot determine density reading, so we have a static calibration factor that was calibrated at 70⁰ F. (or another temperature) and we are using that static factor to now calibrate pounds to gallons at 40⁰ F.
• Scale breaks in 20 lb. increments vs. mass meter measuring in increments of 1/10th of a pound
• Scale cannot account for “slosh” or movement of liquid as truck stops abruptly on the scale

Considering these many variables and the potential for error, it’s no wonder why inventories could, and often would, be way off come year-end. We know that a solution’s density changes constantly if in an ambient environment. For this reason alone, mass meter technology is the preferred method of measurement in many instances. By using a mass meter that can continually read this fluctuation in density on-the-fly, we offer our customers a better method to dispense and record inventory.

Automated Mass Meter Systems—Praxidyn

MixMate Flow Stack System

Choosing the right flow meter for your application can often come down to dollars and cents. Coriolis meters with automated equipment controls like what Praxidyn offers can provide a more accurate way to measure and sell fertilizer and/or chemicals. Praxidyn has a complete line of automated meter systems that fit almost any application, from grower specific operations to global industrial applications. Analysis has proven that an automated system can pay for itself in just one season – based solely on shrinkage/cost savings alone. Figure in the savings from enhanced efficiency and mass meters more than pay for their high initial investment costs.

Flow Meter Price, Performance & Popularity

Unfortunately, there is no universal flow meter that works for every application. Depending on how diversified your operation is, that could mean multiple types of flow meters are needed. While it is fair to research the most popular meters for your industry, don’t buy the first meter you think will work. 

Price, quality, and other key factors do play a significant role in a flow meter’s overall performance. Simply because everyone else uses a certain meter does not mean you should be. Low purchase cost, for instance, shouldn’t be the deciding factor in choosing the best flow meter for your application. When choosing a flow meter, you have to consider not only the initial purchase price, but the overall lifetime costs and long term returns on investment, too.

 

For instance, while a Coriolis meter boasts a hefty price tag at initial investment, it provides a great ROI because less maintenance and greater product savings are realized over the long run. Mass meters’ exceptional accuracy, versatile flow ranges and fluid compatibilities, minimal wearable parts, and the ability to recalibrate without removing the meter from the pipeline all translate to fewer dollars spent overall. When it comes to the bottom line, spending more money upfront can outweigh years of hemorrhaging dollars spent repairing or replacing inefficient meters.

That said, not every operation needs an expensive, high-end flow meter. It’s a good idea to run a cost assessment evaluating application needs against initial investment costs and long term cost savings. This way you have the best picture of whether a certain meter is practical or worth the price tag over the long haul. If you need help assessing meter options and determining what is best for your application(s), we are always just a phone call away at 1-888-677-5054.

Final Words

We hope this article has provided some insight into the world of flow meter solutions. Although we covered some of the most common types, these are by no means the only flow meters out there. Choosing the best type of flow meter for your application all starts with knowing what you need and researching your best options. Compare all associated costs—both short and long term—and avoid making a decision based on price tags alone. Ultimately; however, the manner in which you choose to meter is entirely up to you.

If you have any questions regarding flowmeter selection, give us a call at 888-667-5054 or dultmeier.com. Dultmeier Sales carries a diverse inventory of chemical and water flow meters, flow meter repair parts, and flow meter accessories. No matter what meter your operation requires, our experience and technical expertise will help make sure you select the right one.

Pressure tanks are used in a variety of applications, but a common usage is system efficiency.  For example, one reason someone might install a pressure tank in a plumbing system would be to keep the pump from constantly running.  In doing so, the pressure-regulating tank increases the longevity of the pump/motor and reduces maintenance and down time – ultimately resulting in lower operating costs.  Let’s dive into a step-by-step how to of sizing a pressure tank.  

 

Info You NEED to KNOW Before Starting

Before beginning the process of sizing a tank, there are a few important important input data points to know in order to properly size a pressure tank:

1. Flow Rate
2. Cut-in/Cut-out Pressure
3. Target Run Time

A general rule of thumb, that most manufacturers suggest, is a run time of less than one minute if the horsepower is less than 1HP.  If the motor is over 1HP, then a good guideline to follow, is a run-time of 2 minutes or more.  Always confirm this, with your tank manufacturer of choice, as guidelines can vary.

 

General Rule of Thumb for Sizing a Pressure Tank

Generally, as a rule of thumb, one can follow these guidelines when sizing a pressure tank:

1. 0-10 GPM: 1 gallon of drawdown per 1 GPM of flow
2. 10-20 GPM: 1.5 gallons of drawdown per 1 GPM of flow
3. 20 GPM+: 2 gallons of drawdown per 1 GPM of flow

Drawdown can be defined as the amount of volume loss in the tank as the plumbing system “draws” off this pent up pressure. After all, the purpose of a pressure tank is to maintain pressure in a given system and give the pump a break. This way, the pump doesn’t need to run constantly to remain at system pressure. While a pressure tank can appear costly up front, it will save in the long run. Less run time for the pump means less maintenance and less money in energy costs. 

There are various orientations of pressure tanks and the most common are horizontal, inline, and vertical.  Be sure to determine which orientation works best for your plumbing setup.  

Once we have identified our flow rate in gallons per minute (GPM), have identified our cut-in/cut-out pressure, and confirmed our target run time – we must determine what cut-in/cut-out pressure we want to set the system at.  

 

Pressure Tank Sizing Explained

An important equation to remember when sizing a pressure tank is below:

Flow Rate X Run Time = Tank Draw Down Capacity

Example: 

Let’s say we have a pump that produces 5 GPM and is ran by a ¾ HP motor.  Since I’m operating a motor that is less than 1 HP, we are going to assume that “ABC Manufacturer” recommends a 1-minute runtime.  We want to design this system to cut-in (turn on) at 40psi and cut-out (turn off) at 60psi.  

5 (Flowrate) X 1 (Runtime) = 5 gallons of Draw Down (at 40/60PSI)

So, I will need to select a tank that allows for 5 gallons of draw down at a pressure setting of 40PSI cut-in and 60PSI cut-out.  If I need a vertical tank, I could select a WOMAX-220.  If my plumbing layout would accommodate a horizontal tank better, I could select a WOMAXH-220.  This would give me approximately 3.5 minutes of run time before the pump would cycle back on. Horizontal pressure tanks have a plastic pump stand so you can maximize space when designing a plumbing system. This is certainly a nice feature when working in confined spaces where space is at a premium. 

 

Relationship Between Pressure & Tank Size

An important thing to remember, the higher the operating pressure – the larger the tank must be. Pressure and tank size have a direct correlation – as one increases, so does the other.  The higher the pressure setting, the less the drawdown is and thus, the need for larger tank capacity.  

 

After we have these three points determined, we can then proceed with sizing a pressure tank.  Pressure settings are another important factor with any plumbing system.  The most common pressure settings are 30/50; 40/60; 50/70.  Most manufacturers will have a pressure tank sizing chart that will allow viewers to quickly size a tank’s drawdown based upon their system’s pressure settings. 

We can supply you with this information on the Wilo MaxAir® product line if you want to get into the details. Just give us a ring or visit www.dultmeier.com 24/7. Here is a drawing of a Wilo MaxAir® horizontal tank that outlines some features which set this product line apart from the rest of the pack and really make it one of the top line products in the marketplace. 

Cutaway of Wilo MaxAir Horizontal Pressure Tank

 

You can view the full offering of Wilo MaxAir® Pressure Tanks Right Here on dultmeier.com. As always, should you have further questions about pressure tank sizing or other applications – don’t hesitate to contact us.  That’s what we are here for.  Your Experts in Delivering Fluid Handling Solutions – We Know Flow!

JIT vs. Quarterly Inventory Strategies

Inventory management and the best strategy to successfully achieve maximum efficiency. It’s the long-standing question of any distribution or supply channel.  What is the best methodology to follow when managing inventory?  Just-in-Time (JIT) relies heavily on the concept of inventory turns.  The more inventory turns, the less carrying cost a supplier must maintain.  Lower carrying costs result in a lower market resale price.  

JIT is one method by which suppliers can help control their costs.  Why order a year’s worth of inventory when you can rely on the supply chain to help “offload” some of those costs on your partners?  Furthermore, a JIT strategy allows the business to ebb and flow with demand fluctuations within their respective market(s). 

In certain instances, a JIT strategy does hold merit.  However, at Dultmeier Sales we have a contrarian approach to this type of strategy.  While we have certain products lines where a JIT strategy does work, there are other lines where we cannot afford to not have the products on the shelf – and ready to ship promptly.

Our business is an extremely cyclical one.  Roughly 50% of our revenue comes in about a three-month period.  Due to the nature of our business, we must have inventory on-hand.  Therefore, we load up heavy in the fall and winter in preparation for the spring season.  In doing so, we allow our customers to use a JIT approach to run their businesses.  This helps our customers lower their carrying costs & provide them with fast deliveries.  Furthermore, when critical equipment failure occurs – we have the products on the shelf to get them back to operational status – as soon as possible.  

What We Do For You

We pride ourselves on being a business partner of this nature.  Inventory levels are something we constantly focus upon and look for ways in which we can continually provide better service levels with higher order fill rates and faster, more accurate shipping.  

What We Can Do For You

Because let’s face it, when you’re down and out – you need the part or piece of equipment fast.  By maintaining considerably larger inventory levels than the competition, we can effectively promise a 95%+ fill rate on stock orders.

That means if you order 20 items – we have 19 in stock ready to ship promptly.  And most of the time it’s consolidated from one origination point – meaning we help lower and control freight costs for our customers – by reducing multiple shipment orders.  Consequently, one shipment means one freight bill. 

Who We Are

In addition to healthy inventory levels, we pride ourselves on warehouse accuracy.  In all honesty, if we have the item on the shelf, but cannot get it to the customer for whatever reason – we didn’t live up to our promise of impeccable service.  Therefore, it has been and will continue to be our long-standing goal to exceed and maintain 99.8% shipping accuracy.  This means we accurately ship the item(s), and quantities, written on the sales order over 99/100 times.  

You need it – We have it. That was fast.  Pretty simple concept.  But, to produce extreme simplicity, one must solve the extremely complex.  Therefore, we continue to invest in ourselves and our operating systems.  We continually invest in our people and technology to ensure that we constantly improve and strive for the ever elusive 100% success rate for our customers.

Additional Value Added Services

We back our inventory strategy up with some of the best technical expertise in the industries we serve.  With over 250 years of combined technical experience, we have most likely run across your application question.  Furthermore, if we don’t know, we will help to provide a solution that improves the efficiency of your operation – all the while, doing our best to help lower your operating costs. We invest in our people, technology, and inventory to make your business more profitable and efficient.

We also want to highlight the fact that we have a Free Freight Program that runs throughout the year. This can further help reduce costs for our customers to help them maintain a higher level of profitability. You can check out our Free Freight Program right here. 

Careers

We commonly receive the call to help assist in properly sizing pulleys and sheaves for pump applications.  Generally, this is in high pressure wash applications but we also run into a fair amount of agricultural applications where this knowledge can be leveraged.  Pulleys or "sheaves" are commonly used for connecting pumps to motors or engines via drive belts.  Most pulleys are cast iron or aluminum construction and are offered in either fixed-bore or tapered bushing styles.

Why is it Necessary to Size Pulleys for Each Application?

For proper operation of any brand or pump type, it is critical to size pulleys and sheaves, correctly, in order to maintain correct RPM, (revolutions per minute). RPM speed is what determines the pump output flow rate - in gallons per minute, liters per minute, etc.

Incorrect pump RPM will adversely affect the pump performance.  If the pump is turning too slow - it will not give full performance.  Conversely, if the pump is turning too fast, it could cause premature mechanical failures (i.e. valve wear or elastomer failure).

Therefore, it is absolutely critical to ensure correct pulley sizing and analysis of the drive unit, (motor, engine, etc.) relative to the pump. For the sake of this discussion, we will assume standard electric motors at 1750 RPM and standard gas engines at 3400 RPM.  Do note, one must determine the rpm of their drive unit to be able to accurately calculate the pulley/sheave size.

If you start with an incorrect figure for RPM - you will size your equipment incorrectly.  This could lead to shorter equipment lifespans and/or reduced output flow rates.  Thus, ultimately a less efficient system which equates to more down time and added cost of operation.  The scope of this post will be focused towards plunger pump applications.  We assemble many units using this method in Omaha, Nebraska.  Dultmeier Sales is proud to display the Built in the USA logo on our products.  Here are just a handful of the pulley-driven pump products that we offer.

The Math of Pulley Sizing

There are complicated formulas for determining pulley ratios but in generic, layman terms, simply divide the driven component (pump) by RPM, the driver component (motor or engine) rated by RPM to get the required ratio.  In the example below, the pump RPM is 1070, for full output, while the motor is 1750 RPM.

Therefore, the ratio of the required pulleys would be:

1070 (pump RPM) divided by 1750 (motor RPM) = .611

This means the pulley ratio must be .611 to drive the pump correctly.  Hypothetically speaking, if we had a 4 inch pulley on the motor, we would require a 6.55” pulley on the pump.  That mathematical equation is as follows: 4” divided by .611 = 6.55”

For the same pump, driven by a gas engine

1070 (pump RPM) divided by 3400 (engine RPM) = .315 

If the drive pulley on the engine is 4 inches in diameter, we need to calculate 4/.315 = 12.70.  This means that the pump pulley must be 12.70 inches, in diameter, to run the pump at 1070 rpm.  You can view a technical page from our catalog here - it will help to further explain the calculation process.

Tapered Bushing vs. Fixed Shaft Bores

Most pulleys, or sheaves, are designed with either fixed shaft bores or tapered bushing hubs.  Replaceable hubs fit the required motor or pump shaft size in either inch or mm sizes - depending on the application requirement.  These hubs come with bolts to attach them to the pulley, or sheave.

 

Tapered style hubs simply fit into the pulley opening and then are tightened with two or three set screws, which draw the bushing and pulley together to make one assembly.  The pulleys are then attached to the driver (electric motor or gas engine) and driven components (pump).  The type of hub, H, SD, SH, etc. must match to a pulley with the same designation for proper fit.

Therefore, make sure to identify what type of hub you have PRIOR to ordering.

Pulleys can be measured in a number of ways. Two of the most common methods are belt pitch and outside diameter (O.D.).  When using the, most common A/B, belt pitch method, one must identify both A belt pitch and B belt pitch.  This is the pitch diameter of the V-belt you are using, (A/B) is the measurement of how the belt fits into the groove of the pulley.

 

A belts are not as wide as B belts and, therefore, sit lower in the pulley groove.  While this may seem as a minor detail - it absolutely affects the ratio measurement when properly sizing a pulley.

Pulleys are available with different numbers of grooves. The number of grooves matches the number of belts that the pulley will accept.  A two groove pulley will accept two V-belts.  A single groove pulley will only accept one belt.

Again as a general rule, (but not intended to use in every application) single groove pulleys with single belts can be used up to about 5 horsepower. Two groove belts can be used from 5-15 horsepower and three groove belts up to 25 horsepower.  Use this as a general guideline but always make sure you consult us if you are unsure of your application needs.

Two Groove Pulleys

 

For correct belt sizing, there are charts available that show the sum of the pulley diameters and the center distance they are apart, from each other.  We will be happy to supply you with one of those charts if you wish to have a copy.

For instance, the sum of the two pulleys, in the above electric motor example is 4 inches + 6.5 inches = 10.5 inches.  The mathematical equation to figure this out is as follows:

A - Pump Pulley O.D.    B - Motor Pulley O.D.

Belt Size = [A*1.57] + [B*1.57] + [2*center distance between pulleys]

76.5 = [4*1.57] + [6.5*1.57] + [2*30]

If the pulleys are 30 inches apart, center to center, then the required belt length would be 77 inches.

As the information above shows, there are many things involved in order to determine the correct pulleys required to drive your pumps correctly.  It is important to remember the larger the difference in pulley sizes, the larger the center distance required to maintain minimum contact with the smaller pulley.  We would be glad to help with any sizing for your specific applications.  Your Experts in Delivering Fluid Handling Solutions - We Know Flow!

Hydra-Flex History

Hydra-Flex was started in 2002 in a small machine shop.  The company originated as a 2-man outfit and quickly grew in ranks from there.  The core motivation for HydraFlex was driven by the simple belief to "find a better way" to produce innovative and reliable fluid handling products.

The core values that drive Hydra-Flex are Innovation, Reliability, and Accuracy.  These values are clearly visible in the products they develop.  Hydra-Flex is proud to boast its reputation as The Most Trusted Name in Chemical Dispensing.

This Eagan, MN company holds a committed focus to reduction of waste, salvage of resources, reduction in operating costs and the promise to provide exceptional - and measurable results for end users.  Located within the innovative Twin Cities community, Hydra-Flex continues to strive for nothing short of exceptional product delivery.

Hydra-Flex is listed on Inc. 5000 Fastest Growing Private Companies and winner of Best in Class at the 2016 MN Manufacturing Awards.

Chem-Flex Injectors

Hydra-Flex holds patents on chemical dispensing and nozzle technologies.  Also named one of Minnesota's Top Inventors by Twin Cities Business Magazine, Hydra-Flex continues to be recognized locally, as well as, nationally.  The underlying premise of finding a "better way" to apply fluid handling technologies guides their strategy and solutions offerings.

Taking a common design called a venturi, Hydra-Flex has revolutionized the vehicle washing industry.  A venturi is not a new idea - the venturi was actually discovered by an Italian physicist, Giovanni Battista Venturi in 1797.  A venturi induces a small portion of another fluid into a carrier fluid.  This is created by creating a pressure differential between the inlet and outlet.  Constricting the flow of the carrier fluid actually creates a vacuum, thus allowing the secondary fluid to be induced into the carrier agent.  Furthermore, mixing the two fluids together through a venturi, ensures proper and equal mixture throughout the solution.

Hydra-Flex created the Chem-Flex injector to take venturi technology to the next level.  Chem-Flex injectors use the most chemical-resistant and longest lasting components available on the market.  This includes Kynar venturi inserts, stainless steel connections, a hastelloy spring, teflon check ball and Hydra-Flex's exclusive XFC O-ring.  Chem-Flex injectors are built with the goal of finding a "better way" to induce and mix chemicals.

 

Benefits of Chem-Flex Injectors:

Small Footprint - Forget the need for large mixing tanks.  Do it inline and mount these systems on the wall - maximize the space in your equipment room.

Better Vehicle Coverage - Using the same dilution rate but increasing delivery pressure allows for less solution usage and better coverage.  Chem-Flex injectors have an application pressure capacity of 65-80 PSI versus traditional chemical dispensing systems that generally run from 25-40 PSI.

Consistency - Fluctuations in local water pressure do not affect the dilution rate of the injectors.  Because the injectors use the pump's regulated pressure you need not worry about this variable.  Thus, instilling a greater degree of consistency into your wash system(s).

Reliability - The simplistic design minimizes moving parts and, therefore, reduces the potential for failure due to mechanical wear.  We have already mentioned the added chemical resistance brought on by the internal components used in Chem-Flex injectors - this is an added reliability factor.  Rest assured - Chem-Flex injectors will stand up to some of the toughest chemicals on the planet.

Precision - Color-coded injectors (by flow rate) and metering tips (by dilution ratio) offer precise optimization and easy maintenance of the chemical delivery system.

Environmentally Friendly - Due to the fact that the solution is applied to the vehicle at higher pressure, less solution is needed to clean the same size surface.  This often results in substantial reductions in water and chemical usage.  Furthermore, the use of highly concentrated chemicals can help reduce packaging waste and freight costs.  If you can order in smaller packages you can help reduce a variable cost in freight expenses.

The Nozzles

Hydra-Flex offers five models of nozzles - each one provides a solution to various industry applications.  While there are five different models the nozzles can be split into two larger categories - Rotating Turbo Nozzles and Static, Zero-Degree Nozzles.

Rotating Turbo Nozzles

Blast-Tec Pro (1000PSI) - designed specifically for high-pressure, high-impact wash applications such as wheel blasters, undercarriage cleaning, rinsing and high pressure cleaning.

Ripsaw (3200PSI) - specifically designed for hydro-excavation industry.  An extremely heavy-duty and high impact nozzle that is ideal for pothole applications.  The cone-shaped flow patter provides 18 degrees of coverage.

Aqua-Rocket (4000PSI) - designed and engineered for the industrial cleaning industry.  This nozzle blasts a concentrated 0 degree water jet while rotating at an optimal speed to form a 22 degree cone-shaped spray pattern.  Here is a video below

Static, Zero-Degree Nozzles

Blast-Force (1000PSI) - This nozzle produces a solid-stream and was specifically designed for spinning, high-pressure vehicle wash applicators.  Constructed with corrosion-resistance tungsten carbide nozzle orifices, this critter will get the job done - and then some.

Switchblade (3200PSI) - Dig Faster.  Save Water.  Another hydro-excavation nozzle but in a stationary in design.  Cut deeper, cut faster.  A neat feature of this nozzle is the flexibility it offers.  There are individual, replaceable, color-coded nozzle pills that allow the end user to change water flow rates and pattern based upon various soil conditions.  Here it is in action:

Whether you're in the market for nozzles or chemical injectors, you need to consider Hydra-Flex as a viable option in your decision making process.  For further questions on other products we offer you can stop by our website any time you wish.  Thanks for stopping by and we hope you enjoyed this post.

Dultmeier Sales stocks valves of all different makes, models, and applications.  Here you will find all you need to know about the different types of valves we stock and the various applications they are used for.  More importantly, we will help you determine what you need to know prior to making a valve purchase.  Let's dig in...

Valve Definition & Common Trade Names

What is a valve?  What are some common trade names, associated with, the valves that Dultmeier Sales stocks and distributes?  In a nutshell, a valve is a product which is used to constrict, cut off, redirect, or regulate the flow of a liquid or gas.  While we do sell pneumatic valves we will be primarily focusing liquid, or solution, valves for this educational segment.  Some common trade names associated with the valves we stock are as follows: butterfly, ball, gate, globe, angle, needle, solenoid, check, regulating, diverter, foot, relief, unloader, backflow prevention, and float valves.

As with any product, it's crucial to identify the type of valve, the manufacturer, inlet/outlet size, operating and maximum pressures, solution temperature, and the solution passing through the valve.  It's critical to know what solution is passing through the valve to ensure proper chemical compatibility.  Knowing the solution's PH level can also be another important factor when determining suitable components and materials.

How to Size a Valve

We size valves similar to how we size pipe.  Always measure the inside diameter of the inlet/outlet port.  This will identify the size of the valve in question.  A common mistake is that people measure the outside diameter of the inlet/outlet ports of a valve.  There is one exception to this rule - if working with tubing - measure the outside diameter of the tubing.  For hose and pipe, only pay attention to the inside diameter measurement.

If flow rate is important, the coefficient of volume (Cv) of various valves can be compared.  Now, I understand that sounds rather technical.  However, in layman's terms all that means is the higher the Cv for a valve, the more flow rate will pass thru it with the same pressure loss.  In the majority of applications, this will be a non-factor but it is still important terminology to be aware of in the vast world of valves.

Manufacturer Identification & Valve Type Explained

Most manufacturers will have a metal tag on their valve bodies to identify their brand.  That manufacturer tag will identify the brand of the valve, the model, and serial number.  This is an important first step in identifying what product you currently have. That being said, let's begin with a look at butterfly valves.

Butterfly Valves

Here at Dultmeier Sales, we stock a variety of butterfly valves.  In the butterfly valve world, it's important to first determine which style of butterfly valve you possess.  The two most common styles are Wafer or Lug bodies.  A wafer-style butterfly valve has "thru" bolt holes that run along through the outside rim of both pipe flanges.  In contrast, a lug-style butterfly valve has threaded bolt holes on both sides of the valve body to allow for "end of line" applications.  Lug-style butterfly valves are, generally, less common than wafer-style butterfly valves.  Below, you will see a wafer-style valve on the left and a lug style valve on the right:

 

 

Butterfly Valve Actuators

Next, we get into the topic of valve actuation.  We primarily stock butterfly valves that are manually (seen above with handle) or pneumatically actuated with either double acting or spring return actuators.  A double acting butterfly valve actuator requires air pressure to open the valve and then air pressure to close the valve.

A spring return butterfly actuator is used in fail-safe applications.  If there is a loss of air pressure the valve will automatically close (or open) - due to the spring tension of the actuator.  Spring return actuators are used in many production plants that require system flow to cease once power is cut or lost - as mentioned above, this is a fail-safe application example.

Electric Actuators are also used in many industries.  While we don't stock electric actuators for butterfly valves - we have access to them.  Actuators can also be provided with “positioners”, limit switches and other controls.

We stock Butterfly Valves and Air Actuators from Keystone and Pratt.

Ball Valves

A ball valve is probably the most common type of valve that exists - across all industries.  It gets its name due to the fact that it actually has an internal ball that sits in a "seat".  When the handle or knob is turned 90 degrees from the inlet/outlet ports, the valve is closed and one can see the convex shape of the internal ball.  When the handle is turned parallel with the inlet/outlet ports, the valve is open and one can view through it - unhindered.

On the left, below, is an example of an air actuated, stainless steel, female pipe thread, ball valve.  While on the right, you will see a Banjo, polypropylene, manual, flanged, ball valve.

    

 

Standard Port vs. Full Port

By design, ball valves that are listed as Standard Port actually have less fluid path than the inlet/outlet ports size limitations - this is somewhat misleading to those that are unfamiliar with the concept of Standard vs. Full Port valves.

For example, if you have a 2 inch Standard Port valve your flow characteristics will be closer to that of a 1.5-inch fluid path.  The technical reasoning behind this is the fact that a smaller opening creates more friction loss (i.e. pressure drop) thus resulting in a decreased flow rate.  Standard port ball valves are cheaper than full port valves but restrict the system flow rates; somewhat.  So, if flow rates don't matter or affect your system then you can save money up front by selecting standard port valve(s) for your plumbing system.

Full port valves allow the plumbing system to realize the full flow characteristics of the valving.  If all valves in a system are two inch full port, valves then we can reasonably assume increased flow rates in comparison to a system that contains all standard port valving.  A full port valve has a slight design change that allows for this increase in flow characteristics.  While the valves may look the same externally, there are internal design changes that are not visible to the naked eye.

High Pressure vs. Low Pressure

This is another crucial step in determining the correct valve for a specific application.  If necessary, place a pressure gauge at various points in the plumbing system to determine the system operating pressure.  Never guess the operating pressure of a system.  If a low pressure valve is installed into a high pressure system, serious or fatal injury could occur.  As a general rule of thumb, anything below 150 psi is considered Low Pressure - that being said, there are valves rate for pressure less than 150 psi.

This gets back to one of our core fundamentals when selecting a proper valve - determine operating pressure and maximum pressure for the intended plumbing system.

Ball valves are a perfect example of how the same style valve can be used in multiple applications - both high pressure and low pressure.  We have some ball valve product lines that have use applications which are limited to certain industries - due to their operating/working pressure limitations.  However, we have many ball valve lines that carry over into multiple industry applications.

While we do carry many products that can be cross-utilized in various industries we always want the customer to confirm an operating pressure.  This ensures safety in application and use.  Furthermore, it minimizes the possibility of injury and lessens the chance of damage to the valve and other plumbing system components

Air Actuated & Electric Motor Driven

We carry ball valves that can be remotely operated via automation, as well.  The most common types are pneumatic (air-operated) and electric motor-operated ball valves.  Air operated are most widely used in chemical facilities, fertilizer plants, or industrial plants.  Electric ball valves are most commonly used in agricultural applications for spraying applications.  The trade name electric ball valve or pneumatic ball valve simply refers to how the valve is actuated.

When you drive down the road and see a large self-propelled sprayer, spraying in a field, you can be certain the booms are being remotely controlled.  The boom valves are remotely controlled from the sprayer cab, with the help of electric ball valves.  The sprayer operator sends a signal from his, in-cab, boom controller to turn certain sections of the sprayer boom on/off - based upon the field's specific application requirements.

We also see electric ball valves in the turf industry.  Golf courses or residential sprayers will commonly use this type of ball valve on their sprayer setups.  It is more prevalent in the turf industry due to the fact that the booms are much smaller than the agricultural industry.

Lastly, we do a fair amount of business in the liquid deicing industry.  If you have ever seen a department of roads/transportation vehicle that is applying liquid before a winter storm - you have witnessed this industry in action.  These vehicles are applying a solution called liquid salt brine (sodium chloride, magnesium or calcium chloride solution).  Electric driven ball valves are common in this industry because pneumatic valve airlines would freeze in the frigid winter temperatures.

For those interested, here is a link that further explains the process of creating the salt brine solution.  Below is a picture of a pneumatic-operated ball valve, on the left.  On the right you will see an electric-operated ball valve.

     

 

Gate Valves

A flanged gate valve is used in larger flow applications.  In the Dultmeier world, we most commonly see this style of valve used on large bulk fertilizer, fuel tank storage applications, and float storage tanks in the vehicle and fleet washing industry.  Gate Valves are generally designed with a circular handle that is turned clockwise to close the valve and counter-clockwise to open the valve.

Just as any other valve, we need to confirm the solution that will be passing through the valve to ensure chemical compatibility and then confirm the working or operating pressures that are required by the plumbing system.  Most commonly, we are supplying flanged gate valves for lower pressure ranges.  Below is a picture of a common flanged gate valve used in the bulk fertilizer industry.

 

 

Globe & Angle Valves

A globe valve is very similar, from an external view, to that of a gate valve.  However, when we look at the valves internally, they are quite different.  As can be seen from the previous section, the gate valve operates almost like a wedge or slate that constricts or completely closes off flow.  A globe valve has a different seat structure and more of a plunger that constricts or completely closes off flow.  See below:

 

 

Below is a photo of a couple different sized globe valves on an Anhydrous Ammonia application.  These valves are for a receiving bulkhead system where a plant facility will offload large bulk transports into their bulk storage tanks.  The larger valve is on the liquid line transfer and the smaller valve is on the vapor transfer line.

 

In the Dultmeier Sales world, we most commonly use globe valves in the Anhydrous Ammonia industry.  That is the same for angle valves.  The most common application we see angle valves used in would be on toolbars or supply risers for Anhydrous Ammonia fertilizer applications.  Continental Nh3 Products and Squibb Taylor are our two largest suppliers for these types of valves.  An angle globe valve can be viewed below:

 

Needle Valves

Next up we will take a look into needle valves and the various applications they can be used for.  Most commonly, we see these valves used in higher pressure applications such as car/truck wash and high-pressure cleaning.  Here is a grouping of various needle valves on our website, to further illustrate the variety of options.  That being said, we do sell a fair amount of needle valves in the Anhydrous Ammonia industry for a bleed off application.

As always, in any application we want to confirm the solution passing through the valve, working or operating pressure range, and temperature of the solution.  Below you can view a picture of a needle valve.

 

Solenoid Valves

We carry a wide supply of solenoid valves from a number of suppliers.  The most notable brands we offer are GC Valves, DEMA, KIP, Kingston and more. A solenoid valve is another example of an electric valve.  However, they are drastically different than electric ball valves.  That being said, solenoid valves can be controlled remotely and are used in a number of industries.

We most commonly use them in high-pressure vehicle or fleet washing applications, industrial applications, and agriculture or turf spraying applications.  Some users in the agriculture industry are starting to migrate away from solenoid valves to ball valves - the primary reason being the necessity for the ruggedness of a ball valve versus over a solenoid valve.  Mother Nature in combination with aggressive chemicals is an extremely harsh environment for a valve.

Normally Closed vs. Normally Open

This is an important topic to address - especially in the realm of solenoid valves.  If a valve is "normally closed" it means that the valve is closed in its uncharged state.  More simply put, if there is no electrical current passing through the valve coil then then it will remain closed.  If a valve is "normally open", that means the valve is open in its uncharged state.

Various applications will call for either style.  Coils in these valves can be 12 volt, 24 volt, 110 volt and even 240 volt, which allows for a wide and versatile range of applications.

For example, in the vehicle washing industry, we may want to have a weep application on a spray gun.  We would do this to ensure the gun doesn't freeze shut in lower temperatures.  Therefore, we want ambient water to continuously run through the system or spray gun - if a loss of power occurs.  So, in this instance we would want to ensure a normally open valve be installed in this type of a plumbing system.

Solenoid valves are still highly used in the car/truck wash industries due to the fact that they are generally stored in temperature-controlled environments while limiting exposure to the harshness of the natural elements.

Check Valves

Next up, we will look into the world of check valves.  This product is used to prevent backflow of a solution in a plumbing system.  For instance, a check valve would be utilized when pumping a solution up a vertical pipe and you do not want the solution to backflow, due to gravity, when the pump is turned off.  A check valve is a form of backflow prevention.

Furthermore, check valves keep a plumbing system charged.  By keeping the system charged we can ensure more efficient delivery of product and reduce the number of air pockets that are present in the plumbing system, which reduces pump priming time and other potential pump problems.  The more efficient a plumbing system is - the less it costs to keep it running.

Types of Check Valves

There are multiple types of check valves and each has its own benefits.  We will briefly touch on the different types, here.  First, is the most efficient type - in terms of maximizing flow characteristics.  The swing check valve allows for maximum flow characteristics due to its design that reduces restrictions (i.e. a high coefficient of volume).

Regardless of the check valve style, we need to remember the cracking pressure.  The cracking pressure determines the PSI at which the valve opens.  Therefore, if a check valve has a cracking pressure of 2 psi it will not open until the plumbing system generates an operating fluid pressure greater than 2 psi.  Below is a cross-cut section of a swing check valve:

 

Secondly, we have a ball check valve.  This type of check valve has a preset mechanical spring that allows the valve to open based upon a pre-determined working pressure.  These types of check valves are commonly used in high-pressure applications such as car and truck wash, but also within industrial and agricultural applications.

 

Lastly, there is a plunger style check valve.  This style is pictured below:

 

Things to note when ordering a check valve:

1. Operating and maximum pressure requirements
2. Solution or product passing through the valve - check for chemical compatibility
3. Cracking pressure
4. Inlet/Outlet size
5. Body type (wafer, NPT, flanged, etc)

Shop Check Valves Now

Regulating Valves

A regulating valve can technically be any valve.  In this sense, if you can constrict or control the flow by manipulating the opening threshold of the valve - you have just regulated the system flow.

To that note, we are going to look at this section with this one caveat in mind - a regulating valve needs to be remotely controlled.  To do this, let's first look into electric motor driven valves.

There are certain types actuators of ball valves or butterfly valves that manipulate the flow rate of the solution by opening or closing the valve stem a to a certain degree.  Without getting too technical this is done in conjunction with some type of flow monitor that is able to communicate with the valve actuator through a control mechanism.

This control mechanism can be a simple rate controller in a sprayer cab or as complex as a computer dashboard in a chemical production facility.  The regulating valve communicates to the flow monitor through the system controller to reach and/or maintain the desired flow rate.  This controller can be a simple rate controller or a complex computer system.

Regardless of the application - in order to remotely control a regulating valve we must have a controller that sends a signal to the valve based upon the desired flow rate of the operator.

As always, any application we want to confirm the solution passing through the valve, operating pressure range, and temperature of the solution.

Diverter Valves

A diverter valve functions very similarly to a remotely controlled regulating valve.  The main difference between a regulating valve and a diverter valve lies within the functionality.  A diverter valve is designed only to guide product flow through a system.  Therefore, the most common example of this would be a three-way ball valve.

We look at this section with the same caveat in mind - a regulating valve needs to be remotely controlled.  To do this, let's first look into electric motor driven valves.

The diverter valve would be remotely controlled through a similar mechanism as a regulating valve.  The main difference is that the diverter valve "diverts" flow down fluid path A versus fluid path B - based upon the desired location sent by the controller or computer.

Foot Valves

Foot Valves are commonly used in transfer systems that require the pump to maintain it's prime.  A foot valve is essentially a type of check valve.  Foot valves are placed at the beginning of a suction line and are generally designed with some type of a strainer or screen to protect the plumbing system from sucking in foreign objects.

If you recall the design of the check valve, you will remember that a check valve closes when there is backflow pressure applied on the spring check.  This forces the valve to close and keeps the system suction line primed, with liquid - thus increasing the overall efficiency of the plumbing system.  The less time it takes to prime the pump the more efficient the plumbing system becomes.  Below you can view a diagram of a plumbing system that includes a foot valve, with strainer.

 

Relief & Unloader Valves

Relief and unloader valves are commonly used in higher pressure situations with positive displacement pumps.  These valves are used to protect system components from dead-head scenarios.  A positive displacement pump will continue forcing product downstream in a plumbing system until there is a system failure such as a burst pipe, fitting, hose, etc.  Thus, the term: dead head scenario.  To help combat this scenario, relief and unloader valves were designed.  Here is a diagram that explains a relief valve scenario

Wash Diagrams

This video will explain the difference between the two styles of valves.  As always, Cat Pumps does an amazing job explaining content.

Back Flow Preventers

In any wash down application where an operation has a water supply line connected to a public water source then it's absolutely necessary, by regulation, to have a back flow prevention valve in place.  We distribute for Watts and commonly sell these units in vehicle/fleet wash applications, industrial applications and fertilizer/chemical facility applications.  A backflow prevention system products the main water supply in the scenario where a local business would have a system failure and back up chemical, fertilizer, hazardous material, etc. into the main water supply - backflow prevention systems inhibit this scenario from taking place.

Below is an example of a Watts back flow preventer

 

Float Valves

Float valves are used in a wide array of applications.  Virtually anywhere you need to maintain the level of a supply tank - you can leverage the assistance of a float valve.  Some common float valve product lines that we distribute and carry include BOB Valves, Jobe Valves, Hydro Systems, Kerrick Valve, Dema, Walters Control, and Suttner.

Below is a Dema liquid level proportioning control unit with a siphon breaker.

 

Another application that is extremely common with float valves is in the cattle industry.  We sell a unit that allows the user to tie into a warm water source to keep stock tanks from freezing closed in frigid temperatures.  The Ice Bull Automatic Ice Prevention System is engineered to automatically open when the stock tank water temperature falls below 42 degrees Fahrenheit.

When the Ice Bull sensor valve opens, .20 gallons per minute of warmer water bypasses the float valve and flows into the tank through the discharge hose.  Then, when the water temperature rises above 42 degrees Fahrenheit, the thermo valve shuts off.  The Ice Bull Sensor is pictured below:

 

In Conclusion

We hope that this has been a helpful guide to valves.  While not all valve types are listed in this post, you have certainly enhanced your general knowledge and should be better prepared to choose the correct valve for your desired application needs.

Don't forget to confirm in any application - the solution passing through the valve, operating pressure range, maximum pressure, and temperature of the solution and always confirm chemical compatibility.

As always, thanks for stopping by and come back soon.

What is Pure H2O?

Crystal clean, pure, and without blemish.  If all water entered our appliances, equipment, and food in it's purest form we would have a lot less headaches.  Face it - hard water is tough - not just on equipment but on our bodies.  If we can introduce pure water into a plumbing system it will accomplish things from reducing friction all the way to keeping maintenance costs lower.  Fortunately, we can accomplish this through a process called reverse osmosis.

Think about it this way - let's say you setup two equal plumbing systems but the only factor your change is the water hardness.  If you are pumping water that has 450 Parts Per Million (PPM) in System A, versus water that has 10 PPM in System B - which system will outlast the other?

I hope you guessed System B.  Common sense tells us the less wear and tear we can put on mechanical pieces of machinery the longer it will last.  Therefore, if you have hard water (water that contains more abrasive or suspended particulates) you are going to undoubtedly add to variable expenses in the form of increased operating costs - the upkeep of your equipment will require more routine maintenance and repairs - no way around it.  Below you will see a cut-out view of a membrane used in reverse osmosis systems.

 

But what if I told you a simple investment, up front, could lower those variable costs and effectively keep more money in your pocket?  You keep more money in your pocket by allowing your system to run more efficiently and lessen the likelihood of additional maintenance and repairs costs.

Bottom line - if you can keep your system operating longer and minimize down time, whether that's scheduled maintenance or emergency maintenance, more money stays in your pocket.

Determining Water Hardness

Let's get into the heart of this discussion and throw some numbers out there.  Water hardness is determined on parts per million.  The EPA allows for 500 PPM in drinking water.  Vehicle washing requires, a maximum, 50PPM.

More and more greenhouses are beginning to monitor their water hardness, as well.  Greenhouses and farmers across the country need to monitor their pH levels constantly.  They do this to ensure that their plants are given the correct ratio of nutrients required to improve yields.  By rigorously monitoring the purification of the water supply, an operator can ensure that a clear, and controlled, chemical reaction takes place with their soil matter.

The process of reverse osmosis allows operators and farm/greenhouse managers to effectively oversee this chemical reaction - in a much more efficient manner.

Reverse Osmosis & How it Works

Reverse Osmosis is a process in which microscopic particulates are captured by an extremely fine membrane that allows the solute, in this case, water to pass through.  This process is so effective that it can take water with 500PPM and reduce that number to less than 10PPM - and, in many instances we can do much better than that.

This process is achieved through pressurization and, as noted above, extremely fine membranes or filters.  The solute is retained on the pressurized side of the membrane and the solvent is allowed to pass through the membrane.  The reason this process must occur under pressure is that the solution needs to be forced through the fine holes of the membrane.  In many systems there will be multiple stages of filtration.

The first filtration step will occur through an extremely crude manner.  In many instances, the process will include a sand bed filtration that is gravity fed.  This step is no more complicated than allowing the solution to percolate through a large sand bed - thus extracting many of the large particles that would clog finer filters and membranes - which are downstream in the plumbing system.

The next stage typically involves another filter, or series of filters, that catch particulates and suspended particles that were small enough to pass through the sand bed -which is stage 1 of the filtration process.  By implementing this second stage filter the process, in most instances, the solution is ready to actually pass through the finer filters/membranes - thus completing the reverse osmosis process.

Prior to running the solution through the final filtration stages, it must be ran through a "booster pump" that creates the pressurized portion of the system.

Once under pressure, the solution is ran through another membrane or series of membranes.  Depending on the water hardness, it might be necessary to use a series of reverse osmosis membranes to reach the desired PPM the operation requires.  Basic system components for a reverse osmosis system, used in the vehicle washing industry, can be viewed here.

Upstart University Video Explanation

Here is a video from Upstart University on how reverse osmosis can benefit farmers and greenhouse managers.

For further product questions or inquiries about reverse osmosis systems and or replacement components and parts - don't hesitate to contact us or check out our website at Dultmeier.com - Thanks for stopping by and take care!

Mosmatic At a Glance

The journey to an assured future.  Look no further than Mosmatic Corporation.  The Switzerland-based company specializes in the manufacturing of high-pressure cleaning equipment. With over 40 years of experience, Mosmatic has the common sense knowledge to back up their revolutionary solutions which serve a wide range of industry issues.

The construction of a new facility in Bristol, WI has allowed Mosmatic to better penetrate the US market place.  From high-pressure swivels to rotary nozzles and carwash booms - all the way to roof cleaners and gum removers - this company offers just about everything you need to keep your business clean and looking pristine.  You can view our Mosmatic Manufacturer page here.  This is one of Mosmatic's top videos - which clearly illustrates many of their product high-pressure cleaning offerings.

 

Hurricane Pro

The Hurricane Pro is highly popular.  Not only is one able to clean underneath vehicles but it also allows the user to pivot the spray deck.  This allows for multiple cleaning angles to get into tight crevices and blast debris free.  This adjustable angle feature allows for an "all-around" cleaning of construction equipment, agricultural machinery, fleet vehicles, boats, and the list could go on - you get the picture.  The Hurricane Pro is an extremely versatile undercarriage cleaner that is packaged into one sleek and high-quality model.  Shop Mosmatic Now.  This product can be used with either hot or cold water.

Technical Data

• Maximum Pressure - 4000 Psi
• Maximum Temperature - 250 Degrees Fahrenheit
• Inlet - 3/8"NPTF
• Adjustable Spray Angles - 0 Degree to 90 Degree Spray Deck Adjustment

Here is a product-focused video on the Hurricane Pro.

High-Pressure Vehicle Washing

Mosmatic is also a staple name in the high-pressure vehicle cleaning industry.  From booms to swivels, spray guns, foaming products, and rotary wheel cleaners - Mosmatic offers just about everything one would need.  The Mosmatic Wheelblaster Pro is a highly effective and versatile solution for just about any style or type of vehicle.  Due to the nature of its design, there is no need to be extremely close to ensure a polished clean.

The water pressure actually turns the rotor arm - so as long as there is water pressure the rotor arm is spinning - no added motors are necessary.  Generally, the Mosmatic Wheelblaster Pro is found in automatic car wash facilities, but this product can be used for buses and fleet vehicles, as well.

We hoped that you enjoyed this Manufacturer of the Month highlight.  Mosmatic is a wonderful company that is seriously concerned with the quality of their products.  No one says it better than their managing director, Patrick Rieben.  "For us Quality is not just a slogan, but the bench mark for our efforts, priorities and goals."

Take care and don't forget to stop by Dultmeier or give us a call at 1-888-677-5054.  Thanks for dropping in.

Maui - A Tropical Paradise

We recently traveled to Maui, HI.  The tropical paradise, virtually, has it all.  From breathtaking beaches to arid, Sahara-like, geography, all the way to volcanic rock.  In our travels, it's hard to find an industry in which the products we work with don't have a footprint or an impact.  In this instance, our example is High-Density Polyethylene Pipe (HDPE).  However, let's hold there and get to the island stuff first...

Let's face it - when in Maui you could simply hang by the beach for the entirety of your stay and be able to soak in tons of the island life.  However, for those more adventurous, I challenge you to explore all that this wonderful oasis has to offer.  The Hana Highway is a unique adventure for those interested.

If you plan to take the Road to Hana - make sure you get a Jeep.  The mini-van made it but may or may not have required an alignment check after the trek.  From hairpin turns along the tropical mountainside to sheer cliffs among the arid ocean walls of the Southeast side of Maui, Mother Nature will treat you and leave you stunned at the beautiful sights.

The trip starts on the North shore of Maui and takes you past Jaws aka Pe'ahi - a popular surf destination on the island.  From there one starts to climb - and climb fast.  As you begin to make your way up Mt. Pu'unianiau you will wind your way through a seemingly endless amount of bridges, turns, and stunning views.

 

Don't forget to stop and get your banana bread - it's a little island secret but we don't want to give that away here.  Just make sure where to ask to stop along the Road to Hana and you will won't be sorry that you did.  It is absolutely, hands down, the best banana bread in the world.

Once you get through Hana you will begin making your way around the South side of the island - this is where the topography, as well as, geography begins to drastically change.  What was once luscious jungle gives way to a Sahara-like climate.

 

 

Along the South side of Maui, you will come across the southern end of the Halekala National Park.  Within this national park, you will be able to walk to the Oheo Pools or the Waimoku falls along the Pipiwai Trail.  While embarking on the trek of this trail (3-mile loop) you will make your way through a bamboo forest that is truly remarkable.  The gentle breeze creates a "clicking" and "clanking" that reverberates throughout the forest.

It was here, along the Pipiwai trail that we ran into our instructional scenario of the excursion.  The park uses High-Density Polyethylene Pipe, or HDPE pipe for short, to transfer crystal clear water from the upper pools down to the recreational center hundreds of feet below, along the ocean shoreline.

HDPE Uses - An Extremely Versatile Product

We see HDPE pipe used from agricultural fertilizer applications to the petroleum industry in the oil fields and all the way to municipalities.  The applications and uses for HDPE are endless.  As the product is chemically compatible with a large number of solutions, it is a natural and obvious choice for many scenarios.  Furthermore, it is an extremely economical option in comparison to steel or stainless steel pipe.

The ease of installation makes HDPE another enticing choice - a fusion machine allows installers to, essentially, weld the pipe together in what's called a butt fusion - which is an extremely robust and sure connection.  Below is a simple video that illustrates HDPE pipe and a butt fusion weld to a 45-degree elbow.

While the majority of the applications, with which we are most familiar, are within the agricultural industry we do get into projects ranging from wash facilities to oil pipelines - and everything in between.  If you have further questions about how HDPE pipe and/or fittings could be applied in your specific scenario don't hesitate to contact us.  Here's to a wonderful 2018

~ Aloha Friends ~

Everything You Need to Know About Starting a Car Wash

Have you been pondering the idea of starting a car wash?  Does the idea of passive income sound appealing?  That's because it is.  Do know that there is an extensive amount of upfront work and then there is the issue of on-going maintenance.  That being said, once you have an operational car wash up and running - you can consider it passive income.

The information below is a compilation of countless periodicals, customer surveys, and testimonials.  At any point in the process of your new adventure, should you feel the need to ask about something in more detail don't ever hesitate to contact us.  Let's dig into what you will need to do in order to properly align yourself to start a car wash.

Lot Selection

A general rule to follow when sizing lot is that you will need a lot approximately 100 - 120 feet deep by a minimum of 75 feet wide - depending on the number of bays.  Keep in mind a typical four bay self-serve car wash would need a lot 120 feet long by 100 feet wide - minimum.  Another key attribute when selecting the ideal lot for your car wash is that it is accessible from both directions of traffic flow.

For instance, if you select a lot that is on a one-way street it will negatively affect the volume your wash is capable of producing.  The ideal traffic speed in the area of your lot selection should be around 40 miles per hour.  This ensures that drivers have ample time to select your wash as their destination.  The lot size and shape will determine if you design a "drive-in-back-out" or "drive-through" building.

Data shows that income streams do favor the "drive-through" design. Lastly, when selecting your ideal location it is a good idea to target areas near residential neighborhoods, apartment complexes, or busy traffic routes.  When determining if your ideal lot selection is a good fit for your business plan, you should consider the finances, as well.

A safe rule to adhere to is that the cost of the property (monthly lease payment) should not exceed 15 - 20% of the gross monthly income of the wash.  This ensures that you will not over-extend yourself, financially.

 

Bay & Building Sizing

An ideal bay is 16 feet wide by 28 feet long - these are the interior wall measurements.  If you are planning a semi-truck bay make sure to account for internal wall measurements of 18 feet wide by 28 feet long.  You can make a smaller bay work for trucks but why not just do it right from the start?  The typical pump (equipment) room is 10 - 15 feet wide by 28 feet long (internal measurements).

Furthermore, the typical bay height is 10 feet high for cars and 12 - 14 feet high for semi-trucks.  Your lot size above will vary depending on what your overall wash purpose is (car vs. semi-truck) and the number of bays you intend to have.  That's why we recommend determining the bay purpose and number of bays at the same time you are selecting your ideal lot location.

Building Placement

It's always best practice to consult local regulatory agencies to ensure your building is within code.  That being said, your building should be situated on the lot to allow for one to two cars, minimum, to be parked behind each bay, waiting to wash.  Vacuums should be placed in this area, as well, but should not be an impediment to the normal traffic flow into the bays.  Another important concept to consider is that you ensure there are adequate drying and vacuuming areas.

These areas should be out of the main traffic flow to avoid congestion.  It is a good idea to allow for a southern exposure of your bays.  This helps to reduce ice build-up in colder weather climates.  Finally, make sure you plan for the "set-back" requirements on your building placement - this will vary with local ordinances.

Inside vs. Outside Bays

This aspect really does depend upon your market.  Therefore, drive around and study the target market for the area which you have selected.  That will give you a good idea of whether or not you need to have an outside bay or an inside bay.  Washed located in a rural setting can be built with an open outside bay to accommodate trucks, trailers, and tractors.  While this isn't required it can, and will, only allow for more traffic at your wash.

 

Do keep in mind that an outside bay will bring in 50-60% of the revenue that an inside bay will.  It is always better, from strictly a revenue standpoint, to enclose all bays and build one larger bay for semi-trucks - if you feel that your market will demand that.  This larger bay can always be used for car traffic when an overflow bay is needed.

Revenue Projections

Our experience tells us that it takes a population of about 1000-1500 people to support a single self-serve bay car wash.  Therefore, one can conclude that a town of 5000 people will support a total of 5 self-serve bays - between ALL competitors.  Given the current population level of the United States, the national average one can project roughly $2000/bay per month during peak traffic season(s).  This is an estimated average - revenue can and will vary.

The ideal number of vacuums to have is 1.5 vacuums per bay of service.  Therefore, a three bay wash should have four to five vacuums in an area of the lot that will not affect traffic flow.  The national average per vacuum is approximately $200/vacuum per month.  Again, revenue can and will vary.

National averages of vending revenue are generally around the $400 per month range.  This figure is based on offering at least four to five different vending products.  Do keep in mind that revenue can be increased with multiple product, clear front vending machines.

Operating Cost Projections

One can expect that average operating costs are approximately 50% of gross revenue.  This figure includes 13% for attendant labor, which may or may not be needed.  Do note that lease payments, income tax, debt reduction or depreciation are not factored into this number.  Furthermore, we must be clear that one should recognize these figures can and do vary from region to region.

 

Options & Features

A standard self-serve wash will offer hot wash/hot rinse in the winter and cold rinse in the summer.  Additionally, hot or cold wax, foamy brush and spot-free rinse should be considered.  Spot-Free rinse is an important feature.  It increases revenue due to the fact that customers need to "buy" another cycle of time to get this feature.  What does this mean?  Double the income from each customer that decides to use this feature.  Tire cleaner and pre-soak systems are also options that increase customer satisfaction and increase revenue.

We highly recommend that instantaneous tankless water heaters be used in place of conventional water heaters.  An instantaneous heater can reduce gas consumption by up to 40% in comparison to a conventional heater.  For example, if it rains for an entire week, only the pilot light is using gas in the instantaneous tankless system.  If only the pilot light is running that takes considerably less fuel, and therefore, less money - directly affecting your bottom line - in a positive way.

Conversely, the conventional water heater will continue to heat the water regardless of demand.  Think of it this way - the instantaneous heater only fires when water is needed, thus making the system much more efficient.  Another important feature to consider is floor heat.

Every cold climate wash should have a floor heat system.  Floor heat systems reduce liability and increase customer satisfaction.  An in-floor circulating system is the most popular design.  That being said, above-head radiant tube heaters also give the benefit of heating the floor as well as the customer.  Keeping your customers warm while they are in your bays will keep them happy and ensure they continue to come back as a repeat customer.

It is wise to account for heating a three to four-foot area on the entrance and exit aprons of each wash bay.  This will reduce customer liability in the walk areas as they use bill changers and vending machines.  Ice will build up in colder climates and you want to ensure you do all within your power to mitigate injuries on your property. 

Another important topic to address is the use of proper signage.  It is frustrating to use a wash that is poorly explained due to the lack of proper signage.  Yes, many people will be able to figure it out.  But, why let this be part of your customers' experience?  Don't you want them to get exactly what they want out of your wash?  Get in, get out, and have a clean and sleek finish.  Here are some examples of car wash signs we offer.

 

Additional Revenue Streams

Do not overlook vending products such as towels, Armorall, window cleaner and fragrance trees.  These are additional revenue streams.  Piggybacking off vending machines, every wash should have bill changers.  This is an absolute necessity.  Studies have shown a minimum 10% increase in gross revenues for washes that have bill changers.

 

Another trending area that has taken off in the past few years is the addition of pet washes at car wash facilities.  The demand is there and many people will wash their cars and pets in the same visit.  This has been a profitable investment for our customers that have installed pet wash facilities at their locations.  You can view some options here.  As always, should you have more questions than can be answered by our website don't hesitate to contact us.