Aquify Systems, a leading innovator of aquatic mechanical product solutions, recently opened a state-of-the-art 30,000 sq. ft. warehouse facility in Dallas, TX to support the accelerated year-over-year growth of its North American operations.
A new center of operations
Designated for inventory, assembly, and light manufacturing, the centrally-located Dallas facility enables easy and efficient nationwide and international distribution of Aquify’s products. The facility boasts a large pump test rig, built to Hydraulic Institute standards, to validate pump curves and performance prior to shipping. Aquify can also test and program all variable frequency drives (VFDs) in conjunction with pumps for easy installation.
Aquify is always evolving
“In response to the pandemic-driven global supply chain disruptions, we pivoted from a just-in-time (JIT) inventory control model to the Kanban scheduling system to shorten lead times and create a cost-effective workflow to better meet customer demands,” said Ryan McDowell, President at Aquify. “Our new Dallas facility gives us the capacity, flexibility, and testing capability to keep pace with increasing order volumes while mitigating the impact of the supply chain crisis.”
Herborner has a new North American hub
The warehouse also serves as the new U.S. assembly hub for Herborner Pumpen, the European market leader of commercial aquatic pumps. Aquify is the exclusive distributor of Herborner pumps in North America.
“To facilitate our expansion into North America, we’ve chosen to partner with Aquify to assemble all of our aquatic pumps at their new Dallas facility,” said Wolfram Kuhn, Managing Director at Herborner Pumpen. “Aquify shares our vision to create the most efficient, energy-saving, and environmentally-friendly aquatics mechanical products on the market.”
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Get in touch to learn more about the exciting future of aquatics at Aquify, and how your project can benefit from their extensive product lineup.
Corrosion is the nemesis of aquatic facility owners and operators everywhere. In addition to the corrosive effect of chlorine-based chemicals in pool water which can cause aquatic equipment like filters to corrode, corrosive air pollutants (e.g., chloramine vapor, trihalomethanes) in indoor pool environments can also wreak havoc on exposed metals. Plus, the humid, warm, and chlorine-dense atmospheric environment of the mechanical room promotes corrosion.
At Aquify, we take corrosion very seriously. We’ve implemented a comprehensive corrosion prevention system across all our products to mitigate corrosion risk in our regenerative media filters, strainers and baskets, and reducers, with each process working in parallel to create highly corrosion-resistant products specifically designed for the challenging aquatics environment.
Through a combination of careful material selection, meticulous manufacturing and welding procedures, cathodic protection, and an extremely durable powder coated finish, Aquify delivers best-in-class corrosion prevention across our entire product line.
Material selection impacts corrosion resistance
Fiberglass
The Aquify range of regenerative media filters is available with either a fiberglass vessel or a stainless steel tank. Used in critical applications like chemical manufacturing and marine design, fiberglass composites are designed to be non-reactive. Consequently, fiberglass aquatics products have been used by pool contractors and facility operators for decades.
Key in our composite design, Aquify employs a special corrosion layer as part of the fiberglass structure of the tank which is specifically designed to protect the integrity of the vessel. “We understand that there is wear that happens on these materials during the lifecycle of the equipment. Our corrosion liner is specifically designed to handle any degradation and protect the tank for its lifetime,” says Josh Kravitz, Product Engineer at Aquify.
Aquify strainers and reducers are also available in fiberglass.
Stainless Steel
In addition to fiberglass, we offer regenerative media filters with stainless steel tanks, in contrast to the carbon steel tanks that some other manufacturers use. Carbon steel tanks are coated with a polymer lining to prevent corrosion. “The issue with carbon steel tanks is that the liner becomes a single point of failure,” says Kravitz. “If the liner deteriorates, or is damaged in any way, the entire corrosion protection becomes compromised and, as a result, the structure of the vessel is left completely unprotected.”
Conversely, Aquify uses corrosion-resistant 304L stainless steel across its product line, with no liner required in the filter tank. The chromium in stainless steel reacts with oxygen to form a thin layer of chromium oxide on the surface of the steel. This passive layer prevents rust by acting as a barrier that limits oxygen and water access to the underlying metal surface.
For high-wear components like basket strainers that are under constant assault from debris, Aquify uses the more costly 316L stainless steel to ensure maximum corrosion protection. Due in part to the addition of the alloy molybdenum which helps fight off corrosion from chlorides, 316L stainless steel offers even greater corrosion protection than 304/304L stainless steel. The benefits of this alloy outweigh additional costs of a higher grade of material.
Stringent manufacturing process: the ace up our sleeve
Aquify’s comprehensive corrosion prevention strategy is anchored in our meticulous fabrication process:
Dedicated shop
We manufacture our stainless steel filters in a dedicated stainless steel manufacturing facility that has expertise, procedures, and practices specifically tailored to stainless steel. Plus, with a dedicated fabricator, the risk of cross-contamination with dissimilar metals (e.g., regular carbon steel) is eliminated, further reducing the risk of corrosion.
Aquify stainless steel reducers, tees, baskets and strainers are manufactured in an ISO-certified facility with extremely stringent manufacturing standards and protocols in place.
Correct weld procedures
Aquify follows precise weld procedures and best practices to ensure that vessels are fabricated correctly to maximize strength while minimizing the risk of corrosion. “Any weld that isn’t done correctly can be prone to corrosion so we’re meticulous about our welding practices,” says Paddy Ruzicka, Product Engineer at Aquify.
Passivation
The properties of stainless steel that make it resistant to corrosion are present on the surface of the material. When stainless steel is heated to the point where it can be fused together (i.e., during welding), those protective properties are lost.
To ensure that the corrosion-resistant properties of the stainless steel are brought back to their native state at the weld point, Aquify implements an electrochemical weld cleaning system, a.k.a passivation. By passivating the weld, we regenerate the chromium layer on the surface of the stainless steel which acts as a barrier to the transfer of electrons, thereby mitigating oxidation and corrosion of the metal.
Weld testing
We test all our welds to measure how passive the area of the restored metal is. “Not only do we passivate the welds, but we’re able to measure the passivity to ensure that the optimal level has been attained,” notes Ruzicka. “We also conduct periodic non-destructive weld testing that involves x-ray imaging of the weld joints to verify the welding process and ensure the highest-quality end product.”
An example weld x-ray showing lack of fusion otherwise not visible to the naked eye.
Pickling
Aquify pickles its stainless steel aquatics products using a specialized acid solution. The pickling process promotes the regeneration of the passive layer on the surface of the stainless steel which acts as a barrier to oxidation.
“Pickling and passivating the tank are crucial steps to ensure corrosion protection that not every vendor takes. At Aquify, we’re very proud of the considerable time, effort, and specialized resources we deploy to ensure the integrity of our stainless steel products,” says Kravitz.
New non-metallic blast cleaning
Before powder coating stainless steel filter tanks, Aquify blasts the exterior with new (non-recycled), environmentally-friendly, abrasive blast media. We use this non-metallic blast media to accomplish two key objectives: first to remove any cross contamination that could have happened prior to fabrication, and second to achieve the correct surface profile prior to powder coating. “After blast cleaning we can be confident that the surface of the tank is not contaminated with any dissimilar, foreign metals which could promote corrosion, and proper adhesion can occur between the coating and substrate,” says Ruzicka.
Powder coating
After creating a pristine stainless-steel surface with the new non-metallic blast cleaning, the tanks are sent to a specialized powder coat facility to receive a corrosion-proofing powder finish. An electrostatic paint sprayer imparts a positive electric charge on the powder and accelerates it towards the surface of the tank through the electrostatic charge. The chemical bonding process strengthens the powder coating and, once cured, the bonds solidify to create an extremely durable physical barrier that prevents corrosion on the surface of the tank.
Sacrificial anode
Aquify filters also offer a sacrificial anode as a final level of corrosion resistance, a process commonly used in critical applications (e.g., marine, underground piping). When a sacrificial anode and metal are placed in a corrosive solution, the anode effectively stops the corrosion of the stainless steel by sacrificing itself and corroding instead. “We consulted with a corrosion engineer to design our galvanic battery and recommend the optimal anode for our tanks,” notes Kravitz.
We’ve got your back
Corrosion is a fact of life in the world of aquatics and equipment manufacturers must take into consideration the entire aquatic ecosystem over which they have little control. “Everything in the aquatic environment is connected by water and this connection can transmit corrosion from one thing to another,” says Kravitz. “We take into account that other products in the system — whether that’s a bolt on the waterslide or a pool ladder — may be corroding, causing rusted steel flakes to pass through our filter, or creating stray currents that promote corrosion. Our products are designed to be able to resist corrosion, not only in a pristine indoor pool environment with perfect chlorination levels, but in a real-world setting with potential contamination and sub-optimal conditions.”
Aquify has deployed a comprehensive, multi-layered strategy that mitigates corrosion risk with no single point of failure. “It’s worthwhile noting that just because a product says it’s stainless steel doesn’t mean it’s corrosion-proof,” adds Kravitz. “At Aquify, we go the extra mile to perform all the necessary additional steps and measures to ensure our customers can feel confident in the quality and performance of our products over their entire lifespan. From our extensive material preparation and stringent fabrication process through to detailed installation and bonding instructions in our documentation, we’re committed to helping aquatic operators protect their equipment from corrosion.”
Get in touch to learn more about how Aquify can take your corrosion prevention to a new level with our comprehensive range of stainless steel and fiberglass aquatic products.
Variable Frequency Drives—also known as VFDs—are used for the electronic regulation of the speed of motors. Using frequency converters, you can save a lot of energy and considerably reduce material wear.
VFDs gently start and stop motors in an infinitely variable manner. In contrast with motors operated directly through the mains, no torque or power impulse occurs in the case of the VFD, which means that the entire drive train with motor, pump, and pipeline system, including the seals, is protected.
In this way, speed regulation considerably reduces the wear and the lifetime of the plant is extended. Repair and maintenance costs decrease thanks to longer operating intervals and lower material wear.
APPLICATIONS
A wide range of applications are available for VFDs in pump technology: the advantage of VFDs mainly lies in the adaptability of the duty point to plant requirements through pump speed regulation.
Various duty points can also be operated in this manner, among other things. An example of this is the night-time energy reduction in swimming pools. Other situations, however, also make VFDs absolutely necessary. If the selected pump size is too large, for example, the valve of the pipeline will close, which means that the duty point is not adapted (which makes no sense energetically), and the speed will be adapted using the variable frequency drive. Subsequent plant changes can also be regulated in this way.
Additional applications include the regulation of pumps or the adaptation of pump duty points. This may be necessary in waste water or clean water systems.
The energy savings potential arising through the use of VFDs depends on the type of load to be driven, the optimization of the efficiency of the pump or drive by the VFD, and the time in which the system runs in partial load operation.
SELECTION OF THE SUITABLE VARIABLE FREQUENCY DRIVE
For the selection of the most suitable VFD, you must take the following points into consideration:
1. Voltage and type of the supply network
2. Control (e.g. PLC via external signals)
3. Performance data
4. Ambient temperature
5. Installation height (if above 1000 m)
REGULATION OF ASYNCHRONOUS MOTORS USING A VFD
Frequency regulation is optional and depends on the operating conditions. VFD are used for direct installation (power up to 26.4 kW) and for installation in wall or switch cabinets (all ratings).
The decentralized, integrated or compact drive solution, in which the VFD is directly attached to the motor, provides better coordination between the motor and converter since the problem of electromagnetic compatibility (EMC Directive EN 61800-3) is minimized.
REGULATION OF PM MOTORS
With the introduction of the PM motor (permanent magnet motor) IE5, which is currently the highest energy efficiency class for motors, the pump system receives further impetus in regard to energetic optimization.
Permanent magnet motors cannot be connected directly to the mains, but rather run only by a VFD. The use of these energy-efficient motors is thus an additional factor in favor of a VFD.
A special feature of the PM motor/VFD combination is the process-optimized regulation of the VFD and the resulting energy savings. In this case, the advantages of PM motors over conventional three-phase asynchronous motors can mainly be seen in the reduction of low outputs when speed is decreased.
DUTY POINT CONTROL BY MEANS OF VARIABLE FREQUENCY DRIVE
The basic concept behind the frequency regulation of pumps is speed adjustment. This gives rise to:
1. energy savings if there is a change in duty points and/or
2. a reduction of flow rate and/or adjustment to the system requirements.
Point 2 is an alternative to the possibility of adapting pumps to meet changing operating conditions. Choke regulation have mainly been used up until now for this which exerts an influence on the resistance parabola of the system by means of slide valves or diaphragms. In this case, the resistance parabola 1, for example, changes into the altered resistance parabola 2 (see diagram).
By way of comparison, when actuating the pumps by VFDs, the duty point of the pump under frequency regulation migrates along the original resistance parabola 1. The resulting energy savings are shown in the performance diagram (Q-P set of performance curves) in the difference between Point II and Point III.
Frequency regulation is used predominantly, however, for saving energy with changing duty points (generally two). By applying the example mentioned above, the power input for the pump is reduced from Point I to Point III in the Q-P set of characteristic curves.
If the speed falls below a value at which no acceptable establishment of the flow can take place, the laws can no longer be applied. While it is true that the values Q, H, P and Eta are in line with one another, turbulence and air in the medium lead to imprecise measurement. For this reason, there are limits imposed on frequency regulation.
It is ultimately important when looking at system optimization to take optimal efficiency into account also (Eta optimal). This also has an influence on matching the best possible pump to the system.
The energy savings generated from frequency regulation can be calculated using the similarity rules for centrifugal pumps. Centrifugal pumps achieve the greatest energy savings potential. They are fluid kinetic machines with a square torque curve for which the adjacent proportionality laws apply.
The decisive factor for the energy savings is the cubic relation between speed and energy consumption. A pump running at half speed requires an eighth of the output required for operation at full speed.
EXAMPLE OF USING A VFD IN SWIMMING POOL TECHNOLOGY
Night-time energy reduction
Duty point:
Q = 215 m3/h H = 14 m P = 11.5 kW
Night-time energy reduction by switching off one pump:
Q = 170 m3/h H = 11 m P = 5.5 kW
Frequency regulation of two pumps:
Q = 107.5 m3/h H = 6 m P = 4.5 kW
Energy savings by night-time energy reduction:
ΔP = 1.0 kW
Operating hours per year in night-time energy reduction:
3000 h
Savings:
3000 kWh
If you have any questions about hernorner pumps or the energy savings they can provide, contact Aquify today.
When building an aquatic system for a commercial or residential project, the multiple types of commercial pool filters available today add a level of complexity to the design process. Should you go with a regenerative media filter or high-rate sand? Is stainless steel or fiberglass a better option? What about cartridge filters or ones that use diatomaceous earth (DE)?
Although there’s not necessarily a right or wrong answer to these questions, there’s a variety of criteria that impact your choice of filter: total volume of your facility’s pools, square footage of the mechanical room, required turnover rate for your pools, available budget, to name a few.
Let’s take a look at one of the many factors in the filter selection process: the type of tank material. While both stainless steel filters and fiberglass filters can be excellent options for your aquatic project, consider the following:
Design parameters
Stainless steel filters offer greater flexibility for custom fabrications compared to fiberglass filters, which tend to be “one-off” molds. If you encounter space limitations in the mechanical room or need to make alterations down the road, stainless steel filters are more adaptable to change.
Weight is another consideration when choosing a pool filter. Since fiberglass is one-third lighter than stainless steel, fiberglass filters are easy to ship and install. It’s worthwhile noting that although fiberglass is lighter than steel, its higher strength-to-weight ratio means it’s just as strong.
Height may also play a role in the decision-making process, particularly if you’re facing space constraints in the mechanical room. Aquify fiberglass filters are anywhere from 15” to 20” shorter than their stainless steel counterparts.
Some clients are concerned about the appearance of the filter, especially if being used in a residential project or if the filter will be visible to the public. If aesthetics is a factor, stainless steel filters can look sleek and high-end, while fiberglass filters tend to have a rougher, unpolished appearance.
Environmental impact
Aquatic designers, pool contractors, and facility owners are recognizing the importance of making environmentally-friendly and eco-efficient choices when designing an aquatic project. Similarly, more and more customers are choosing to spend their money with organizations that value sustainability in their approach to delivering products and services. Recreational pools and aquatic centres are not immune to this growing shift in demand, whether installing pool equipment that saves energy and limits water consumption or ensuring the air and water quality of the facility meet the highest environmental standards.
Stainless steel is a cradle-to-cradle (C2C) material. The C2C model promotes the use of construction materials and products that are 100% recyclable, or preferably, can be up-cycled. Existing within a closed cycle, stainless steel has the ability to be melted down and reused in an endless lifecycle of products.
Stainless steel filters are an environmentally-responsible choice in support of regenerative design and are ideal for LEED design projects or any aquatic project with an environmental impact or sustainability goal. Conversely, while fiberglass is designed to be durable and long-lasting—a positive quality in product design—, it doesn’t decompose. This means that when it’s time to upgrade your pool equipment, the old fiberglass filter will sit in a landfill forever.
Maintenance
When selecting the filter for your next project, consider the labor requirements for repairs. For stainless steel filters, you’ll need a skilled welder who understands the finishing requirements of stainless steel to maintain its corrosion protection (i.e., passivation).
For a fiberglass filter, you’ll need a skilled fiberglass repair person who is competent in fiberglass pressure vessel repair. Some fiberglass reinforced plastic (FRP) tanks may not be able to be repaired in all cases, due to the nature and type of construction (e.g., fiber-wrapped shell).
You can expect filter repairs to be similar to a boat. Stainless steel parts need to be maintained more frequently but require less specialization, while fiberglass repair is typically more specialized but less frequent.
Aquatic environment
Are you working with a salt water or chlorine pool? While both salt water and chlorine systems are harsh environments for aquatic equipment, from a corrosion engineering perspective, the effects of a salt water environment are more pronounced and create an additional level of corrosion on the metal parts. Simply stated, saltwater pools require very high quality equipment and special care for each component in the system, regardless of material type.
While no material is 100% resistant to corrosion, a high-quality stainless steel or fiberglass tank will help reduce corrosion concerns. If selecting a stainless steel filter, the use of a sacrificial anode will dramatically reduce the galvanic corrosion effects, both in chlorine and salt water environments.
Budget
Budget is always top of mind when designing an aquatic system and the mechanical room equipment comprises a significant portion of the total cost of the project. For contractors looking to find ways to minimize costs without compromising quality, fiberglass pool filters may be a better, more affordable option. Stainless steel aquatic filters are generally considered to be a premium filter which means they often come with a higher price tag.
Decision Time: Selecting Your Pool Filter
Although it may seem like a lot to think about, choosing a filter that meets the unique demands of your environment, budget, and design requirements will be a huge advantage, both from an operational perspective and for the patrons using your facility. While filtration range varies depending on the type of filter (e.g., high-rate sand, regenerative media) and choice of media (e.g., sand, DE, perlite), both stainless steel and fiberglass filters can provide excellent water clarity and quality for many years to come.
It’s not often that a project comes along that provides a unique challenge and a chance to mark your company’s place among a rich history. The Glenwood Hot Springs project was a great opportunity to prove Aquify’s ability to customize a solution that not only met but exceeded the client’s expectations.
The pool area before renovation
The History
The hot waters from Glenwood Hot Springs have been bubbling up from the earth for millions of years. It’s been a place of healing and relaxation for Native Americans, pioneers, movie stars, and many other visitors throughout history.
First developed in 1880’s by James Devereaux & Walter Horace it has been a source of health, a post-war hospital, a place for family fun, and a large piece of American history sitting on the banks of the Colorado River.
Getting the opportunity to help the hot springs lifelong tradition of adapting with the times, offered us a chance to impact the lives of countless families who will enjoy the fruits of this project in the future. A chance to become a part of that history brought an allure to this project that instantly got us excited.
The Project
The sheer volume of hot water from the hot spring is staggering. The spring flows 2500 gpm and allows them to have the largest hot springs pool in the world. The pool holds over 1 million gallons and is kept at 90° F all year long. Glenwood Hot Springs uses the hot mineral water for recreation, relaxation and resort utilities but passes all the water back to the Colorado river.
Glenwood Hot Springs had a goal of updating many of their aged amenities including an overhaul of the swimming pool into a more family friendly environment.
Several of the mechanical systems had reached the end of their lifespan and it was time to update them with better and more efficient technologies.
In the process Glenwood pulled out the old waterslides and replaced them with multiple family centered pools that enhanced the properties “Authentic Colorado” experience. They added a rapid river tube ride, kids slide area, a giant waterfall and teen pool and a fountain that engages youngsters by day and thrills spectators by night.
The Challenge
The main challenge in the Glenwood Hot Springs project came from what makes the hot springs such a unique experience: the thermal water. It comes out at a whopping 123° F and is used to heat the various pools water as well as the hotel.
The second challenge we faced was finding a solution that worked within their limited infrastructure. Glenwood needed a solution that would work with their available mechanical room space while offering a premier pumping solution.…And Aquify offered just that.
“Running the world’s largest hot springs pool isn’t always easy, the mineral water is highly corrosive, not to mention all the “normal” maintenance such a property requires. Keeping a facility that’s well over 125 years old in first class condition is probably the hardest day-to-day challenge”
— Kjell Mitchell– President/CEO Glenwood Hot Springs
The Solution
With the help of our pump partner, Herborner Pumpen (who brought the expertise in working with thermal water) we were able to take the water data provided by Glenwood and run a water analysis to customize a pumping and filtration solution that would ensure their pumps wouldn’t corrode or fail under the extreme condition of the hot spring’s water. While our pumps surpassed the test of Glenwood’s thermal water, they saw another opportunity where our pumps would be better utilized for their facility.
Herborner’s X-Series Vertical Pumps created spacial efficiency which significantly reduced clutter in their mechanical room. From the planning stages to installation and opening, we were able to leverage the experience and expertise of our team, our partners, and our dedication to pool pumping technology to make sure that we covered all considerations of a complex project like this one.
Further reducing clutter was the installation of an Aquify Regenerative Media filter to support the new splash pad with clean water for kids to play in. When working with kid-friendly fountains we take health and safety seriously, surpassing the same expectations in place for pool safety. Not only has the Aquify Regenerative Media filter been designed to filter particulates down to 1 micron, it also boasts the smallest footprint and shortest height in the industry, saving a large amount of space in a compact mechanical room.
Here are the attractions that our team worked on a solution for:
Shoshone Chutes: A whitewater river open air tube ride that plunges you downhill with plenty of twists and turns and screams. You’ll feel like you’re riding down a mountain creek in Colorado—with lush landscaping, cascading tiers, and boulders.
Sopris Splash Zone: A new children’s play area with three mini-water slides, waterfalls modeled after the popular Hanging Lake hike in Glenwood Canyon, interactive water features, shallow play areas, and shade structures for sun protection.
Grand Fountain: A water feature that acts as a kid-friendly splash pad by day — by night it becomes a lighted fountain that can be seen by pool-goers and Glenwood Springs visitors strolling across the pedestrian bridge.
The unique challenges presented by this project were solved by our flexibility, knowledge, and creativity. We approach each client and every new project with the same focus to provide a specific and dedicated solution that uses less and provides more!
Aquify filters also offer a sacrificial anode as a final level of corrosion resistance, a process commonly used in critical applications (e.g., marine, underground piping). When a sacrificial anode and metal are placed in a corrosive solution, the anode effectively stops the corrosion of the stainless steel by sacrificing itself and corroding instead. “We consulted with a corrosion engineer to design our galvanic battery and recommend the optimal anode for our tanks,” notes Kravitz.
The pool area before renovation
Further reducing clutter was the installation of an 
